Research on Rapid Prototyping Using Functional Materials

从三维CAD几何数据中自动快速地制造各种形状的实体物体的技术被称为“快速成型”。本研究的目的是提出一种快速成型的基本技术，使用多种不同性质的材料，如弹性和导电性，使所得到的固体物体具有一些功能和几何形状。本文的研究结果总结如下：1。通过对固体自由曲面制造方法的比较，选择了熔融沉积建模（FDM），因为FDM的材料使用范围广。经过理论计算和基础实验，设计并制造了一种基于螺杆和圆柱挤压的FDM快速成型系统。该系统有多套螺杆和气缸，每一套包含不同的材料。该系统在加工过程中选择螺旋气缸，从而可以加工由多种材料组成的固体物体。用于快速成型的传统数据格式，如STL（立体光刻）最初并不是为处理多种材料而设计的。本研究通过扩展现有STL和VRML （Virtual Reality Modeling Language，虚拟现实建模语言）格式的解释，提出了一种新的多材料加工数据处理方法，以保持当前数据格式之间的兼容性。在制造由多种材料组成的物体时，在某些材料组合中，两种材料之间在边界处的结合不够强。为了加强粘接，提出了相邻、同一层两种材料的路径重叠法和不同材料两层的路径交错法。上述方法以快速成型系统的形式实现。通过聚丙烯、弹性体、导电树脂等多种材料组成的物体的制备，考察了该方法的有效性、可行性和目前的局限性。少

Technologies to fabricate solid objects of various shapes automatically and rapidly from 3-D CAD geometry data are called "rapid prototyping". The purpose of this study is to propose a fundamental technology of rapid prototyping using multiple materials of different properties such as elasticity and electric conductivity so that the resulting solid objects have some functions as well as geometry. The results of this study are summarized as follows :1. By comparing solid freeform fabrication methods, fused deposition modeling (FDM) was adopted because of its capability of utilizing wide range of materials. After some theoretical calculation and basic experiments, a rapid prototyping system based on FDM using extrusion by screws and cylinders was designed and made. The system has multiple sets of screw and cylinder, each of which contains different materials. The system selects the screw-cylinder during fabrication process so that it can fabricate a solid object consisting of multiple ma … More terials.2. Conventional data formats for rapid prototyping such as STL (STereo-Lithography) are not originally designed to handle multiple materials. This study proposed a new data processing method for multiple material, fabrication by extending' the interpretation of existing STL and VRML (Virtual Reality Modeling Language) format so that the compatibility between current data formats is maintained.3. When fabricating an object consisting of multiple materials, bonding between two materials at the boundary is not strong enough in some material combination. To strengthen the bonding, path overlapping method for neighboring, two materials in the same layer and path interlace method for two layers of different materials were proposed.4. The methods mentioned above were implemented as a rapid prototyping system. By fabricating objects consisting of multiple materials such as polypropylene, elastomer and conductive resin, efficacy, possibility and current limitation of this study were examined. Less