隨著積層製造（Additive Manufacturing , AM）技術的出現，現在可以實現更加複雜的仿生設計，並且可以為終端用戶及其應用製作客製化與優化的產品。然而，目前的積層製造技術仍存在許多挑戰，並限制其製造最終產品的能力。而該行業面臨的其中一個挑戰，是如何將傳統的量產技術與積層製造相輔相成，從而增加使用3D列印設計的機會。
這一挑戰可以透過正確實施積層製造設計（Design for Additive Manufacturing, DfAM）的原則來解決；但在大規模採用積層製造技術中有另一個鮮少被討論的問題，那便是不同的積層製造技術中所牽涉到的後處理（Post-Processing , PP）也不盡相同。在3D列印的後處理階段中，像支撐材料、粉末或樹脂的去除，仍是一個需要手動移除的過程，此過程需要大量人力且不易掌控結果，這無疑增加了成本並可能降低列印零件的品質。為此，本研究提出了一種新的積層製造設計和後處理（DfAM＆PP）方法。
結合增材製造和傳統製造、大規模定制和按需製造進行大規模生產的高速 3D 打印的關鍵在於使用基於粉末床的增材製造技術。在本論文中，將透過設計應用於多種粉床成型技術中的仿生晶格結構，來解決上述挑戰。首先，製作了一款基於桁架所設計的晶格結構，其結構透過選擇性雷射熔融技術（Selective Laser Melting , SLM）與傳統注塑成型技術，將塑膠與金屬在界面上相互接合，製造出塑膠和金屬一體成型的零件。接下來，本研 究的重點在於仿生晶格結構的設計和流體力學分析，以解決例如HP公司的Multi Jet Fusion（MJF）粉末床製造技術的粉末後處理。同時對新型仿生晶格結構和其他不同晶格結構進行了流體力學（CFD）和有限元素（FEA）分析，以預測其機械性能，隨後再進行實驗驗證。
最後，為了分析流體力學以及熱傳導，設計並製造出針對粉末移除的晶格結構，並於專為熱流分析的環境中，測試不同的晶格結構。而該結構使用Digital Metal的金屬黏著劑噴印技術製作，常用於電子元件的冷卻管道和散熱裝置。本研究中討論的新型設計方案和晶格結構具有廣泛的工業應用，包括生物醫學植入物、鞋子中底和鞋墊設計、食品和藥品投遞系統，特別是電動汽車的能源管理系統。

With the advent of advanced technologies for additive manufacturing (AM), more sophisticated bioinspired designs can now be realized for products that are customized as well as optimized for end users and their applications. However, there are still many challenges in the present AM technologies that limits them from making the final end use products. One of the challenges that the industry is facing is to how to combine or complement their traditional mass-manufacturing techniques with AM so as to leverage the design opportunities of 3D printing. This challenge can be addressed by proper implementation of the principles of design for additive manufacturing (DfAM). But the other seldomly talked about challenges for large-scale adoption of AM in the industries is the post-processing (PP) challenges involved in the various techniques of AM. The removal processes, like the support, powder, or resin removal at the PP stage after 3D printing remains to be a largely labour-intensive, uncontrolled and manual process that adds to the cost and may deteriorate the quality of the parts fabricated by 3D printing. Therefore, a novel methodology of design for additive manufacturing and post-processing (DfAM&PP) has been proposed in this research work.
The powder-bed based AM technologies holds the key for high-speed 3D printing for mass production with combined additive and traditional manufacturing, mass customisation and on-demand manufacturing. In this thesis, the above challenges have been tried to address by designing bio-inspired lattice structures for fabrication by several powder-bed based AM technologies. Firstly, the truss-based lattice structures were designed and made by selective laser melting (SLM) technology to obtain a metal-polymer interface during the traditional injection molding technology. Later, the major focus of the research lies in designing and analyzing of flow-based bio-inspired lattice structures to address the post-processing powder removal challenges of polymer powder-based AM, like the HP multi-jet fusing (MJF) technology.
Computational fluid dynamics (CFD) and finite-element analysis (FEA) of the novel bio-inspired lattices and various other lattices were carried out for analyzing and predicting their mechanical behavior, followed by experimental verifications. Finally, the flow functional based lattice structures designed for powder removal was used for analysis of flow and heat transfer application in the design of cooling channels and heat sinks for the thermal management for modern electrical machines and electronics devices. These lattice structures were then made by the Digital Metal metal binder jetting technology and tested in an experimental setup designed for the flow and heat transfer analysis of different lattices. The novel design method and the lattice structures discussed in this study have a wide range of industrial applications, including bio-medical implants, mid-sole and insole designs for footwear, food and drug delivery systems, and particularly energy management systems for electric vehicles.

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