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The paper reflects on the development of a medical product using rapid prototyping technologies and customer interaction through a quality function deployment (QFD) approach to speed up the process, and to result in customer satisfaction. The purpose of the specific medical product was to develop a device for fixing an Endo‐tracheal (ET) tube in a patient during anaesthesia, as it is common for an ET tube to move and/or become dislodged due to various extraneous reasons. If the tube deviates from the correct position it can cause one or both lungs to collapse, which can be fatal. The paper reviews how the anaesthetist's idea, which was to develop a product that could hold an ET tube in place in a more secure manner than is possible with current technologies, was brought to fruition through customer interaction.

Using an action‐research approach, the design evolved through series of design concepts, which through customer interaction contributed to a total optimized design. Virtual and physical prototypes, together with silicone mouldings were used as part of the customer interaction.

As with any new product, some functional parts were needed to conduct tests, which in turn would help to prove the product, and hence, the design. Traditionally this meant the manufacturing of a hard tool and proving of the design through trial and error. Hard tooling allows for some small changes to be made, but if the changes are radical a new tool will have to be designed and manufactured.

Following a developmental approach through the application of various types/stages of prototyping (such as virtual prototypes), revolutionised this process by simplifying and accelerating the development iteration process – it also developed a new version/paradigm of QFD.

Opposed to traditional forms of QFD where customer inputs are gathered through questionnaires, this case study proved that functional models provide an efficient client‐feedback, through constant involvement in the development process, as well as evaluation of the systematic progress.

The case study shows that experts in other disciplines can become involved in the product development process through the availability of functional prototypes, and builds on previous work to introduce a concept of customer interaction with functional prototypes.

This chapter is dedicated to presenting the essential features and technical capabilities of the prototype ‘Integrated early price assessment system’, with an overview of how the machine learning system interacts with an expert evaluation system. The functional structure of the prototype’s operation is presented by means of an overview of the prototype’s communication flow diagram.

The last decade has seen major advances in rapid prototyping (RP), with it becoming a multi‐disciplinary technology, crossing various research fields, and connecting continents. Process and material advancements open up new applications and manufacturing (through RP) is serving non‐traditional industries. RP technology is used to support rapid product development (RPD). The purpose of this paper is to describe how the Integrated Product Development research group of the Central University of Technology, Free State, South Africa is applying various CAD/CAM/RP technologies to support a medical team from the Grootte Schuur and Vincent Palotti hospitals in Cape Town, to save limbs – as a last resort at a stage where conventional medical techniques or practices may not apply any longer.

The paper uses action research to justify the proposal of a new method to use CAD/CAM/RP related technologies to substitute lost/damaged bone regions through the use of CT to CAD to.STL manipulation.

A case study where RP related technologies were used to support medical product development for a patient with severe injuries from a road accident is discussed.

The paper considers current available technologies, and discusses new advancements in direct metal freeform fabrication, and its potential to revolutionise the medical industry.

The paper examines whether additive manufacturing can deliver durable injection‐moulding tools – fast, reliable, accurate and economic. Researchers from the Central University of Technology, Free State (CUT), South Africa, are involved in rapid prototyping (RP) applications‐based research, simultaneously using results to support small‐ and medium‐sized enterprises (SMEs) on a national basis – both with contract research and technology transfer[1]. SMEs in South Africa involved in product development, are often hampered by economies of scale. Many new products simply disappear in the product development valley of death, partly due to manufacturing costs and limited product development budgets. RP has been used extensively by Technimark, one of the CUT's industrial partners, to evaluate and verify designs in various design stages. To remain competitive in the global market, Technimark and the CUT often have to apply RP directly as the manufacturing method. The paper discusses the use of RP to support (accelerated) limited production of moulded plastic parts.

The hypothesis is to use additive manufacturing for direct production of injection‐moulding tooling, subject to time, cost and quality constraints.

A case study where both development costs as well as lead‐time forced our industrial partner to trial Alumide as a tooling medium is discussed.

The paper introduces a new rapid tooling material, which may be of cost and time benefit to the product development and plastic injection‐moulding fraternity.

In a previous Rapid Prototyping Journal paper, the authors reviewed the first decade of rapid prototyping (RP) use within the Republic of South Africa (RSA). The paper analysed its strengths, weaknesses, opportunities and threats, and proposed a “road map” for future development. Much has happened in the intervening years since that article was published and this paper seeks to update readers on the current situation in RSA. In particular, it reports the extensive development of research in the field of RP and additive manufacturing (AM).

The paper uses a literature review approach combined with reflective analysis to distill the most important developments within the RP community in RSA since 2004. These are compared to the previous road map to ascertain if there are any required actions that have been overlooked or any additional lessons that have been learnt.

The paper shows that there has been good progress against the previous road map and that current plans should remain in place with the addition of a greater educational dimension.

This paper provides readers with an overview of important RP/AM developments in the RSA. The analysis from this paper will aid RSA academics, industrialists and government agencies to assess their performance and to plan for their future roles within the RP community.

As with the previous paper, this paper provides a useful model for other countries to follow since it demonstrates both good practice but also the need to learn from past experience.

Additive Manufacturing (AM) technologies have conventionally focused on producing prototypes. However, recent trends show that AM is being increasingly used for production parts. With this shift from prototypes to production parts, there is a need to determine whether established engineering design techniques can be applied to AM processes, particularly techniques characteristic of the final implementation phase such as virtual (mathematical) modeling, or whether AM process‐specific adjustments must be made.

The effectiveness of applying virtual models to design problems utilizing AM processes was addressed using two approaches in this research. Literature was first reviewed to determine the current focus of the AM industry on virtual modeling, both analytical and numerical, and its implementation. Second, experiments were conducted to validate virtual models applied to fastener mechanism designs manufactured using laser sintering (LS).

Limited research has been published that demonstrates the effectiveness of applying established design techniques, particularly virtual modeling techniques, to parts manufactured with AM processes. The experimental case study has demonstrated that, for the limited cases considered, design techniques capable of accommodating the complex material properties of LS materials, such as finite element analysis, are effective methods for predicting part performance in accordance with desired outcomes.

The research indicates that designers can focus on designing quality LS parts with existing technology and methods rather than revamping their design methods due to the introduction of a new manufacturing technology.

This research provides support for the application of established design methods to LS AM processes; validating what has previously been an assumed part of AM.

This paper aims to convert surface data directly to a three-dimensional (3D) stereolithography (STL) part. The Geographic Information Systems (GIS) data available for a terrain are the data of its surface. It doesn’t have information for a solid model. The data need to be converted into a three-dimensional (3D) solid model for making physical models by additive manufacturing (AM).

A methodology has been developed to make the wall and base of the part and tessellates the part with triangles. A program has been written which gives output of the part in STL file format. The elevation data are interpolated and any singularity present is removed. Extensive search techniques are used.

AM technologies are increasingly being used for terrain modeling. However, there is not enough work done to convert the surface data into 3D solid model. The present work aids in this area.

The methodology removes data loss associated with intermediate file formats. Terrain models can be created in less time and less cost. Intricate geometries of terrain can be created with ease and great accuracy.

The terrain models can be used for GIS education, educating the community for catchment management, conservation management, etc.

The work allows direct and automated conversion of GIS surface data into a 3D STL part. It removes intermediate steps and any data loss associated with intermediate file formats.

The purpose of the present work is to develop a methodology for making physical models of catchment areas and terrains by rapid prototyping (RP) using geographic information systems (GIS) data. It is also intended to reduce data loss by minimising intermediate data translations.

The GIS data of a catchment area or a terrain were directly translated to an stereo lithography (STL) file. The STL surface was then manipulated in Magics‐RP to obtain a solid STL part, which can then be downloaded to a RP machine to obtain a physical model or representation of a terrain or catchtment area.

Intricate geometries of landforms were created with ease and great accuracy in RP machines. Terrain models were created in less time and lower cost than with conventional methods.

DEM ASCII XYZ (digital elevation model) data were used to input the required GIS data of specific terrains. Software can be developed for translation and manipulation of DEM, STL and other relevant file formats. This will eliminate any data loss associated with intermediate file transfer.

Terrain models were created with ease and great accuracy in RP machines. It takes less time and can be done more cost‐effectively. Terrain models have intricate geometries and for complex models, it may take months to make using conventional methods.

STL surfaces were obtained directly from GIS data for terrain modeling. This work fulfils the need of terrain modeling for catchment management, town‐planning, road‐transport planning, architecture, military applications, geological education, etc.

There are differing views and results in the literature regarding whether the user’s participation has a positive or negative impact, if any, on the success of an information system (IS) project. The purpose of this paper is to develop a comprehensive model with four main hypotheses to test the relationships between seven constructs using survey data conducted in the USA.

The authors develop a structural equation model (SEM) with four constructs defining the activities the user participates in and three constructs defining user satisfaction as a measure of project success. As such, the proposed SEM is the most comprehensive among the models offered in the literature to date, and includes, for the first time, a presentation requirement construct as a specific system requirement for possible user participation.

The authors find that a business user’s participation in functional requirements benefits project outcome, whereas business users should not participate in gathering presentation requirements unless they are experienced middle managers.

This study surveyed many industries across the USA and provided a solid statistical base for analysis. Future research should consider exploring IS projects in other countries since various cultures can differ in how they approach to such projects. Additionally, industries are known to have dissimilar needs; therefore, a study exploring specific industries would add to the available research.

The authors find that when the general business user participates in certain activities that relate to presentation of the system, his/her involvement negatively impacts the project success. However, if that business user is a middle manager, he/she has a positive impact on the project success. Similarly, when the business user participates in managing the projects, that involvement negatively impacts the project outcome (although the amount of negative impact is relatively small). These results should have an influence on the way the IS project managers allocate business resources to activities, and their decisions regarding whether and where the business users participate.

The authors expect higher levels of business user satisfaction on IS projects if they are allocated to a limited subset of project activities that has a positive impact on project outcomes.

The authors believe these findings contribute to this research domain considerably since they are based on a large sample size on a new comprehensive model of business users that can be generalized across industries. The separation of business requirements into functional and presentation requirements has suggested that there are differing impacts to the project depending on the type of business user involved.