Solidica's Formation CT ultrasonic consolidation rapid prototyping tooling process pushes the boundaries of short run manufacturing excellence through its ability to produce lower-cost, highly-accurate 'soft' aluminium tooling in a single solution - for the production of parts via plastic injection moulding, investment casting, sand casting, lost foam, blow moulding and vacuum forming in a multitude of materials. And it can do this in super-quick timeframes.

• Formation is quicker and lower cost than alternative rapid prototyping/small batch processes - an average three-day turnaround and at 50 to 90 per cent lower cost.
• Formation eliminates the lengthy lead times and multiple operations associated with conventional tooling.
• Formation is easy to learn and use.
• Formation is the leading worldwide example of CNC rapid prototyping product.
• And with Formation, payback can be expected within 12 to 16 months of installation!

For example, a 10 inch by 12 inch by 3 inch wax injection tool can be produced in two days with Formation: it would take four to six weeks with most other rapid tooling systems. And compared with other systems, Formation tools are unrivalled for their accuracy, reliability, stability and re-usability.

In addition, Formation also offers designers unique possibilities in terms of next-generation products, within the one CNC machine enabling the creation of deep slots and complex forms, as well as features with narrow (0.065 inch) clearances. The possibilities are limited only by the designer's imagination.

Formation's ability to accommodate lightweight materials, produce components with embedded sensors and process metal matrix composites also makes the process relevant to every industry sector.

• Enhance product visualisation and testing by producing parts in end-use engineering materials and with the dimensional accuracy of machining
• Create deep slots and complex features
• Enable multiple material builds.