• Journal of the Korean Society of Manufacturing Process Engineers
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• v.6 no.4
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• pp.65-70
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• 2007

In this study, we analyzed about that after design form manufacture master pattern in Rapid Prototyping-RP through design program, processes to manufacture prototype using Vacuum Casting. In Rapid Prototyping-RP, there is an en-or by shrinkage of resin and, in Vacuum Casting, there is an error by shrinkage of silicon. To select condition which shrinkage become the minimum of each process, manufactured prototype after using Full Factorial Design of Design of Experiments, We could confirm shrinkage using reverse engineering and that result came into effect ANOVA 2-way. We applied errors of each process to master pattern, and then presented the method to improve flood control precision of prototype of Vacuum Casting.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.757-760
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• 2005

The technology of rapid prototyping (RP) is used for design verification, function test and fabrication of prototype. The current issues in RP are improvement in accuracy and application of various materials. In this paper, a hybrid rapid prototyping system is introduced which can fabricate nano composites using various materials. This hybrid system adopts RP and machining process, so material deposition and removal is performed at the same time in a single station. As examples, micro gears and a composite scaffold were fabricated using photo cured polymer with nano powders such as carbon black and hydroxyapatite. From the micro gear samples the hybrid RP technology showed higher precision than those made by casting or deposition process.

• Journal of Industrial Technology
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• v.21 no.B
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• pp.281-286
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• 2001

In this study, product design and prototype manufacturing of a plastic water-pump pulley has been tried. The designed model is supposed to be made of 33 % glass reinforced resin of which the tensile strength is 180 MPa, and has 24 ribs on each side to increase its structural strength. Structural analysis under a static load of 300 kgf acting on both edges of the belt has been carried out using a commercial finite element code, MARC. The analysis result showed the maximum effective stress near a rib of designed model would be at most 35 MPa (less than 20% of the tensile strength), therefore, the plastic product would be sufficiently safe under that loading condition. On the basis of the structural analysis, a prototype of the designed model has been manufactured by using the fused deposition modelling (FDM) method which is one of the rapid prototyping (RP) methods, using ABS resin and support materials. The CAD data exported to the RP system in STL format was prepared by a commercial solid modeling software, SolidWorks. It has been proved that the plastic pulley can successfully replace the existing flow-formed steel product.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.2 no.2
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• pp.14-21
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• 2003

Rapid prototyping(RP) has been used for design verification and proto sample or mold manufacturing. Many RP systems have been introduced into the market during the past 15 years. However, until now, the systems have used mainly for external physical models (mono function), and have the basic but critical limitation of one material on one stage (mono material). To overcome the limitations of mono-material and mono-function of conventional. RP systems, the concept of Functional Phototype Development (FPD) is newly proposed in this paper FPD provides the necessary prototype functions such as mechanical, optical, chemical and electrical properties in order to meet the broad requirements of the industry. The paper illustrates the representative achievements of electronic components such as the multi-layer printed circuit board(MLB). Experimental results demonstrate that FPD has great potential applied to broad industrial uses and that It Will be a powerful tool in the neat future.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.3
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• pp.146-153
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• 2012

RP system which is widely used to reduce the time of product development is to resolve the problem of cutting work. It is a method using laminated thin films to produce many forms. The RP equipment used for this experiment is FDM system. This can produce 3D model with using 3D CAD designed file within a relatively short time. Not only this, this system also through 3D file preparation, 3D product manufacture, removal support these 3 step operating process can easily produce goods, but product can be different from original design. This research has been conducted to minimize this error. To apply to the circular product made a circular specimen and measured several times with 3D scanner and find out average 99.622% of accuracy. This result is applied to RP system, and with this changed design produced a specimen, and found out the accuracy is increased to 99.958%. If this is applied to circular products, we can produce more precise products with less process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.416-421
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• 1997

This study presents a way to construct 3D shape in STL format from 2D slice data. Nowadays ahape reconstruct has been done in many ares, the application of this method is important especially in Reverse Engineering which reconstructs original shape from cross-section data. Current RP (Rapid Prototyping) is used not only for the verification of a part designed but also for the production and tooling in more effective way. In RP technology, data should be prepared in STL format. In this paper, the way to make 3D shape data in STL format form 2D slice data is described which can be used to reconstruct an original shape in RP equipment.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.767-770
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• 2000

A novel process is newly developed for building RP(Rapid Prototyping) parts using a sheet lamination technique. The build process of existing sheet lamination type RP machines consists of the following steps : feeding, lamination and cutting. In this process, the laminated part of an object is often scratched by a cutter or damaged by a laser beam due to the cutting operation preceded by lamination, In addition, decubing of the unused portion from the laminated block is difficult. In the new process, cutting operation is performed before lamination. The cutting operation takes place while a paper sheet is firmly attached on the plate using electrostatic force. Then liquid glue is applied to the calculated region of the given contour for lamination. The process aims to manufacture a $2k RP machine, what we call the Freeform Mater I, that can use A4 or latter-size used papers. A prototype machine that demonstrates the design concept is built and further research issues are discussed.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.6
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• pp.131-137
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• 2007

In metal casting process, it is very difficult to predict the form accuracy of cast part and reduce repeatability error. In this study, the variations of form accuracy were measured in the process of metal cast prototyping, where RP part is manufactured from CAD model in the first, and then, wax part is cast in the vacuum environment using the RP part as master model, and finally metal prototype is cast using ceramic mold and the wax part as pattern. To investigate the variations of form accuracy, the averages and standard deviations of error distribution of the parts measured by 3D scanner were compared. It was observed that the biggest shrinkage is generated during the extraction of wax part in the second step and the biggest deterioration of form accuracy is generated during the metal part casting in the last step.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.1 no.1
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• pp.23-28
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• 2002

Fused deposition modelling(FDM) is a rapid prototyping(RP) process that fabricates part layer by layer by deposition of molte thermoplastic material extrude from a nozzle. RP system has benefits. Benefit would be the ability to experiment with physical objects of any complexity m a relatively short period of time. But it has a matter of surface roughness and geometric accuracy. We study on Influence of tangent line angle on surface roughness at fused deposition.

• Korean Journal of Computational Design and Engineering
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• v.12 no.1
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• pp.50-57
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• 2007

In recent years, many robotics researches have been focused on developing human-friendly robots, that is, humanoid biped robots. The researches of humanoid robots include various areas such as hardware development, control of biped locomotion, artificial intelligence, human interaction, etc. The present work concerns the hardware development of a mid-size humanoid robot, BONOBO, focusing on rapid development of outer body parts with integrated application if CAD/CAM/CAE/RP. Most parts are three-dimensionally designed using 3D CAD, and effectively connected with CAE analyses using both kinematic simulation and structural analysis. In order to reduce lead time and investment cost for parts developments, Rapid Prototyping (RP) and CAM are selectively utilized for manufacturing body parts. These master parts are then replicated using the vacuum casting process, from which we can obtain plastic parts repeatedly. Through this integrated approach, the first prototype of BONOBO can be successfully developed with relatively low time and investment costs.