碳纖維複合材料由於高比強度、高比模量、低密度的優點，近年
來在船舶、飛機、汽車等工業的應用上有逐年上升的趨勢。而隨著人
工智慧 (Artificial Intelligence, AI)產業的興起，機械手臂的材料選擇
逐漸從金屬、合金到碳纖維複合材料，以提升機械手臂單位重量的負
載 (Payload)。而在製程上，雖有短碳纖之3D 列印技術，但其強度與
一般塑料相比無太大提升，而長碳纖列印較為困難。為製作複雜之碳
纖維零件，本研究先以NX 有限元素分析軟體模擬零件貼合與裁剪碳
纖預浸布、von-Mises 應力分佈等，找出設計缺陷並改良，開發適合
複雜形零件之碳纖維疊層貼合方法。之後以機械性質測試方式量化碳
纖維預浸布強度，並以不同角度之碳纖維試片驗證貼合方法。製程方
面以3D 列印快速設計與鏤空形狀列印之優勢製作PLA 模具，再以
石膏灌注方式翻模，最後以碳纖維預浸布貼合模具，去除模具後完成。
最後以非破壞性之方式檢測此零件孔隙與缺陷、纖維分佈等，評估零
件品質。製作出之碳纖維外殼可以與3D 列印芯材結合形成三明治結
構，其重量相比同體積之不鏽鋼減輕77.5%，同體積鋁減輕42%，良
好的輕量化增加整體機械手臂之Payload，未來可望漸漸取代金屬材
料，減少機械手臂能量消耗。

In the manufacturing process of carbon fiber reinforced plastic, although there are short fiber 3D printing technologies, its strength is not much improved compared with ordinary plastics, and long fiber carbon fiber printing is more difficult. In order to produce complex carbon fiber components, this study first used NX finite element analysis software to simulate the fitting and cutting of carbon fiber prepregs, von-Mises stress distribution, etc., to find design defects and improve them, and developing carbon fiber lay-up methods suitable for complex components. After that, the strength of the carbon fiber prepreg was quantified by mechanical property testing, and the carbon fiber test strips with different angles were used to verify the lay-up method. In terms of manufacturing process, PLA molds are made with the advantages of 3D printing : rapid design and hollow shape printing. The molds are turned over by plaster infusion, and then the carbon fiber prepregs can be attached to the molds to do lay-up. At last, non-destructively inspect the components for pores and defects, fiber distribution, etc. to evaluate the quality of the components. The manufactured carbon fiber shell can be combined with the 3D printing core material to form a sandwich structure. Its good light weight increases the payload of the overall mechanical arm. It is expected to gradually replace metal materials in the future and reduce the energy consumption of the mechanical arms.

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