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Traditionally, process improvement is considered a defect prevention effort. Current cost models consider the coupled effect of both prevention and appraisal costs on the cost of failure. This paper proposes a new model for the cost of quality, which captures the value of continuous process improvement in achieving economic operation. The model is developed to incorporate two cost functions. The first accounts for quality related costs incurred while maintaining a stable level of operation, while the second accounts for the cost of process improvement. Using incremental economics, the two cost functions are assembled and an economic criterion for evaluating improvement alternatives is developed. Numerical examples are used to illustrate potential applications and performance of the model.

The purpose of this paper is to present a study of the stereolithography apparatus SLA 250‐50 motivated by the introduction of the new epoxy resin AccuGen™.

Several process variables are examined using a Box‐Behnken design and optimization techniques are employed to determine their optimal settings.

The results indicate operating conditions at which high levels of performance can be achieved.

The results reported in this research are process specific, however, the methodology employed can be readily applied to different rapid prototyping processes.

Effective utilization of the SL process.

Quantitative understanding of the process capability in relation to key process variables.