在快速原型技術領域中，目前發展最迅速，產值增加最明顯的當屬快速模具(Rapid Tooling, RT)技術。而現行可結合RP/RT技術直接製造澆鑄金屬快速模具之機台，其造價及相關耗材均相當昂貴。有鑑於此，本研究已成功研發出二種價格低廉之石膏基複合粉末，且此二種粉末皆能於價格低廉之Z402機台上成型模具，直接澆鑄不同溫度等級之合金熔液成型金屬工件，此製程不啻為RT產業之革命性的重大突破。研究過程中，已成功歸納出石膏基複合粉末成型與否之判定條件為：(1)級配分佈曲線須為一優良級配且曲率係數(Cc)值須介於1.1~1.5間，而均勻係數(Cu)則須大於3.35以上；(2)安息角須小於43度；(3)凝固時間須少於40分鐘且飽和度為100%時所調成之漿液須能延展拉伸達15 mm以上之長度；須同時具備以上(1)~(3)之條件時，方可於粉末型之快速原型機(Z402)上成型。而在製程參數最佳化方面，針對泛用型粉末(NCKU-1)與耐溫型粉末(NCKU-FR)之製程參數的最佳化設定值也已做出結論，依據此設定值製成之原型件的尺寸精度，NCKU-1粉末在X向可達到13± 0.08 mm；Y向為126± 0.07 mm；而Z向則為7± 0.06 mm；而NCKU-FR粉末在X向可達到13± 0.04 mm；Y向為126± 0.06 mm；而Z向則為7± 0.08 mm，三個方向之尺寸精度均已遠超過原廠所宣稱之精度值。而在與原廠粉末(ZP100)之品質特性量測值相較時，NCKU-1之製作時間約可縮短16.71%、膠水用量約可省下35.37%、強度約可增加172.92%；而NCKU-FR之製作時間約可縮短7.96%、膠水用量約可省下26.53%、強度約可增加194.12%。

In the field of rapid prototyping, the fastest technique in the-state-of-the-art and the most pronounced increase in output value is rapid tooling (RT). It is expensive in manufacturing cost associated with its consumed materials to combine the RP/RT manufacturing technologies with the current rapid metal-casting machinery. The author has developed two kinds of new formula of gypsum-based compound (NCKU-1 and NCKU-FR) which are compatible with the Z402 machine. The costs of these two powders are inexpensive, and these powders could form a direct metal-casting mold on the Z402 machine for casting a high-temperature metallic solution. The achievement of this process is indeed a revolutionary breakthrough for the field of RP and RT production. Also, the author has established the criteria for successfully forming the mold of gypsum-based compound. These criteria include: (1) the particle size distribution curve must be a well-graded curve --- its coefficient of curvature (Cc) needs to be in a range from 1.1 to 1.5 and the coefficient of uniformity (Cu) needs to be greater than 3.35; (2) the angle of repose must be less than 43 degree; and (3) the solidification time must be less than 40 minutes. Besides, the length of saturated mixing powder slurry must be able to extend to more than 15 mm. While developing a new powder mix formula, the above-mentioned three criteria must be established simultaneously in order to be allowed to form on a powder-based RP machine (Z402). With respect to optimization of process parameters, this research study has established optimal parameters conditions based on the universal type powder (NCKU-1) and the thermal-resisted type powder (NCKU-FR), and minimal errors for dimensional accuracy: (1) dimensional accuracy of NCKU-1 powder is optimized as 13 ± 0.08 mm in the X-direction, 126 ± 0.07 mm in the Y-direction and 7 ± 0.06 mm in the Z-direction, which are superior to the claimed value by the original manufacturer; while (2) dimensional accuracy of NCKU-FR powder is optimized as 13 ± 0.04 mm in the X-direction, 126 ± 0.06 mm in the Y-direction and 7 ± 0.08 mm in the Z-direction, which are also superior to the claimed values by the original manufacturer. Finally, the quality of manufacturing process between the original manufacturer (ZP100) and the present study (NCKU-1 and NCKU-FR) is being compared. It is concluded that manufacturing time decreases 16.71 %, binder used reduces 35.37 %, and flexural stress increases 172.92 % if the powder used was switched from ZP100 to NCKU-1. It is also concluded that the manufacturing time decreases 7.96 %, binder used reduces 26.53 %, and flexural stress increases 194.12 % if the powder used was switched from ZP100 to NCKU-FR.

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