雷射金屬積層製造是工業上加法加工法之一，也是3D列印中技術層次較高且具實用性的方法，影響金屬積層製造品質主要的因素有：加工過程中融池溫度以及加工層表面平整度。
為了能掌握兩個重要的參數，本碩士論文開發出結構光3D表面造影成像系統量測表面結構與平整度，利用結構光像移影像在高低起伏的表面樣貌形成不連續的變形條紋，兩組不同相位條紋影像拍攝對比參考平面和待測表面，經過程式影像解調以此還原解析待測物的表面形貌；另外結合實驗過去開發的同軸比色式高溫計系統加以改良優化，藉由分光的設計，測量不同波長的功率，以此計算出物體的相對溫度。
後半段實驗將表面輪廓量測系統以及高溫計光學系統整合至積層製造熔池設備，規劃整個過程為：2次表面輪廓探測、1次高溫計溫度監測，藉由硬體零件架設連接與軟體程式設計連動，完成自動化加工雷射、投影機、相機，以及高溫計，最後在連續兩層雷射燒熔流程中，成功實現即時同步監測表面結構平整度和溫度特性，改善雷射金屬3D列印製程，提高加工的良率！

Laser additive manufacturing system is an important industrial technique for 3D
printing and related application. It is known that the melting pool temperature and smoothness of the fabricated layer play important roles in achieving high fabrication quality in laser additive manufacturing process.
Real-time on-line monitoring of the melting pool temperature and surface profile of the fabricated layers thus become crucial subsystems that aid the quality control and cost reduction of laser additive manufacturing process. In this thesis, an integrated phase-shifted fringe projection profilometer is developed to monitor the surface profile. Using structured light illumination with projector, the distorted fringes projected on the samples are recorded by cameras. The proposed phase-offset approach reconstructs the surface profile proportional to the unwrapped phases. This system is then integrated to a laser additive manufacturing system along with a previously designed colorimetric pyrometer system to fulfill the real-time monitoring purpose.
We also completed the automatic processing of lasers, projectors, cameras, and pyrometers by the developing the communicating protocol, and demodulating and managing software along with hardware installations. The monitoring procedure includes two surface structure flatness imaging and on-axis temperature characterization. System automation was tested when laser additive manufacturing is in progress. This work realizes an all optical monitoring system prototype for real-time on-line monitoring of surface structure flatness and temperature characteristics, which provide quantified information that can be used to improve the laser metal additive manufacturing process.

中文論文審定書 i
摘要 ii
Abstract iii
目錄 iv
圖目錄 vii
表目錄 xii
1 第一章 緒論 1
1-1 前言 1
1-2 3D列印 1
1-3 工業的應用 2
1-4 表面輪廓量測 7
1-4.1 接觸式表面輪廓量測 7
1-4.2 非接觸式表面輪廓量測 9
1-5 研究動機 13
2 第二章 理埨分析與實驗介紹 15
2-1 理論分析 16
2-1.1 結構光3D造影成像原理 16
2-1.2 結構光3D造影成像模擬程式 18
2-2 硬體裝置 22
2-2.1 投影機 22
2-2.2 相機 23
2-2.3 超連續光譜白光雷射 25
2-3 軟體程式 26
2-3.1 Matlab 26
2-3.2 DLP LightCrafter 4500 Control Software 27
2-3.3 Pylon Viewer(Baslor) 28
3 第三章 結構光3D表面造影成像系統的開發 29
3-1 實驗架構 29
3-1.1 灰階相位圖 29
3-1.2 DLP LightCrafter 4500 結構光投影 32
3-1.3 測試樣品—砂紙 34
3-1.4 樣品載台—伺服馬達 35
3-2 實驗流程 36
3-2.1 最佳視角量測 36
3-2.2 P40砂紙量測 39
3-2.3 P220砂紙量測 45
3-2.4 P800砂紙量測 51
4 第四章 系統整合 52
4-1 3D表面造影成像量測系統整合 52
4-1.1 實驗架設模擬 53
4-1.2 實際機台架設 55
4-2 同軸比色式高溫計光學系統 58
4-2.1 以焦距50 mm凹面鏡反射聚焦至光纖陣列 62
4-2.2 反射鏡搭配25 mm凸透鏡反射聚焦至光纖陣列 65
4-2.3 反射鏡搭配50 mm凸透鏡反射聚焦至光纖陣列 69
4-2.4 實際機台架設 71
4-3 系統通訊協定與成像軟體 75
4-3.1 硬體架構 75
4-3.2 信號流程 77
4-3.3 硬體驅動程式 79
4-4 系統整合成果 81
4-4.1 雷射加工模式 81
4-4.2 未鋪粉燒熔測試 83
4-4.3 鋪粉燒熔測試 85
5 第五章 結論與未來展望 95
5-1 結論 95
5-2 未來展望 96
6 第六章 參考文獻 97

[1] mybest “2022最新推薦十大3D列印機排行榜” https://my-best.tw/36791
[2] “金属3Dプリントの発売Velo3Dが最初の製品をリリース– TechCrunch”
https://hitechglitz.com/japan金属3dプリントの発売velo3dが最初の製品を
リリース-techcrun/
[3] King, Wayne E., et al. "Laser powder bed fusion additive manufacturing of metals;
physics, computational, and materials challenges." Applied Physics Reviews
2.4 (2015): 041304.
[4] PART community
https://b2b.partcommunity.com/community/knowledge/en/detail/939/Fused+depositi
on+modeling
[5] Jacob, Gregor, et al. The influence of spreading metal powders with different
particle size distributions on the powder bed density in laser-based powder bed
fusion processes. Gaithersburg, MD: US Department of Commerce, National
Institute of Standards and Technology(2018).
[6] Malekipour, Ehsan, and Hazim El-Mounayri. "Common defects and contributing
parameters in powder bed fusion AM process and their classification for online
monitoring and control: a review." The International Journal of Advanced
Manufacturing Technology 95.1 (2018): 527-550.
[7] Tapia, Gustavo, and Alaa Elwany. "A review on process monitoring and control in
metal-based additive manufacturing." Journal of Manufacturing Science and
Engineering 136.6 (2014).
[8] Jamshidinia, Mahdi, and Radovan Kovacevic. "The influence of heat accumulation
on the surface roughness in powder-bed additive manufacturing." Surface
Topography: Metrology and Properties 3.1 (2015): 014003.
[9] Venuvinod, Patri K., and Weiyin Ma. Rapid prototyping: laser-based and other
technologies. Springer Science & Business Media (2004).
[10] Zhu, H. H., L. Lu, and J. Y. H. Fuh. "Study on shrinkage behaviour of direct laser
sintering metallic powder." Proceedings of the Institution of Mechanical
Engineers, Part B: Journal of Engineering Manufacture 220.2 (2006): 183-190.
[11] “Contact-type Surface Roughness/Profile Measuring Instruments” https://www.key
ence.com/ss/products/microscope/roughness/equipment/surface_01.jsp
[12] “Atomic Force Microscopes (AFM)”
https://www.keyence.com/ss/products/microscope/roughness/equipment/atomic-
force-microscopes.jsp
[13] “White Light Interferometers”
https://www.keyence.com/ss/products/microscope/roughness/equipment/interferometers.jsp
[14] “Profile-Measuring Laser Microscopes” https://www.keyence.com/ss/products/microscope/roughness/equipment/laser-microscopes.jsp
[15] “Confocal Microscopy”
https://youtu.be/QFtZFbug1SA
[16] “Wide-area 3D profile-measuring instrument”
https://www.keyence.com/ss/products/microscope/roughness/equipment/wide-area-
3D-measurement-instrument.jsp
[17] Neef, Arne, et al. “Low coherence interferometry in selective laser melting.”
Physics Procedia 56 (2014): 82-89.
[18] Kanko, Jordan A., Allison P. Sibley, and James M. Fraser. "In situ morphology-
based defect detection of selective laser melting through inline coherent
imaging." Journal of Materials Processing Technology 231 (2016): 488-500.
[19] Dickins, Andrew, et al. "Multi-view fringe projection system for surface
topography measurement during metal powder bed fusion." JOSA A 37.9 (2020):
B93-B105.
[20] 黃駿翔,“適用於雷射積層製造過程溫度監測之比色式熱影像系統”, 國立
中山大學光電工程所, 2020.
[21]Zuo, Chao, et al. "Phase shifting algorithms for fringe projection profilometry: A
review." Optics and Lasers in Engineering 109 (2018): 23-59.
[22] Zhang, Bin, et al. "In situ surface topography of laser powder bed fusion using
fringe projection." Additive Manufacturing 12 (2016): 100-107.
[23] “TEXAS INSTRUMENTS”
https://www.ti.com/tool/DLPLCR4500EVM
[24] “BASLER the power of sight”
https://www.baslerweb.com/en/products/cameras/area-scan-cameras/ace/aca2500-
14um/
[25] “NTK Photonic”
https://www.nktphotonics.com/products/supercontinuum-white-light- lasers/
superk-compact/