熔融沉積法(Fused Deposition Modeling)屬於積層製造(Additive Manufacturing)技術的一種，將三維立體結構透過電腦輔助工程軟體(Computer Aided Engineering)切割成層狀之二維結構，並將材料熔融擠出，至下而上逐層堆疊，此種製造技術可突破傳統加工製造限制，對於複雜結構可直接製造，如內流道、空心結構等。本研究應用積層製造的優勢於隱形眼鏡壓鑄模的金屬模具製造，結合異型冷卻水路(Conformal Cooling Channel)設計，解決傳統金屬加工無法製造複雜水路結構的問題。
在模具設計方面，本研究藉由電腦輔助設計軟體(Computer Aided Design)自行設計隱形眼鏡壓鑄模之射出模具，輔以電腦輔助工程軟體(Moldex3D)進行射出成型製程的模擬，由模擬結果分析並改善模具及水路設計，增加塑膠射出成型製程中冷卻的效率，改善射出成型產品良率。
熔融沉積法使用的材料大多為高分子或金屬/高分子複合材料，本研究將使用金屬材料直接製造，相較於金屬/高分子複合材料擁有較佳的強度。另外，本研究將自行建構一積層製造平台，自行設計擠出頭，解決商用擠出頭容易溢料的缺陷，並使用自行設計之擠出頭於實際金屬成型，針對製程參數進行優化，達成金屬熔融沉積法製造隱形眼鏡壓鑄模之金屬射出模具之目的。
關鍵字:積層製造、熔融沉積法、射出模具設計、異型水路、模流分析

The aim of this study is to develop fused deposition modeling of metal (FDMm) to fabricate smart mold with conformal cooling channel.
From conformal mold design, we design the injection mold with conformal cooling channels with computer aided design (CAD) software. The location for sprue gate and sensor are optimized through mold flow analysis. Mold with conformal cooling channel is proved that the cooling efficiency is greater than traditional cooling channel.
From the development of FDMm, we construct the additive manufacturing machine. New melting extruding nozzle is designed to solve the excessing materials problem in commercial nozzle. We integrate additive manufacturing machine and metal extruding nozzle to develop FDMm. The fabrication parameters are optimized so that we can achieve the purpose of fabricate metal mold through fused deposition modeling.
Finally, we successfully deposit 3D parts by FDMm. However, there are defects between layer and layer causing the bonding are not well. In future, we will modify the fabrication process to enhance the bonding between layers.

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