3D列印/積層製造 3D Printing/AM
成新科技深耕金屬3D列印技術多年,
為國內提供金屬3D列印全方位解決方案之領導者。
4DMEN, the total solution provider of metal 3D printing in Taiwan.


        3D列印 ( 3D Printing ) 又稱為增材製造或積層製造 ( Additive Manufacturing, AM ) 。
相較於傳統減法製造 ( Subtractive Manufacturing ) 是從一大塊材料,雕琢切削出可用的部分,3D列印利用數位立體模型、特殊材料與製程,藉由3D列印機以層層疊加的方式,製造出各種形狀的立體物品。隨著工業3D列印技術日益成熟,今天的3D列印技術不僅僅能用於原型製造來協助企業縮短產品開發流程,更可以透過自由度更高的設計來使產品達到更佳的性能,在汽車、國防、航空與太空等產業的使用愈趨增加,成為現代製造流程不可或缺的重要一環。

3D printing is also known as additive manufacturing. Compared with the traditional subtractive manufacturing, which is to carve and cut out the usable parts from a bulk of material, 3D printing uses digital 3D models, special materials, processes, and 3D printer to stack arbitrary shape layer by layer. Today's 3D printing technology can not only be used for prototyping for shortening the product development process, but also to achieve better product performance through design with a higher degree of freedom. Industries such as automotive, defense, aerospace and space are increasingly used and become an integral part of modern manufacturing processes.

3D列印技術具備許多優勢,包含:
3D Printing has many Pros, including:
  1. 加法製造,可突破傳統減法製造的工法限制,使設計從Design for Manufacturing轉變為Design for Performance。
AM can break through the limitations of traditional subtractive manufacturing methods and transform design from Design for Manufacturing to Design for Performance.
  1. 近乎淨成型,能降低原物料使用。同時也能大幅減少加工的時間與刀具的耗用。
Near net shape forming, which can reduce raw material usage. At the same time, it can greatly saving the processing time and tool consumption.
  1. 客製化實現程度高,設計修改成本低。
The degree of customization is high, and the cost of design modification is low.
 
  1. 生產不再以量制價,成本固定化,小批量生產將可具成本優勢。
Production cost is no longer just based on quantity. Advantages in small batch production.
  1. 近乎零庫存,眾多種類的實體庫存變成立體模型的數位庫存與數種原材料。
Nearly zero stock, varied physical inventory transfer into digital files and several raw materials.

透過充分運用3D列印的優勢,成新科技能協助客戶的產品取得眾多競爭優勢:
By using the advantages of AM, 4DMEN brings competitive advantages to our clients.

 
  • 輕量化 ( 省油、省動力、價格競爭力 )
  • Weight-Lightening (oil saving, power saving, price competitive)
       3D列印技術搭配優化設計,可以成型許多傳統製程難以或無法製作的輕量化幾何形狀,如拓樸優化與晶格狀結構。可以使零組件至於系統進行整體輕量化設計,在載具 ( 如汽車、飛機 ) 應用上,可以降低載具負載進而減少油耗、提升燃油效率;在其他應用上,也可以獲得如較小的轉動貫量,使設計人員得以採用功率較低的馬達,達到成本精簡等競爭優勢。
  • 多件整合 ( 可靠度提升、減少組裝誤差、供應鏈精簡 ) 
  • Consolidation (improving reliability, minimized assembley tolerance, simplfied supply chain)
       慣常設計零組件時會優先考量可成型性,使得設計受限於傳統加工工法而將一件成品拆為眾多組件,分別製造後再行組裝。這導致成品供應鏈複雜,且需多餘設計以容許組裝造成的誤差,造成成品效能的降低。3D列印工法可以成型複雜幾何形狀,一體成型所需的零組件,這可減少組裝造成的誤差累積,提升產品可靠度與性能,並可以精簡過去複雜的供應鏈。
  • 適型化流路 ( 熱管理 )
  • Conformal Cooling (thermal management)
       3D列印的優化設計技術可以運用在適型化流路 ( 或稱異型水路 ) 的設計,使得優化流路可以貼合需要進行熱管理的部位,不再是受限傳統鑽銑製成的直進直出直角轉彎,可提升熱交換效能。


3D列印應用案例:
3D Printing Applications:

   
 1.GE Advanced Turboprop ( ATP ) Engine
       
  ( 出處 : YOUTUBE  https://www.youtube.com/watch?v=BnBMN0zgB10 )
  本案例應用3D列印技術進行輕量化與多件整合 ( 855件合併成12件 ) 使得整體減重100磅,降低燃油使用 20 %,且提高輸出馬力從850 ~ 1650。
   
 2.AIRBUS A380 Hydraulic Valve Block
                 
    ( 出處 : https://www.liebherr.com/en/usa/latest-news/news-press-releases/detail/world-premier-first-ever-3d-printed-primary-flight-control-component-from-liebherr-aerospace-flown-on-an-airbus-aircraft.html )

  本案例應用3D列印技術進行輕量化與多件整合 ( 10件合併成1件 ) 使得整體減重 35 %。
   
3.GE Fuel Nozzle tip for LEAP Engine
      
    ( 出處 : GE Additive https://www.ge.com/additive/stories/new-manufacturing-milestone-30000-additive-fuel-nozzles )
  本案例應用3D列印技術進行輕量化與多件整合 ( 20件合併成1件 ) 使得整體減重並減重 25 %,且此構型已經於2018年10月量產突破30,000件。