Accurate exterior, fast interior layered manufacturing

Describes a new approach to fast layered manufacturing. The improvements in speed are achieved entirely through software control of existing commercial layered manufacturing equipment. In particular, the exterior regions of a part are built with thin layers to provide a precise, smooth exterior surface, while its interior regions are built with fast, thick layers to reduce overall build time. This approach has been implemented and tested with .STL CAD models on a Stratasys FDM 1600 rapid prototyping system, where a 50‐80 per cent reduction in build time of dense parts has been achieved without reducing surface quality or part integrity.