下照式面光源快速原型機相較於單點雷射掃瞄方式快速原型機具有建構工件快速的優點，雖然大幅縮短建構的時間，但卻無人探討其精度，因此本論文藉由田口方法(Taguchi’s method)探討下照式面光源動態光罩快速原型機(rapid prototyping)之最佳建構參數研究，以得到工件之最佳輪廓尺寸精度。
實驗載具的設計包含2.5D規則幾何形狀與曲面輪廓，藉由田口方法之L18直交表實驗，並計算2.5D規則幾何形狀及曲面輪廓之實驗載具輪廓精度之S/N Ratio值，再依不同的權重分配去合成綜合加工參數，該組參數組合可針對規則幾何形狀及曲面輪廓加工具最佳輪廓精度，而此組合參數分別為白光光源、切層厚度0.05 mm、曝光時間25 sec、Z軸上升速度2.5 mm/sec與輪廓強化曝光時間0 sec，加工完成之實驗載具的輪廓精度之RMSE(root-mean-square error)為0.172 mm。最後將最佳建構參數應用於3D自由曲面載具與工業用小型風扇之製作，分別以CNC五軸三次元量測座標儀（CMM）檢測3D自由曲面載具，OTM3A-20雷射探頭檢測工業用小型風扇，檢測結果經運算後，3D自由曲面載具輪廓精度之RMSE為0.07 mm，工業用小型風扇輪廓精度之RMSE為0.158 mm。

The down-projected DLP-based rapid prototyping (RP) system, like top-projected solid ground curing RP system, has the advantage of high fabrication speed in comparison with the traditional stereolithography RP system. However, the profile accuracy of the RP parts fabricated by this system has not been investigated before. The objective of this research is to determine the optimal fabrication parameters for the DLP-based rapid prototyping system using the Taguchi’s method, so that the optimal profile accuracy of a RP part can be obtained.
A test specimen, including some regular geometric profiles (triangle, rectangle, and cylinder) and a sphere surface profile, was designed to carry out the experiments configured by Taguchi’s L18 orthogonal table. The S/N ratios for the regular geometric profiles and the sphere surface profile were calculated individually after carrying out the experiments. A synthetic index was determined by mixing some different S/N ratios of the regular geometric profiles and the sphere surface profile with different weighting factors, to obtain the optimal profile accuracy of the RP specimen. The optimal fabrication parameters could then be determined based on the synthetic index. The determined optimal combined parameters were: white light source, slicing thickness 0.05 mm, exposed time 25 seconds, z-axis speed 2.5 mm/s, contour exposed time 0 second. The root mean square error (RMSE) of the tested specimen profile was about 0.172 mm in average by utilizing the optimal fabrication parameters. The optimal fabrication parameters were applied to manufacture a 3D freeform surface test RP part. The RMSE of the 3D freeform surface test RP part was about 0.07 mm, measured by a coordinate measuring machine (CMM). Applying the optimal fabrication parameters to fabricate an industrial heat-dissipated fan, the profile accuracy manufactured by the determined optimal fabrication parameters was better than that manufactured by the default fabrication parameters.

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