臺灣博碩士論文加值系統

本研究研製利用積層製造原理中的光聚合固化成型技術(Vat Photopolymerization , VP)為主軸，並配合數位光固化技術(Digital Light Projection, DLP)輸出每一層光罩搭配下照式(Bottom Up)成型技術來固化所調配的不銹鋼漿料。利用數位光固化(DLP)的快速光罩輸出優勢與下照式系統(Bottom Up)成型技術的低材料使用量，來降低整體製程的成本與加工時間，並提高經濟效益。市面上常見的光固化三維列印機材料幾乎都為單純的樹脂，難以成為金屬漿料，因為需要克服快速沉澱的問題。因此、本研究測試金屬漿料配方的比例，將不銹鋼材料混入樹脂，以下照射式DLP光固化機列印不銹鋼綠胚，再進行燒結不銹鋼綠坯，因不銹鋼粉與樹脂材料熔點不同使樹脂材料氣化，進而獲得不銹鋼的列印製品。但不銹鋼材料在燒結時會產生收縮。綠胚的模型需要依據收縮率而放大列印，則燒結後才能獲得較精確的尺寸。實驗結果發現漿料每100g裡包含60wt%不銹鋼粉末與40wt%光固化樹脂，在經過球磨提高分散性與降低粒徑，可以成功的利用下照射DLP光固化三維列印機製作出綠胚，其放大率為111%。在藉由放大原始設計模型尺寸進行列印綠胚可以獲得小於0.05mm的誤差量。

Lithography-based additive manufacturing (AM) is becoming popular in manufacturing industry. In this study, Digital Light Processing (DLP) is chosen as the light source in our developed 3D printer. Photo-curable resin is the most popular materials used in the market which can’t be preserved for a long time and broken easily. DLP and ceramic are successfully applied in the printing of dental model. Most of the structures of machine are Top-Down. Compared with Top-Down design, the Bottom-up 3D printer can not only reduce wasting of the materials but also enhance the efficiency of manufacturing. So, the Bottom-up structures is chosen in this study. The stainless steel-based 3D printer is designed and developed for the metal 3D printing. Slurry of this study is photo-curable resin "3DV1" and stainless steel powder is "304". 60wt% powder and 40wt% resin are the slurry dispersed by ball milling which can increase the distribution and reduce the particle size. The high size control is needed for the accuracy of the green part during printing process because the green part of stainless steel fabrication will shrink after sintering. In this study, the 60wt% stainless steel slurry is successfully fabricated, measured, and sintered.

中文摘要...i
Abstract...ii
誌謝...iii
目錄...iv
表目錄...vi
圖目錄...vii
第一章 緒論...1
1.1前言...1
1.2研究背景...3
1.3研究導論...3
1.4論文架構...5
第二章 文獻回顧...6
2.1積層製造原理...6
2.2材料擠製成型技術(Material Extrusion, ME)...7
2.3黏著劑噴塗成型技術(Binder Jetting, BJ)...8
2.4材料噴印成型技術(Material Jetting, MJ)...9
2.5粉末床熔融技術成型技術(Powder Bed Fusion, PBF)...9
2.6光聚合固化成型技術(Vat Photopolymerization, VP)...10
2.6.1立體光雕技術(Sterolithography Apparatus, SLA)...11
2.6.2 數位光固化成型技術(Digital Light Processing, DLP)...11
2.6.3上照式與下照式投影固化之區別...12
第三章 實驗系統規劃...15
3.1實驗規劃...15
3.2 機台建構...15
3.2.1疊層系統...16
3.2.2樹脂槽系統...17
3.2.3光源系統...19
3.2.4驅動硬體...20
3.2.5機器實體輸出...21
3.3 實驗流程...22
3.3.1 電腦輸出端...23
3.3.2光罩處理...24
第四章 漿料調配...27
4.1材料選擇...28
4.2粉體改質...30
4.2.1鈦酸酯偶聯劑...30
4.2.2粉體表面噴塗...31
4.3球磨研磨...32
第五章　實驗結果...34
5.1樹脂槽系統比較 34
5.2列印誤差 34
5.2.1光輻照度與波形區間量測...35
5.2.2 2.5D影像量測儀之應用...36
5.3建構對象(生胚)...37
5.3.1齒輪列印(生胚)...39
5.4高溫燒結...40
第六章　結論與未來展望...41
6.1結論...41
6.2未來展望...42
參考文獻...43
Extended Abstract...44

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