Laser sintering technology has taken a quantum leap forward in speed with the latest research from the HoW Research Centre, based in the Wye Valley.
Traditional laser sintering creates components in a slow laminating process with powder sintered, layer by layer, to build up a 3D component, a process taking several hours. The new innovative optically optimised laser sintering process can make objects instantly - in the blink of an eye.
It seems like science fiction and, ironically, some of the initial research was a by-product of special effects digital modelling and image capture breakthroughs made as a result of the film industry's current trend for 3D movies.
While working with some 3D holographic laser capture equipment Steve Nicol, a freelance 3D effects specialist, had a flash of inspiration to reverse part of the process and contacted HoW.
In simple terms, the new process creates a high intensity laser hologram in a chamber flooded with microscopic plastic dust particles floating in the air. A high intensity laser burst, lasting half a millisecond, sinters the dust instantly in the shape of the hologram to create a solid 3D object.
Dr Simon Blake (pictured), HoW research director, comments: "The technology is at the early stages of development and a long way from being commercially available. So far we have only created some small toy models using 3D data from Steve's CGI database, such as the spaceship from Star Trek."
The research has already attracted £5 million investment from both Japan-based Weyland-Yutani and FLAG, part of US-based Knight Industries.
"My research team," continued Dr Blake, "is excited at the possibility that in a few years we could be seeing this technology revolutionise manufacturing by producing complex metal and plastic components instantly (in milliseconds) and, within the decade, homes could have their own 'Star Trek'-like replicators."
A detailed international technology patent is due to be accepted in April: For Optically Optimised Laser Sintering under reference code - April: F.O.O.L.S.
