Rapid prototyping driven design and realisation of large components

Purpose - The purpose of this paper is to demonstrate the use of three-dimensional printing (3DP) process as a base technology for rapid manufacturing of components, larger than the machine's build volume. This extends the 3DP applications field beyond its existing domain. The paper gives process chains and design for manufacturing and assembly guidelines. Design/methodology/approach - Several parameters influencing the process chains are identified and their interrelations investigated. Based on this study, new process chains are developed for specific functional and material requirements. The new process chains are validated with several case studies. Where applicable, the process chains are compared qualitatively with existing methods. Findings - The results show that the new process chains are as fast as or faster than existing methods and have similar accuracy. The most significant advantage is a more geometric freedom. There is also more opportunity for checking physical models before making the final part. Some limitations to the processes are identified and given as design guidelines. Research limitations/implications - A quantitative comparison of existing methods with the new process was not possible. Practical implications - The study provides useful design for manufacturing guidelines. Originality/value - This paper shows how 3DP technology, originally only conceived as a concept modeller, can be used to manufacture components that are larger than the rapid prototyping machine's build volume. It gives guidelines for designers wishing to follow a similar route.