• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.1085-1088
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• 2001

The process of styrofoam pattern that has been used for material of press die pattern depends chiefly on handwork. Laser manufacturing system developed to increase precision and efficiency of process that is also able to convert the design easily. Applying the RP(rapid prototyping) concept reversely, the unnecessary part of section is vapored away by heat source of laser beam after converting 3-D CAD model into cross-sectional shape information. Laser beam is line-scanned in plane specimens to measure the depth and width of cut, surface roughness, cross-sectional shape as converting laser power, scanning speed, cutting gas pressure. With these basic data, plane surface, inclined surface, hole, outer contour trimming process is experimented and optimum condition are obtained. In plane and inclined surface experiments, 15W laser power and 50mm/s scanning speed make superior processing property and 30W, 10mm/s make processing efficiency increase in trimming process. With these results, simple patterns were manufactured and the possibility of applying laser manufacturing system to styrofoam pattern was convinced.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.45-48
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• 2001

SL(Stereolithogrphy) part is made by piling up thin layers which causes the stair stepping effect at the surface of SL parts. This effect causes excessive surface roughness and requires additional postprocess finishing such as abrasive basting which is detrimental to part geometry and time consuming. Hence paraffin coating and grinding postprocess is proposed to raise the surface quality of SL part. The paraffin which has suitable properties for the proposed postprocess is coated all over the part surface. By grinding the thin layer of coated on the SL part only, the surface roughness can be improved without any damage on the part. From the experimental result, It is verified as very practical for die casting with silicon rubber mold.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.330-333
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• 2000

Dimensional accuracy and surface quality are very important in rapid prototyping especially when the models are used for the production of tools. This paper presents the development of benchmarking part to investigate dimensional accuracy and surface finish. A new test part is designed to perform benchmarking of major rapid prototyping processes such as selective laser sintering, laminated object manufacturing, stereolithography apparatus, and fused deposition modeling. The test part design includes basic manufacturing features such as holes, walls, squares, cylinder and etc. In addition, the small features are included in order to evaluate the fine details that can be manufactured by a specific RP process. The CMM program that automatically measures different features in the test part is also developed. The evaluation of accuracy as well as surface roughness are discussed for major rapid prototyping processes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.105-108
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• 1997

To reduce design period, demands for rapid prototyping system is increasing. Among the rapid prototyping system, as a concept modeler, 3D Printer appears before the footlights. In spite of short production time and convenience, 3D Printer causes post processing problem. And that is too slow to adapt to the demand of workshop. In this research, we developed a system for reducing build time and roughness using splitting operation. Also, propose BFS(B-rep For STL) data structure to maintain model data, split STL model and implement Euler Operation for input and output.

• Journal of Welding and Joining
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• v.23 no.2
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• pp.47-51
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• 2005

Rapid Prototyping (RP) technology has helped successfully to reduce time and costs since first emerged in 1986. Recently, RP using functional materials like as metal have been researched. However RP using molten metal and brazing material have been struggling to resolve several drawbacks, such as dimensional inaccuracy, poor surface finish and post finishing because occurring shrinkage and warpage at cooling. So, the purpose of this study is to develop a new RP technique using sheet metal and projection welding for reducing several drawbacks in occurring RP using molten metal. And optimum process variables were determined using desist of experiment(DOE).

• Journal of the Korean Society for Precision Engineering
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• v.17 no.8
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• pp.46-52
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• 2000

3D Welding and Milling is a solid freeform fabrication process which is based on the combination of welding as additive and conventional milling as subtractive technique. This hybrid approach enables direct building of metallic parts with high accuracy and surface finish. Although it needs further improvements it shows an application potential in rapid tooling of injection mold inserts as the investigation results show. To optimize the process for higher surface quality and accuracy effectively Taguchi method is applied to the experimental investigation. in this way relationships between process parameters and final product qualities such as tensile strength and surface hardness are found with minimal efforts.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.10
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• pp.56-62
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• 2000

A fast and precise technique to make 3-dimensional object which is called direct metal shaping process is processed. It is very useful technique in design and inspection. Using this developed system, a solid object is made. In experiment, test parts are built by varying three factors, laser power, scan path, scan speed. This process used device, which is different from the widely used in rapid prototyping in that powder feeding device is used. Spraying powder directly at the focused laser beam and then three dimensional object is made by the deposit of melted metal powder. The optimum scanning path is found to be zigzag path, which had little thermal affection on base metal. As a result of these experiments, it was found that optimum scanning speed is 15mm/sec laser power is 50W. This constructed 3-dimensional object could be used in mold manufacturing directly.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.02a
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• pp.180-186
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• 2002

The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce Al, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared as the die-castings and the thin walls of the plaster mold cavity may not be completely fillet Because of lower mechanical properties induced by the large grain structure and incomplete Idling, the conventional plaster casting process is not suitable for the trial die-casting Process. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have runner system, are made using these patterns. Imparted pressurized vibration to molten metal has made grain structure of castings much finer and improved fluidity of the molten metal enough to obtain complete filling at thin walls which can not be filled in the conventional plaster casting process.

• Journal of the Korean Society for Precision Engineering
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• v.27 no.6
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• pp.98-104
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• 2010

Rapid Prototypes with internally colored objects are convenient by visualizing. A rapid prototyping method has been developed to fabricate mono-colored or multi-colored objects. In this work, a new process was proposed that can fabricate internally visible colored 3D objects in stereolithography parts. The process consists of projection stereolithography process using transparent photocurable resin for outer shapes and molten ink deposition process using molten solid ink for internal shapes. In molten ink deposition process, molten solid ink could be deposited uniformly in a designed pattern. To make molten solid ink uniform over a designed region, parametric study through a patterning solid ink was performed. By laminating resin and solid ink in sequence, the process can make colored 3D objects in StereoLithography(SL) parts. The practicality and effectiveness of the proposed process were verified through fabrication of colored basic 3D objects in SL parts.

• Journal of the Korean Society for Precision Engineering
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• v.21 no.1
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• pp.149-158
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• 2004

In most RP processes, the inherent stair-stepped surfaces and shrinkage-induced warping of the parts require post processing such as surface finishing. To minimize such defects, VLH-ST, a newly developed RP process, employs a 3.9-mm thick expandable polystyrene (EPS) foam sheet and a hot wire to contour it to have slant linear-interpolated sides. The use of relatively thick sheets for layers, however, limits the process capability of constructing fine details, especially smaller than the layer thickness. This study is focused on the development of a post processing method fo fine details of VLM-ST parts. The post-processing tool was designed to meet all the requirements for the desirable post processing. It adopted a hot wire as a means of melting the EPS foam sheet. Various basic experiments on the post processing were carried out to obtain the optimal process conditions. The dominant process parameters such as the radiated heat input, the tool speed, and the gap between the tool tip and the foam sheet (tool height) were considered in the experiments. The effectiveness of the developed post-processing method fo forming or engraving fine details on the VLM-ST parts has been thus demonstrated. The experiments on engraving several sets of letters, such as CANESM, 인간, and 한국과학기술원, on the EPS foam sheet were carried out. In addition, a flowery shape was engraved on a three-dimensionally curved surface of a pottery-shape VLM-ST part.