本研究目標為將「彈性3D成形技術」(FAM)中的基本表面製程步驟自動化，並與佈料程序整合，以便輸出電腦模型並直接製造出一個3D物件。表面製程步驟的特徵在於熱刮，乃以加熱後的刮棒沿著列印表面進行表面刮平，並與佈料程序連續切換來得到光滑的物體表面。本研究以一個葉輪的部分模型為測試案例，使用ABS作為測試材料，發展熱刮程序如垂直牆、直立的3D表面以及水平表面等典型3D幾何形狀的自動化表面製程步驟，並且製作出用於切換熱刮頭和佈料頭的旋轉機構，以利於交替佈料程序和熱刮程序。實驗上熱刮程序的軌跡與佈料的軌跡相同，但深度資訊、速度資訊、重複次數、去毛邊步驟、工具形狀和溫度控制都會影響表面精度。這些結果將有助於未來在「彈性3D成形技術」(FAM)的佈料和熱刮的自動化發展。

This research develops basic process steps of a surface processing procedure that is to be automated and integrated with the forming process of the Freeform Additive Manufacturing (FAM) to make a 3D object with smooth surfaces directly from a computer model. The surface processing procedure features a hot scraping process that is applied over surfaces of a portion of the 3D object after material dispensing of that portion; and successive steps of material dispensing followed by surface scraping complete an object with smooth surfaces. This research tested and developed automated process steps of hot scraping of typical 3D geometries including vertical wall, erected curved 3D surface and horizontal surface using a partial model of an impeller as test case and ABS as test material. A rotary mechanism for switching between dispensing head and hot scraping head was made to facilitate the alternating dispensing-scraping steps. Trajectories of the hot scraping process steps are basically based on trajectories of material dispensing; but detailed scraping parameters such as depth, feed, speed, number of repeated passes, deburring steps, tool shape and temperature were determined by experiments. The results will be useful for full automation of the dispensing-scraping steps of the FAM process in the future.

[1] 曹哲之，科技部專題研究計畫書《彈性變向佈料高速3D成形技術》計畫編號MOST 103-2218-E-007-011(未公開文件)
[2] Kim, G. D., and Y. T. Oh. (2008) "A benchmark study on rapid prototyping processes and machines: quantitative comparisons of mechanical properties, accuracy, roughness, speed, and material cost." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 222.2: 201-215.
[3] EOS (Germany) product brochure, 數可科技公司(EOS代理)，(2013)台北國際光電展
[4] Lamikiz, A., Sanchez, J. A., de Lacalle, L. L., & Arana, J. L. (2007), “Laser polishing of parts built up by selective laser sintering”, International Journal of Machine Tools & Manufacture 47 2040-2050
[5] Dolenc, A. and Makela, I. (1994) “Slicing procedures for layered manufacturing techniques”, Computer Aided Design, Vol. 26 No. 2, pp. 119-126
[6] Sabourin, E. et al. (1996) “Adaptive slicing using stepwise uniform refinement”, Rapid Prototyping Journal, Vol. 2 No. 4, pp. 20-26
[7] Chakraborty, D. et al. (2008), “Extruder path generation for curved layer fused deposition modeling”, Computer Aided Design, Vol. 40 No. 2, pp. 235-243
[8] Huang, B. (2009), “Development of a Software Procedure for Curved Layered Fused Deposition Modeling (CLFDM) ”, Diss. Auckland University of Technology
[9] Huang, B. and Singamneni, S. (2012), “Evaluation of deposition strategies for a curved fused deposition modeling part”, paper presented at The GCMM2012, Auckland
[10] Page, J.S.(2015), “Systems and Method for Improved 3D Printing” US Patent NO 0266244A1
[11] Robert L. Zinniel(2011), “Vapor Smoothing Surface Finishing System” US Patent NO. 8075300
[12] Priedeman Jr, W. R., & Smith, D. T. (2012), “Smoothing Method for Layered Deposition Modeling” US Patent NO 8123999
[13] Smooth-On Inc. 參閱 :
http://www.smooth-on.com/Epoxy-Coatings-XTC/c1397_1429/index.html
[14] Polymaker_polysmooth，參閱 :
http://www.polymaker.com/alcohol-vs-acetone-polysmooth-vs-abs/
[15] Kulkarni, P.,Dutta, D.(2000), “On the Integration of Layered Manufacturing and Material Removal Processes” Journal of Manufacturing Science and Engineering, Vol. 122, pp100-108
[16] Taufik, M., & Jain, P. K. (2019), “Development and Analysis of Accurate
and Adaptive FDM Post-finishing Approach” 3D Printing and Additive Manufacturing Technologies pp. 66-78 , Springer Nature Singapore Pte Ltd.
[17] 張禾炘(2016)，《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》，國立清華大學碩士論文
[18] Gadelmawla, E. S., et al. (2002), “Roughness parameters” Journal of Materials Processing Technology 123. 133-145
[19] 張萬欽(2006)，表面粗度，參閱:
http://dragon.ccut.edu.tw/~mejwc1/p-mea/content/ch_18.pdf
[20] Che-Chih Tsao. (2018)《彈性變向佈料高速3D 成形技術》ROC Patent No. I611909
[21] Che-Chih Tsao*, Ho-Hsin Chang , Meng-Hao Liu, Ho-Chia Chen, Yun-Tang Hsu, Pei-Ying Lin, Yih-Lin Chou, Ying-Chieh Chao, Yun-Hui Shen, Cheng-Yi Huang, Kai-Chiang Chan, Yi-Hung Chen , (2018), “Freeform Additive Manufacturing by vari-directional vari-dimensional material deposition”, Rapid Prototyping Journal, vol. 24, No. 2, pp. 379-394
[22] EPCIO Series運動控制函式庫使用手冊V.5.10.(2010)，參閱 : https://www.epcio.com.tw/paper/EPCIO%20Series%E9%81%8B%E5%8B%95%E6%8E%A7%E5%88%B6%E5%87%BD%E5%BC%8F%E5%BA%AB%E4%BD%BF%E7%94%A8%E6%89%8B%E5%86%8A(V.5.10).pdf，工研院
[23] Acetone MSDS, “http://www.sciencelab.com/msds.php?msdsId=9927062”