Additive processes, which generate parts in a layered way, have more than 15 years of history. These processes are not exclusively used for prototyping any longer. New opportunities and applications in appropriate manufacturing tasks open up, even though the economical impact is still modest. This review starts with the definition of Rapid Manufacturing and Rapid Tooling, dealing only with direct fabrication methods of components. A systematic material dependent classification of layer manufacturing and process oriented metal part manufacturing techniques are proposed. The generic and the major specific process characteristics and materials are described, mainly for metallic parts, polymer parts and tooling. Examples and applications are cited. The paper attempts to understand the state of the art and the prospective, to put questions, to understand limits, to show opportunities and to draw conclusions based on the state of the art.

The motivations applying to layer manufacturing emerging technologies in the product development cycle are considered. The interaction between virtual reality computer applications and physical manufacturing primarily rapid tooling is studied. This paper describes a holistic approach and optimization methodology in time and cost for injection moulded plastic parts, applicable for further tooling applications. Furthermore, some applications for die-casting and forming tools are cited. The bene®ts of optimization stages, cost, time and obtained ®nal results are discussed. The bene®t of using principally selective laser sintering with interactive modelling and simulation is demonstrated. Trends and concluding remarks round up the authors' reported experience and the state-of-the-art.

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