• Journal of Korea Foundry Society
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• v.20 no.5
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• pp.330-335
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• 2000

Functional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported. But a system which can build directly 3D parts of high performance functional material as metal park would get long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we translated the wax patterns to numerous metal tool prototypes by new investment casting process combined conventional investment casting with rapid prototyping & rapid tooling process. With this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P pare to metal part.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.25 no.8
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• pp.1021-1029
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• 2001

Rapid prototyping(RP) is a novel technology to create 3D products directly from CAD system. This study proposes a new RP method which uses the PZT ceramic plate to make a Drop-On-Demand liquid jet from the nozzle. The characteristic of drop formation in the new system is investigated both numerically and experimentally. The optimal drop for 3-D Printing can be obtained by the proper amplitude and frequency of the applied voltage. Also the process of the drop formation is analyzed using the pressure wave theory and verified by numerical simulation. First, the pressure wave generated by the deformation of the Piezo-plate at the nozzle is analyzed by solving the 2D axisymmetric wave equation via Finite Element Method. Finally, the drop formation process is simulated using a commercial software, FLOW 3D considering the pressure at the nozzle obtained by solving the wave equation as the boundary condition.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.824-828
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• 2000

As production cycle has become more and more shorter, the demand of rapid prototyping technology has increased largely. There are many methods for rapid prototyping technology, such as SLA. SLS, FDM. INK JET, LOM and so on. Of all methods, SLA has been most widely used for fabricating precision parts. But products manufactured by this method have limitation of single color and single material. So the principal purpose of this study is to overcome the limit of single color product. If the internal structure of manufactured product is visible with multi-color characteristic, it is possible to check easily the designed model with reality. In order to give multi-color characteristic to the product, photocurable resin mixed with pigment is used in this study. First, transparency of photocurable resin without pigment is evaluated, and then color characteristic and curing characteristic of the mixture is evaluated changing mixing ratio. Through the basic experiments, it becomes possible to fabricate multi-color 3D prototype without assembly.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2002.10a
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• pp.566-569
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• 2002

Rapid Prototyping is a prototyping technology that produces complicated parts directly form three dimensional CAD data with high efficiency, and has been extensively applied to various manufacturing processes. The aim of this research is to apply a 3D printer part as wax pattern in the investment casting process. The difference between conventional pattern wax and 3D printer wax is compared by experiments. The direct casting method is developed for ceramic-shell investment casting.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.11a
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• pp.841-845
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• 1996

Reverse engineering enables a fast creation of CAD model from an existing part without any technical drawing or digital data. This method of data acquisition is necessary in several industrial applications when the modification of an existing product design has to be performed and verified afterwards. In this paper, the surface of an existing ship propeller was measured by a tactile measuring system and the acquired point data of the surface were used for modeling of a solid model in CAD system. By using LOM and casting processes, an aluminum propeller for functional test was manufactured and then its accuracy was measured by a laser scanner and compared with the origin릴 CAD data. As the results show, the use of LOM as a rapid prototyping process and casting as a secondary process delivers a functional prototype propeller which can be used for test purposes.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.11-14
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• 2001

In all Rapid Prototyping(RP) processes, computer-aided design(CAD) solid model is sliced into thin layers of uniform, but not necessarily constant, thickness in the building direction. Each cross-sectional layer is successively deposited and, at the same time, bonded onto the previous layer, the stacked layers form a physical part of the model. The objective of this study is to develop a method for obtaining necessary coordinates$(x,\;y,\;\theta_x,\;\theta_y)$ to position linear hotwire of the cutting system in three-dimensional space for the Variable Lamination Manufacturing process (VLM-S), which utilizes expandable polystyrene foam sheet as part material. In order to examine the applicability of the developed method to VLM-S, various three-dimensional shapes, such as a spanner, a patterned columm, and a pyramid were made using data obtained from the method.

• Archives of design research
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• v.11 no.1
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• pp.237-244
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• 1998

Rapid prototyping is an efficient method to evaluate the usability of electric home appliances. However, the use of rapid prototyping method in usability tests has not been sufficiently validated. The purpose of this study was to validate computer-generated prototypes whether they can replace real products in usability tests. The control-display panel of a refrigerator was selected for this study. Sixteen female subjects participated in a between-subjects experiment: Eight subjects of them used the real refrigerator while others used the computer-generated prototype of the refrigerator. The difference between the refrigerator and the prototype was analyzed in terms of task failure rate, task completion time, and the number of buttons pressed for three typical tasks: clock setting, selecting an operation mode for refrigerating room, and selecting an rapid freezing mode. The results of a non-parametric statistical test showed that the prototype was not significantly different from the real refrigerator. Therefore, the rapid prototyping technique can be applied to the usability tests for the simple electric home appliances such as the refrigerator.

• Proceedings of the KIEE Conference
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• 2001.11c
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• pp.146-148
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• 2001

Pressures on the development of embedded control systems with higher performance and quality are increasing now, and the development of embedded control systems are still difficult. Hence, fast and reliable development method for implementing embedded control systems are necessary. Rapid prototyping is a powerful method to solve these problems. With the use of this method, the graphical representation of a model is converted to code that executes the model. In this paper, the development procedure of embedded control systems has been automated using this new technology. Also, an application example about lambda control in automotive engine has been carried out.

• Proceedings of the Korea Multimedia Society Conference
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• 2002.05d
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• pp.901-906
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• 2002

This paper is a research about method, that is used in Rapid Prototyping system, that inserts and extracts watermark in STL(standard transform language) that has a 3D geometrical model. The proposed algorithm inserts watermark in the vertex domain of STL facet without the distortion of 3D model. If we make use of a established algorithm for watermarking of STL, a watermark inserted to 3D model can be removed by simple attack that change order of facet. The proposed algorithm has robustness about these attack. Experiment results verify that the proposed algorithm, to encode and decode watermark in STL 3D geometrical model, doesn't distort a 3D model at all. And it shows that the proposed algorithm is available.

• Archives of Craniofacial Surgery
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• v.13 no.2
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• pp.125-129
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• 2012

Purpose: Methylmethacrylate is the most commonly used alloplastic material in cranioplasty. However during the polymerization of methylmethacrylate, a significant exothermic reaction takes place. This reaction may result in thermal injury to the brain tissue and other soft tissues. Also it is difficult to make three-dimensional methylmethacrylate implant that is perfectly matched to the defect during the operation time. We report on the molding technique of methylmethacrylate implant using plaster mold and the rapid prototyping model in cranioplasty. Methods: A 44-year-old male was referred to the department for severe frontal hollowness. He was involved in an automobile accident resulting in large frontal bone defect with irregular margin. The preformed patient-specific methylmethacrylate implant was made using plaster mold and the rapid prototyping model before the operative day. The methylmethacrylate implant was placed in the frontal defect and rigidly fixed with miniplates and screws on the operative day. Results: The operation was performed in an hour. In the 6 months follow-up period, there were no complications. Patient was satisfied with the results of cranioplasty. Conclusion: Safe cranioplasty was performed with the preformed patient-specific methylmethacrylate implant using plaster mold and the rapid prototyping model. The result of this method was satisfactory, aesthetically and functionally.