This paper describes a new approach for rapid prototyping based on volumetric
skeletonization. Contrary to most of the popular techniques for Solid Freeform
Fabrication (SSF) based on 2-1/2 -axis layering as planar slices, this approach suggests
the growth of the component along all three coordinate axes. While this approach offers
many advantages in terms of the elimination of the support structures for the reduction of
the staircase effects and the elimination of various post processes for the functional parts,
this approach also offers challenges towards process planning. For various complicated
shapes it may not be possible to generate the required shape using this approach;
however, a hybrid approach which also incorporates the deposition by layers, may offer
an optimum solution. Preliminary results are based on the successful laser-based
additive deposition along multiple g-vectors. The material properties and the problems of
possible porosities are still to be investigated. Advantages, process planning,
applications, experimental results, and the challenges of this new method are the subject
of this paper.This work was financially supported by THECB (Texas Higher Education Coordinating
Board) Grants 003613-0022-1999 and 003613-0016-2001, NSF (National Science
Foundation) Grants DMI-9732848 and DMI-9809198 and by the US Department of
Education Grant P200A80806-98.Mechanical Engineerin
