Additive fabrication (AF) technology encompasses a wide range of applications, including design review, concept modeling, prototyping, fit and function testing, pattern making and tooling. It also is applied to the manufacture of fixtures, assembly aids and test rigs, as well as parts that end up in final products.

Unlike machining processes, which are subtractive in nature, AF systems join together liquid, powder or sheet materials to form objects. Parts that may be difficult or impossible to fabricate by any other method can be produced by additive fabrication. Based on thin, horizontal cross sections taken from a 3-D computer model, AF systems produce plastic, metal, ceramic or composite parts, layer upon layer.

By most measures, additive fabrication has developed and evolved impressively. The impact it is having on new product development continues to capture the attention of entrepreneurs, investors, government agencies, researchers and others around the world. The following estimates provide perspective on the past and, hopefully, some insight into the future.

In the past four years (2004–2007), products and services for additive fabrication grew by an estimated $612 million. Put another way, the industry grew by 116 percent during this period.

Annual unit sales grew by more than 31 times from 1993 to 2007.
The installed base of CAD solid modeling seats for commercial use has nearly doubled since 2003.

The ratio of CAD solid modeling seats (for commercial use) to AF system installations is about 83 to 1.

AF systems were sold in 67 countries in 2007, with an estimated 71 percent of them being installed in the top six countries.

3-D printers sold over the past four years (2004–2007) represent about 72 percent of the total number of additive systems installed during this period.

Nearly 58 percent of the Stratasys and Z Corp. installed base (combined) was shipped in the past three years (2005–2007).

These numbers may be impressive, yet there is tremendous untapped potential, especially when considering the role that AF could play in manufacturing. Producing end-use parts is much more challenging than building parts for modeling and prototyping, so this application will require time to develop. Yet, rapid manufacturing has caught the attention of many. Wohlers Associates expects it to become the largest application of AF technology in the future.

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