彈性變向佈料高速3D成形技術：熱塑型塑膠佈料系統與製程開發

High Speed Flexible 3D Freeform Technique: Material Dispensing System and Process Development for Thermoplastics

張禾炘

快速成形技術 ； 積層製造 ； 製程開發 ； rapid prototype ； Additive Manufacturing ； process development

清華大學動力機械工程學系學位論文

2016年

碩士

曹哲之

繁體中文

本研究的目的是發展「彈性變向佈料高速3D成形技術」製造熱塑型塑膠製品的佈料系統及製造程序。此技術的主要特徵為帶狀出料以及沿著3D製件表面的切線方向佈料，有別於現行各種水平積層的快速成形方法，因此首先試驗出料的可行性，爾後展示彈性變向佈料3D成形技術的基本成形動作：帶狀出料(Dispensing and Shaping by trajectory)、疊合(Stacking)、接合(Attaching)與縫合(Stitching)，並研究動作完成方法(佈料頭與塑料相對位置)及相關製程參數，如進料速度、出料速度、工作溫度，接下來依照掌握的材料特性進行佈料系統設計，包含進料機構的規格評估及設計、佈料頭的型式，以及寬度調變的設計與自動化，最後為因應未來各種可能製造的物件，本研究以各種物件幾何特徵為範例發展製造程序，研究成形的方法及相關製程參數。

This research aims to develop a set of material dispensing system and process that meets the requirement of manufacturing thermoplastic product by using the new “High Speed Flexible 3D Freeform Technique”. Dispensing ribbon-shaped material and forming along the trajectory tangent to the surface of three-dimensional manufacturing part are the characteristics of the High Speed Flexible 3D Freeform Technique that makes it different from other existing rapid prototyping processes. Accordingly, this research tested the feasibility of ribbon-shaped dispensing and five basic process operations: dispensing, shaping, stacking, attaching and stitching. It was found that operation details such as relative position between the dispensing head and the dispensed material and the process parameters including dispensing speed, material feed rate and dispensing head temperature were important factors. Separate experiments were conducted to determine the ranges of these factors for best dispensing and forming results. According to the above results, a prototype material dispensing system including a feeding mechanism, a dispensing head and a mechanism for adjusting the width of dispensed material were design and built. Using the prototype system, ribbon-shaped material dispensing, the five basic process operations were demonstrated and various example 3D objects were successfully fabricated according to the features of the High Speed Flexible 3D Freeform Technique.

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