Rapid Prototyping allow freeform fabrication of complex-geometry parts directly from their CAD models. By directly or indirectly employing Rapid Prototyping technologies in tool, die and mold fabrication, rapid tooling (RT) process is accomplished. These tools may serve the purpose of forming a prototype part in the end use material or produce a product where only a small quantity needs to be manufactured. This paper presents a novel rapid prototyping process with water, called rapid freeze prototyping. The advantages of this process include cleanness, lower cost, better surface finish and potential building accuracy, faster potential building speed, and ease of stress compensation. We will present our recent progress in the development of this novel process. An experimental system has been built for conducting the research. Examples of three-dimensional ice parts with good surface finish and fair part accuracy have been successfully built. Key challenges encountered during the development of this process are discussed. Some preliminary experiments of ice part application with UV light curable silicone molding and investment casting are also conducted to demonstrate the application feasibility.
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