In addition to the issues above there are also significant problems with overhangs (and let's face it, no one likes cleaning support during post processing).
Sure we have ways of overcoming these issues by varying speed and process settings or in the extreme we go full crazy and "pre-slice" prints to eliminate overhangs completely.
When all else fails or we don't want to risk weak joints due to assembling individual parts into a final product, there is an additional (albeit much more expensive) option. The use of third party service bureaus can allow a designer to get strong parts (near injection molded strength with SLS), with great surface finish, and improved features.
Though there are many "pros" to using a service bureau there are also drawbacks. The model printed above was purchased through Shapeways so let's compare there service to a reprap:
This matrix shows Shapeways as the clear winner but upon closer inspection there are certainly some drawbacks to the Shapeways process. At $22.00/cu. in the resin cost will quickly overshadow the reprap initial investment, especially when doing iterative design. Also when designing a system, waiting two weeks for parts can be an eternity. With those reasons in mind I use reprap for primary development and Shapeways for special cases.
