Rather than making a master stereolithography pattern around which a material is cast, it also is possible to build the cavity directly on the stereolithography machine.

3D Systems (Valencia, CA) has named this process Direct AIM. (AIM stands for ACES Injection Molding. ACES stands for “Accurate Clear Epoxy Solid,” which is a stereolithography build style.) Although not nearly as strong or hard as conventional tooling, it is possible to inject a range of thermoplastics into these cavities and produce useable parts. At present, only less abrasive and lower melting point polymers are being molded, although research is underway to improve this application.

Stereolithography tools are generally produced with the standard commercially-available stereolithography resin. Up to 500 parts have been molded from a single tool, although 10 to 50 parts is more typical. Research into the development of high temperature and filled resins also is being undertaken by several organizations.
The process is quick and it produces parts using production thermoplastics. Low tool strength and the risk of failure are disadvantages.