One of the most common Rapid Prototyping (RP) technologies, the stereolithography apparatus (SLA) fabricates 3-dimensional parts using a layer-based. additive fabrication process by tracing part cross-sections on the top surface of a vat of liquid photopolymer. Typically, usage of the SLA process has been limited to piece parts. We are interested in greatly expanding the application of SLA and other RP technologies by fabricating assemblies of parts as working mechanisms or static, complex structures which we call "live or smart" models. To accomplish this, we are investigating methods for building around embedded components, where these components are motors, printed circuit boards, metal bushings, etc. In this paper, we present example prototypes to illustrate the power of building around inserts (embedded components). We report on our problem formulation and a solution approach in the form of a procedure for building around inserts. We believe that our procedure and results lend insight into promising new applications of SLA technology, as well as novel methods of implementing additional functionality into SLA and other RP technologies.
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