3D Texture鞋材生產製程之快速替換式模具探討

Tunghai University Institutional Repository > 創意設計暨藝術學院 > 工業設計學系所 > 碩士論文 > Item 310901/29933

Please use this identifier to cite or link to this item: http://140.128.103.80:8080/handle/310901/29933

Title:	3D Texture鞋材生產製程之快速替換式模具探討
Other Titles:	A Rapid Replacement Mold for 3D Texture Shoes Production Processes
Authors:	楊惠茹 YANG,HUI JU
Contributors:	柯耀宗工業設計學系碩士在職專班
Keywords:	快速模具;快速原型;數位光處理技術;TRIZ Rapid Tooling;Rapid Prototyping;Digital Light Processing;TRIZ
Date:	2018
Issue Date:	2018-03-30T01:05:06Z (UTC)
Abstract:	鞋業在快速時尚的趨勢下，短開發週期成為了掌握商機的重要條件。而鞋材除了鞋面以外需要模具的輔助射出製造，在初步打樣會要求製作符合實際材質，且往往需要樣品需求約三到十個不等，以便設計者確認鞋品上獨特的紋理和觸感，並進行後續相關性之信賴性測試。然而模具價格與品質存在著相對的關係，尤其縮短開發時程與成本，才能使其產品具有絕對競爭力。本研究利用TRIZ創新設計理論手法，並由模具設計專家經驗，提出快速共用模具之概念設計，應用於鞋工材質(Texture)開發之初期塑膠軟料射出模具的多樣化設計與製作上。結合多種入子採用了3D列印之製程技術製作，大幅縮短了模具製程時間與成本，達到試樣期快速批量生產樣品，實現快速製造的目的。本研究主要以四個觀點切入探討，以本實驗入子為樣本，分別用傳統CNC切削加工製造與3D列印快速製造所產生的成本：(1) 加工設備成本：傳統製造高達約220萬；而快速製造約33.1萬，降低85%。(2) 材料成本：以相同體積計算，快速製造列印用光敏樹酯材料之成本，為傳統製造用鋁合金材料的20倍。(3) 加工工時：傳統製造約28小時；而快速製造約5小時，以工時來說足足省下82%。(4) 入子加工費用：傳統製造約5.5萬；快速製造約0.3萬，降低了94.5%。鞋材所用到的塑膠材質有TPR、TPU、PU、RUBBER、EVA、PVC、EVA MD等等，而目前3D列印材料為光敏樹酯，尚未完全普遍成熟發展其他類材。但能利用3D列印技術製作入子，使製造端能快速射出製作PU或TPU等的鞋材。節省開發時程與成本，即是達到雙贏的目標。 Shoe industry is in the trend of rapid fashion; to seize the business opportunities, short development cycle becomes one of the critical factors. To make shoes, it is required to sample around 3~10 pieces for designer to verify the unique texture, tough and the reliable tests most of which relies on mold injection, vamp not included. Nevertheless, the cost of a mold relates to its quality. How to keep the developing process short and the cost low brings your products competitiveness in shoe industry.This study applies the innovative design theory - TRIZ (Theory of Inventive Problem Solving) along with experienced mold designer to propose a concept for rapid and mutual mold. It can be utilized for the multiple design and fabrication of mold for soft plastic material to get different material texture at the preliminary design phase. Combining various inserts built by 3D printing, it not only shortens the lead time of mold and also lowers the manufacturing cost to achieve the goal of rapid batch production at the prototype phase. Calculation has been conducted based on facility, material, manufacturing cycle time and insert cost to compare one insert design by CNC machining and 3D printing.a. Facility cost: NTD 2.2 million for CNC machining and NTD 331K for 3D printing,lower cost 85%b. Insert material cost: The cost of the same volume, the traditional material in ALUM ALLOY cost 20 times higher than the photosensitive tree Ester 3D uses.lower cost 94.5% c. Manufacturing cost: the traditional manufacturing takes 28 hours while rapid printing takes 5 hours only to save 82% machining cycle.d. Machining cost: 55K for traditional manufacturing and 3K for rapid priniting.The plastic material that shoes applies includes TPR, TPU, PU, Rubber, EVA, PVC, EVA MD, etc. The current 3D printing uses photosensitive tree Ester that is not yet mature to develop a series of different types. However, applying 3D printing technology for insert production could shorten lead time of mold and complete PU or TPU prototype in quite a short time to achieve both goals of short developing timeline and low cost consideration.
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