Laser Engineered Net Shaping

Sandia National Laboratories has developed a new technology to fabricate three-dimensional metallic components directly from CAD solid models. This process, called Laser Engineered Net ShapingT (LENS®), exhibits enormous potential to revolutionize the way in which metal parts, such as complex prototypes, tooling, and small-lot production items, are produced.

http://www.sandia.gov/mst/technologies/net-shaping.html

Fused Deposition Modeling

Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. The technology was developed by S. Scott Crump in the late 1980s and was commercialized in 1990.

FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to anextrusion nozzle which can turn on and off the flow. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided manufacturing (CAM) software package. The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle.

Several materials are available with different trade-offs between strength and temperature properties. As well as acrylonitrile butadiene styrene (ABS) polymer, polycarbonates, polycaprolactone, polyphenylsulfones and waxes. A "water-soluble" material can be used for making temporary supports while manufacturing is in progress, this soluble support material is quickly dissolved with specialized mechanical agitation equipment utilizing a precisely heatedsodium hydroxide solution.

http://en.wikipedia.org/wiki/Fused_deposition_modeling