Abstract: A method for constructing a structural foam part. The method comprises three steps. Step one calls for utilizing a rapid prototyping process to create a polymer mold. Step two requires filling the polymer mold with a material. The last step calls for heating the polymer mold and the material to heat set the material and to remove the polymer mold thereby forming the structural foam part. More specifically, the rapid prototyping process may be stereolithography, and the structural foam part may have a varying density such that different mechanical properties exist in different sections of the structural foam part.

Abstract: In accordance with the present invention, there is provided a method of producing a formblock utilizing stereolithography for producing a sheet metal part. A computer formblock model is first designed. Stereolithographic techniques are utilized to create the formblock using the computer formblock model. A part may be formed from a sheet metal blank using the formblock, whereby force is applied to the sheet metal blank to bend it about the formblock.

Abstract: In accordance with the present invention, there is provided a method of producing a sheet metal part utilizing stereolithography. A computer formblock model is first designed. Stereolithographic techniques are utilized to create a formblock using the computer formblock model. A part is formed from a sheet metal blank using the formblock, whereby force is applied to the sheet metal blank to bend it about the formblock.