Rapid Fabrication of Large-Sized Solid Shape using 3D Scanner and Variable Lamination Manufacturing : Case Study of Mount Rushmore Memorial

This paper describes the method to rapidly fabricate the large-sized physical model with the envelope model size of more than 600 mm${\times}$ 600 mm${\times}$ 600 mm using two type semi-automatic VLM-ST processes in connection with the reverse engineering technology. The fabrication procedure of the large-sized solid shape is as follows: (1) Generation of STL data from 3D scan data using 3D scanner, (2) generation of shell-type STL data by Boolean operation, (3) division of shell-type STL data into several pieces by solid splitting, (4) generation of USL data for each piece with VLM-Slicer, (5) fabrication of each piece by cutting and stacking according to USL data using VLM-ST apparatus, (6) completion of a shell-type prototype by zigzag stacking and assembly for each piece, (7) completion of a 3D solid shape by foam backing, (8) surface finish of a completed 3D solid shape by coating and sanding. In order to examine the applicability of the proposed method, the miniature of the Mount Rushmore Memorial has been fabricated. The envelope model size of the miniature of the Mount Rushmore Memorial is 1,453 mm${\times}$ 760 mm${\times}$ 853 mm in size. From the result of the fabricated miniature of the Mount Rushmore Memorial, it has been shown that the method to fabricate the large object using two type semi-automatic VLM-ST processes in connection with the reverse engineering technology are very fast and efficient.

삼차원 스캐너와 가변 적층 쾌속조형공정을 이용한 대형 입체 형상의 쾌속 제작 : 러쉬모어산 기념물 제작 사례