本研究的目的是發展「彈性變向佈料高速3D成形技術」製造金屬材料製品的佈料系統及製造程序。研究以錫合金及鋼鐵為材料，以模具為應用目標。經由研究過程中實驗裝置的設計與試驗，作定性地觀察及系統性地記錄與歸納，了解錫合金及鋼鐵材料的熔化、流動、結合、凝固等成形特性，讓熔融材料能依據佈料頭的設計以出料、成形，完成彈性變向佈料高速3D成形技術的幾個成形基本動作的試驗。在錫合金成形方面，使用烙鐵系統作為加熱源，選擇紅銅合金來製作佈料頭，並根據成形的目的，設計不同的佈料頭樣式，讓熔融材料能順利且連續地成形。在鋼鐵成形方面，使用微電弧焊接機作為系統的加熱源，根據熔焊加工技術的要領，再加上佈料頭、微分模具的設計與配置，完成彈性變向佈料高速3D成形技術的成形基本動作。本研究目標為製作表面光滑度更好的金屬模具，使用錫合金，製作消失式模鑄造所需使用的模具，取代原本製蠟型需要的鋁模，可大幅降低生產成本；使用鋼鐵材料，可以製作具有複雜異型冷卻水路的塑膠射出成形模具模心，藉由一加減複合加工的製程方式，減少模具生產時間，也因不使用雷射，可顯著降低製造上的成本。

The purpose of this research is to develop the material dispensing head and manufacturing processes of the new “Flexible 3D Freeform Techniques” using tin alloys and steel. The research made systematic tests and observations using prototype devices of various designs with the target metals in order to understand the forming characteristics of molten metal, such as melting, flowing, bonding and solidifying. By analyzing 3D geometry, five basic process operations were summarized as the fundamental operations to build a 3D object by the Flexible 3D Freeform Techniques. In the forming of tin alloys, a soldering iron system was used as the heat source and copper was used to make the dispensing heads. Various dispensing head prototypes were developed and successfully tested to dispense and form tin alloys of different geometric shape features and demonstrated the five basic process operations. In the forming of steels, a micro plasma arc welding system was used as the heat source and similar demonstrations were achieved. The potential application of this technique is rapid prototyping and production of injection molding molds with good surface finish at significantly higher speeds and lower costs compared to existing rapid prototyping processes.

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