Intricate shape prototypes obtained by FDM

Fused deposition modelling (FDM) is a filament based rapid prototyping system. FDM allows to build the components layer by layer by extruding a semi-molten thermoplastic polymer, thus allowing to overcome common drawbacks of the conventional machining. Complex shapes like curved shell-type structures (skull bones, turbine blades, marine propellers) can be therefore manufactured without the use of any special tools. Further, process parameters are minimally or not influenced by the final shape of the components. Nowadays, the planning of new components design mostly relies on Computer Aided Design (CAD) environments where each curve or surface is approximated by manual or semi-automatic definition of nets of control points. This leads to an intrinsic limit of the modelling capability above all at the early stage of the product development. In this paper an innovative approach to components design and manufacturing is proposed using Wolfram Mathematica platform. It is based on the employment of parametric mathematical formulations to model the component being manufactured. This method is applied to manufacture some intricate shape prototypes. The experimental findings emphasize how significant the decrease in time to market can be, avoiding the use of time consuming procedures typical of the CAD environments.