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A shrinking defense budget has forced severe competition within the Aerospace community. Systems that were usually sole source to one company are now up for grabs. To meet the competitive marketplace Hughes is examining all avenues and approaches to provide the same high quality systems at a much lower price. Rapid prototyping using Stereolithography provides a technology that is applicable to the manufacturing of many parts Hughes provides to the defense industry. Over the past two years a documented savings in excess of $5 million dollars was realized in the metal castings area alone. It is estimated that for 1993 similar savings will be realized for present production contracts. A complete change in the philosophy on how Hughes approaches system production was necessary and is being accomplished through rapid prototyping using stereolithography.

The pressing demand for American companies to be World Class producers has brought about a change in philosophy on how they do business. One major change is the approach to manufacturing. The change requires the adoption of tools and techniques that provide form, fit and function in ways that shorten production lead time with a reduction in cost. Rapid prototyping (RP) technologies using Solid Free Form Fabrication (SFF) offers industry the opportunity to reduce cost, shorten schedules and give Concurrent Engineering a tool that will provide an interface with manufacturing. From the design review to manufacturing SFF parts can be used to smooth the transition from concept into production with over 50% cost reductions while cutting 50% off the cycle time. The cost and time for the modifications associated with adopting these new methods and training personnel presents a major challenge to manufacturing companies.