JP2007098822A - Method for shaping three dimensional formative article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for shaping a three dimensional formative article which can improve the shaping accuracy of a three dimensional formative article to be made so as to prevent the formation of an interlaminar step such as a gap and a concave in a divided plane. <P>SOLUTION: In a method for shaping the three dimensional formative article comprising repeated steps of forming an auxiliary material layer by cutting an auxiliary material and forming a formative material layer by cutting a formative material, and a step of removing the auxiliary material layer thereafter in order to make a three dimensional formative article on which only a plurality of the formative material layers are laminated, when the auxiliary material layer is formed by cutting the auxiliary material supplied on the formative material layer, the auxiliary material layer is formed by cutting the auxiliary material to a region lower than a boundary between the formative material layer and the other formative material layer overlaid on the formative layer, when the formative material of the other formative material layer is supplied on the formative material layer, the formative material is supplied also to the auxiliary material layer cut to reach the lower region beyond the boundary, and when the other formative material layer is formed by cutting the formative material of the other formative material layer, the formative material is cut to reach the auxiliary material layer cut to reach the lower region beyond the boundary. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a three-dimensional modeling method, and more particularly, to a three-dimensional modeling method for producing a three-dimensional model using an auxiliary material layer formed of an auxiliary material and a modeling material layer formed of a modeling material. .

  Conventionally, for example, after a predetermined portion of an auxiliary material layer formed of a water-soluble auxiliary material is removed by cutting with a cutting tool such as an end mill, the removed portion is subjected to, for example, light insoluble in water. By forming a modeling material layer with a modeling material such as a curable resin and repeating these, a tertiary that allows a desired three-dimensional model to be obtained by stacking two-dimensional cross-sectional shapes An original modeling apparatus is known (for example, refer to Patent Document 1).

  Here, referring to the examples conceptually shown in FIGS. 1A to 1G, a conventional 3D modeling method implemented by such a 3D modeling apparatus will be described in detail. First, on the table 200 An auxiliary material is supplied to the substrate, and the supplied auxiliary material is cut into a desired shape by a cutting tool (not shown) to form an auxiliary material layer 202 (see FIG. 1A).

  Next, a modeling material is supplied onto the auxiliary material layer 202, and the supplied modeling material is cut into a desired shape by a cutting tool (not shown) to form a modeling material layer 204 (FIG. 1 ( b)).

  Here, even if the modeling material layer 204 is formed in the shape as shown in FIG. 1B, the modeling material layer is formed as shown in FIG. 1C due to expansion, contraction, warpage, or the like when the modeling material is cured. The shape of 204 is deformed.

  Next, an auxiliary material is supplied onto the modeling material layer 204 deformed as described above (see FIG. 1D), and the supplied auxiliary material is cut into a desired shape by the cutting tool 300. 206 is formed (see FIG. 1E).

  Next, a modeling material is supplied onto the modeling material layer 204 and the auxiliary material layer 206 formed in the above (see FIG. 1F), and the supplied modeling material is cut into a desired shape by the cutting tool 300. Then, the modeling material layer 208 is formed (see FIG. 1G).

  Then, by removing the auxiliary material layer, a three-dimensional structure in which only a plurality of modeling material layers are stacked can be obtained.

As described above, according to the conventional three-dimensional modeling method, even when the auxiliary material layer or the modeling material layer is formed according to a predetermined size, the auxiliary material or the modeling material is expanded or contracted during curing. Deformation may occur in the shape of the auxiliary material layer or the modeling material layer due to warpage or the like.

  And when such a deformation | transformation arises, as shown in FIG.2 and FIG.3, when the three-dimensional modeling object by which only the modeling material layer was laminated | stacked was obtained, the boundary (henceforth "" There is a problem in that a stacking step such as a dent or a gap is generated in the “divided surface” as appropriate.

Also, due to the difference in frictional resistance between the auxiliary material layer and the modeling material layer, when the cutting tool passes the boundary between them, the split surface is missing by the cutting tool, causing unnecessary chipping. As shown in FIG. 2 and FIG. 3, there was a problem of causing a stacking step such as a dent or a gap on the dividing surface. Therefore, according to the conventional three-dimensional modeling method, it was produced due to the above-mentioned problems. It was pointed out that the modeling accuracy of the three-dimensional model was inferior.

Note that FIG. 2 shows a photograph of a stacking step such as a dent or a gap formed on a split surface of a three-dimensional structure produced by a conventional three-dimensional modeling method, and FIG. 3 is an enlarged photograph of FIG. is there.
JP-A-8-318573

  The present invention has been made in view of the various problems of the prior art as described above, and the object of the present invention is to prevent the occurrence of stacking steps such as dents and gaps on the dividing surface, It is an object of the present invention to provide a three-dimensional modeling method that can improve the modeling accuracy of a three-dimensional model to be produced.

  In order to achieve the above object, the three-dimensional modeling method according to the present invention repeatedly performs the step of cutting the auxiliary material to form the auxiliary material layer and the step of cutting the modeling material to form the modeling material layer. In the three-dimensional modeling method of removing the auxiliary material layer and producing a three-dimensional structure in which only the modeling material layer is laminated, the auxiliary material supplied on the modeling material layer is cut to form the auxiliary material layer When forming the auxiliary material layer by cutting to the lower region than the boundary between the modeling material layer and the other modeling material layer to be laminated on the modeling layer, the above-mentioned modeling material layer When supplying the modeling material of the other modeling material layer, it is also supplied onto the auxiliary material layer cut to the lower region beyond the boundary, and the modeling material of the other modeling material layer is cut to the other When forming the modeling material layer, it is cut to the lower region beyond the boundary. It is obtained so as to cut down to the auxiliary material layer.

  In the three-dimensional modeling method according to the present invention, the lower region is a region located 0.2 to 1.0 mm below the boundary.

  Therefore, according to the three-dimensional modeling method according to the present invention, it is possible to improve the modeling accuracy of the three-dimensional model to be manufactured by compensating for the stacking steps such as the dents and gaps generated on the divided surfaces.

  Since the present invention is configured as described above, it is possible to prevent the occurrence of stacking steps such as dents and gaps on the dividing surface, and to improve the modeling accuracy of the three-dimensional structure to be manufactured. There is an excellent effect of being able to do it.

  Hereinafter, an example of an embodiment of a three-dimensional modeling method according to the present invention will be described in detail with reference to the accompanying drawings.

  First, an example of a three-dimensional modeling apparatus that can be used when implementing the three-dimensional modeling method according to the present invention will be described with reference to FIGS. 4 and 5.

  The three-dimensional modeling apparatus 10 includes a U-shaped gate-shaped arm configured by a pair of substantially quadrangular columnar support portions 12L and 12R extending in the vertical direction and a bottom portion 12B connecting the support portions 12L and 12R. Part 12 is provided. Furthermore, the rail part 14 supported by the upper ends of each of the pair of support parts 12L and 12R, and the rail part 14 are within a predetermined range in the X-axis direction in the XYZ orthogonal coordinate system (see the reference diagram showing the coordinate system in FIG. 2). The carriage 16 is disposed so as to be freely movable.

  Further, a spindle 28, a dispenser 24 for discharging an auxiliary material, and a modeling material are discharged to a head (see FIGS. 2 and 3) provided movably within a predetermined range in the Z-axis direction with respect to the carriage 16. A dispenser 26 is also provided.

  Further, on the frame portion 18, a table 22 having a flat upper surface that is movable within a predetermined range in the Y-axis direction is disposed. On the upper surface 22a, an auxiliary material layer formed by an auxiliary material and a modeling process are provided. A modeling material layer formed of the material is laminated to form a three-dimensional modeled object.

  Note that the entire operation of the three-dimensional modeling apparatus 10 is controlled by a microcomputer. The dispenser 24, the dispenser 26, and the spindle 28 are moved in the Z-axis direction along with the movement of the head and X along with the movement of the carriage 16. The table 22 is moved in the axial direction and in the Y-axis direction.

  Accordingly, the relative positional relationship between the end mill 30 supported by the dispenser 24, the dispenser 26 and the spindle 28 and the three-dimensional structure formed on the table upper surface 22a moves in any direction in the X, Y, and Z axis directions. It is possible.

  Next, FIG. 5 shows a schematic configuration explanatory view (perspective view) in which the carriage 16 portion of the three-dimensional modeling apparatus 10 shown in FIG. 4 is enlarged, and detailed description will be given below.

  The dispenser 24 is designed so that auxiliary material accommodated in a tank (not shown) is supplied to the syringe 24b with a built-in heater, and can heat the auxiliary material stored in the syringe to a predetermined temperature.

  In this embodiment, a metal, particularly a low melting point alloy is used as an auxiliary material. For example, solder.

  The low melting point alloy heated to a predetermined temperature is melted in the syringe 24b, connected to the syringe 24b and discharged from the discharge port 24a located at the tip of the dispenser 24, and drops into a predetermined droplet. It is controlled so that a predetermined amount is applied to the position.

  The dispenser 26 is designed so that the modeling material accommodated in a tank (not shown) is supplied to the syringe 26b. One drop of the modeling material is connected to the syringe 26b from the discharge port 26a located at the tip of the dispenser 26. It is controlled so that a single droplet is ejected and applied to a predetermined position as a flying droplet.

  In this embodiment, an ultraviolet curable resin that cures when irradiated with ultraviolet rays is used as the modeling material.

  Further, a light guide member 42 is disposed so as to be positioned on the outer peripheral side of the discharge port 26a of the dispenser 26. The light guide member 42 is designed such that the optical fiber 50 for irradiating the ultraviolet rays drawn from the introduction tube portion 42c is positioned on the inclined surface 42s through the connecting portion 42b. For this reason, the ultraviolet rays irradiated from the distal end portion of the optical fiber 50 are irradiated in a 360 ° ring shape, and are condensed in a spot shape immediately below the through-hole 42h drilled in a substantially central portion of the main body portion 42a.

  Therefore, as described above, the ultraviolet curable resin applied at a predetermined position from the discharge port 26a of the dispenser 26 is controlled so as to be cured by the ultraviolet rays irradiated from the light guide member 42.

  The end mill 30 is connected to a rotating spindle 28 and cuts an auxiliary material layer and a modeling material layer by a cutting portion 30a.

In the above configuration, referring to the example conceptually shown in FIGS. 6A to 6F together with FIGS. 4 and 5, the three-dimensional modeling method of the present invention using the three-dimensional modeling apparatus 10 described above, The process of producing a three-dimensional structure will be described in detail.

  First, droplets of a low-melting-point alloy, which is an auxiliary material, are substantially dot-formed to a predetermined position on the table upper surface 22a from a discharge port 24a of the dispenser 24 that is positioned at a predetermined interval from the upper surface 22a of the table 22. Supply in the form. When the supplied auxiliary material is solidified by natural cooling, the solidified auxiliary material is cut into a desired shape by the end mill 30 and finished to form the auxiliary material layer 102 (see FIG. 6A).

  Next, an ultraviolet curable resin, which is a modeling material, is placed at a predetermined position on the auxiliary material layer 102 from a discharge port 26a of the dispenser 26, which is positioned at a predetermined distance from the upper surface 102a of the auxiliary material layer 102, under the control of the microcomputer. The droplets are supplied in the form of dots. At this time, as described above, the light guide portion 42 irradiates ultraviolet rays to simultaneously cure the ultraviolet curable resin. Then, the cured modeling material is cut into a desired shape by the end mill 30 and finished to form the modeling material layer 104 (see FIG. 6B).

  Next, the auxiliary material is supplied onto the modeling material layer 104 in the same manner as described above and solidified (see FIG. 6C). Then, the auxiliary material layer 106 is formed by cutting the solidified auxiliary material to a region further below the dividing surface by the end mill 30 (see FIG. 6D). That is, when the auxiliary material supplied on the modeling material layer 104 is cut to form the auxiliary material layer 106, the modeling material layer 104 and the modeling material layer 108 to be laminated on the modeling material layer 104 are formed. The auxiliary material layer 106 is formed by cutting to a region below the dividing surface that is the boundary. In addition, when the auxiliary material supplied on the modeling material layer 104 is cut to form the auxiliary material layer 106, the modeling material layer 104 and the modeling material layer 108 to be laminated on the modeling material layer 104 The region below the dividing surface that is the boundary of is a region that is located below the dividing surface by a distance L.

  Here, according to the experiment of the present inventors, the distance L is preferably 0.2 to 1.0 mm, and more preferably 0.5 mm, for example.

  Next, a modeling material is supplied onto the modeling material layer 104 and the auxiliary material layer 106 formed above, and the modeling material is solidified in the same manner as described above (see FIG. 6E). At this time, stacking steps such as dents and gaps generated in the divided surface due to chipping or deformation in the modeling material layer 104 and the auxiliary material layer 106 are compensated by stacking the modeling material below the dividing surface. That is, when the modeling material of the modeling material layer 108 is supplied onto the modeling material layer 104, the modeling material is also supplied onto the auxiliary material layer 106 that has been cut to the lower region beyond the dividing surface, and dents and gaps on the dividing surface, etc. Preventing the occurrence of

  Next, the solidified modeling material is cut into a desired shape by the end mill 30 to form the modeling material layer 108 (see FIG. 6F). That is, when the modeling material layer 108 is formed by cutting the modeling material of the modeling material layer 108, the modeling material layer 108 is cut to reach the auxiliary material layer 106 that has been cut to the lower region beyond the dividing surface.

Here, FIG. 7 shows a photograph of the divided surface of the three-dimensional structure produced by the three-dimensional structure forming method according to the present invention. As shown in the photograph of FIG. 7, the divided surface of the three-dimensional structure formed by the three-dimensional structure forming method according to the present invention has no stacking step such as a dent and a gap, and the three-dimensional structure manufactured. The molding accuracy is significantly improved.

The embodiment described above may be modified as described in the following (1) to (4).

  (1) In the above embodiment, a low melting point alloy is used as an auxiliary material and an ultraviolet curable resin is used as a modeling material. However, the present invention is not limited to this, and various materials are supported. It may be used as a material or as a modeling material.

  For example, as an auxiliary material, a thermoplastic resin such as wax may be used, and as a modeling material, a photo-curing resin that is cured by visible light, electron beam, or other light of radiation different from ultraviolet rays, Similarly to the auxiliary material, a thermoplastic resin such as wax may be used.

  (2) In the above-described embodiment, the auxiliary material and the modeling material are both supplied in a substantially dot shape. However, the present invention is not limited to this, and only the auxiliary material or Even if only the modeling material is supplied in a substantially dot shape, the material can be applied with high accuracy. Also, depending on the type of auxiliary material and modeling material, the range to be applied, etc., a method different from a substantially dot shape, for example, a linear shape or a predetermined amount may be applied.

  (3) In the above-described embodiment, the 3D modeling apparatus 10 shown in FIG. 2 and FIG. 3 is used. However, the present invention is not limited to this. You may make it add a structure or use another modeling apparatus.

  Therefore, various configurations such as using other cutting tools such as a cutter different from the end mill 30 or changing the relative positional relationship between the three-dimensional structure to be produced and the dispensers 24 and 26 in the three-dimensional direction can be employed. Is. Moreover, the process of removing the part formed with the auxiliary material to obtain a three-dimensional structure may be performed in a system in the modeling apparatus.

  (4) You may make it combine the above-mentioned embodiment and the modification shown in said (1) thru | or (3) suitably.

  The present invention can be used in a three-dimensional processing apparatus such as a modeling machine, a two-dimensional engraving apparatus that performs cutting with a tool, or the like when producing parts or design models in trial production or mass production.

1 (a), (b), (c), (d), (e), (f), and (g) are conceptual explanatory views of a conventional three-dimensional modeling method implemented by a three-dimensional modeling apparatus. FIG. 2 is a photograph of a layered step such as a dent or a gap formed on a split surface of a three-dimensional structure produced by a conventional three-dimensional modeling method. FIG. 3 is an enlarged photograph of FIG. FIG. 4 is a schematic configuration explanatory diagram illustrating an example of a three-dimensional modeling apparatus that can be used when the three-dimensional modeling method according to the present invention is performed. FIG. 5 is an explanatory schematic diagram (perspective view) showing an enlarged view of the carriage portion of the three-dimensional modeling apparatus shown in FIG. 6A, 6B, 6C, 6D, 6E, and 6F are conceptual explanatory views of the three-dimensional modeling method according to the present invention. FIG. 7 is a photograph taken of a split surface of a three-dimensional structure produced by the three-dimensional modeling method according to the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 3D modeling apparatus 12 Gate type arm part 14 Rail part 16 Carriage 18 Frame part 22 Table 24 Dispenser 26 Dispenser 28 Spindle 30 End mill 42 Light guide member 50 Optical fiber 102 Auxiliary material layer 104 Modeling material layer 106 Auxiliary material layer 108 Modeling material layer 200 Table 202 Auxiliary Material Layer 204 Modeling Material Layer 206 Auxiliary Material Layer 208 Modeling Material Layer 300 Cutting Tool

Claims (2)

After repeatedly performing the process of cutting the auxiliary material to form the auxiliary material layer and the process of cutting the modeling material to form the modeling material layer, the auxiliary material layer is removed, and only a plurality of the modeling material layers are laminated. In a three-dimensional modeling method for producing a three-dimensional model,
When forming the auxiliary material layer by cutting the auxiliary material supplied on the modeling material layer, it is below the boundary between the modeling material layer and the other modeling material layer to be laminated on the modeling layer. Cut to the area to form an auxiliary material layer,
When supplying the modeling material of the other modeling material layer on the modeling material layer, supplying the auxiliary material layer cut to the lower region beyond the boundary,
When forming the other modeling material layer by cutting the modeling material of the other modeling material layer, cutting is performed until the auxiliary material layer is cut to the lower region beyond the boundary. Three-dimensional modeling method. In the three-dimensional modeling method according to claim 1,
The lower region is a region located 0.2 to 1.0 mm below the boundary.