目前要快速及量產製作大型工件，皆須藉由模具來製造，而最常見到製作模具的方法則為砂模鑄造。傳統製作模具皆是藉由木模進行製作，除了成本較高，以及生產的模具複雜度較低之外，且砂模與砂心由於強度需求不同，因此必須分開設計及製作，造成模具開發上的時間增加。因此本研究研發出一套以多壓電噴頭及黏著劑噴印技術之積層製造系統，使用商用矽砂與呋喃樹酯材料。導入灰階與波型設計方法，可同時印製出不同強度需求的砂模如砂心，最後以熔融金屬液澆鑄於砂模進行驗證。
本系統藉由PC-Based控制系統，進行多壓電噴頭控制、三軸向控制、供墨模組以及鋪層機構的整合，人機介面則是利用C#進行撰寫。壓電噴頭則是採用八排交錯且共高達1024個噴孔，可印製出400DPI解析度的圖案。並藉由三個壓電噴頭拼接，有效噴印範圍最大達到長280 mm、寬194 mm、高200 mm，最小層厚為0.3 mm，列印能力可達到3.91 L/hr。在印製不同黏結強度的模具部分，係設計一套灰階調整系統，藉由調整匯入圖檔的灰階度，以及設計壓電噴頭的波型控制黏著劑噴印墨量，來達到黏結強度差異性。並藉由壓力測試，量測印製出的模具黏結強度，來驗證噴印墨量與模具黏結強度關係。同時參考鑄造丙級證照之鑄件，將模具設計成上、下兩模，並以本系統印製出來，進行合模完成後，利用A356鑄鋁成功的進行澆鑄，經冷卻固化完成拆模後可獲得完整鑄件成型。

關鍵字：積層製造、黏著劑噴印、壓電波形、砂模強度。

Recently, it is necessary to manufacture larger scale parts quickly and mass-produced by molds. The most common method for making molds is sand casting. The traditional process method applied the wooden mold to make the sand mold. However, the sand molds and cores have different strength requirements which are restricted to the part’s complexity. It costs highly, and must be designed and manufactured separately. It results in longer develop time. Therefore, the purpose of this study is to setup a Binder-Jetting (BJ)-based additive manufacturing system with multiple piezoelectric heads by using commercial sand and furan resin. The system can print sand molds with different strength requirements such as sand cores by employing grey and waveform design methods simultaneously. Finally, some casted parts were obtained from the printed sand molds with casting molten metal.
The developed system utilizes a PC-Based controller to integrate multiple piezoelectric heads, motion control, continuous ink supply module, paving mechanism, and the human-machine interface which was written by C#. The used piezoelectric head has a total of 1024 nozzles in eight rows. The resolution of 400 dpi can be obtained by using all rows. By using width combination of three piezoelectric heads, the effective printing range can be up to 280 mm long, 194 mm wide, 200 mm high, with a minimum layer thickness of 0.3 mm and a printing capacity of 3.91 L/hr. The molds can be printed under different bonding strengths by using a gray scale pattern to control the amount of printed ink by the piezoelectric nozzle with a corresponding waveform design. Through the pressure test, one can measure the bond strength of the printed mold to verify the relationship between the amount of sprayed ink and the bond strength of the mold. At the same time, referring to the required part of the casting grade C license, the mold is designed into upper and lower molds, and printed by this system. After the molds were assembled, the casting part of the A356 cast aluminum is successfully achieved after the cooling and solidification process.

Keywords: additive manufacturing, binder jetting, piezoelectric waveform, sand mold strength.

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