• Proceedings of the Korean Operations and Management Science Society Conference
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• 2000.04a
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• pp.724-727
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• 2000

Rapid Prototyping(RP)이란 3차원 솔리드 모델을 단면화한 뒤 하나씩 적층하는 가공방식을 총칭한다. 이때 단면화하는 방법에 따라서 uniform, adaptive slicing으로 나뉘며, 입력 모델에 따라서 direct slicing과 STL을 이용한 방식으로 나뉜다. 적층 방법에 따라서는 연속된 2D 윤곽을 기반으로 적층하는 vertical layer 방식과 인접한 두 개의 2D 윤곽들을 연결하며 만들어진 3D layer를 기반으로 가공하는 sloping layer방식으로 나뉠 수 있다. 현재 상용 RP 시스템들에서는 거의 모든 경우 vertical layer 방식이 채택되어 사용되고 있다. RP와 절삭 공정, 예를 들면 CNC 밀링의 장점을 효율적으로 결합하기 위해서는 임의의 복잡한 형상을 갖는 솔리드 모델을 정밀도에 제한이 없이 제조할 수 있어야 한다. 그러나 절삭 공정은 특별한 전문적 지식들을 필요로 한다 또한 상용 RP에서 사용하는 순차적인 적층 작업으로는 가공할 수 없는 형상들이 많다. 대표적인 것으로 지지대를 필요로 하는 형상들이 있다. 이러한 형상들을 지원하기 위해서는 복잡한 3D 형상을 절삭 가능한 형식으로 분할하는 것과 적층 가능한 순서대로 공정 계획하는 것이 필요하게 된다. 본 연구에서는 SDM에서 제시된 3D 분할 방법이 솔리드 모델을 기반으로 전개되어 STL file과 같은 삼각다면체 형식으로 근사화된 모델에 적용하기 어렵다는데 착안하여 STL file에서 읽어들인 삼각 다면체 모델을 가공 가능한 3D 형상으로 분할하는 알고리즘을 제시하고자 한다.

• Maxillofacial Plastic and Reconstructive Surgery
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• v.23 no.4
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• pp.366-375
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• 2001

Bone shaving for surgical correction is general method in facial asymmetrical patient with fibrous dysplasia. Therefore, decision of bone shaving amount on the preoperative planning is very difficult for improvement of ideal occlusal relationship and harmonious face. Preoperative planning of facial asymmetry with fibrous dysplasia is generally confirmed by the simulation surgery based on evaluation of clinical examination, radiographic analysis and analysis of facial study model. However, the accurate postoperative results can not be predicted by this method. By using the computed tomography based RP(rapid prototyping) model, simulation of facial skeleton can be duplicated and 3-dimensional simmulation surgery can be perfomed. After fabrication of postoperative study model by preoperactive bone shaving, preoperative and postoperactive surgical index was made by omnivaccum and clear acrylic resin. Amount of bone shaving is confirmed by superimposition of surgical index at the operation. We performed the surgical correction of facial asymmetry patients with fibrous dysplasia using surgical index and prototyping model and obtained the favorable results.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.763-766
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• 2000

Rapid Prototyping(RP) techniques have their unique characteristics according to the working principles: stair-stepped surface of parts due to layer-by-layer stackin, low build speed caused by line-by-line solidification to build one layer, and additional post processing to improve surface roughness, so it is required very high cost to introduce and to maintain RP apparatus. The objective of this study is to develop software for automatic generation of unit shape part (USP) for a new RP process, Variable Lamination Manufacturing using linear hotwire cutting technique and expandable polystyrene foam sheet as part material (VLM-S). In order to examine the applicability of the developed software to VLM-S, USP's of general three-dimensional shapes, such as an auto-shift lever knob and a pyramid shape were generated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.262-265
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• 2002

Fused deposition modelling(FDM) is a rapid prototyping(RP) process that fabricates part layer by layer by deposition of molten thermoplastic material extrude from a nozzle. RP system has many benefit. One of the benefit would be the ability to experiment wiか physical objects of my complexity in a relatively short period of time. But it has a matter of surface roughness and geometric accuracy. We study on Influence of angle of tangent line and area error on sphere surface roughness at fused deposition.

• Korean Journal of Computational Design and Engineering
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• v.7 no.2
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• pp.96-101
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• 2002

Rapid Prototyping (RP) technology has been advanced to fabricate initial prototypes from various materials. Stratasys′ Fused Deposition Modeling (FDM) is one of the typical RP processes that provide functional prototypes of ABS plastic. In order to predict the behavior of final ABS parts, it is critical to understand the material properties of the raw FDM process material, and the effect that FDM build parameters have on the FDM part. In this paper, we seek to characterize the properties of ABS parts fabricated by the FDM 1650. Using the Design of Experiment (DOE) approach, the process parameters of FDM, such as raster orientation, air gap, bead width, color, and model temperature were examined. Tensile strengths of crisscross specimens, 〔45°/-45°〕, cross specimens, 〔0°/90°〕, and directionally fabricated tensile specimens (〔0°〕 and 〔90°〕) were measured and compared with the injection molded FDM-ABS P400 material. For the FDM parts made with a -0.003"air gap, the typical tensile strength ranged between 50 percent and 83 percent of the strength of injection molded ABS P400. From the experiments, a couple of build rules for designing FDM parts were obtained.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.136-144
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• 1997

Usually triangular patches are used to transfer geometric shape in Rapid Prototyping CAM system. STL, a list of triangles, is de facto standard in RP industry. Because STL does not have topological infoma- tion, it can cause errornous results. So STL should be verified before using. After adding support structures to anchor the part to the platform and to prevent sagging or distortion, slicing and layer by layer manufactur- ing process are done. But triangular patch is surface model and cannot provide sufficient information on geometry in the above processes. So, geometric modeling is necessary in verifying STL, adding support structures and slicing. It is natural that triangle based modeling is the best when tringular patches are used as input. Considering support structures, solid and faces coexist in RP process. Therefore non-manifold modeler is required. In this study, triangle based non-manifold geometric modeling is proposed for RP sys- tem consistent with STL input.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.05a
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• pp.536-539
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• 2002

The reverse engineering (RE) technology can quickly generate 3D point cloud data of an object by capturing the surface of a model using a 3D scanner. In the rapid prototyping (RP) technology, prototypes are rapidly produced from 3D CAD models in a layer-by-layer additive basis. In this paper, a physical human head shape is duplicated using a new RP process, the Transfer-type Variable Lamination Manufacturing process using expandable polystyrene foam sheet (VLM-ST), after the point cloud data of a human head shape measured from 3D SNX scanner are converted to STL file. From the duplicated human head shape, it has been shown that the VLM-ST process in connection with the 3D scanner is a fast and efficient process in that shapes with free surface, such as the human head shape, can be duplicated with ease. Considering the measurement time and the shape duplication time, the use of 3D SNX scanner and the VLM-ST process is expected to reduce the lead-time fur the development of new products in comparison with the other existing RE-RP connected manufacturing systems.

• Journal of the Korean Society for Precision Engineering
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• v.20 no.4
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• pp.165-173
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• 2003

As the cycling time of new products have become more and more short in recent years, the demand for lowering the cost and reducing the production time becomes stronger. In order for the demand, the rapid prototyping and rapid tooling technology have been used. It has been widely known that RP technology has advantages with fabricating 3-D object having a complicated geometric shape. RP products, however, have a limitation with applying to the real die and mold because soft materials such as resin, paper and wax has been mostly used in RP technology. So in this paper, the RP products have been copied to semi-metallic soft tools using the mixture of metal fillers and epoxy resin. In order to evaluate the effect of the fillers on the characteristics of semi-metallic soft tools, three fillers are used including commercial aluminum powder, cast iron powder recycled by machining chips, and aluminum short fiber made by self-excited vibration technique. Besides, in the case of aluminum powder, the change of characteristics of semi-metallic soft tools is also tested according to the volume fraction of the powder.

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

• Proceedings of the KSME Conference
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• 2001.06c
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• pp.158-163
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• 2001

This study is the selection of optimum forming condition for RP system using ADS. Program using ADS reduces the required time for feedback between design and manufacturing of workpiece. When we produce rapid prototype using RP system, we investigate the relationship between Facetres in system variable number of AutoCAD and roundness of rapid prototype, and we will find optimum forming condition in RP system.