Desktop Factory

Desktop Factory is a start up company that tried to launch the first low-cost rapid prototyping appliance, the Desktop Factory 125ci 3-dimensional printer. The device, anticipated for release in 2009 (previously 2008 but delayed) was to use a halogen lamp rather than costly selective laser sintering to print objects from a mixture of nylon, aluminum and glass. While selective laser sintering devices use the same mixture of materials, printers of that type cost well over $100,000 , while the Desktop Factory aimed for a price of US$5,000
The machine prints a solid object layer by layer, 0.01 inches (0.25 millimeters) at a time. A layer of granular substrate is deposited, then melted and fixed by a halogen lamp. Only the nylon component of the substrate melts; the aluminum and glass (silica) exist as strengthening agents to enhance stability of the finished product. The maximum build volume of the initial product is 5 x 5 x 5 inches (127 x 127 x 127mm).
The estimated cost of an object printed by the machine is roughly $1 per cubic inch. A rubber duck used as a demonstration object cost approximately $5 to produce and took between five and six hours to print.
While the printer can produce complex geometric shapes, some finishing work is required in some cases. If an overhang exists on the designed shape, supporting material deposited by the printer must be removed following the printing process. The machine cannot currently print in color; all objects are created with the same gray substrate material, but can be painted. The printed material is rather strong, and can be drilled, tapped, or machined following printing.
In August 2009, Desktop Factory canceled reservations, refunded the deposits and announced the sale of their business due to lack of cash flow. On August 31, 2009, the core assets and IP of Desktop Factory were sold to 3D Systems.
Other initiatives for low cost 3D printers, such as the open source RepRap project and Fab@Home, might one day deliver a desktop 3D printer. Other commercial initiative such as CreateItReal are also targeting the launch of a sub $5000 3D printer by the end of 2009.

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