• Journal of Welding and Joining
• /
• v.32 no.4
• /
• pp.10-14
• /
• 2014

Laser aided Direct Metal Tooling(DMT) process is a kind of Additive Manufacturing processes (or 3D-Printing processes), which is developed for using various commercial steel powders such as P20, P21, SUS420, H13, D2 and other non-ferrous metal powders, aluminum alloys, titanium alloys, copper alloys and so on. The DMT process is a versatile process which can be applied to various fields like the mold industry, the medical industry, and the defense industry. Among of them, the application of DMT process to the mold industry is one of the most attractive and practical applications since the conformal cooling channel core of injection molds can be fabricated at the slightly expensive cost by using the hybrid fabrication method of DMT technology compared to the part fabricated with the machining technology. The main objectives of this study are to provide various characteristics of the parts made by DMT process compared to the same parts machined from bulk materials and prove the performance of the injection mold equipped with the conformal cooling channel core which is fabricated by the hybrid method of DMT process.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2006.05a
• /
• pp.199-200
• /
• 2006

It will not be an exaggeration to say that one of the most important features of RT (Rapid Tooling) technology is to easy manufacturing complex shape of cooling channel in injection mold. That is, RT technology is hardly influenced complex shape of tool, Therefore, mold designer can optimize the position and shape of cooling channel whatever they want. In this study, we optimized cooling channel through CAE analysis to solve the problem; prototype-connector-mold applied conventional cooling channel, locally warped by internal stress: The effect of three-dimensional cooling channel was supported by simulation result. But it is impossible to produce injection mold applied three-dimensional cooling channel through machining operation. Therefore, we produced the prototype-connector-mold with three-dimensional cooling channel using Direct Metal Laser Sintering (DMLS) process, and get good-quality prototype-connector without warpage.

• Journal of the Korean Society for Precision Engineering
• /
• v.31 no.12
• /
• pp.1093-1100
• /
• 2014

The goal of this paper is to investigate preliminary the applicability of 3D printing technologies for the development of the hot bulk forming process and die. 3D printing technology based on the plastic material was applied to the preform design of the hot forging process. Plastic hot forging dies were fabricated by Polyjet process for the physical simulation of the workpiece deformation. The feasibility of application of Laser-aided Direct Metal Rapid Tooling (DMT) process to the fabrication of the hot bulk metal forming die was investigated. The SKD61 hot-working tool steel was deposited on the heat treated SKD61 using the DMT process. Fundamental characteristics of SKD 61 hot-working tool steel deposited specimen were examined via hardness and wear experiments as well as the observation of the morphology. Using the results of the examination of fundamental characteristics, the applicability of the DMT process to manufacture hot bulk forming die was discussed.

• Proceedings of the KSME Conference
• /
• 2007.05a
• /
• pp.1243-1248
• /
• 2007

In recent, rapid manufacturing (RM) technology is widely used to develop an injection mould with a high performance. The objective of this paper is to develop the injection mould with a high productivity using a hybrid RM technology combining Laser-aided Direct Metal Tooling process with a machining process. The geometry decomposition has been utilized to improve the speed of the manufacturing for the mould. Mould with conformal cooling channels has been designed to improve cooling characteristics. Several experiments have been carried out to evaluate characteristics of the mould manufactured from the hybrid RM technology. In addition, injection molding tests have been performed to examine the performance of the manufactured mould. The results of the injection molding tests have been shown that a cooling time and the injection time of the designed mould are reduced to one-fifth and one-second that of the mould with convention cooling channels.

• Journal of Welding and Joining
• /
• v.33 no.6
• /
• pp.1-5
• /
• 2015

Additive Manufacturing defines the fabrication of objects by successive consolidation of materials, layer by layer, according to a three-dimensional design. The numerous technologies available today were recently standardized into seven categories based on the general method. Each technology has its own set of advantages and limitations. Though it very much depends on the field of application, major assets of additive manufacturing compared to conventional processing routes are the ability to readily offer complexity (in terms of intricate shape and customization) and significant reduction of waste. On the other hand, additive manufacturing often suffers of relatively low production rates. Anyhow, additive manufacturing technologies is being given outstanding attention. In particular, metal additive manufacturing emerges as of great significance in industries like aerospace, automotive and tooling. The trend progresses toward full production of high value finished products.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.17 no.4
• /
• pp.64-69
• /
• 2018

This paper investigates the compressive deformation behavior of direct metal tooling (DMT), processing titanium alloy (Ti-6Al-4V) parts under high strain loading conditions. Split Hopkinson Pressure Bar (SHPB) experiments were performed to determine the flow stress and the coefficients of the Johnson-Cook model. This model is described as a function of strain, strain rate, and temperature. SHPB experiments were performed to characterize the deformation behavior of specimens made with 3D printers, using Ti-6Al-4V material under high temperature and dynamic loading.

• Design & Manufacturing
• /
• v.1 no.1
• /
• pp.27-32
• /
• 2007

In the optical application demand for high quality lens is increasing. Plastics lenses are demanded more than glass lenses for large size lenses as well as micro-size lenses. It is difficult to apply typical straight cooling channels of injection mold to lens molding due to its non-uniform temperature distribution. In this study, we manufactured molds for plastic lenses with the conventional cooling channels and conformal cooling channels produced by the DMLS process. We evaluated cooling performance for the 2 molds by injection molding experiment. Also, uniformity of the temperature distribution was tested by infrared camera and temperature monitoring. We confirmed that the cooling performance and temperature uniformity with the conformal cooling channels is much improved from the ones with the conventional. The cooling time with the conformal cooling channels was reduced 30% compared with the conventional cooling channels.

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.3
• /
• pp.88-94
• /
• 2002

Recently, the life cycle and the lead-time of a product are to be shortened in order to satisfy consumer's demand. It is thus important to reduce the time and cost in manufacturing trial products. Several technique have been developed and successfully commercialized in the market of RPM(Rapid Prototyping and Manufacturing). However, most commercial systems currently use resins or waxes as the raw materials. So, the limited mechanical strength for functional testing is regarded as an obstacle towards broader application of rapid prototyping techniques. To overcome these problems, high-speed machining technology is being investigated worldwide for rapid manufacturing and even for direct rapid tooling application. In this paper, some fundamental experiments and analyses are carried out to obtain the filling time, materials, method, and process parameters for HisRP(High-Speed RP) process. HisRP is a new RP process that is combined high-speed machining with automatic filling. In filling process, Bi58-Sn alloy is chosen as filling material because of the properties of low-melting point, low coefficient of thermal expansion and no harm to environment. Also the use of filling wire it if advantage since it needs simple and flexible mechanism. Then the rapid product, for example a skull, is manufactured for aluminum material by HisRP process with an automatic set-up device thor 4-faces machining.

• The Journal of Korean Academy of Prosthodontics
• /
• v.56 no.2
• /
• pp.173-178
• /
• 2018

The direct metal laser sintering (DMLS) technique would be promising for the full-arch implant-supported restorations due to reduced cost and manufacturing time without potential human errors and casting defects. The aims of this case report were to describe the successful outcome of an implant-supported fixed dental prosthesis in the edentulous maxilla by using the DMLS technology and computer-aided design and computer-aided manufacturing (CAD/CAM) monolithic zirconia crowns, and to describe its clinical implications. A healthy 51-year-old Korean woman visited Seoul National University Dental Hospital and she was in need of a rehabilitation of her entire maxilla due to severe tooth mobility. In this case, all maxillary teeth were extracted and an implant-supported fixed dental prosthesis was fabricated that involved a cobalt-chromium (Co-Cr) framework with the DMLS technique and CAD/CAM monolithic zirconia crowns. Six months after delivery, no distinct mechanical and biological complications were detected and the prosthesis exhibited satisfactory esthetics and function. In this case report, with the DMLS system, the three-dimensional printed prosthesis was created without additional manual tooling and thus, reliable accuracy and passive fit were obtained.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2001.04a
• /
• pp.28-31
• /
• 2001

Recently, in order to satisfy the consumer's demand the life cycle and the lead-time of a product is to be shortened. It is thus important to reduce the time and cost in manufacturing trial products. Several techniques have been developed and successfully commercialized in the market RPM(Rapid Prototyping and Manufacturing). However, most commercial systems currently use resins or waxes as the raw materials. So, the limited mechanical strength for functional testing is regarded as an obstacle towards broader application of rapid prototyping techniques. To overcome this problems, high-speed machining technology is being investigated worldwide for rapid manufacturing and even for direct rapid tooling application. In this paper, some fundamental experiments and analyses are carried out to obtain the filling time, materials, method, and process parameters for HisRP process. HisRP is a combination process using high-speed machining technology with automatic filling. In filling process, Bi58-Sn alloy is chosen because of the properties of los-melting point, low coefficient of thermal expansion and enviromental friendship. Also the use of filling wire is of advantage in term of simple and flexible mechanism. Then the rapid manufacturing product, for example a skull, is machined for aluminum material by HisRP process with an automatic set-up device of 4-faces machining.