JP2007307742A - Powder sintering laminate shaping apparatus and its use method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance the recycling ratio of a powder material by making it possible not only to prevent the insufficiency of the powder material but also to soon reuse the excessive powder material. <P>SOLUTION: This powder sintering laminate shaping apparatus comprises a control means for adjusting the powder material 16 so that the surface of the powder material 16 on the powder material supply table 14a or 14b on the supply side of the powder material 16 is upward protruded from the surface of a powder material housing container 12a or 12b when the powder material 16 is supplied to a shaping container 11 by moving a recoater 15 and the surface of the powder material 16 on the powder material supply table 14b or 14a on the other side becomes downward from the surface of the powder material housing container 12b or 12a on the same side. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a powder sintered additive manufacturing apparatus and a method for using the same, and to a powder sintered additive manufacturing apparatus for manufacturing a three-dimensional object by stacking a plurality of sintered thin layers on a forming table and a method for using the same.

  In recent years, there has been an increasing demand for modeling apparatuses capable of modeling functional test prototype parts and parts used in a small variety of products.

  There exist an optical shaping | molding apparatus, a powder sintering layered shaping apparatus etc. as what satisfy | fills this request | requirement. Above all, the powder sintering additive manufacturing equipment is one of the major features that can be used with a wide variety of tough materials, unlike the modeling equipment that uses UV curable resin (hereinafter "Optical modeling equipment"). It has also been used for various purposes.

  Conventionally, a powder sintering additive manufacturing apparatus that is commercially available includes a laser beam emitting unit, a modeling unit, and a control device. FIGS. 8A and 8B are a cross-sectional view and a top view, respectively, of a modeling portion of a powder sintering additive manufacturing apparatus that is commercially available. A laser beam emitting unit (not shown) is installed above the modeling unit.

  In the laser beam emitting section, a laser beam source and a mirror for controlling the laser beam irradiation direction are provided.

  In the modeling part 101, as shown in FIGS. 8A and 8B, a modeling container 1 that is installed in the center part and is modeled by laser light irradiation to produce a three-dimensional modeled object, There are provided powder material storage containers 2a and 2b installed on both sides for storing the powder material, and storage containers 3a and 3b for supplying excess powder material. Also, a modeling table 4 that descends along the inner wall of the modeling container 1 is installed in the modeling container 1, and a powder material supply that rises along the inner walls of the powder material containers 2a and 2b is installed in the powder material containers 2a and 2b. Tables 5a and 5b are installed.

The control device lowers the modeling table 4 by one thin layer, raises the powder material supply table 5 a, causes the recoater 6 to supply the powder material 7 onto the modeling table 4, and thins the powder material on the modeling table 4. The layer 7a is formed, and then the thin layer 7a of the powder material is selectively heated and sintered based on the slice data (drawing pattern) of the three-dimensional structure to be produced by the laser beam and the control mirror, and these operations are performed. Repeat. In this way, a three-dimensional structure is formed, and finally, the three-dimensional structure is cooled.
Japanese Patent No. 2620353

  By the way, in the conventional powder sintering additive manufacturing apparatus, when the thin layer of the powder material supplied to the modeling region is selectively irradiated with laser light and sintered, the sintered portion is melted and the volume is reduced. At least, it is necessary to supply a powder material that only supplements the volume of the modeling table 4 in the modeling container 1 that has been lowered and the volume that has been reduced by sintering.

  However, while the volume of the molding table 4 is lowered, the volume of the portion reduced by the sintering is reduced by only a part due to the cross-sectional area of the sintered portion of each layer and the deviation of the cross-sectional position. It is difficult to predict. In this case, since it is necessary to prevent the shortage of the supply amount of the powder material in the worst case, it is necessary to always supply a larger amount of the powder material. In addition, since the entire powder material supply tables 2a and 2b are raised, the powder material 7 is excessively supplied to the portion where the volume is not reduced.

  Therefore, the powder material 7 overflows from the modeling container 1 for each layer. In particular, when the modeling area is large and the sintering area is small, the amount of the excessive powder material 8 increases.

  Therefore, the conventional apparatus is provided with storage containers 3a and 3b for storing the excessively supplied powder material 8 as shown in FIGS. 8A and 8B, and measures such as dropping the excessively supplied powder material 8 there are provided. Adopted.

  However, even when there is little deterioration of the powder material 8 and the powder material 8 does not have to be discarded, the powder material 8 stored in the storage containers 3a and 3b of the excessively supplied powder material 8 is cold, and Since they are stored in the storage containers 3a and 3b, they cannot be immediately supplied to the modeling area and cannot be used. Since the excessively supplied powder material 8 cannot be used on the spot, it cannot be treated as a new article regardless of deterioration due to heat. As a result, the recycling rate is reduced.

  In addition, when the excessively supplied powder material 8 is generated, there is a situation in which the powder material 8 is insufficient and the molded article cannot be completed. In order to prevent this, it is necessary to enlarge the powder material containers 2a and 2b, but in that case, it is necessary to increase the lateral width of the apparatus, which is not preferable.

  The present invention was created in view of the above problems of the conventional example, and prevents the shortage of the powder material and allows the excessive powder material to be reused immediately, thereby increasing the recycling rate of the powder material. It is an object of the present invention to provide a powder sintering additive manufacturing apparatus that can be improved and downsized, and a method for using the apparatus.

In order to solve the above-mentioned problems, the first invention relates to a powder sintering additive manufacturing apparatus, a modeling container that defines a modeling region, and a modeling table that moves at least downward along the inner wall of the modeling container, First and second powder material storage containers that are provided on both sides of the modeling region and store powder materials used for modeling, and a first powder that moves up and down along the inner wall of the first powder material storage container A material supply table, a second powder material supply table that moves up and down along the inner wall of the second powder material storage container, the first powder material storage container, the modeling container, and the second powder material A recoater that moves along the surface of the powder material stored in the storage container, and a powder material that supplies the powder material when the recoater is moved to supply the powder material to the modeling container The surface of the powder material on the supply table protrudes above the surface of the powder material storage container on the same side, and at the same time the surface of the powder material on the powder material supply table on the other side is the same side of the powder material storage container And a control means for adjusting so as to be below the surface of
A second invention relates to the powder sintering additive manufacturing apparatus according to the first invention, wherein the recoater includes a sensor for detecting the amount of powder material supplied to the modeling container,
A third invention relates to the powder sintering additive manufacturing apparatus according to any one of the first and second inventions, and the control device, when the supply amount of the powder material detected by the sensor is less than a reference, It is characterized by further raising the powder material supply table on the side for supplying the powder material than when detected,
A fourth invention relates to the powder sinter additive manufacturing apparatus according to any one of the first to third inventions, and includes an outflow protective wall for the powder material installed so as to sandwich the moving area of the recoater. Features
A fifth invention relates to the powder sintering additive manufacturing apparatus according to any one of the first to fourth inventions, wherein the powder sintering additive manufacturing apparatus is a thin layer of powder material formed on the modeling table. It comprises a laser light irradiation means for selectively irradiating laser light,
6th invention is related with the usage method of a powder sintering layered modeling apparatus, the modeling container which demarcates a modeling area | region, the modeling table which moves at least below along the inner wall of the said modeling container, and the said modeling area | region First and second powder material storage containers that are provided on both sides and store the powder material used for modeling, and a first powder material supply table that moves up and down along the inner wall of the first powder material storage container, The second powder material supply table that moves up and down along the inner wall of the second powder material storage container, the surface of the first powder material storage container, the modeling container, and the second powder material storage container And a means for selectively heating a thin layer of the powder material formed on the modeling table, comprising: (1) the first 1 powder material The powder material is placed on a table and raised to cause the powder material to protrude onto the surface of the first powder material storage container. (2) The recoater is moved to move the surface of the first powder material storage container. (3) The recoater is moved to supply the scraped powder material to the modeling container, and a thin layer of the first powder material is formed on the modeling table. (4) selectively heating the thin layer of the first powder material to form a sintered thin layer, and (5) moving the recoater to supply the remaining powder to the modeling container The material is placed on the lowered second powder material supply table and stored in the second powder material storage container,
A seventh invention relates to a method of using the powder sintered additive manufacturing apparatus of the sixth invention, and after the step (5), (6) raising the second powder material supply table, And (7) moving the recoater to scrape off the surface layer of the powder material protruding on the surface of the second powder material storage container, and (8) The recoater is moved to supply the scraped powder material to the modeling container, and a thin layer of the second powder material is formed on the thin layer of the first powder material on the modeling table. 9) Selectively heating the thin layer of the second powder material to form a sintered thin layer, and (10) moving the recoater to lower the remaining powder material supplied to the modeling container. The first powder material storage container placed on the first powder material supply table. And characterized in that it is housed in,
The eighth invention relates to a method of using the powder sintered additive manufacturing apparatus of the seventh invention, characterized in that the steps (1) to (10) are repeated,
A ninth invention relates to a method of using the powder sintered additive manufacturing apparatus according to any one of the sixth to eighth inventions, wherein the recoater detects a supply amount of a powder material supplied to the modeling container. When the supply amount of the powder material detected by the sensor is smaller than the reference, the powder material supply table on the side on which the powder material is supplied is further raised than the time of detection, and the powder on the same side After projecting the powder material on the surface of the material container, the steps (2) to (5) are performed, or the steps (2) to (5) and the steps (7) to (10). It is characterized by performing.

  In the powder sintering additive manufacturing apparatus of the present invention, the first powder material supply table that moves up and down along the inner wall of the first powder material storage container and the vertical movement along the inner wall of the second powder material storage container A second powder material supply table, a first powder material storage container, a modeling container, a recoater that moves along the surface of the second powder material storage container, and a recoater that moves the powder to the modeling container. When supplying the material, the surface of the powder material on the powder material supply table on the side on which the powder material is supplied protrudes above the surface of the powder material storage container on the same side, and on the powder material supply table on the other side And a control means for adjusting so that the surface of the powder material is lower than the surface of the powder material storage container on the same side.

  Therefore, the powder material protruding above the surface of the first powder material storage container is supplied from the first powder material storage container to the modeling container, and the remaining powder material is supplied to the second powder material supply table. And the powder material projecting above the surface of the second powder material storage container can be converted into the second powder material storage container. To the modeling container and the remaining powder material can be placed on the first powder material supply table and stored in the first powder material storage container.

  This allows excess powder material to be reused immediately on site. Thereby, the recycling rate of powder material can be improved. Further, since the recycling rate can be improved, the powder material storage container can also be made small.

  Furthermore, since the recoater includes a sensor for detecting the amount of powder material supplied to the modeling container, an appropriate amount of powder material can be supplied to the modeling container and all powder materials can be used without waste. be able to.

  In addition, when the supply amount of the powder material detected by the sensor is smaller than the reference, the control device further raises the powder material supply table on the side on which the powder material is supplied than when it is detected. A sufficient amount of powder material can be supplied even in cases where it is difficult to predict, for example, when the cross-sectional area of the tie portion or the partial position is largely reduced due to the deviation in the cross-sectional position.

  In addition, it has a powder material outflow protection wall installed so as to sandwich the recoater movement area, so that the powder material that has been scraped by the recoater and raised on the surface of the area is prevented from flowing out of the modeling area. can do. Thereby, the recycling rate of powder material can be improved.

  In the method of using the powder sintering additive manufacturing apparatus of the present invention, the first powder material supply table on which the powder material is placed is raised to project the powder material on the surface of the first powder material storage container, and the recoater is moved. The surface layer of the protruding powder material is scraped off, the powder material is supplied from the first powder material storage container to the modeling container, a thin layer of the powder material is formed on the modeling table, and the thin layer is selectively To form a sintered thin layer, and move the recoater to place the remaining powder material supplied to the modeling container on the second powder material supply table where the powder material is lowered, and in the second powder material storage container It is stored in.

  Therefore, thereafter, by supplying the powder material from the second powder material storage container to the modeling container using the recoater, the excess powder material can be immediately reused on the spot. Thereby, the recycling rate of powder material can be improved.

  In addition, when the supply amount of the powder material is less than the standard, the powder material supply table on the side where the powder material is supplied is further raised to increase the supply amount of the powder material. Can be supplied.

  Embodiments of the present invention will be described below with reference to the drawings.

(Description of powder sintering additive manufacturing equipment)
The powder sintering additive manufacturing apparatus according to the embodiment of the present invention includes a laser beam emitting unit, a modeling unit, and a control device.

  Fig.1 (a) is sectional drawing which shows the structure of the modeling part 111 among the powder sintering layered modeling apparatuses which concern on embodiment of this invention. FIG. 1B is a top view of the same.

  2A is a side view showing a state in which the recoater 15 is moved and the powder material is supplied in the powder sintered additive manufacturing apparatus of FIG. 1, and FIG. 2B is a front view of the same. The recoater 15 has an overall configuration as shown in FIG. 3, but in FIGS. 2A and 2B, only the transport plate 15 a is shown among the members constituting the recoater 15.

  Although not shown in FIGS. 1A and 1B, the laser beam emitting portion is disposed above the modeling portion 111 and has the following functions. The control device also has the following functions, which are not shown in the drawing. Details of each part will be described below.

  First, the laser beam emitting part will be described.

  In the laser beam emitting section, a laser beam source and a mirror for controlling the laser beam irradiation direction are provided. The laser beam emitted from the light source is selectively irradiated onto the thin layer 16a of the powder material on the modeling table 13 of the modeling unit 111 by mirror control by a computer. For example, mirror control by a computer is performed based on slice data (drawing pattern) of a three-dimensional structure to be produced.

  Next, the modeling unit 111 will be described.

  In the modeling part 111, as shown in FIG. 1, the rectangular cylindrical container 11 in which modeling is performed by irradiation with laser light to produce a three-dimensional modeled object, and the powder material 16 installed on both sides thereof Are provided with first and second powder material storage containers 12a and 12b having a rectangular cylindrical shape. A region surrounded by the inner wall of the modeling container 11 is a modeling area, and a region surrounded by the inner walls of the first and second powder material storage containers 12a and 12b is a powder material storage area. In addition, the first powder material storage container 12a has a flange portion 17a on the left side, the second powder material storage container 12b has a flange portion 17b on the right side, and the first powder material storage container 12a Over the entire region of the container 11 and the second powder material storage container 12b, a flange portion 17c is provided on the front side, and a flange portion 17d is provided on the back side.

  A modeling table 13 that can be moved up and down along the inner wall is placed in the modeling container 11 and can be moved up and down along the inner wall. The thin layer 16a is formed, and each thin layer 16a of the powder material is heated and sintered. Further, the first and second powders that supply the powder material 16 by placing the powder material 16 in the first and second powder material storage containers 12a and 12b and moving up and down along the inner walls of the storage containers 12a and 12b. Material supply tables 14a and 14b are respectively installed.

  As shown in FIG. 1A, the modeling table 13 includes a plate-like member 13a having a flat surface that serves as a mounting surface for a modeled object. Although not shown, the cylinder 13 is arranged so that when the cylinder 13 is set in the modeling container 11, a gap is not generated between the cylinder 13 and the inner wall of the container 11 and the powder material 16a leaks. In order to maintain the adhesion between the container 11 and the inner wall of the container 11, packing rubber or the like is attached over the entire side surface of the plate member 13a.

  Further, the first and second powder material supply tables 14 a and 14 b are also made of plate-like members 14 aa and 14 ba having flat surfaces to be the placement surfaces of the powder material 16, similarly to the modeling table 13. Although not shown, in this case as well, when the cylinders 14a and 14b are set in the powder material storage containers 12a and 12b, a gap is generated between the cylinders 14a and 14b and the inner walls of the storage containers 12a and 12b. In order to prevent the material 16 from leaking, packing rubber or the like is attached to the entire side surfaces of the plate-like members 14aa and 14ba in order to maintain adhesion between the cylinders 14a and 14b and the inner walls of the storage containers 12a and 12b. .

  Support shafts 14ab and 14bb are attached to the modeling table 13 and the first and second powder material supply tables 14a and 14b. The support shafts 14ab and 14bb are connected to a drive device that causes the support shafts 14ab and 14bb to move up and down.

  The modeling table 13 can be freely attached to and detached from the modeling container 11. Moreover, the 1st and 2nd powder material supply tables 14a and 14b can be freely attached to and detached from the first and second powder material containers 12a and 12b.

  Furthermore, a recoater 15 is provided that moves along the surface of the area over the entire area of the first powder material storage area, the modeling area, and the second powder material storage area. The recoater 15 before moving is placed on the flange portions 17a and 17b.

  The recoater 15 is provided with a transport mechanism 15a for scraping and transporting the powder material 16 protruding from the surface of the area. As shown in FIGS. 2A and 2B, the recoater 15a moves on the first or second powder material supply table 14a, 14b by moving along and in contact with the surface of the area. The stored powder material 16 is carried and supplied onto the modeling table 13, and the surface of the powder material 16 is leveled to form a thin layer 16 a of the powder material on the modeling table 13. Therefore, the supply amount of the powder material 16 is determined by the rising amount of the first or second powder material supply table 14 a, 14 b, and the thickness of the thin layer 16 a of the powder material is determined by the lowering amount of the modeling table 13. As powder material 16, nylon, polypropylene, polylactic acid, polyethylene (PE), polyethylene terephthalate (PET), polystyrene (PS), acrylic, tolyl-butadiene-styrene copolymer (ABS), ethylene-vinyl acetate copolymer (EVA), styrene -At least 1 sort (s) selected from the group which consists of an acrylonitrile copolymer (SAN) and polycaprolactone, or metal powder etc. can be used.

  Further, the recoater 15 has a sensor 15 that detects the supply amount of the powder material 16.

  The sensor function of the recoater 15 will be described below with reference to FIGS. 3 (a) and 3 (b). FIGS. 3A and 3B are side views showing how the recoater 15 detects the supply amount of the powder material.

  The recoater 15 includes a detection plate 15d and a sensor switch 15e that are horizontally held at two positions before and after the vertical transport plate 15a and at an appropriate interval from the lower end. The detection plate 15d has a fulcrum from a horizontal position. The sensor switch 15e is turned on by turning upward about the center. The detection plate 15d is horizontally held at the lower end of the second support plate 15c that is vertically attached at the two front and rear ends of the first support plate 15b that is attached to the upper end of the transport plate 15a and projects horizontally. The holding point is the fulcrum. The sensor switch 15e is fixed to at least one of the peripheral plates 15a, 15b, or 15c.

  Since the powder material 16 being transported accumulates on the front side in the traveling direction of the transport plate 15a and pushes up the detection plate 15d from below, the detection plate 15d rotates upward and the sensor switch 15e is pressed to turn on. It can be confirmed that the powder material 16 is supplied.

  With the sensor function of the recoater 15 as described above, in FIG. 3A, the detection plate 15d remains horizontal, so it is determined that sufficient powder material 16 has not been supplied, while in FIG. 3B, Since the detection plate 15d is rotated upward, it is determined that sufficient powder material 16 is supplied.

  In the modeling part 111, as shown in Drawing 1 (b), Drawing 2 (a), and (b), over all areas of a modeling area and a storage area of powder material, on flange parts 17c and 17d, An outflow protection wall 18 for the powder material 16 is provided across the moving area of the recoater 15. Since the powder material 16 has fluidity, the powder material 16 scraped by the moving recoater 15 and swelled on the surface of the modeling area or the like on the front side in the traveling direction of the recoater 15 tends to flow out around the modeling area or the like. The outflow protective wall 18 can prevent the powder material 16 from flowing out to the surroundings. Thereby, the recycling rate of the powder material 16 can be further improved.

  Next, the control device will be described.

  The control device has the following functions. That is, the first powder material supply table 14a on which the powder material is placed is raised, the shaping table 13 is lowered by one thin layer, and the recoater 15 is moved to move the recoater 15 from the first powder material storage container 12a. The powder material 16 is supplied to the container 11, the thin layer 16a of the powder material is formed on the modeling table 13, the second powder material supply table 14b is lowered, the recoater 15 is moved, and the remaining powder material 16 is moved. The material is stored on the second powder material supply table 14b in the second powder material storage container 12b. Next, the thin layer 16a of the powder material is selectively heated and sintered based on the slice data (drawing pattern) of the three-dimensional structure to be produced by the laser beam and the control mirror (heating and sintering means).

  Contrary to the above, the second powder material supply table 14b on which the powder material 16 is placed is raised, the modeling table 13 is lowered by one thin layer, and the recoater 15 is moved to move the second powder material. The powder material 16 is supplied from the storage container 12b to the modeling container 11, a new powder material thin layer 16a is formed on the powder material thin layer 16a on the modeling table 13, and a first powder material supply table is formed. 14a is lowered, the recoater 15 is moved, and the remaining powder material 16 is stored on the first powder material supply table 14a in the first powder material storage container 12a. Next, the thin layer 16a of the powder material is selectively heated and sintered based on the slice data (drawing pattern) of the three-dimensional structure to be produced by the laser beam and the control mirror (heating and sintering means).

  And these operation | movement is repeated and the some sintered thin layer 16b is laminated | stacked, and a three-dimensional molded item is produced.

  Furthermore, when the supply amount of the powder material detected by the sensor provided in the recoater 15 is smaller than the reference, the control device returns the powder material to the powder material supply table 14a or 14b once, and the powder material is more than when it is detected. The powder material supply table 14a or 14b on the side to which 16 is supplied is further raised.

  As described above, in the powder sintering additive manufacturing apparatus according to the embodiment of the present invention, the first powder material supply table 14a that moves up and down along the inner wall of the first powder material storage container 12a, and the second The surface of the second powder material supply table 14b that moves up and down along the inner wall of the powder material storage container 12b, the first powder material storage container 12a, the modeling container 11 and the second powder material storage container 12b. , And the first or second powder material supply table 14a, 14b on which the powder material 16 is placed are raised, and the recoater 15 is moved to move the first or second powder material storage container 12a, The powder material 16 is supplied from 12b to the modeling container 11, the second or first powder material supply table 14b, 14a is lowered, the recoater 15 is moved, and the remaining powder material is moved to the first. 2 or the first powder material storage containers 12b, 12a, and a control means for storing them on the second or first powder material supply tables 14b, 14a.

  Therefore, the powder material 16 can be supplied from the first powder material storage container 12a to the modeling container 11, and the remaining powder material can be stored in the second powder material storage container 12b. The powder material 16 can be supplied from the powder material storage container 12b to the modeling container 11, and the remaining powder material can be stored in the first powder material storage container 12a.

  As a result, excess powder material can be reused immediately on the spot, so that the recycling rate of the powder material can be improved. Further, since the recycling rate can be improved, the powder material storage containers 12a and 12b can also be made small. For example, the ratio of the width of the powder material storage containers 12a and 12b to the width of the modeling container 11 can be reduced from the conventional 0.737 to 0.536.

  Furthermore, since the recoater 15 includes sensors 15d and 15e that detect the supply amount of the powder material 16 supplied to the modeling container 11, a sufficient amount of the powder material 16 is supplied to the modeling container 11 in all cases. can do.

  In addition, when the supply amount of the powder material detected by the sensor provided in the recoater 15 is smaller than the reference, the control device sets the powder material supply table 14a or 14b on the side for supplying the powder material 16 as compared with the detection time. Since it can be further increased, a sufficient amount of powder material can be supplied even in the case where it is difficult to predict, for example, when it is difficult to predict, for example, a small decrease due to the cross-sectional area of the sintered portion of each layer or the deviation of the cross-sectional position.

  Further, since the outflow protection wall 18 is provided, the powder material 16 can be prevented from flowing out to the surroundings. Thereby, the recycle rate of powder material can be improved further.

(Description of how to use powder sintering additive manufacturing equipment)
Next, a method for performing modeling using the above-described powder sintering additive manufacturing apparatus will be described with reference to FIGS. 4 to 7 are sectional views. 4 to 7, the sensor switch of the recoater 15 is omitted.

  First, the modeling container 11, the first and second containers 13, 14 a, 14 b can be moved up and down along the inner walls of the modeling container 11, the first and second powder material storage containers 12 a, 12 b. Are attached to the powder material storage containers 12a and 12b.

  Next, in the modeling unit 111, the left and right powder material supply tables 14a and 14b are lowered, the powder material 16 is supplied onto the powder material supply tables 14a and 14b, and a sufficient amount of the powder material 16 is stored.

  FIG. 4A shows a state after such a preparation and after a single layer of sintered layers has been formed, but before the next thin layer of powder material is formed.

  Next, as shown in FIG. 4B, the modeling table 13 is lowered by an amount corresponding to one thin layer. Next, the powder material supply table 14a on the left side is raised so that the powder material 16 comes out from the flat surface. At this time, the powder material supply table 14b on the right side is lowered so that the remaining powder material 16 after supply can be stored.

  Next, as shown in FIG. 5 (a), the recoater 15 is moved so that the powder material 16 coming out from the flat surface on the powder material supply table 14a on the left side is leveled. Move on the table 13. At this time, it is confirmed that a sufficient amount of the powder material 16 is supplied by a sensor installed in the recoater 15 that detects the supply amount of the powder material.

  When the supply amount of the powder material detected by the sensor is small, before the powder material 16 is moved into the modeling container 11, the powder material 16 is returned to the first powder material storage container 12a by the recoater 15, and then After the first powder material supply table 14a is further raised than when it is detected that the supply amount of the powder material is small, the recoater 15 is moved to supply the powder material 16 to the modeling container 11, and the remaining Is stored in the second powder material storage container 12b.

  Thereby, as shown in FIG.5 (b), the thin layer 21a of a new layer of powder material is formed on the sintered thin layer 21b of the 1st layer on the modeling table 13. FIG. At this time, the surface of the thin layer 21 a of the powder material is powdered by a heater (not shown) installed on the inner wall of the modeling container 11 or an infrared heating device (not shown) provided obliquely above the modeling container 11. Preheat to a temperature about 5-15 ° C. below the melting point of the material.

  Further, as shown in FIGS. 6A and 6B, the recoater 15 is moved to store the remaining powder material 16c on the second powder material supply table 14b in the second powder material storage container 12b.

  When the powder material supply table 14a on the left side is raised in the previous step so that the powder material 16 comes out from the flat surface, the amount of extra material may be considerably increased. Thereby, since the remaining powder material 16c after supply to the modeling container 11 becomes a large amount, when the powder material 16c is stored in the second powder material storage container 12b, the second weight material 16c has a second weight due to its own weight. This has the effect of increasing the density of the powder material 16 stored in the powder material storage container 12b. Further, since the sintering region is biased in the modeling region, even when the remaining powder material 16c is biased and stored in the powder material storage container 12b accordingly, by increasing the extra amount, The bias of the remaining powder material can be reduced.

  Next, the laser beam is emitted from the light source of the laser beam emitting unit, and the mirror is controlled by a computer based on the slice data of the three-dimensional structure to be produced, so that the laser beam is selectively applied to the thin layer 16a of the powder material. Irradiate. Thereby, as shown in FIG. 6B, the thin layer 16b of the powder material is heated and sintered.

  Next, as shown in FIG. 7A, the modeling table 13 is lowered by one thin layer, and the second powder material supply table 14b is raised. Further, the first powder material supply table 14a is lowered.

  Next, as shown in FIG. 7B, the recoater 15 is moved from the right side to the left side, contrary to the case described above. Then, a new powder material 16 is supplied from the second powder material storage container 12b onto the modeling table 13, and a new powder material thin layer 16a is formed on the sintered thin layer 16b. Subsequently, heat sintering → formation of a thin layer 16a of powder material → heat sintering →..

  In this way, a three-dimensional structure is completed. Finally, the preliminary heating is stopped and natural cooling is performed. When the temperature reaches around room temperature, the three-dimensional structure buried in the powder material 16 is taken out of the modeling container 11.

  As described above, according to the method of using the powder sintering additive manufacturing apparatus of the present invention, the first powder material supply table 14a on which the powder material is placed is raised, the shaping table 13 is lowered, and the recoater 15 is moved. The powder material 16 is supplied from the first powder material storage container 12a to the modeling container 11, the thin layer 16a of the powder material is formed on the modeling table 13, and the second powder material supply table 14b is lowered, The recoater 15 is moved to store the remaining powder material 16c on the second powder material supply table 14b in the second powder material storage container 12b.

  Further, after that, the second powder material supply table 14b in the second powder material storage container 12b is raised, and the recoater 15 supplies the powder material 16 from the second powder material storage container 12b to the modeling container 11. ing.

  As a result, it becomes possible to reuse the excessive powder material immediately, so that the recycling rate of the powder material can be improved.

  Further, when the supply amount of the powder material 16 is smaller than the reference, the powder material supply table 14a or 14b on the side where the powder material 16 is supplied is further raised, and the supply amount of the powder material 16 is increased. Even in this case, a sufficient amount of powder material can always be supplied.

  As mentioned above, although the powder sintered additive manufacturing apparatus of this invention was demonstrated in detail by embodiment, the scope of this invention is not restricted to the example specifically shown in the said embodiment, The summary of this invention is shown. Modifications of the above-described embodiment without departing from the scope of the invention are included in the scope of the present invention.

  For example, in the powder sinter molding apparatus of this embodiment, the sensors 15d and 15e, which are installed in the recoater 15, detect the supply amount of the powder material, the detection plate 15d rotates around a fulcrum, and the sensor switch 15e. However, the detection plate 15d may be lifted up and down in an elevator manner to press and turn on the sensor switch.

  Moreover, you may use the sensor of a structure which can measure the absolute amount of the supply amount of a powder material.

(A) is sectional drawing which shows the structure of a modeling part among the powder sintering lamination-modeling apparatuses which are embodiment of this invention, (b) is a top view similarly. (A) is a side view which shows a mode that the recoater is moved and the powder material is supplied in the powder sintering additive manufacturing apparatus of FIG. 1, (b) is also a front view. (A), (b) is a side view which shows a mode that the recoater detects supply_amount | feed_rate of powder material in the powder sinter additive manufacturing apparatus of FIG. (A), (b) is sectional drawing (the 1) which shows the usage method of the powder sinter additive manufacturing apparatus which is embodiment of this invention. (A), (b) is sectional drawing (the 2) which shows the usage method of the powder sinter additive manufacturing apparatus which is embodiment of this invention. (A), (b) is sectional drawing (the 3) which shows the usage method of the powder sintering laminated modeling apparatus which is embodiment of this invention. (A), (b) is sectional drawing (the 4) which shows the usage method of the powder sinter additive manufacturing apparatus which is embodiment of this invention. It is sectional drawing which shows the powder sintering modeling apparatus of a prior art example.

Explanation of symbols

11 Modeling container 12a First powder material storage container 12b Second powder material storage container 13 Modeling table 14a First powder material supply table 14b Second powder material supply table 15 Recoater 15a Transport plate 15d Detection plate 15e Sensor Switch 16 Powder material 16a Powder material thin layer 16b Sintered thin layer 16c Remaining powder material 17a, 17b, 17c, 17d Flange portion 18 Powder material outflow protection wall 111 Modeling portion

Claims (9)

A modeling container for defining a modeling area;
A modeling table that moves at least downward along the inner wall of the modeling container;
First and second powder material storage containers that are provided on both sides of the modeling area and store powder materials used for modeling,
A first powder material supply table that moves up and down along the inner wall of the first powder material storage container;
A second powder material supply table that moves up and down along the inner wall of the second powder material storage container;
A recoater that moves along the surface of the powder material stored in the first powder material storage container, the modeling container, and the second powder material storage container;
When the recoater is moved to supply the powder material to the modeling container, the surface of the powder material on the powder material supply table on the powder material supply side is the same as the surface of the powder material storage container on the same side. And a control means for adjusting the surface of the powder material on the powder material supply table on the other side to be lower than the surface of the powder material storage container on the same side. Powder sintering additive manufacturing equipment.   The powder sinter layered manufacturing apparatus according to claim 1, wherein the recoater includes a sensor that detects an amount of the powder material supplied to the modeling container.   When the supply amount of the powder material detected by the sensor is smaller than a reference, the control device further raises the powder material supply table on the side that supplies the powder material, compared to the time of detection. The powder sintering additive manufacturing apparatus according to claim 2.   The powder sintered additive manufacturing apparatus according to any one of claims 1 to 3, further comprising an outflow protection wall for the powder material installed so as to sandwich the moving area of the recoater.   5. The powder sintering additive manufacturing apparatus includes laser light irradiation means for selectively irradiating a thin layer of a powder material formed on the modeling table with laser light. The powder sinter additive manufacturing apparatus as described in any one. A modeling container for defining a modeling area;
A modeling table that moves at least downward along the inner wall of the modeling container;
First and second powder material storage containers that are provided on both sides of the modeling region, and store powder materials used for modeling,
A first powder material supply table that moves up and down along the inner wall of the first powder material storage container;
A second powder material supply table that moves up and down along the inner wall of the second powder material storage container;
A recoater that moves along the surfaces of the first powder material storage container, the modeling container, and the second powder material storage container;
A method of using a powder sintering additive manufacturing apparatus comprising a means for selectively heating a thin layer of a powder material formed on the modeling table,
(1) Place and raise the powder material on the first powder material supply table to project the powder material on the surface of the first powder material storage container,
(2) The recoater is moved to scrape off the surface layer of the powder material protruding from the surface of the first powder material storage container.
(3) Move the recoater to supply the scraped powder material to the modeling container, and form a thin layer of the first powder material on the modeling table,
(4) selectively heating the thin layer of the first powder material to form a sintered thin layer;
(5) The rest of the powder material supplied to the modeling container by moving the recoater is placed on the lowered second powder material supply table and stored in the second powder material storage container. The usage method of the powder sintering additive manufacturing apparatus characterized by these. After the step (5),
(6) Raising the second powder material supply table to project the powder material on the surface of the second powder material storage container,
(7) Move the recoater to scrape off the surface layer of the powder material protruding on the surface of the second powder material storage container,
(8) The recoater is moved to supply the scraped powder material to the modeling container, and a thin layer of the second powder material is formed on the thin layer of the first powder material on the modeling table. Forming,
(9) selectively heating the thin layer of the second powder material to form a sintered thin layer;
(10) The rest of the powder material supplied to the modeling container by moving the recoater is placed on the lowered first powder material supply table and stored in the first powder material storage container. A method of using the powder sintering additive manufacturing apparatus according to claim 6.   8. The method for using a powder sintering additive manufacturing apparatus according to claim 7, wherein the steps (1) to (10) are repeated. The recoater includes a sensor that detects a supply amount of the powder material supplied to the modeling container,
When the supply amount of the powder material detected by the sensor is smaller than the reference, the powder material supply table on the side on which the powder material is supplied is further raised, and the powder material storage container on the same side than the detection time. After projecting the powder material on the surface, the steps (2) to (5) are performed, or the steps (2) to (5) and the steps (7) to (10) are performed. A method of using the powder sinter additive manufacturing apparatus according to any one of claims 6 to 8.

Images