Rapid Fabrication of Large-Sized Solid Shape using 3D Scanner and Variable Lamination Manufacturing : Case Study of Mount Rushmore Memorial

삼차원 스캐너와 가변 적층 쾌속조형공정을 이용한 대형 입체 형상의 쾌속 제작 : 러쉬모어산 기념물 제작 사례

  • 이상호 (한국과학기술원 대학원 기계공학과) ;
  • 김효찬 (한국과학기술원 대학원 기계공학과) ;
  • 송민섭 (한국과학기술원 대학원 기계공학과) ;
  • 박승교 ((주)메닉스) ;
  • 양동열 (한국과학기술원 기계공학과)
  • Published : 2004.12.01


This paper describes the method to rapidly fabricate the large-sized physical model with the envelope model size of more than 600 mm${\times}$ 600 mm${\times}$ 600 mm using two type semi-automatic VLM-ST processes in connection with the reverse engineering technology. The fabrication procedure of the large-sized solid shape is as follows: (1) Generation of STL data from 3D scan data using 3D scanner, (2) generation of shell-type STL data by Boolean operation, (3) division of shell-type STL data into several pieces by solid splitting, (4) generation of USL data for each piece with VLM-Slicer, (5) fabrication of each piece by cutting and stacking according to USL data using VLM-ST apparatus, (6) completion of a shell-type prototype by zigzag stacking and assembly for each piece, (7) completion of a 3D solid shape by foam backing, (8) surface finish of a completed 3D solid shape by coating and sanding. In order to examine the applicability of the proposed method, the miniature of the Mount Rushmore Memorial has been fabricated. The envelope model size of the miniature of the Mount Rushmore Memorial is 1,453 mm${\times}$ 760 mm${\times}$ 853 mm in size. From the result of the fabricated miniature of the Mount Rushmore Memorial, it has been shown that the method to fabricate the large object using two type semi-automatic VLM-ST processes in connection with the reverse engineering technology are very fast and efficient.


Rapid Prototyping;Reverse Engineering;Variable Lamination Manufacturing;Large-Sized Solid Shape


  1. Jacobs, P. E, 1996, Stereolithography and other RP&M Technologies from Rapid Prototyping to Rapid Tooling, ASME Press
  2. Kim, H. C., Hur, S. M., Lee, S. H., 2002, 'STL Generation in Reverse Engineering by Delaunay Triangulation,' Transactions of the KSME, A, Vol. 26, No.5, pp. 803-812
  3. CAM/CAM Publishing, Inc., 2003, 'Rapid Prototyping Large Objects,' Rapid Prototyping Report, February 6
  4. Nove, A., Kaza, S., Wang, Z. and Thomas, C., 1996, 'Techniques for Improved Speed Accuracy in Layered Manufacturing,' Solid Free Fabrication Symposium Proceedings, pp. 609-617
  5. Hope, R. L., Riek, A. T. and Roth, R. N., 1996, 'Layer Building with Sloping Edges for Rapid Prototyping of Large Objects,' Proceedings of the 5th European conference on Rapid Prototyping and Manufacturing, pp. 47-57
  6. Broek, J. J., Horvath, I., de Smit, B., Lennings, A. F., Rusak, Z. and Vergeest, J. S. M., 2002, 'Free-foam thick layer object manufacturing technology for largesized physical models,' Automation in Construction, Vol. 11, pp. 335-347
  7. Hur, J. H., Lee, K. W., Zhu-hu and Kim, J.w., 2002, 'Hybrid rapid prototyping system using machining and deposition,' Computer-Aided Design, Vol. 34, pp. 741-754
  8. Ahn, D. G, Lee, S. H., Choi, H. S., Yang, D. Y., Park, S. K., 2002, 'Investigation into Development of Transfer Type for Variable Lamination Manufacturing Process and Apparatus,' J. of KSPE, Vol. 19, No.2, pp.95-105
  10. Chae, H. C., Chung, I. S., 1993, 'A study on the split triangle-based solid modeling,' J. of KSPE, Vol. 10, No.1, pp. 89-99
  11. Mantyla, M., 1988, An Introduction to Solid Modeling, Computer Science Press, pp. 263-300
  12. Kripac, J., 1987, 'Algorithm for Splitting Planar Faces,' CAD, Vol. 19, No.6, pp. 293-298
  13. Lee, S. H., Ahn, D. G, Choi, H. S., Yang, D. Y, Moon, Y B., Chae, H. C., 2002, 'Generation of Unit Shape layer on CAD/CAM System for VLM-ST,' Trans. of the Society of CAD/CAM Engineers, Vol. 7, No.3, pp. 148-156
  15. Lee, S. H., Kim, H. C., Yang, D. Y., Ahn, D. G., Song, M. S., Park, S. K.,2003, 'Development of Surface Finishing Methodology for the Laminated Pattern Removal of VLM-ST Parts,' Proceedings of KSPE, October, pp. 92-95