JP2003001714A - Method and apparatus for producing three-dimensional shaped article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a three-dimensional shaped article in a short time. SOLUTION: When an inorganic or organic powder layer 20 is formed on a sintering table 3, a prescribed part of the layer 20 is irradiated with light beams to be sintered, a new powder layer is formed on the layer 20, and a prescribed part of the new powder layer is irradiated with light beams to repeat the formation of a sintered part 21 integrated with the sintered part 21 of a lower layer so that the three-dimensional formative article is produced lamination-wise by one layer after another from powder. A base 1 to be the lower part constitution material of the three-dimensional shaped article to be produced is set on the table 3 after necessary processing is applied on the surface of the base 1, the alignment between the base 1 and a light beam irradiation starting position is done, and the formation of the powder layer covering the base 1 and the sintering of the prescribed part of the powder layer by the light beams are repeated. The repeating of the formation of the powder layer and sintering by the light beams can be omitted by the portion of the thickness of the base 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for producing a three-dimensional shaped article for producing a three-dimensional shaped article by selective sintering of powder material.

[0002]

2. Description of the Related Art As a method for producing a three-dimensional shaped object, the one disclosed in Japanese Patent No. 2620353 is well known. This involves forming an inorganic or organic powder layer on a sintering table, irradiating a predetermined portion of this powder layer with a light beam to sinter, and then forming a new powder layer on the powder layer. By repeating the process of forming and sintering the predetermined part with a light beam to form a sintered part that is integrated with the lower sintered part, a three-dimensional shaped object is formed from powder. Since each layer is manufactured layer by layer, a complex three-dimensional shaped object can be manufactured in a short time.

[0003]

However, in order to prepare all the parts of the three-dimensional shaped object by the powder sintering method, that is, the procedure of irradiating each layer with a laser beam for sintering is taken. In addition, it may take a long time depending on the shape of the three-dimensional shaped object to be manufactured.

The present invention has been made in view of the above points, and an object of the present invention is to provide a method and a method for producing a three-dimensional shaped article capable of producing a three-dimensional shaped article in a shorter time. To provide the equipment.

[0005]

SUMMARY OF THE INVENTION In the method of manufacturing a three-dimensional shaped object according to the present invention, however, an inorganic or organic powder layer is formed on a sintering table, and a predetermined portion of the powder layer is exposed to light. By irradiating with a beam to sinter, and then forming a new powder layer on the above-mentioned powder layer and irradiating the predetermined part with a light beam to sinter, the sintered part of the lower layer is integrated. By repeating the process of forming a sintered part that has become a three-dimensional shaped object in layers one by one by stacking from powder, the base that will be the lower component of the three-dimensional shaped object to be produced Is set on a sintering table, the surface of the base is subjected to required processing, the base is aligned with the light beam irradiation start position, and then the powder layer covering the processed surface of the base. Of forming a powder layer and sintering a predetermined portion of the powder layer with a light beam are repeated. It has a feature. It is possible to omit repeating the formation of the powder layer and the sintering of the light beam by the thickness of the base.

At this time, the processing on the base set on the sintering table is based on a preliminary comparison between the processing time and the time required to form the same shape by sintering the powder layer. Therefore, the processing is completed in a shorter time than the latter.

The processing on the base set on the sintering table is not only the shape processing for the surface on which the powder layers are laminated, but also the one for forming the concave portion for accommodating the sintered portion and the sintered portion. Concavo-convex processing or the like may be performed on the surface. When the concavo-convex processing is performed, it may be performed only on the surface where the contour of the sintered portion is formed.

Further, the processing on the base set on the sintering table may be any of cutting, laser processing, and plastic processing. In the case of laser processing, the processing is performed in an oblique direction with respect to the surface of the base. Laser irradiation is preferably performed, and in the case of plastic working, blasting with sintered powder can be preferably used.

It is also possible to simultaneously perform the formation of the concave portion for accommodating the sintered portion and the concavo-convex processing on the surface where the sintered portion is formed.

When the three-dimensionally shaped article to be formed is an injection molding die, it is preferable to form the parting surface of the die by a cutting surface to the base, and further to the parting surface. It is preferable that the convex portion is formed by sintering and the concave portion is formed by processing the base.

The base may be processed by forming a cooling water passage. At this time, it is preferable to form a cooling water passage connected to the cooling water passage of the base in the laminated portion of the sintered portion.
The cooling water passage provided in the base may be a discharge passage for the unsintered powder in the cooling water passage provided in the laminated portion of the sintered portion.

In addition, the base plate may be processed by forming knockout pin insertion holes.

Regarding alignment, the surface of the base is irradiated with a light beam, the irradiation position of the light beam is corrected based on the irradiation result, and then a powder layer is formed on the base and the light beam is used. It is preferable to form a sintered portion.

In addition, after forming the sintered portion of an arbitrary layer, the surface of the sintered portion may be cut, and thereafter, the formation of the powder layer and the formation of the sintered portion may be further performed. When cutting the surface of the sintered portion, irregularities may be formed on the surface of the sintered portion.

The apparatus for producing a three-dimensional shaped object according to the present invention comprises a sintering table on which an inorganic or organic powder layer is formed, and an irradiation device for irradiating a predetermined portion of the powder layer with a light beam. And a powder supply device for sequentially forming a powder layer on the sintering table in a layered manner, a position of a base set on the sintering table which has been subjected to required processing in advance, and the base. It is characterized in that it comprises an alignment means for aligning the light beam irradiation position with respect to the powder layer, and a processing means for physically processing the base set on the sintering table.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below in detail based on an example of an embodiment. FIG. 2 shows an example of a manufacturing apparatus according to the present invention. A sintering table 3 and this sintering table 3 are shown. An elevating table 30 for elevating and lowering 3, a powder supplying device 4 for supplying an inorganic or organic powder onto the sintering table 3,
A light beam irradiation device 5 for generating a light beam to be irradiated onto the sintering table 3 via a polarization device 50, a control device 6 for controlling these, a positioning means 7, and a processing means 8 for performing physical processing. The position adjusting means 7 is constituted by a camera 70 for photographing the sintering table 3 as a component thereof and mainly by a position adjusting program in the control device 6. As the processing means 8, a cutting machine such as an end mill or a drill, a laser processing machine, or a blasting machine that plastically processes an object by injecting sintered powder can be preferably used. It is not limited.

When a desired three-dimensional shaped object is manufactured using this manufacturing apparatus, all or part of the lower structure of the three-dimensional shaped object to be obtained is constructed by the base 1 which is separately prepared. The base 1 may be made of any material as long as it becomes an integral part of the sintered portion when the powder is sintered on the surface thereof.

Then, the base 1 is set on the sintering table 3 and the base 1 is processed by the processing means 8 as required. This processing is the CA of the three-dimensional shaped object.
Conditions are set in advance from the D data to create data on the processed shape, and the processing is performed according to this data. The locus of the contour data for modeling may be used to perform the machining only by the data instruction up to the height at which the machining is performed.

After the base 1 has been processed in this way, the base 1 set on the sintering table 3 is then set so that the sintering start position on the surface of the base 1 coincides with the laser irradiation position. The position is confirmed by picking up an image of the object and detecting the contour of its plane shape, and then the position is marked with the low-energy light beam L on the surface of the base 1 while the position of the camera 7 is marked.
The coordinate deviation between the base 1 and the light beam irradiation system is deduced from the light beam irradiation planned position a for the base 1 and the position b actually irradiated to the base 1 which is imaged at 0 and captured by the contour as shown in FIG. The control device 6 measures and corrects this.

When the alignment is completed in this way,
As shown in FIG. 1 (c), the powder 2 is supplied onto the sintering table 3 and the powder surface is leveled by a blade 40 so that a powder layer 20 having a thickness of Δt is produced on the surface of the base 1. Then, the light beam L is irradiated to a predetermined area to sinter the predetermined area. At this time, the base 1 and the sintering part 21
And are integrated using sintering. Then, as shown in FIG. 1D, the formation of the powder layer 20 and the sintering by the light beam L are repeated until finally the sintering table 3 is moved to the base 1
By removing the powder and removing the powder remaining unsintered, a three-dimensional shaped object having the base 3 as the lower structure and the laminated sintered portion 21 as the upper structure is obtained. Base 1
Since the time required for stacking and sintering the powder layer 20 is reduced by the thickness of, the time required for the step of powder sintering can be shortened.

Formation of new powder layer 20 and this powder layer 20
During the repetition of the sintering of the predetermined region, the processing means 8 may be used to perform the next processing on the sintered portion 21. That is, since the side surface and the upper surface of the sintered portion 21 have a high surface roughness, as shown in FIG. 4A, after the side surface and the standing wall of the deep groove forming the outer shape are sintered. , Processing the relevant part with the processing means 8 for cutting,
As shown in FIG. 4 (b), the portion to be the bottom surface of the groove is processed. The side surface need not be processed for each layer, but may be collectively processed for a plurality of layers corresponding to the effective span length in the processing means 8. Of course, when the overhanging sintered portion 21 is formed on the upper layer, the sintering is performed before forming the upper layer. Further, as shown in FIG. 4C, processing may be performed for the purpose of further increasing the surface roughness of the sintered portion 21. The adhesion strength between the laminated sintered parts 21 can be improved.

By the way, if the time required for processing to be provided on the base 1 is longer than the time required for forming the same one by powder sintering, the whole manufacturing time will be conversely lengthened. The processing for the base 1 is completed in a shorter time than the latter in comparison with the time required for processing the base 1 and the time required for forming the same shape by sintering the powder layer 20. I will do it. For example, as shown in FIG. 5, when a recess having a depth A is processed on the surface of the base 1 and then the sintered portion 21 is laminated on the recess,
If the time required to form the sintered portion 21 having the required shape by the depth of the recess is shorter than the time required to form the recess by cutting, and the time is reversed, the basic It is assumed that the sintered portion 21 is formed only in the upper portion B without providing the concave portion on the table 1. The above required time is obtained by performing a pre-machining simulation.

When the processing for the base 1 is a shape processing, as shown in FIG. 6, a recess 15 having the same size as the bottom area of the sintered portion 21 of the lowermost layer is formed in the base 1, and the recess 15 is formed. 1
The space inside 5 may be filled with the sintered portion 21. Since the joint area between the base 1 and the sintered portion 21 becomes large, it is possible to reduce the occurrence of peeling and cracks at the boundary between the two.

Further, the processing for the base 1 may be uneven processing. As shown in FIG. 7, by forming the unevenness 18 in the portion where the sintered portion 21 is formed on the upper surface, the adhesion strength between the base 1 and the sintered portion 21 can be improved.

Further, when the machining of the base 1 is performed by the machining means 8 of the cutting system, in addition to the shape machining shown in FIG. 8 (a), the concavo-convex machining shown in FIG. 8 (b), the figure shown in FIG. 8 (c). As shown in FIG. 5, dovetail groove processing is possible, and if such a dovetail groove 19 is formed, the bonding strength between the sintered portion 21 and the base 1 is further increased by the anchor effect.

As the processing means 8, a laser may be used as described above. Also in this case, as shown in FIG. 9, shape processing and uneven processing can be performed on the base 1. Further, as shown in FIG. 10, when unevenness processing is performed by performing laser irradiation from an oblique direction (preferably the laser incident angle on the base 1 is 60 ° or less), the unevenness 18 exhibits an anchor effect. The adhesion between the base 1 and the sintered part 21 is improved.

When the unevenness 18 is formed on the surface of the base 1, the unevenness 18 is not provided on all the portions where the sintered portion 21 is located on the upper surface, but as shown in FIG. You may make it provide only in the part in which a part (range of width 5-10 mm) is mounted. Since the processing time is short, the time is shortened. In particular, it is very effective under the condition that the inside has a low density (a density of about 80%) and the outside has a high density (a density of about 100%) to produce a three-dimensional shaped object.

When the base 1 is processed only by concavo-convex processing, as shown in FIG. 12 (a), knurling in which a cylindrical roller having a concavo-convex surface is pressed for traveling, or by FIG. 12 (b). As shown in, the unevenness 18 may be formed by a plastic working such as a blasting process of spraying powder. Particularly in the blasting process, the sintered powder can be used as a jet, and in this case, since the powder material is the same, there is no loss in the material recovery and the device maintenance work process.

Not only one of the above-mentioned shape processing and uneven processing may be performed, but both may be performed.
As shown in FIG. 3, when the cutting-type processing means 8 is used, both kinds of processing can be performed simultaneously. The same applies when the laser processing means 8 is used.

The use of such a base 1 is particularly effective when the cross-sectional area of the lower structure portion of the three-dimensional shaped object to be obtained is considerably larger than that of the upper structure portion. FIG. 14 shows a three-dimensional shaped object having the lower structure part and the upper structure part as described above.
An example of such an injection molding die is shown in this case. In this case, the parting surface P of the die can be formed on the surface of the base 1.

When the molded product 90 is formed with the other mold in the cavity 9 as shown in FIG.
As shown in FIG. 6, the part that is more convex than the part that becomes the parting surface P on the surface of the base 1 is the sintered part 21, and the part that is concave is formed by processing the base 1. In addition, the die manufacturing time can be greatly shortened, and the three-dimensional shaped object (die) having fine grooves with a high aspect can be easily manufactured.

When the three-dimensional shaped object to be obtained is a mold, as shown in FIG. 17, a cooling water passage 13 is formed in the base 1 which constitutes the lower structure part thereof, and one end thereof is formed. When the opening is opened on the surface of the base 1, the sintered part 21
Cooling water passage 23 provided inside the modeling part by stacking layers
And the cooling water passage 13 provided on the base 1 and the base 1 and the sintered portion 2
You can get what is connected at the boundary with 1. In addition, when the cooling water passage 13 is also opened on the side surface of the base 1, it is sufficient to open a lateral hole after the fact as shown in the drawing.

In this case, the unsintered powder 2 in the cooling water passage 23 can be discharged through the cooling water passage 13 of the base 1 as shown in FIG. The cooling water passage 13 shown here does not have to be used as a passage for actually passing the cooling water. The three-dimensional shaped object may function only as a hollow portion provided to reduce the weight.

FIG. 19 shows the case where the base 1 is processed by the knockout pin insertion hole 14 in the mold.

In the above example, the one in which the base and the light beam irradiation position are aligned by image processing using a camera is shown. In addition to this, a laser measuring device, a contact probe, etc. are used. It is also possible to measure a predetermined portion of the base and set the origin of processing by the light beam based on this measurement position to form the laminated portion of the sintered portion 21.

[0036]

As described above, in the present invention, an inorganic or organic powder layer is formed on a sintering table, and a predetermined portion of this powder layer is irradiated with a light beam to be sintered,
After that, a new powder layer is formed on the powder layer, and a predetermined portion of the powder layer is irradiated with a light beam and sintered to form a sintered portion that is integrated with the lower sintered portion. By repeating this process, when manufacturing a three-dimensional shaped object in layers one by one from powder, the base that will be the lower component of the three-dimensional shaped object to be produced is set on the sintering table. After performing the required processing on the surface of the base, the base is aligned with the light beam irradiation start position, and then a powder layer covering the processed surface of the base is formed and a predetermined portion of the powder layer is formed. In order to repeat the sintering with the light beam, it is possible to omit repeating the formation of the powder layer and the sintering of the light beam by the thickness of the base. Products can also be manufactured in a short time. Further, a three-dimensional shaped object having fine grooves with a high aspect ratio can also be manufactured.

If the processing of the base is to form a concave portion for accommodating the sintered portion, or if the surface on which the sintered portion is formed is processed to have irregularities, the base and the sintered portion are closely joined. Strength can be increased.

[Brief description of drawings]

FIG. 1 is an explanatory view of a manufacturing method according to the present invention.

FIG. 2 is a perspective view of the above manufacturing apparatus.

FIG. 3 is an explanatory diagram of alignment.

4 (a), (b) and (c) are explanatory views of processing for a sintered portion.

FIG. 5 is a cross-sectional view of an example of the above-mentioned three-dimensional shaped object.

6A and 6B are cross-sectional views showing an example of processing for a base.

7 (a) and 7 (b) are cross-sectional views showing another example of processing of the base.

8 (a) and 8 (b) are perspective views of an example of cutting work on a base,
(c) is a cross-sectional view of an example of processing a dovetail groove.

9A and 9B are perspective views of an example of laser processing on a base.

10A and 10B are a perspective view and a cross-sectional view of another example of laser processing performed on a base.

11A and 11B are cross-sectional views of an example of processing on a base.

12A and 12B are cross-sectional views of an example of plastic working on a base.

13A and 13B are cross-sectional views of another processing example of the base.

FIG. 14 is a perspective view of an example of a three-dimensional shaped object.

15 (a) and 15 (b) are a cross-sectional view of the entire structure of a mold and a cross-sectional view of a molded product.

16 (a) and 16 (b) are cross-sectional views of the base of the above mold.

FIG. 17 is a cross-sectional view showing a procedure for manufacturing a three-dimensional shaped object having a cooling water passage.

FIG. 18 is an explanatory diagram of discharging of unsintered powder of the above.

FIG. 19 is a cross-sectional view showing a manufacturing procedure of a three-dimensional shaped object having a knockout pin insertion hole.

[Explanation of symbols]

1 base 2 powder 3 Sintering table 20 powder layers 21 Sintering part

Continued front page    (72) Inventor Tokio Yoshida             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Kima Higashi             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Hirohiko Togeyama             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Satoshi Abe             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Seizo Maeda             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company (72) Inventor Masataka Takenan             1048, Kadoma, Kadoma-shi, Osaka Matsushita Electric Works Co., Ltd.             Inside the company F-term (reference) 4F213 AA03 AA13 AA14 AA23 AA24                       AA28 AA29 AP06 AP11 AR07                       AR12 WA25 WL03 WL10 WL67                       WL85 WL87 WL96

Claims (22)

[Claims] 1. An inorganic or organic powder layer is formed on a sintering table, and a predetermined portion of this powder layer is irradiated with a light beam to be sintered, and then a new layer is formed on the powder layer. By forming a powder layer and irradiating a predetermined part of the powder layer with a light beam to sinter it, forming a sintered part that is integrated with the sintered part of the lower layer is repeated. When manufacturing a layered product of layers one by one, set a base, which is a lower component of the three-dimensional model to be manufactured, on a sintering table, and apply the required processing to the surface of the base. After performing the treatment, the base is aligned with the light beam irradiation start position, and then the formation of the powder layer covering the processed surface of the base and the sintering of the predetermined portion of the powder layer with the light beam are repeated. A method for producing a characteristic three-dimensional shaped object. 2. The processing on the base set on the sintering table is based on a preliminary comparison between the processing time and the time required to form the same shape by sintering the powder layer. The method for producing a three-dimensional shaped object according to claim 1, wherein the processing is completed in a shorter time than the latter. 3. The three-dimensional shaped object according to claim 1, wherein the processing on the base set on the sintering table is a shape processing for the surface on which the powder layer is laminated. Production method. 4. The process according to claim 1, wherein the processing of the base set on the sintering table is to form a recess for accommodating the sintered part. A method for manufacturing a three-dimensional shaped object. 5. The method according to claim 1, wherein the processing on the base set on the sintering table is uneven processing on the surface on which the sintered portion is formed. A method for producing a three-dimensional shaped article as described. 6. The method for manufacturing a three-dimensional shaped article according to claim 5, wherein the uneven processing is performed on the surface on which the contour portion of the sintered portion is formed. 7. The process for forming the base set on the sintering table is a cutting process.
The method for producing a three-dimensional shaped object according to any one of 1. 8. The laser processing is used for processing the base set on the sintering table.
6. The method for producing a three-dimensional shaped object according to any one of items 6. 9. The method for producing a three-dimensional shaped object according to claim 8, wherein the laser processing is performed by irradiating the surface of the base in a diagonal direction. 10. The process for forming a base set on a sintering table is a plastic process.
6. The method for producing a three-dimensional shaped object according to any one of items 6. 11. The method for producing a three-dimensional shaped object according to claim 10, wherein the plastic working is blasting with a sintered powder. 12. The process for forming a base set on a sintering table is to form a recess for accommodating the sintered part and to form an uneven surface on the surface on which the sintered part is formed, and simultaneously perform both processes. The method for producing a three-dimensional shaped object according to any one of claims 1 to 9, characterized in that. 13. The method for producing a three-dimensional shaped article according to claim 1, wherein the three-dimensional shaped article to be formed is an injection molding die. 14. The parting surface of the die is formed by cutting a base.
A method for producing a three-dimensional shaped article as described. 15. The tertiary structure according to claim 14, wherein the convex portion with respect to the parting surface is formed by sintering, and the concave portion is formed by processing into a base. Manufacturing method of original shape molded article. 16. The cooling water passage is formed on the base, and a cooling water passage connected to the cooling water passage of the base is formed in the laminated portion of the sintered portion.
A method for producing a three-dimensional shaped article as described. 17. The tertiary according to claim 16, wherein the cooling water passage provided in the base is used as a discharge passage of the unsintered powder in the cooling water passage provided in the laminated portion of the sintered portion. Manufacturing method of original shape molded article. 18. The method for manufacturing a three-dimensional shaped article according to claim 13, wherein the processing on the base is forming a knockout pin insertion hole. 19. The surface of the base is irradiated with a light beam, the irradiation position of the light beam is corrected based on the irradiation result, and then a powder layer is formed on the base and a sintered portion is formed by the light beam. The method for producing a three-dimensional shaped object according to claim 1, wherein 20. After the formation of the sintered portion of an arbitrary layer, the surface of the sintered portion is cut, and thereafter, the formation of the powder layer and the formation of the sintered portion are further performed. A method for producing a three-dimensional shaped article as described. 21. The method for producing a three-dimensional shaped article according to claim 20, wherein unevenness is formed on the surface of the sintered portion when cutting the surface of the sintered portion. 22. A sintering table on which an inorganic or organic powder layer is formed, an irradiation device for irradiating a predetermined portion of the powder layer with a light beam, and a powder layer laminated on the sintering table. For the purpose of aligning the position of the pedestal that is set on the sintering table that has been subjected to the required processing in advance and the light beam irradiation position for the powder layer that covers this pedestal. And a processing means for physically processing a base set on a sintering table.