Generally electrical circuits are fabricated as PCB(Printed Circuit Board) and mounted on a casing of the product. And it requires lots of other parts and some labor for assembly. Recently a molding technology is increasingly applied to embed simple circuits on a plastic casing. The technology is called as MID(Molded Interconnected Device). Therefore this paper introduces a new MID fabrication process by using direct 3D printing technology.

To date, biomedical application of three-dimensional (3D) printing technology remains one of the most important research topics and business targets. A wide range of approaches have been attempted using various 3D printing systems with general materials and specific biomaterials. In this review, we provide a brief overview of the biomedical applications using 3D printing techniques, such as surgical tool, medical device, prosthesis, and tissue engineering scaffold. Compared to the other applications of 3D printed products, the scaffold fabrication should be performed with careful selection of bio-functional materials. In particular, we describe how the biomaterials can be processed into 3D printed scaffold and applied to tissue engineering area.

Multi-material Additive Manufacturing (AM) is being focused to apply for direct manufacturing of a product. In this paper, a three-dimensional circuit device (3DCD) fabrication technology based on the multi-material AM technology was proposed. In contrast with conventional two-dimensional Printed Circuit Board (PCB), circuit elements and conducting wires of 3DCD are placed in threedimensional configuration at multiple layers of the structure. Therefore, 3DCD technology can improve design freedom of an electronic product. In this paper, 3DCD technology is proposed based on AM technology. Two types of 3DCD fabrication systems were developed based on the Stereolithography and the Fused Deposition Modeling technologies. And the 3DCD samples which have same function were fabricated, successfully.

Recently, 3D printing has received increasing attention due to its boundless potentials. Because 3D printing starts from 3D geometry information, computer-aided design (CAD) is an essential technology to build 3D geometry data. These days, education of 3D CAD for engineering students has been changed from the theoretical lecture to practical design training using commercial CAD software. As a result, open-ended design projects have replaced the traditional theoretical examinations to evaluate students’ outcomes. However, such design projects are not enough to evaluate students’ outcomes because their results are expressed in two-dimensional ways. In this paper, applications of 3D printing in engineering design education are discussed by describing the procedure and outcomes of design projects. It was found that the use of 3D printing could improve students’ outcomes by fabricating real physical models out of their designs.

The goal of this paper is to investigate preliminary the applicability of 3D printing technologies for the development of the hot bulk forming process and die. 3D printing technology based on the plastic material was applied to the preform design of the hot forging process. Plastic hot forging dies were fabricated by Polyjet process for the physical simulation of the workpiece deformation. The feasibility of application of Laser-aided Direct Metal Rapid Tooling (DMT) process to the fabrication of the hot bulk metal forming die was investigated. The SKD61 hot-working tool steel was deposited on the heat treated SKD61 using the DMT process. Fundamental characteristics of SKD 61 hot-working tool steel deposited specimen were examined via hardness and wear experiments as well as the observation of the morphology. Using the results of the examination of fundamental characteristics, the applicability of the DMT process to manufacture hot bulk forming die was discussed.

Hybrid manufacturing technology has been advanced to overcome limitations due to traditional fabrication methods. To fabricate a micro/nano-scale structure, various manufacturing technologies such as lithography and etching were attempted. Since these manufacturing processes are limited by their materials, temperature and features, it is necessary to develop a new three-dimensional (3D) printing method. A novel nano-scale 3D printing system was developed consisting of the Nano-Particle Deposition System (NPDS) and the Focused Ion Beam (FIB) to overcome these limitations. By repeating deposition and machining processes, it was possible to fabricate micro/nano-scale 3D structures with various metals and ceramics. Since each process works in different chambers, a transfer process is required. In this research, nanoscale 3D printing system was briefly explained and an alignment algorithm for nano-scale 3D printing system was developed. Implementing the algorithm leads to an accepted error margin of 0.5% by compensating error in rotational, horizontal, and vertical axes.

In this article, the megasonic cleaning system for cleaning micro/nano particles from flat panel display (FPD) surfaces was developed. A piezoelectric actuator and a waveguide were designed by finite element method (FEM) analysis. The calculated peak frequency value of the quartz waveguide was 1002 ㎑, which agreed well with the measured value of 1003 ㎑. The average acoustic pressure of the megasonic cleaning system was 43.1 ㎪, which is three times greater than that of the conventional type of 13.9 ㎪. Particle removal efficiency (PRE) tests were performed, and the cleaning efficiency of the developed system was proven to be 99%. The power consumption of the developed system was 64% lower than that of the commercial system. These results show that the developed megasonic cleaning system can be an effective solution in particle removing from FPD substrate with higher energy efficiency and lower chemical and ultra pure water (UPW) consumption.

In this article, a 20 kHz ultrasonic waveguide for nano-surface treatment was designed and manufactured. When designing the system, finite element analysis with ANSYS software was performed to find optimal dimensions of the waveguide, which can raise energy efficiency. Consequently an anti-resonance frequency of an Al waveguide with a piezoelectric actuator was 20 ㎑, which predicted the experimentally obtained value of 18 kHz well. For the assessment of the performance, Steel Use Stainless (SUS) 304 and chromium molybdenum steel (SCM) 435 specimens were tested. Cross-sectional microscopies of SUS304 were taken and they showed that the treated thickness was 30 ㎛. Additionally, hardness tests of SCM435 were done and the hardness before the process was 14.0 Rockwell Hardness?C scale (HRC) and after the process was 20.5 HRC, respectively, which means 46% increase. Considering these results, the developed ultrasonic system is thought to be effective in the nano-surface treatment process.

To compensate location error of ultrasonic horn, the laser scanning system based on the galvanometer scanner is developed. It consists of the 3-Axis linear stage and the 2-Axis galvanometer scanner. To measure surface shape of three-dimensional free form surface, the dynamic focusing unit is adopted, which can maintain consistent focal plane. With combining the linear stage and the galvanometer scanner, the scanning area is enlarged. The scanning CAD system is developed by stage motion teaching and NURBS method. The laser scanning system is tested by marking experiment with the semi-cylindrical sample. Scanning accuracy is investigated by measured laser marked line width with various scanning speed.

Fast tool servo (FTS) is an enabling technology to fabricate various shapes of functional surface geometries in a precise and controllable manner. FTS can be also employed as a straightforward and efficient surface treatment way of making such products more durable. In this work, process characteristics using high-precision FTS-based surface texturing were qualitatively and quantitatively investigated to provide a class of surface design rule. The morphologies of surfaces processed with different conditions were first examined by observing the resultant 2D/3D surface profiles. In addition, the effects of the surface treatment using FTS on hardness and wear properties were characterized and compared to those without treatment.

This paper proposes a simple method to improve a sensitivity of a straightness measurement system for a linear stage, which is applied to a system based on a geometric optic method. An optical system for this method is composed of a corner-cube retro-reflector, a ball-lens and a twodimensional position sensitive detector (2D PSD). The effectiveness of the proposed method was examined theoretically, and verified experimentally using a prototype measurement system. The results show that the measuring sensitivity was dependent on the size of the ball-lens and the setup position of PSD from the ball-lens, and that the proposed method is efficient method to improve the measuring sensitivity.

As life expectancy becomes longer, reduction of human muscular strength threatens quality of human life. Many robotic devices have thus been developed to support and help human daily life. This paper deals with a new type of in-wheel actuator that can be effectively used for the robotic devices. BLDC motor, drive board, brake, ARS (Attribute Reference System), and torque sensor are combined in the single actuator module. The torque sensor is used to recognize human intention and the in-wheel actuator drives walking aids in our system. Its feasibility was tested with the active walking aid device equipped with the in-wheel actuator. Based on it, we designed an admittance filter algorithm to react on uphill and downhill drive. By adjusting mass, damping, and spring parameters in accordance with the ARS output, it provided convenient drive to the old on uphill and downhill walks.

Generally, motor controller design is based on its motor dynamics. Therefore, it requires precise information of its motor dynamics. However, most of the low cost DC motors, which are widely used in industries and academia, are provided without such precise information. Even if it is given, the information is mostly imprecise. Following circumstances require one to calculate the motor dynamics information for oneself. This paper presents a simple method to readily apprehend the DC motor dynamics. First, how to establish the model of DC motor dynamics along with the model parameter identification is presented. Then, the parameter values are finetuned until the simulation response based on the dynamics model is close to the experimental response of the motor. Finally, the controller is designed with the established dynamics model. The validity of the designed controller is confirmed by the comparison of the experiment and simulation.

Thermal barrier coating (TBC) which is used to protect the substrate of gas turbine is exposed to high temperature environment. Because of high temperature environment, thermally grown oxide (TGO) is grown at the interface of thermal barrier coating in operation of gas turbine. The growth of TGO critically affects to durability of TBC, so the evaluation about durability of TBC with TGOs of various thickness is needed. In this research, TGO was inserted by aging of TBC specimen to evaluate the effect of the TGO growth. Then thickness of TGO was defined by microstructure analysis, and thermal fatigue test was performed with these aging specimens. Finally, the relation between thermal fatigue life and the TGO growth according to aging time was obtained.

Delta sash is an important part of automobile door, which has the functions of supporting and guiding seesaw of car’s window, preventing dust and air from outside. In previous manufacturing process, each part of the delta sash was independently formed by tandem processes, and rubber is bonded to steel by poisonous glue. So, the previous processes, including roll forming process and toxic gases, had low production rate and high failure rate. In this study, progressive process design of the delta sash was proposed in order to increase productivity and high utilization of the materials. And instead of the poisonous glue used for adhesion of rubber in the previous tandem process, embossing and piercing processes were designed in the new guide to help the rubber to adhere well to steel. And the optimal piercing distance was designed to ensure structural safety, and prototypes were manufactured for verifying reliability of the processes.