低耗減廢模具積層製造技術

傳統大型射出異形水路3D列印模具常面臨加工需多餘預留量（1–2 mm）、材料浪費、變形量大於1 mm及列印時間冗長（30–40 天）等問題。為改善此瓶頸，本研究提出三項技術方案：其一，透過熱變形優化列印參數以降低後加工預留量；其二，導入專利加熱平台以減少熱裂紋並提升良率；其三，應用可調控緻密度（孔隙率）之快速列印技術。實驗結果顯示，二次加工預留量可降至0.2–0.5 mm，材料節省7.8 %；大型模具（180 mm 以上）變形量控制於0.1–0.2 mm，製程穩定性顯著提升；列印時間則縮短至13–18 天，減幅超過56 %。綜合而言，本研究之低耗減廢積層製造技術可有效提升模具製程效率與品質，具實務應用推廣價值。

Conventional 3D printing of large injection molding tools with conformal cooling channels often suffers from excessive machining allowance (1–2 mm), material waste, deformation exceeding 1 mm, and long printing cycles (30–40 days). To address these challenges, this study introduces three technical solutions: (1) optimization of printing parameters to reduce thermal deformation and post-processing allowance, (2) implementation of a patented heated platform to minimize thermal cracking and improve yield, and (3) application of variable porosity control for accelerated printing. Experimental results demonstrate that the secondary machining allowance can be reduced to 0.2–0.5 mm, saving 7.8 % of material volume. For large molds (over 180 mm), deformation is controlled within 0.1–0.2 mm, significantly enhancing process stability. Furthermore, printing time is shortened to 13–18 days, achieving a reduction of more than 56 %. Overall, the proposed low-waste additive manufacturing technology effectively improves both efficiency and quality of mold fabrication, showing strong potential for industrial application.