選擇性雷射熔融(Selective Laser Melting, SLM)，現今主流的金屬積層製造技術之一，多應用於高精度與高複雜度的三維結構樣品製程，同時也廣泛應用在陶瓷材料及其他功能性材料之產品生產。本研究以選擇性雷射熔融積層製造進行鎳鐵軟磁複合材料之樣品製造，以了解製程參數對於此材料之磁特性與機械性質的影響。為提高實驗效率，本研究以田口實驗設計中L9直交表進行實驗設計並執行三次實驗與一次驗證組實驗。首次實驗參數分別為氧濃度0-6000 ppm、雷射功率150-250 W、雷射掃描速度400-1000 mm/s、以及線間距0.05-0.07 mm。實驗結果顯示以掃描速率與線間距為主要影響因子，隨掃描速率與線間距越低時，鐵損、磁導率與極限拉伸應力越高，同時也確立後續實驗設計以低氧濃度、高雷射功率、低掃描速率與低線間距為最佳化趨勢。在第二次與第三次實驗中以氧濃度作為主要影響因子，最佳化趨勢維持低氧濃度、高雷射功率、低掃描速率與低線間距。在所有實驗中，磁導率、鐵損與極限拉伸應力具有相同的因子反應趨勢。最後驗證實驗中，參數組合為氧濃度~0ppm，雷射功率260W，掃描速率200mm/s，線間距0.08mm，磁導率在操作頻率50、200、400、800赫茲下分別為1361.95, 574.70, 406.20, 220.86，極限拉伸應力則達到619.42MPa，與第三次實驗中最佳數據相比，所有頻率下之磁特性均有提升，特別是50赫茲下提升超過30%，而機械性質也維持較佳的表現，且標準差較小，數值更加穩定，證實了以低氧濃度、高雷射功率、低掃描速率與低線間距對磁與機械特性之最佳化效果。

Selective Laser Melting (SLM) is one of modern popular additive manufacture methods. With less geometry limit and outstanding precision, SLM has been investigated to process soft magnetic components for the applications such as acoustics, motors, recording heads, and integrated inductors. Permalloy generally refers to the iron-nickel alloy with 30 ~ 90% nickel content. Due to its high permeability, low coercivity, and almost zero hysteresis, permalloy is widely applied in high-frequency sensors, transformers, induction devices, etc. In this study, we investigated the mechanical and magnetic properties of Fe-79Ni-4Mo soft magnetic alloy manufactured by SLM process. Three experiments were conducted based on L9 orthogonal array to improve the properties progressively. The optimized parameters were the oxygen concentration ~0 ppm, laser power of 260 W, scanning speed of 200 mm/s, and hatch distance of 0.08 mm. The validation test performed the optimized average relative permeability of 1361.95, 574.70, 406.20, and 220.86 at the operating frequencies of 50, 200, 400, and 800 Hz, respectively; while the ultimate tensile strength was 619.42 MPa.

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