本論文目的為提出一誤差補償方法以減少非球面軟式隱形眼鏡殼模在射出成形製程上所產生之收縮誤差。殼模材料為聚丙烯(Polypropylene, PP)，殼模作為二次模造製程之工具以製作非球面軟式隱形眼鏡。本研究主要以Moldex3D R13.0模流分析軟體對非球面軟式隱形眼鏡殼模Z軸向最佳收縮翹曲量作多項式曲線擬合(Polynomial Curve Fitting)，將收縮誤差量之點資料回饋至SolidWorks軟體，重新建構出補償後之殼模，並修正模具之模仁的實體，最後匯入Moldex3D模擬比較誤差補償前後之收縮翹曲量差異性。經模流分析後顯示誤差補償的效果是非常明顯，整體改善率達80.1%。模擬實驗中根據迴歸方程式結果得知熔膠溫度為影響收縮翹曲最主要參數，熔膠溫度的影響程度最高占41.30%，其次為射出速度影響程度為11.95%與保壓壓力的影響程度11.95%。此外藉由表面輪廓量測儀比對分析殼模誤差補償前後之形狀誤差以確保產品品質，並利用鑄模成形法製作軟式隱形眼鏡，實驗結果得知隱形眼鏡之中心厚度平均為0.082mm與設計值誤差僅2.5%。本研究成果未來可進一步使用在非球面元件與多非球面曲面元件。

This study aims to develop a method to estimate and reduce the shrinkage error of PP part of shell mold produced by injection molding process and further used for casting of soft contact lens as HEMA material. A two-stage molding process has been commonly used with shell mold as molding tool for casting of contact lens. In this study, a CAE simulation software, Moldex3D R13.0 has been used to simulate and analyze the shrinkage warpage of the Z-axis of the shell parts by injection molding. The feedback shrinkage error from Moldex3D to SolidWorks software can be used to construct the shell mold profile imported after compensation. Comparison with these results is to verity the difference of shrinkage error. From CAE analysis after error compensation, it is improved as 80.1%. Experimental results show that the melt temperature is the main parameter for shrinkage and warpage of part of shell mold. Comparison analysis of from error compensation before and after the part of shell mold has been ensured for product quality in cast molding method to manufacture soft HEMA contact lenses. Results show that the center thickness of HEMA contact lens is 0.082mm as compared with design specification as error 2.5%. Further research can focus on aspherical element and multi-aspheric elements for progressive contact lens applications.

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