3.3 Electrode manufacturing using rapid prototyping and rapid tooling Rapid prototyping is a motivating innovative additive technology for quickly creating physical models and functional prototypes directly from CAD models. Rapid tooling, is generally, related with fast tooling production using prototypes made by rapid prototyping. Technologists involved in rapid tooling processes development are now devoting much of their efforts in reducing lead-times and development costs. Rapid prototyping (RP) technology offers great advantages like improved quality, shortening time to market, and reduction in the cost of fabrication process of complex shaped EDM electrodes [67, 68]. Between 1991 and 1996, several attempts were made to develop applications and techniques for rapid prototyping EDM tooling [70-80]. Arthur and Dickens [72] have investigated manufacturing parameters and discovered that when the copper plating layer on the electrode prototype is above 175 μ m thick coal it can help in preventing the electrode prototype from breaking during EDM. Arthur et al. [77] have investigated wear and fracture mechanism of stereolithography SL-EDM electrodes. Such electrodes present wear and failure mechanisms that are detrimental. Arthur et al. [74] used RP parts as electrodes for EDM. They have found a direct generation route with rapid prototype parts as EDM electrodes. Thin-coated stereo lithography models were successfully used in machining hardened tool steel up to a depth of 4 mm. The photo-polymer electrode
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