Manufacturing parts for end-use directly from a rapid prototyping system is an emerging process. This technique is already used for short-run production, individualized part manufacturing, and custom repair-part building. Rapid manufacturing is being fostered in part by advances in materials used by rapid prototyping systems. These advances include high-performance production plastics that offer high strength at high temperatures.

This paper will discuss recent material advances in fused deposition modeling that benefit rapid manufacturing. The materials discussed include polycarbonate and polyphenylsulfone and also water-soluble support material, which automates the support-removal process. This paper will also briefly address the material blend of ABS / PC, on the horizon for FDM.