臺灣博碩士論文加值系統

一套典型的彩色光固化積層製造(Additive Manufacturing, AM)3D列印系統包含3D數位設計技術、色彩學、材料噴印技術、材料科學、數位製造與智慧控制的機電整合系統。從簡而論，堪用的光固化積層製造系統即是列印端、光敏樹酯固化模組與軸向控制結合編碼器回授整合。然而，以使用多壓電噴頭的材料噴印作為列印技術核心，簡易的系統，會遇到諸多問題而妨礙系統的長時間穩定運作，如液滴尺寸不均、印刷過程不穩定以及成品質量低等問題，甚至是引起壓電噴頭模組損壞。
本研究主要目的是採用多壓電噴頭，開發基於材料噴印技術(Material-jetting)之光固化彩色3D列印系統，達成穩定連續列印、三維物件成型、高色彩表現、系統參數優化與監測系統的開發為核心目的。首先，在列印模組端結合五種光固化材 (青色、洋紅色、黃色、白色、黑色)和支撐材的光固化列印系統；並結合壓電噴頭驅動波形設計與列印行程規劃，達到列印模組運作最佳化。本研究已具備了色彩混色、壓電材料處理技術、CMYKWS光固化材料技術與多噴頭控制技術整合於系統中。再建立連續供墨系統、正負壓系統與除廢料系統使維持列印穩定，墨量增加設計與列印模式開發讓系統能更有效率的列印。
綜上所述，本研究對於原先的多噴頭多色光固化系統進行軟、硬體層面優化，提升列印效率與品質，物件疊層控制更加精確，整體列印解析度達到600dpi、最大層厚達到20μm、3D成型物件有高於256以上的色彩表現。

A traditional additive manufacturing (AM) system is composed of 3D digital design technology, chromatics, material jetting, material science, digital manufacturing and intelligent control of a mechatronics system. In short, the light-cured additive manufacturing system is combined with printed side, photosensitive resin curing module, axial control and encoder feedback. However, there are plenty of disadvantages in such a system such as uneven size of droplet, unstable printing process and low quality of end product, which may cause damage of piezoelectric heads and module.
The main purpose of this study is to develop a Material Jetting (MJ)-based high color performance 3D printing system by using multiple piezoelectric heads, optimizing sub-system parameter, designing a stable module and setting monitoring system. First of all, capability of printing five different colors (CMYKW) and ultraviolet (UV) curable support material were studied. The waveform editing and printing program planning were integrated to maximize the performance of print modules. The integration of color mixing, piezo material process, CMYKWS curable process and multi-inkjet head control have been carried out in the system. The establishment of continuous ink supply system, pressure system and waste removal system are utilized to maintain a stable printing. Increased ink volume design and print mode development allow a more efficient printing.
The experimental results show that this material jetting based color 3D printing system could achieve both high resolution of 600dpi and more than 256 colors. This study conforms to the future development trend and market demand on color 3D additive manufacturing industry.

中文摘要 I
Abstract II
誌謝 III
目錄 IV
圖目錄 VII
表目錄 IX
第一章 緒論 1
1.1 研究背景 1
1.2 研究動機與目的 2
1.3 研究方法與步驟 3
1.4 本文架構 4
第二章 文獻回顧與技術探討 5
2.1 彩色積層製造技術發展 5
2.1.1 材料擠製成型(Material Extrusion) 8
2.1.2 疊層製造成型(Sheet Lamination) 9
2.1.3 黏著劑噴膠成型(Binder Jetting) 10
2.1.4 材料噴塗印技術(Material jetting) 11
2.2 噴頭噴印技術介紹 12
2.3 壓電波形設計 14
2.4 色彩分色技術 16
2.5 3D列印系統開發相關專利 17
第三章 系統開發環境 18
3.1 噴印控制模組 18
3.2 Ricoh Gen5 壓電噴頭 20
3.3 運動控制模組 21
3.4 列印成型模組 24
3.5 週邊優化模組 25
第四章 彩色3D列印系統架構優化 29
4.1 彩色3D列印系統架構 29
4.1.1 光敏樹酯材料適應性驅動波型設計 31
4.1.2 多噴頭列印系統建立 32
4.2 優化系統控制介紹 34
4.2.1 連續供墨系統架構 37
4.2.2 穩定正負壓系統架構 41
4.2.3 整平裝置控制優化 43
第五章 控制程式設計優化 46
5.1 整合人機介面介紹 46
5.2 列印程式運作流程 48
5.3 標準列印模式 50
5.4 圖像分割列印模式 51
5.4.1 列印模式設定 51
5.4.2 基準點介紹 52
5.4.3 圖像像素計算 53
5.4.4 圖像分割列印流程 55
5.5 增加墨量設計 56
5.5.1 編碼器回授 56
5.5.2 增加墨量實踐 58

第六章 研究成果 61
6.1 點線尺寸驗證 61
6.1.1 標準列印 62
6.1.2 墨量增加設計 63
6.2 色彩表現 65
6.3 有無墨量增加設計層厚比較 66
6.3.1 無滾平堆疊厚度比較 67
6.3.2 有無墨量增加設計層厚比較 68
6.3.3 基於墨量增加設計之圖檔補償列印 69
6.4 圖像分割列印 70
6.4.1 噴印尺寸極限實驗 71
6.4.2 圖像分割列印實際測試 71
6.5 邊緣銳利度 72
6.6 色彩漸層與疊層關係 73
6.7 滾平成效與紋理展示 73
6.8列印塌陷 74
6.9顏色侵蝕 74
第七章 結論與未來研究方向 75
7.1 結論 75
7.2 未來研究方向 76
參考文獻 77

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