• Korean Journal of Computational Design and Engineering
• /
• v.8 no.4
• /
• pp.212-221
• /
• 2003

In order to reduce the lead-time and cost, the technology of rapid prototyping (RP) has been widely used. A new rapid prototyping process, transfer-type variable lamination manufacturing process by using expandable polystyrene foam (VLM-ST), has been developed to reduce building time, apparatus cost and additional post-processing. At the same time, VLM Slicer, the CAD/CAM software for VLM-ST has been developed. In this study, algorithms for accuracy improvement of VLM-ST, which include offset and overrun of a cutting path and generation of a reference shape are developed. Offset algorithm improves cutting accuracy, overrun algorithm enables the VLM-ST process to make a shape of sharp edge and reference shape generation algorithm adds additional shape which makes off-line lamination easier. In addition, proposed algorithms are applied to practical CAD models for verification.

• Journal of the Korean Society for Precision Engineering
• /
• v.22 no.10 s.175
• /
• pp.26-30
• /
• 2005

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1997.10a
• /
• pp.1047-1050
• /
• 1997

Rapid Prototyping(RP) is an efficient method for rapid design verification and trial manufacturing. In order to improve their unique characteristics according to the working principles. Variable Lamination Manufacturing process and corresponding CAD/CAM system is developed. The objective of this study is to improve dimensional accuracy of VLM-ST process, and it can be done by offset for cutting error correction, cutting path correction for sharp edge and reference shape generation. To verify the proposed algorithms, they applied to three-dimensional shapes, such as spanner and mechanical part.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.11a
• /
• pp.759-762
• /
• 2000

Rapid Prototyping (RP) techniques have their unique characteristics according to the working principles: stair-stepped surface of parts due to layer-by-layer stacking, 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 and design a new RP process, Variable Lamination Manufacturing using expandable polystyrene foam sheet as part material (VLM-S), which can make up for the disadvantage of existing techniques, and to develop an apparatus to implement the process. In order to examine the possibility of practical utilization of the proposed VLM-S process for prototyping of a general three-dimensional shape, an auto-shift lever knob and a pyramid shape were fabricated.

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

• Journal of the Korean Society for Precision Engineering
• /
• v.19 no.7
• /
• pp.97-105
• /
• 2002

The use of rapid prototyping (RP) has reduced time to market, cut total costs and improved product quality by giving design and manufacturing teams the opportunity to verify and fine tune designs before committing them to expensive tooling and fabrication. In order to improve their unique characteristics according to the working principles, Variable Lamination Manufacturing process (VLM-ST) and corresponding CAD/CAM software (VLM-Slicer) is developed. The objective of this study is to improve the accuracy of VLM-ST process, and it can be done by offset fur cutting error correction, cutting path overrun fur sharp edge and reference shape generation for off-line stacking. It has been shown that, through the verification experiments for given practical shapes, the proposed algorithms are effective for diverse categories of three-dimensional shapes.

• Journal of the Korean Society for Precision Engineering
• /
• v.18 no.8
• /
• pp.64-70
• /
• 2001

In all the Rapid Prototyping (RP) techniques, the computer-aided design (CAD) model of a three-dimensional part is sliced into horizontal 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 software for automatic generation of unit shape part(USP) for a new RP process, Variable Lamination Manufacturing using the 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, USPs of general three-dimensional shapes, such as an auto-shift lever knob and a pyramid shape were generated.

• Proceedings of the KSME Conference
• /
• 2001.11a
• /
• pp.760-765
• /
• 2001

A new rapid prototyping process, as a transfer type of Variable Lamination Manufacturing by using expandable polystyrene foam (VLM-ST), has been developed to reduce building time, apparatus cost including the introduction and the maintenance and additional post-processing. The objective of this study is to propose a VLM-ST process and to develop an apparatus for implementation of the process. Design criteria of the apparatus were defined and the techniques were proposed to satisfy the design criterion. In order to examine the efficiency and applicability of the developed process, various three-dimensional shapes, such as a world-cup logo, a knob shape and a character, Son-o-kong, were fabricated on the apparatus in which unit shape layer (USL) was generated to build up each layer.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2001.04a
• /
• pp.910-913
• /
• 2001

Rapid Prototyping(RP) techniques have unique characteristics according to their working principle: the stair-stepped surface of a part due to layer-by-layer stacking, low building speed, and additional post-processing to improve surface roughness. A new RP process, Variable Lamination Manufacturing by using expandable polystyrene foam(VLM-S), has been developed to overcome the unfavorable characteristics. The objective of this study is to investigate the thermal characteristics and skeleton size effects as the hotwire cuts EPS foam sheet in order to improve dimensional accuracy of the parts, which is produced by VLM-S. Empirical and analytical approaches are performed to find the relationship between cutting speed and heat input, and the relationship between maximum available cutting speed and heat input. In addition, empirical approaches are carried out to find the relationship between cutting error and skeleton size, and cutting deviation and skeleton size. Based on these results, the optimal hotwire cutting condition and available minimum skeleton size are derived. The outcomes of this study are reflecting in the enhancement of VLM-S input data generation S/W.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2002.10a
• /
• pp.599-602
• /
• 2002

A novel rapid prototyping (RP) process, an automated transfer type variable lamination manufacturing process (Automated VLM-ST) has been developed. In Automated VLM-ST, a vacuum chuck and linear moving system transfer the plate type material with two pilot holes to the rotation stage. A four-axis synchronized hotwire cutter cuts the material twice to generate Automated Unit Shape Layer (AUSL) with the desired width, side slopes, length, and two reference shapes in accordance with CAD data. Each AUSL is stacked on the stacking plate with two pilot pins using the pilot holes in AUSL and the pilot pins. Subsequently, adhesive is supplied to the top surface of the stacked AUSL by a bonding roller and pressure is simultaneously applied to the bottom surface of the stacked AUSL. Finally, three-dimensional shapes are rapidly fabricated. This paper describes the procedure for generating the cutting path data (AUSL data) f3r automated VLM-ST. The method for the generation of the Automated Unit Shape Layer (AUSL) in Automated VLM-ST was practically applied and fabricated for a various shapes.