3D 프린터 / 양동렬 교수(카이스트)

1. 3D 프린팅: 현황과 전망
July 15, 2014
진대제AMP
- 길 포럼-
교수 양동열
KAIST, 기계공학과

2. <SOURCE : sericeo.org, 2013>
Ultra-light Material
Wearable Computer
3D Printing
Context-Awareness
Driverless Car
Gene Therapy
Post Batteries

3. 3D Printed Airbike EADS(European Aerospace and Defense Group)
Made by ALM process
(Additive Manufacturing)
Material: Nylon+Metal powder

4. 6,000 CFM Leap jet engines sold
x 19 nozzles each = 114,000
GE Fuel nozzlesAirbus Wing Brackets
40% weight saving Courtesy: J. Harrop@ IDTechEx
Light weight Innovation

5. Real car prototyping
First 3D printed Car (Urbee*)
Price  50,000 dollars, Fuel Ethanol + Gasoline
All parts are manufactured
by 3D printing
Manufacturing time
: 2500 hours
Time consuming
but, It’s beginning
*2011, KOR EcoLogic using Stratasys’s 3D printing service

6. 3D Printing
Rapid Prototyping
Free Form Fabrication
Additive Manufacturing
On Terminologies
3D 프린팅/ 3차원 인쇄술
쾌속조형(고속, 급속, 신속)/ 쾌속시작
임의형상제조
부가적층제조(공정)

7. What is 3D Printing/ Rapid Prototyping?
Technology that can manufacture 3D prototypes
through layer-by-layer deposition of materials from
CAD data or measurement data
Layer by layer
FlexibleMetalColored material
3D Printing vs. Rapid Prototyping vs. Free Form Fabrication
vs. Additive Manufacturing

8. Diverse needs of customers
& Shortening of Product Life Cycle
Complexity and Low Volume of
products
Increasing Competition
Rapid Product
Development
• Fast & Cost Effective
manufacturing technology
• Minimization of Trial-and-errors
• Concept of Concurrent Engineering
• Fast & Cost Effective
manufacturing technology
• Minimization of Trial-and-errors
• Concept of Concurrent Engineering
3D Printing taking a central role of RPD
RPD : Rapid Product Development

9. ProductsProducts
Subtractive
Manufacturing
Rapid Prototyping
Virtual
Prototyping
Reverse EngineeringReverse Engineering
3D CAD Modeling3D CAD Modeling
SolidEdge SolidWorks
I-DEAS CATIA
3D Laser Scanner
WB4(CyberWare) SNX(Solutionix)
How Rapid Product Development works?
RapidproductDevelopment

10. CAD Modeling for manufacturing new products
How can we realize imaginary products? CAD modeling
1. Imaginary product
: Manufacturing fish
2. CAD Modeling
: Using software to model
3. Rapid Prototyping machine
: Putting SLA file to RP machine
4. Real products
Manufacturing products
by 3D CAD Modeling
Manufacturing products
by 3D CAD Modeling
Transferring CAD file
to SLA file

11. CAD Modeling to make Virtual Prototypes
SolidWorks (Solid Modeler)
Pro-Engineer
CAD modeling data are transformed to STL file format.
STL(“STereoLithography”) file:
Example
STL file
3D CAD Model
STL file
3D Scan data
The surface of a 3D object is approximated
by facet mesh of a number of triangles
Each facet consists of 3 points
and unit normal vector of a triangle

12. 3D scanners
Equipment to acquire 3D shape data of objects
Geometry data (X, Y, Z) & Color data (Texture)
3D scanner (H/W) + Software (S/W)
Equipment to acquire 3D shape data of objects
Geometry data (X, Y, Z) & Color data (Texture)
3D scanner (H/W) + Software (S/W)
3D CMM(Coordinate
Measuring Machine)
3D Scanner
3D CMM(Coordinate
Measuring Machine)
3D Scanner
Contact type
3D coordinate
measuring machine
 Encoding type with
Touch Probe
High accuracy
Laser scanner
Non Contact type
 Laser beam
White light projector
Non Contact type
 Optical interference
Stabilizing, flexible
attachment
High accuracyAdvantage
Disadvantage
Slow to measure,
Objects should be solid
Decreased accuracy
Advantage
Disadvantage Weak to
outside interference
Advantage
Disadvantage
Digitizing 3D shape with 3D scanner

13. CT/MRI Scanner
CT/MRI Image
DICOM format
cf. DICOM (Digital Imaging & COMmunications in medicine) : International medical imaging standard
STL
Mimics
BioBuild
Medical RP
Siemens
Philips
GE DAT
GE Advantage
GE YMS
Picker
Toshiba
Elscint
IMPORT
Objet
Skull
FDM
Spine
3D scanning Procedure of Medical Rapid Prototyping
MRI, CT 기술을 이용한 신체 내부의 형상데이터 획득
CT 촬영
체내 횡단면 데이터 획득
데이터 획득
데이터
들여오기 STL 파일 변환 의료용 RP장비 제작

14. Introduction to
Rapid Prototyping

15. SLA(Stereo lithography)
Patented in 1986
By Charles Hull
1993 : “3D Printing” by Prof. E. Sachs (MIT)
First mentioned “3D Printing”
Now “3D Printing” is widely mentioned as the original
meaning of Rapid Prototyping
1988 Product release
Rapid
prototyping
(Additive
Manufacturing)
SLA(Stereo lithography)
Patented in 1986
By Charles Hull
Rapid Prototyping & 3D Printing
1984 : The Birth of Rapid Prototyping
SLA-250
(1988, 250ⅹ250ⅹ250)
Rapid Prototyping includes 3D Printing.
“3D Printing” in wide sense
 Rapid Prototyping
3D
Printing
Rapid Prototyping
Cf. High Speed machining
Cf. Additive Manufacturing

16. Trend of Rapid Prototyping(RP) Market
(Source: Wohlers Report 2012 & KT)
0
2
4
6
8
10
12
14
2001 2011 2019E
RP printer market
Secondary service
related to RP
Value of products
manufactured by RP
Expansion of application fields
includes Education, Leisure,
Manufacturing, and etc
CAD design and additional service
related RP
Supplying Personal 3D printer
(Unit : One billion dollars)
14
12
10
8
6
4
2
0
13.3
3.7
1.1
2001 2011 2019
(Expected)
7.2
3.3
2.8
Scale of the world market
20%
20%
15%
12%
11%
8%
6%
3% 5%
Automotive
Goods
Medical app.
Aerospace
Industry
Education
Military
(Source: Wohlers Report 2012)
Application fields It’s expected that RP market
has potential to grow.
By expanding application fields,
there are more value of products
manufactured by RP

17. Regional usage
0
10
20
30
40
(Source: Wohlers Report 2012)
Percent(%)
Accumulated data on 1968~2011
Rapid Prototyping machine market
Trend of Rapid Prototyping(RP) Market
53%
22%
8%
2%
4%
11%
Stratasys
3D systems
Envision Tec.
EOS
Beijing Tiertime
Etc
(Source: Wohlers Report 2012)
Market share
U.S. leads the RP market.
RP companies from U.S.
dominate the RP market
(U.S.)
(U.S.)
(Germany)
(Germany)
(China)

18. Courtesy: J. Harrop@ IDTechEx
Pink Zone
: Red Ocean !
Size-dependent
Material-dependent
Precision-dependent

19. Subtractive
manufacturing
Subtractive
manufacturing
According to the method to manufacture:
Rapid Prototyping TechnologyRapid Prototyping Technology
Additive
manufacturing
Additive
manufacturing
Classification of Rapid Prototyping process
High speed
Machining
or 3D Printing
Chemical Bonding SinteringSintering GluingGluing
Deposition
Photocuring
Cf. Metal Deposition by Melting

20. Principle
SLA-7000 (500*500*580)
Part & Supports
Post-processing
SLA StereoLithography Apparatus (3D Systems, U.S.)
Apparatus & Part
Laser scanning system + Liquid photopolymer resin
1 Layer thickness [mm] : 0.025 ~ 0.125
Products
High resolution
Expensive

21. SLA-250
(1988, 250ⅹ250ⅹ250)
SLA-7000
(1999, 500ⅹ500ⅹ580)
Commercial machines [Unit : mm]
iPro™ 9000
(2008, Max.1500 x 750 x 550)
SLA StereoLithography Apparatus (3D Systems, U.S.)
Applications
Jaw nerve partArtificial product
Fashion Shoes

22. Micro Stereolithography
MicroStereolithography:
Two photon lithography Pattern mask light beam
+ Liquid photopolymer resin
Part
 Multi Microstructures
can be fabricated.
Ref.) Nicholas Fang’ group at UIUC

23. Layer-by-layer accumulation method
for 3D nano/microfabrication
Cover
glass
Immersion
Oil
Photocurable
Resin
Voxel
(90 nm)
at focal point
x
z
Femtosecond laser
Nano Stereolithography
Nano resolution laser
+ Liquid photopolymer resin
Nano scaled thinker
(D.Y. Yang et al., KAIST,
Korea)
10㎛
z
yx
ceramic precursor
before pyrolysis
5㎛
5㎛
y
x
x y
z
4.6㎛
fabricated using
SCR500 polymer resin
Electric device
Optics Express, 2010.Advanced Materials, 2011.
Optical device
10 ㎛
Ormocer toroid
CLEO Int. conference, 2011.
Applications
nRP
(nano Replication Printing)

24. 1 Layer thickness [mm] : 0.178 ~ 0.356
The cost of the machine
and the material is economical.
FDM : Fused Deposition Modeling (Stratasys, U.S.)
Part
Part supports
Base
Platform
Support
material
Build
material
Extrusion head
Wheel
Heater
Nozzle
Apparatus & Part
FDM Maxum-Stratasys
(600mm by 500mm by 600mm)
Extrusion head
Principle
ABS Models
Heated extrusion nozzles + Thermoplastic filament

25. rocess
SLS : Selective Laser Sintering
Working Principle
Audio : front panel Mold by RapidSteel 2.0
Applications
After secondary processes
Electronics HousingDuraForm Flex Ductwork
Functional Materials
DuraForm ® Flex Plastic : Rubber-like material
DuraForm ® EX Natural Plastic : Impact resistance
DuraForm ® HST Composite : Fiber-reinforced plastic
(sProTM140)
• Plastic powders + CO2 laser
• Layer’s thickness : 0.1-0.15 mm
• Functional materials
Characteristics
Sintering powder by laser

26. Finished 3D PartZ810 (1800 jets)
(600mm by 500mm by 400mm)
Engine Block
(460mm by 480mm by 330mm)
Architectural Model
(360mm by 410mm by 230mm)
3DP: Three-Dimensional Printing
(Z Corp., U.S.)
Apparatus & Part
Powder + Water-based liquid binder
Dyes added to the liquid binder
Spraying liquid binder
with dye by inkjet

27. 1 hours
20 minutes
Toy
FEA Model (180*350*250 mm)
Phone Sneakers
Ship Tire
Sample parts
3DP: Three-Dimensional Printing (3D systems, U.S.)

28. How It Works : Dual-jet process
Two UV
lamps
Inkjet head 1
Inkjet head 2
Inkjet head for
Support material
Products
Material 1
Material 2
Multi-nozzle stereolithography (Objet)
(Objet Geometries, Israel)
Inkjet Deposition of
Photopolymers with UV lamp
Characteristics
Dual-jet process to combine two materials
Functional materials can be mixed
Materials
Vero family
(Rigid materials)
Tango family
(Flexible materials)
FullCure 720
(Transparent materials)
High accuracy
 Min. 16μm resolution
Polyjet

29. Sample parts
Multi-nozzle Inkjet Deposition of Photopolymers (Objet Geometries, Israel)
Objet Connex500TM
(2007, 500ⅹ400ⅹ200)
Objet Connex350TM
(2009, 350ⅹ350ⅹ200)
Equipment Sample parts

30. Objet500 Connex3
(2014, 490ⅹ390ⅹ200)
Equipment
Sample parts
Multi-nozzle Inkjet Deposition of Photopolymers (Stratasys, U.S.)
Photopolymer with
blended colors & translucent colors
Hybrid colored materials
: Functionality & Visualization
Sample parts
Multi-nozzle stereolithography (Recent Innovation)
Connex3

31. Rapid Prototyping of Metals
Direct metal fabrication process
Subtractive manufacturing
 High Speed Machining

32. Direct Fabrication
tooling
Mold with RP:
Secondary process
Direct Fabrication
Characteristics
Reduced number of steps
Minimized dimensional inaccuracy
RP processes that produce metallic parts or molds
directly from CAD solid models.
Metal
Prototypes,
Molds
Rapid
Prototyping
Secondary
Processes
Direct Fabrication
Processes
Time (days)
REDUCED
TIME-to-MARKET
CAD
Modeling
Direct metal fabrication processes

33. Melt Pool
Powder
Delivery
Nozzles
Powder
Injection
Substrate
Nd:YAG
..............
......
......
..
. .............
......
......
.. .
.
Laser
Cladding
LENS : Laser Engineered Net shaping
How It Works:
Sintering metal powder by laser
with delivery nozzles
Characteristics
Material: Stainless Steels, Titanium Alloy, Nickel
Layer Thickness: 125 µm (H13)
Metal molds repair and modification
Applications
Injection Mold Housing
Complex inner
shape part
Mold Repair & Modify
before
after
Different material
adapted die

34. Scanner
system
Loose
powder
Build
plate
Build station
piston
Mold
Powder
coater
Powder delivery
system
Laser
How It Works:
DMLS : Direct Metal Laser Sintering : a kind of SLS
Powders: Mixtures of different
metallic components
Material : Steel or Bronze based
Layer Thickness: 20 µm
Characteristics
Sintering metal powder by laser
Parts : Dashboard & support
High quality functional component in a short time
Applications
Y stent for
artery branches
Injection mold
Tire Tread
Pattern Mold
(High precision using two sizes of metal powders)

35. Most expensive: Sciaky
Up to $6M for a single printer
8.4m3 build volume
Combination of 3D Printing with CNC Machining
Sciaky's Electron Beam Additive Manufacturing Solution
Titanium part(Airplane)
Prints in titanium, tantalum, Inconel, …
Ideal for the aerospace market

36. www.sciaky.com

37. Subtractive manufacturing as Rapid Prototyping
Raw material is carved into a desired final shape
Raw material
Product
Subtractive
process
FinishingRough carvingRaw material

38. High-speed machiningSubtractive Manufacturing
Offering practical advantages
 precision and versatility
Machining of the impeller
HisRP(KIMM & KAIST)
(High-speed Rapid Prototyping)
High speed machining with automatic fixturing
B. S. Shin & D. Y. Yang et al., 2003
0˚ 180˚
automatic fixturing for holding
5-axis Machining
Reduced manufacturing time
Lower manufacturing cost
Wide variety of available materials
Increased product accuracy

39. Large scale Rapid Prototyping
: Thick-layered RP Systems

40. Large scale RP : Thick-layered RP Systems
Thin Layer with Square Edges
Thick Layer with Sloping Edges

Boundary of CAD Model
t=1 mm
Sloping surface
(first
approximation)
t < 1 mm
Stair-stepped
surface
• High build speed
• Removal of stair-stepped
effect
How It Works:
Thickness of raw material is thick  Sloping surface

41. Dolphin (1,692 mm x 660 mm x 1,274 mm)
Cutting Principle
Surface contours
Surface normal
Cutting vector
Surface tangent
Waterjet cutter  Sloping surface thick layers
Styrofoam
(10,20,30mm)
Trusurf
Large scale RP : Thick-layered RP Systems
Finished & Painted Dolphin
Experimental Setup
CAM-LEM
Laser
Characteristics
Thick Tangent-cut layers
5-axis laser cutter
Ceramic, Stainless steel
, Foam (6 mm thick)
Sample Parts
Styrofoam Spheres
84 mm-tall)
Laser cutter  Thick materialsCAM-LEM

42. Hotwire
Cutter
USL GenerationUSL Generation Cutter Path
USL
Pilot Pin
Stacking & BondingStacking & Bonding
Reference
shape
VLM process, DY Yang et al., KAIST
Large scale RP : Thick-layered RP Systems
How It Works
: Hotwire cutting styrofoam
Mount Rushmore Memorial
Apparatus
• VLM; Variable Lamination Manufacturing
• U.S. Patent No. 6,702,918, March 9, 2004

43. Advanced Applications
High functionality Bio application
Visual aids Personal Manufacturing

44. The State of the Art of
Rapid Prototyping Applications
High functionality & Bio Appl.
Wider variety of available materials
High Performance
Precision, High-speed, Low cost
Visual Aid: Colored Object Personal manufacturing

45. Application of 3D printing
Entertainment
Contents
Fashion
Toy
Functional product
Aerospace &
Automotive products
Die & Mold
Medical application
Visual product
Architecture
Medical application
Prototype

46. Mercedez-Benz GL class
Aluminum Engine Support Replaced by Engineering Plastic
Engine Weight Support
Shock Absorber
Crash-
worthiness
30% Weight
Reduction
Engine Noise
Reduction
Use of Engineering Plastics

47. Use of Engineering Plastics
PA Compound -3kg
(RVR, Mitsubishi) Fender(Civic, Honda) Rear Glass
PC Compound -2kg
(A8, Audi) Tire Carrier
PA Compound -4kg
(Fofour, Smart) Sun Roof
PC Compound-3kg
Indirect
3D Printing Opportunity

48. The world's first Carbon Fiber 3D Printer
https://markforged.com/
Cutaway of aeromotions race car wing support
가격 : 4,999$ (약 530만원)

49. Anatomy of a continuous filament fabrication part
(1) Nylon base +
3 carbon fiber layers
(2) Nylon honeycomb
structure
(3) Final carbon fiber
CFF + nylon case
사용 가능 재료
Carbon fiber filament
Fiberglass filament
Nylon filament
PLA filament

50. Building Construction by 3D Printing
Conventional Contour Crafting
including Curved 3D Shapes
On-site Building Whole Houses On-site Reinforced Wall Construction
Building Innovation
by 3D Printing
to build Custom-
tailored Houses

51. 3D Printing in Fashion as Visual Aids
3D printed dresses at Paris Fashion Week (2013)
Iris van Herpen’s Haute Couture show, ‘VOLTAGE’
3D printing does what no other form of clothing manufacture can do
when complex shapes need to be created quickly and as one piece
Interview with Iris van Herpen
3D Printed glass
3D Printed footwear

52. Visual Aids for Entertainment
Imagination into reality
User customized guitar 3D printed figures
Kids Drawings Into 3D Printed Figures Mobile RP/ 4D RP

53. 3D Printing Pen as Free Rapid Prototyping
Materials :
Plastic(ABS,
PLA)
3D Printing Pen: 3Doodler
Without Computer Modeling
3D Printing by yourself
Melted plastic  Extrusion
(99$)
(WobleWorks LLC)

54. 4D Printing and Self transformation
Concept of 4D printing : Self transformation of products
with programmable material printed by 3D printer
Inspirations from Nature
DNA
Protein
Self transformed strand Self assembled cube
Skylar Tibbits, MIT
TED talks, (2013. 4.4)

55. Prospective applications of 4D Printing
Extreme Environments
(Aero space constructions)
Manufacturing
Construction
Infrastructure
Aerospace
Eliminating human error and the confusion of complex instructions
Industrial infrastructure
MIT & Geosyntec.(2012)
Current Application
: Underground adaptive piping
Expand and contract to regulate water flow

56. Visual aids :
Scientific and Architectural Models
Architecture
Complex geometries can be easily generated.
Complex mathematical surface*
*Minimal surface
Growth of nautilus

57. Shapeways
(Producing, Delivering products with 3D-Printing)
Market place to make, buy and sell products by individuals
Possible to Personal Rapid Product Manufacturing
What is shapeways? iPhone 5 case Interior
Lamp
Personal manufacturing

58. Price : 2,199 $
Personal RP machine Personal Rapid Manufacturing
1 layer
: 0.27mm~0.32mm
RP process : FDM
Materials
: ABS, PLA
MakerBot(USA) NP-MENDEL
(Korea)
RP process : FDM
Materials
: ABS, PLA
Price : About 1,200 $
1 layer
: 0.1mm~0.35mm
by personal RM
“Liberator” Gun
Personal manufacturing

59. www.printrbot.com
Printrbot
: the Cheapest
Prices start at $350
8000 Printrbots sold since 2011
Education market worth $260M

60. CARIMA : DLP(Digital Light Processing) type
Product : Master +plus
Material : Photopolymer, visible light lamp
Max. resolution thickness : 40μm~100μm
ROKIT : FDM type
Product : EDISON (About 1,500$)
Material : PLA (plastic)
Max. resolution thickness : 50 μm
SOLISYS : DLP type
Product : SRP
Material : Photopolymer, visible light lamp
Max. resolution thickness : 50-100 µm
NP-Mendel : FDM type
Product : NP-Mendel (About 1,200$)
Material : ABS, PLA (plastic)
Max. resolution thickness : 35μm~100μm
Personal RP machine in Korea
Menix(With KAIST) : Thick–layered RP
Product : VLM series
Material : Styrofoam
Max. resolution thickness : 1~4mm
Personal manufacturing

61. Metal RP machine in Korea
InssTeK : Laser cladding type
Product : MX series
Material : Cu, Al, Ni, Stainless powder (Metal)
Max. resolution thickness : 100μm~2000μm
(Metal-based deposition)

62. Aerospace applications
World’s First 3D Printed airplane (2011)
Rocket part by 3D printing
Functional component
Airbus A380 component
SLS(Selective laser sintering) with titanium

63. Rapid Tooling Process for
functional dies &molds and
Mass production
3D printing을 이용한 쾌속 금형
제작과 대량생산

64. Die and mold manufacturing
Conventional die and mold manufacturing
 Subtractive process such as machining
3D printing can produce the die and mold
directly and indirectly !
Disadvantage of subtractive process
Reproducing sharp corners is difficult
Modification of the die geometry is difficult

65. DMLS : Direct Metal Laser SinteringSDM : Shape Deposition Manufacturing
Direct 3D printing of Metals for Die & Mold Making
DMT(Direct Metal Tooling) process
(InssTek INC, Korea)
LENS (Laser Engineered Net shaping)

66. High performance multi-material dieDirect mold fabrication
Copper interior
Steel exterior
Conformal cooling channels
Die with conformal cooling channels
cooling channels
Modification and restoration
Damaged part Restoration
Modification of the die geometry
3D printing changes the die and mold manufacturing trend
Die and mold manufacturing

67. Visualization,
Verification of Design,
Check of
Manufacturability, …
Functional Prototypes and
Manufacturing of small lot size
Manufacturing of Parts using Rapid Tooling
RT Parts (functional material)RP Parts (non-functional material)
Indirect Rapid Tooling
(Single reverse, Double reverse
and Triple reverse process)
Direct Rapid Tooling
Rapid Tooling Technologies

68. Direct Tooling Construction
• Use RP Method to Create Inserts for Injection Mold Tooling
• Mold Made from RP Material
• Method : SLS Rapid Tool
2 Green Part:
Steel particles
with polymer
binder
4 Full dense
metal mold:
steel + copper
3 Brown Part: binder
burned out, infiltrate
with copper
1. Inserts
designed in
CAD
• SLS process used to sinter cavity and
core inserts from Rapid Steel material
- carbon steel powder coated with
polymer
• Inserts infiltrated with polymer solution
for
strength during processing
• Inserts processed in furnace to burn off
polymer and sinter steel.

69. Single Reverse Tooling Methods
• Requires RP Master Pattern of Shape to be Molded
• Parting Line Block Required
• First Side of Tool Cast against Pattern Imbedded in Parting Line Block
• Second Side of Tool Cast against First Side
Create Pattern Create Parting
Line Block
Cast First Side
of Tool
Invert and Remove
Parting Line Block
Cast Second
Side of Tool
Remove Pattern

70. Double Reverse Tooling Construction
• Requires Master Pattern of Cavity and Core Inserts
• Cast Reverses
• Cast Mold Insert Against Reverse
• Double Reveres tooling Method: Quickcast Tooling
Create Insert
Pattern
Cast Reverse Remove Pattern Cast Tool Remove
Reverse
Double Reverse Construction
Process

71. Create Pattern Create Parting
Line Block
Cast First Side
of Dummy Mold
Invert and Remove
Parting Line Block
Cast Second Side
of Dummy Mold
Remove
Pattern
< Single Reverse to Create Dummy Molds >
Dummy
Mold
Cast
Reverse
Remove
Pattern
Cast Tool Remove
Reverse
< Double Reverse to Create Tooling >
Triple Reverse Tooling Construction

72. Cast Epoxy Tooling Complex Mold with Insets
and Cooling

73. Cast Epoxy Tooling
• Rigid, Low Shrink Epoxy
– Two Part Materials
– Cures Over Time (Hours)
• Straight Epoxy Face Coat
• Epoxy/Aluminum Backing
Mold Frame
Parting Line Block
Pattern
Aluminum Chips mixed with epoxy
for strength and conductivity
Completed Mold
Mixture poured to cast mold

74. Spray Metal Tooling
• Depositing a thin layer of metal using an arc spray process to create the
surface of the mold
• Materials : Kirksite, zinc-based alloy, steel
• Approx. 0.1” (2.54 mm) Layer Deposited
• Backed with Epoxy or a Low Melting Point Metal alloy
• Advantages :
- Good for large parts
- Little or no additional shrink at the process of mold-making
• Disadvantages :
- limited mold life
- adding metal inserts, increasing cost and lead time for complex shapes
• Applications : parts of significant size with low-to-medium complexity
Completed MoldArc Spray Process
cf. Kirksite - Composite of Al and Zn

75. Electroformed Tooling
• Metal (Usually Nickel) deposited on Pattern in Parting Line Block
• Layer Built Up Over Period of Time
• Backed with Epoxy, Metal, or Ceramic
Electroformed Tool Backed with Chemically Bonded Ceramic

76. Cast Kirksite/Aluminum Tooling
• Rubber, Urethane, or Epoxy Dummy Molds
• Plaster Reverses
• Kirksite/Aluminum Cast Against Plaster
< Rubber Dummy Mold > < Plaster Reverse > < Aluminum Cast >

77. Spray forming (Ford)
• Depositing the metal onto the pattern to produce the metal shell by wire
spray guns
• Licensed by Ford
• Shell thickness : up to 19 mm (0.75 inch)
• Deposition rate : about 6.8 kg (15 lbs) of wire material per hour
• Work cell : 760 x 1015 x 250 mm (30 x 40 x 10 inches)
• Accuracy : ±0.15 mm (0.006 inch)
• Significant cost reductions (about 10-15% less than conventional CNC
machining processes)
• Much less time than CNC components
• Embedded conformal cooling channels on the backside of the tool
• Applications : primarily to produce production dies for sheet metal
stampings
One million
Turbine blades
Sample
Tools
&
Parts
60,000
production
Latch covers
Aluminum trim
die

78. Ceramic Shell Casting
Sample
Tools
&
Parts
A Ceramic shell casting process that uses an ceramic slurry
with an EPS pattern or Wax pattern placed inside of the mold
Definition
 Thin thickness possible ( layer thickness 5 – 6 mm )
 Good tolerance (0.003-0.005”) : Mold does not shrink
 Better surface finish
 Higher productivity ( automation possible)
 Less disposal cost
Advantage

79. Ceramic shell casting process (lost wax)Ceramic shell casting process (lost wax)
1. Making the slurry 2. dipping the wax into the slurry 3. Drying process 4. Dewaxing
5. Pour molten metal 6. Solidification 7. Removing shell
using hammer
Complete
Parts

80. 1. Design CAD model 2. Fabricate foam model 3. Coated with ceramic slurry
4. Coated with sand5. Pouring molten metal
into mold
6. Final part after the
ceramic shell is
broken
EPC(Evaporable Pattern Casting) Proc. for Part ManufacturingEPC(Evaporable Pattern Casting) Proc. for Part Manufacturing
Lost-Foam Process

81. Signal Transmitter Housing for Wireless
Communications Network System
Oil Filter Adapter
Aluminum Transmission Housing L61 Engine Block and Head (General Motors)
ApplicationsApplications

82. Prostheses and Dental implants
Tissues Engineering and Biotechnology
Operation Aids
Bio-Medical Applications

83. Bio application
: Prostheses and Dental implants
First 3D printed jaw
transplant (2012)
Material : Titanium
3D printed
skull implant
Prosthetic legs
 Optimized to customer
Direct 3D printing of human parts
: Hearing Aid
Customized by
3D printing

84. Building Process of a Cranial Prosthesis(1/2) (두개골 인공 삽입물)
Ref) http://www.phidias.org, Phidias Rapid Prototyping in Medicine, No. 2, pp. 4, June, 1999.
Prototyping
(Solidscape)
Clinical case
두개골 함몰  인공 삽입물 필요
3D Reconstruction
(Mimics)
Prosthesis Modelling
(SolidWorks)
MRI 측정  인공 삽입물 설계
Custom-made Cranial Prosthesis 필수  빠른 제작, 정확한 삽입물 형상 제작
SLA
Skull
인공 삽입물 형상과 두골형상 비교

85. Bio application : Surgical planning
Minimally invasive surgery with Surgical Planning
Case 2 : Siamese twins
Case 1 : Orthopedic Fracture

86. Bio application : Operation Aids
Siamese twins
CT scan data  3D Printing  3D Print : Replica of twins
UCLA(U.S.) 2002
Ref. cavendishimaging.com
Successful! Operation time : 97hours  22 hours
(Surgical Planning)

87. Advanced Tissue Sciences,
Bio applications in Tissue Engineering
RP기술을 접목한 조직공학  피부, 장기 조직, 장기 제작에 응용

88. Cell isolation
Cell proliferation
Cell seeding
into scaffold
In-vitro cell culture/
Tissue regeneration
Tissue transplantation
General procedure for application of 3D scaffold
Bio application : 2D/3D bio scaffolds by RP

89. Bio application : 3D printing of Human Organs
Direct 3D printing of human ear
3D printed artificial ear on a mice
Vacanti mouse Artist Stelios Arcadious
20072002
Conventional method
Cow cartilage cell
to human ear
shaped-mold
2013
Lawrence Bonassar,
(Cornell University)

90. Bio application :
Organovo Holdings Inc.Human Organs (Bio paper + Bio ink)
Bio paper
Bio ink
3D printed artificial blood vessel
(Fraunhofer
Institute, 2011)
Direct 3D printing of human organs
3D printed Bionic ear
Princeton Univ. (2013)

91. Future prospects of
Rapid Prototyping
Limitations
Future prospects

92. Current Trend of
Visual aids: extended appl. Personal manufacturing
High functionality
Wide variety of available materials
More industrial applications
Bio/Medical Application
Customized shape, Bio compatibility
Medical
Operation Aid
Rapid Prototyping Applications

93. Future prospects of RP & 3D Printing
Volumetric manufacture of RP
Animation-enabled(Mobile) RP
Advance of secondary processes
Specialized RP service bureaus
Enhanced surface quality, e.g.
quasi-real life
User-friendly Data Connection
RP Enhancement
& Visual aids
RP Enhancement
& Visual aids
Increased Speed of RP/ Mass
production: Rapid manufacture
Increased Precision of RP
More variety of materials
satisfying required properties,
i.e. functionally gradient
property and foam-like material
Multi-material, metals
Higher and Diverse FunctionalitiesHigher and Diverse Functionalities
Enhancement of customized RP
Low cost 3D printers and low
operation cost
Simplified Data handling for RP
Low cost scanner and data
connection, i.e. camera-based
scanning method (Smart phone
assisted data scanning)
Personal RP machinePersonal RP machine
RP of human skins and hairs
RP of various human organs
RP of bone structures
Simplified handling/ connection
of CT data
RP of stem cells
RP of blood vessels
Diversified Bio/
Medical application
Diversified Bio/
Medical application

94. Expected Future Technologies
Courtesy: J. Harrop@ IDTechEx
Facilitated data acquisition ( cf. Mobile Phone).
- New 3D Scanning solutions
Courtesy: J. Harrop@ IDTechEx

95. Courtesy: J. Harrop@ IDTechEx
Expected Applications in Positive Prospect

96. Thank you for your
attention!
Questions and Discussions