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Conceptual information on the Sapient can be found on this page: Sapient.

In November 2008 I begun the lengthy process of creating 3d printed models of the current marker version (version 1.5.5c.6.6c.10). This was done for a number of reasons, primarilly to highlight some of the intricate internal features and display how they will be machined in real life.

Current Pictures: (last updated Dec 19)
I can't show pictures of some internals quite yet, and the same goes for much of the internal design besides. However I will add what pictures I can post to this page as they become available, and eventually a full marker.

Eye covers
The printing process is lengthy, so I don't have a complete marker available to show at this point.

What is rapid prototyping?
The prototype shown here is an example of a 3d printed model. This is a process by which each layer of the part is printed out in a polymer resin, afterward the unused material is washed away, revealing the printed component. There are several other types of rapid prototyping, but in my experience this is the easiest for a number of reasons. Other methods include multi-axis milling machines which are unnecessarially complex and limited, stereolithography which involves etching each layer of a part from photoreactive liquid, or laser sintering which is a method using powdered metal. Laser-sintered models are extremely expensive to produce, as well as being heavy and requiring design changes. Stereolithograph models are inexpensive, but require a lot of design changes too, as well as a lengthy cleanup process once the model is made. 3d printing is easy and inexpensive in comparison.
However, this doesn't mean all you need do is snap your fingers to have a model produced. 3d printers and the CAD technology driving them have limitations, so some changes are needed before a part can be printed. 3d printers can only print wireframe models which is a different type of CAD file than is typically used in mechanical design (called solid models) and the conversion process can be very lengthy depending on the complexity of the part. The most complex portion of this prototype assembly was the frame, standing at over 75 thousand polygons, which took several hours to successfully convert.

Depending on the material and design, 3d printed models can hold air pressure, can be tapped for threads, can be made into flexible hinges, etc. The material I used here is an opaque and pale flexible ABS polymer with reasonable strength, but not strong enough to hold pressure. Higher-strength materials have the drawback of using looser tolerances, so the detail wouldn't be as great, and the parts would have to be modified to fit a new sized tolerance window (a very aggravating process).
These models were created on a Dimension SST Elite 3d printer.

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