JP3555489B2

JP3555489B2 - 3D shape manufacturing method

Info

Publication number: JP3555489B2
Application number: JP08230999A
Authority: JP
Inventors: 喜万東; 徳雄吉田; 勲不破; 良幸内野々
Original assignee: Matsushita Electric Works Ltd
Current assignee: Panasonic Electric Works Co Ltd
Priority date: 1999-03-25
Filing date: 1999-03-25
Publication date: 2004-08-18
Anticipated expiration: 2019-03-25
Also published as: TW509602B; JP2000272018A

Description

【０００１】
【発明の属する技術分野】
本発明は、粉末材料が硬化される硬化層を順次に積層形成して三次元形状の造形物を得る三次元形状物製造法に関するものである。
【０００２】
【従来の技術】
従来から、図４０に示す如く、粉末材料１が硬化される硬化層２を順次に積層形成して三次元形状の造形物を得る三次元形状物製造法は知られている。これは「選択的焼結によって部品を製造する方法」として特許第２６２０３５３号公報に開示されたもので、ここでは、金属等の無機質材或いは樹脂等の有機質材でなる粉末材料１が堆積され、そこにレーザや指向性エネルギービーム等の光ビーム（レーザビーム１２）が照射され硬化されて硬化層２が形成され、該硬化層２が順次に積層形成されて三次元形状の造形物が得られる。
【０００３】
この場合、図４０（ａ）に示す如く、粉末材料１はホッパー２９から包囲構造３０内に供給され、その上から、図４０（ｂ）に示す如く、レーザビーム１２が所定部位に選択的に照射され、これが繰り返されて硬化層２が積層形成される。又、レーザビーム１２はレーザヘッド３１から照出され、その走路がプリズム３２を含む走査系３３で方向変換されるように操作されて、包囲構造３０内で最上層となる粉末材料１の所定部位に選択的に照射される。したがって、この場合には、複雑な形状の造形物を比較的容易に製造することができる。
【０００４】
【発明が解決しようとする課題】
しかしながら、上記従来の技術においては、粉末材料１の充填密度が低くて照射、硬化後の密度は１００％とならず、そのため、製造される造形物の強度が材料本来の機械的強度に比して弱くなるという問題があった。又、硬化層２を形成するためにレーザビーム１２を走査する工程が必要となり、しかも、造形物の輪郭線内の走査データ量が多いため造形時間が長くなるという問題があった。又、粉末材料１が硬化する際に収縮するため、硬化層２が変形して精度良く造形物を製造することができないという問題もあった。
【０００５】
本発明は、上記従来の技術における問題を悉く解決するために発明されたもので、その課題は、複雑な形状でありながら高強度で高精度な造形物を容易に製造することができる三次元形状物製造法を提供することである。
【０００６】
【課題を解決するための手段】
本発明の請求項１記載の三次元形状物製造法は、粉末材料が硬化される硬化層を順次に積層形成して三次元形状の造形物を得る製造法であって、埋設用部材を設置しておき、該埋設用部材の周辺に粉末材料を充填し、該粉末材料を同埋設用部材の近傍でこれと一体化されるように硬化させて、硬化層を順次に積層形成する製造法である。
【０００７】
したがって、この場合、埋設用部材を高密度で強固に形成しておくことで、全体としては高強度な造形物を製造することができる。しかも、埋設用部材の周辺付近のみの粉末材料を層構成として順次に硬化させるだけで良く、その際、硬化させるためのビームを走査する走査データ量も造形物の輪郭線内で少なくなって走査時間は短くなり、複雑な形状であってもその造形時間の短縮化を図ることができる。又、硬化される粉末材料の量が少なくなることで、その硬化時の収縮による変形も防止されて、高精度な造形物を製造することができる。
【０００８】
また、この場合において、埋設用部材を周壁体で囲まれたプレート上に設置し、該プレートを同周壁体の上端部から硬化層の厚みに相当する寸法分づつ順次に降下させて、同周壁体で囲まれたスペース内に粉末材料を同プレートの降下ごとに充填して硬化させてもよい。
【０００９】
このようにすることで、埋設用部材が硬化層の厚みに相当する寸法分づつ降下されながら、その周辺に同硬化層が順次に積層形成されるので、硬化後ごとに粉末材料を容易に充填することができ、これに照射するビームの距離設定等も容易になって、最適な製造設備となすことができる。
【００１０】
また、本発明の請求項１記載の三次元形状物製造法は、上記の三次元形状物製造法において、シート材料を積層一体化して埋設用部材を形成することを特徴とするものである。
【００１１】
したがって、この場合は特に、複雑な形状の造形物であっても、これに埋設される埋設用部材をシート材料の積層一体化により形成することによって、簡単に製造することができる。
【００１２】
しかも、本発明の請求項１記載の三次元形状物製造法は、上記の三次元形状物製造法において、各硬化層を形成するごとにその前に各シート材料を順次に積層設置して、埋設用部材を形成することを特徴とするものである。
【００１３】
したがって、この場合は特に、シート材料を予め積層一体化して形成しておく必要がなく、各硬化層を形成するごとにその前に各シート材料を順次に積層設置して、埋設用部材を簡単に形成することができ、同埋設用部材は粉末材料の充填の際に邪魔になることもない。
【００１４】
本発明の請求項２記載の三次元形状物製造法は、上記請求項１記載の三次元形状物製造法において、積層される各シート材料に穿設された貫通孔に粉末材料を充填し、該粉末材料を硬化させることによって同各シート材料を結合させることを特徴とするものである。
【００１５】
したがって、この場合は特に、貫通孔に充填される粉末材料の硬化によって各シート材料は結合されるので、シート材料間の結合強度が向上されると共に粉末材料硬化時の熱影響によるシート材料の変形も防止され、造形物の高強度化、高精度化を図ることができる。
【００１６】
本発明の請求項３記載の三次元形状物製造法は、上記請求項２記載の三次元形状物製造法において、各シート材料の間で貫通孔を連通させることを特徴とするものである。
【００１７】
したがって、この場合は特に、シート材料間で連通した貫通孔に充填される粉末材料の硬化によって各シート材料が結合されるので、各シート材料は相互に位置決めされて横ズレなく結合され、造形物の更なる高強度化、高精度化を図ることができる。
【００１８】
本発明の請求項４記載の三次元形状物製造法は、上記請求項１記載の三次元形状物製造法において、各シート材料の厚みを埋設用部材の外側面の傾斜がきつくなる部位では厚く、同傾斜が緩くなる部位では薄くなるように変化設定することを特徴とするものである。
【００１９】
したがって、この場合は特に、埋設用部材の外側面の傾斜がきつくなる部位では、シート材料の厚みが厚くなるように変化設定されて該シート材料の積層枚数は削減され、造形時間の更なる短縮化を図ることができる。逆に、埋設用部材の外側面の傾斜が緩くなる部位では、シート材料の厚みが薄くなるように変化設定されて該シート材料の端部で発生する段差は小さくなり、造形物の水平に近い表面を滑らかに仕上げることができる。
【００２４】
【発明の実施の形態】
図１は、本発明の一参考例を示し、該参考例の三次元形状物製造法は、粉末材料１が硬化される硬化層２を順次に積層形成して三次元形状の造形物を得る製造法であって、埋設用部材３を設置しておき、該埋設用部材３の周辺に粉末材料１を充填し、該粉末材料１を同埋設用部材３の近傍でこれと一体化されるように硬化させて、硬化層２を順次に積層形成する製造法である。
【００２５】
該参考例の三次元形状物製造法においては、埋設用部材３を周壁体４で囲まれたプレート５上に設置し、該プレート５を同周壁体４の上端部６から硬化層２の厚みに相当する寸法Ｌ分づつ順次に降下させて、同周壁体４で囲まれたスペース７内に粉末材料１を同プレート５の降下ごとに充填して硬化させる。
【００２６】
この場合、図１（ａ）に示す如く、プレート５上に埋設用部材３を予め設置しておき、図１（ｂ）に示す如く、プレート５を硬化層２の厚みに相当する寸法Ｌだけ降下させ、これにより形成される周壁体４で囲まれたスペース７内に、図１（ｃ）に示す如く、粉末材料１を充填する。ここで、プレート５の周囲には周壁体４の内面に密接状態で摺動するスライダ１１が設けられており、粉末材料１の漏れ出ないスペース７が、同周壁体４の上端部６から所定の深さ（寸法Ｌ）となって確実に形成される。
【００２７】
次に、図１（ｄ）に示す如く、埋設用部材３の周辺付近の粉末材料１にのみビーム１２を照射して硬化させ、その際、該粉末材料１が硬化する硬化層２を同埋設用部材３の外側面にも結合一体化させる。ここで、ビーム１２としてはレーザや指向性エネルギービーム等の光ビームが照射され、粉末材料１は焼結により硬化する。粉末材料１は金属等の無機質材或いは樹脂等の有機質材でなり、前記ビーム１２によって必要部分のみが選択的に焼結され効率良く確実に硬化される。又、埋設用部材３の材質は、これに粉末材料１が硬化され結合一体化されることから該粉末材料１と同質材料であることが好ましく、同埋設用部材３は高密度で高強度に形成されるが、安価で高強度に形成される別材料が採用されても良い。
【００２８】
上記図１（ｂ）〜（ｄ）の工程が繰り返され、最終的に図１（ｅ）に至って造形物が完成する。この場合、金属でなる粉末材料１を硬化積層させて金属部品や金型等を製造することができ、樹脂でなる粉末材料１によって樹脂部品を製造することができ、有機質材と無機質材とが混在する造形物や部品等を製造することもできる。
【００２９】
したがって、該参考例の三次元形状物製造法においては、埋設用部材３を高密度で強固に形成しておくことで、全体としては高強度な造形物を製造することができる。しかも、埋設用部材３の周辺付近のみの粉末材料１を層構成として順次に硬化させるだけで良く、その際、硬化させるためのビーム12を走査する走査データ量も造形物の輪郭線内で少なくなって走査時間は短くなり、複雑な形状であってもその造形時間の短縮化を図ることができる。又、硬化される粉末材料１の量が少なくなることで、その硬化時の収縮による変形も防止されて、高精度な造形物を製造することができる。
【００３０】
又、該参考例の三次元形状物製造法においては、埋設用部材３が硬化層２の厚みに相当する寸法Ｌ分づつ降下されながら、その周辺に同硬化層２が順次に積層形成されるので、硬化後ごとに粉末材料１を容易に充填することができ、これに照射するビーム12の距離設定等も容易になって、最適な製造設備となすことができる。しかも、この場合に、プレート５は周壁体４の上端部６から硬化層２の厚みに相当する寸法Ｌ分づつ降下されるので、該寸法Ｌ分の厚さ寸法となる程度に粉末材料１が正確に適量だけ充填される。
【００３１】
図２は、本発明の別の参考例を示し、該参考例の三次元形状物製造法においては、シート材料８を積層一体化して埋設用部材３が形成されている。この場合、シート材料８は無機質材或いは有機質材で、予め積層一体化されてプレート５上に設置される。
【００３２】
したがって、この場合は特に、複雑な形状の造形物であっても、これに埋設される埋設用部材３をシート材料８の積層一体化により形成することによって、簡単に製造することができる。なお、それ以外は、上記図１に示した参考例と同様に構成されて同様の工程となっており、同上記参考例におけると同様の作用効果が奏される。
【００３３】
図３は、本発明の請求項１に対応する一実施形態を示し、該実施形態の三次元形状物製造法においては、各硬化層２を形成するごとにその前に各シート材料１を順次に積層設置して、埋設用部材３を形成するものである。この場合、シート材料８は所定の大きさ形状に切断され、その厚み寸法は硬化層２の厚みに相当する寸法Ｌに略等しく形成されており、該寸法Ｌだけプレート５を降下させる前に予め該プレート５上に同シート材料８は設置されているが、プレート５を降下させた後に該プレート５上に同シート材料８を設置しても良く、すなわち、図３（ａ）（ｂ）の工程が入れ替わっても良い。
【００３４】
したがって、この場合は特に、シート材料８を予め積層一体化して埋設用部材３を形成しておく必要がなく、各硬化層２を形成するごとにその前に各シート材料８を順次に積層設置して、埋設用部材３を簡単に形成することができ、同埋設用部材３は粉末材料１の充填の際に邪魔になることもない。又、充填された粉末材料１から埋設用部材３が上方へ突出しないので、ビーム12を照射する同粉末材料１の硬化作業の際にも支障を来すことがない。なお、それ以外は、上記図２に示した参考例と同様に構成されて同様の工程となっており、同上記参考例におけると同様の作用効果が奏される。
【００３５】
又、上記各参考例、実施形態においては、図４に示す如く、下層から上層領域を除いた領域部分に粉末材料１を充填している。すなわち、シート材料８の輪郭線周辺に粉末材料１は充填されて、該粉末材料１が同シート材料８の間には介設されていない。この場合、各シート材料８の端面間の隙間が粉末材料１の硬化層２によって閉塞されると共に、強固に接着されて同端面からのシート材料８のめくれ上がり変形が防止され、しかも、接着部分が少ないため熱歪み等の影響も少なく、高精度の造形物を得ることができる。
【００３６】
又、上記各参考例、実施形態において、図５に示す如く、各シート材料８の間に粉末材料１を塗布介設し、該シート材料８間の粉末材料１を溶融或いは焼結することによって、各シート材料８を相互に接合させることも可能である。この場合、図５（ａ）（ｂ）に示す如く、下層のシート材料８の表面に粉末材料１を塗布して粉末接着層13を形成し、図５（ｃ）に示す如く、同粉末接着層13上に上層のシート材料８を設置し、図５（ｄ）に示す如く、同上層のシート材料８の上から該シート材料８を通してレーザ等のビーム12を照射し、これにより、前記粉末接着層13を溶融或いは焼結させて該粉末接着層13により上下層のシート材料８を相互に接着結合する。
【００３７】
したがって、この場合は、シート材料８の相互間の接着強度が向上して、造形物の機械的強度を増強させることができる。又、この場合には、シート材料８よりも低融点の粉末材料１が用いられ、これによって、該シート材料８にはビーム１２の熱影響によるダメージを与えることなく造形することができ、同シート材料８に変形を生じることなく高精度の造形物が得られる。
【００３８】
図６は、本発明の請求項１、２に対応する別の実施形態を示し、該実施形態の三次元形状物製造法においては、積層される各シート材料８に穿設された貫通孔９に粉末材料１を充填し、該粉末材料１を硬化させることによって同各シート材料８を結合させるものである。この場合、図６（ａ）（ｂ）に示す如く、複数の貫通孔９が穿設されたシート材料８の上から、該シート材料８の周辺と各貫通孔９内とに粉末材料１を充填し、図６（ｃ）に示す如く、同シート材料８の上からレーザ等のビーム12を照射して、前記シート材料８の周辺及び各貫通孔９内に充填された粉末材料１を硬化させる。この図６（ａ）〜（ｃ）の工程が繰り返され、最終的に図６（ｄ）に至って造形物が完成する。
【００３９】
したがって、この場合は特に、貫通孔９に充填される粉末材料１の硬化によって各シート材料８は結合されるので、各シート材料８間の結合強度が向上されると共に、粉末材料１硬化時の熱影響による各シート材料８の変形も防止され、造形物の高強度化、高精度化を図ることができる。なお、それ以外は、上記図３に示した実施形態と同様に構成されて同様の工程となっており、同上記実施形態におけると同様の作用効果が奏される。
【００４０】
図７は、本発明の請求項１〜３に対応する更に別の実施形態を示し、該実施形態の三次元形状物製造法においては、各シート材料８の間で貫通孔９を連通させている。この場合、全シート材料８に貫通孔９は連通しており、該連通した貫通孔９が複数個所に配設されている。
【００４１】
したがって、この場合は特に、シート材料８間で連通した貫通孔９に充填される粉末材料１の硬化によって各シート材料８が結合されるので、各シート材料８は相互に位置決めされて横ズレなく結合され、造形物の更なる高強度化、高精度化を図ることができる。なお、それ以外は、上記図６に示した実施形態と同様に構成されて同様の工程となっており、同上記実施形態におけると同様の作用効果が奏される。
【００４２】
又、該実施形態において、図８に示す如く、貫通孔９を傾斜して連通するように穿設することもできる。この場合、図８（ａ）に示す如く、シート材料８の各層ごとで貫通孔９を交互に異なる方向へ傾斜させても良く、或いは、図８（ｂ）に示す如く、複数層のシート材料８ごとで貫通孔９を交互に異なる方向へ傾斜させても良いものである。この場合には、シート材料８の重ね合わせ方向で、各シート材料８が相互に剥がれ難くなり、造形物の更なる高強度化を図ることができる。
【００４３】
又、該実施形態において、図９に示す如く、上下層のシート材料８間で連通する両貫通孔９の上側の貫通孔９ｂを、下側の貫通孔９ａで充填硬化される粉末材料１の逃がし孔としても良い。この場合には、下側の貫通孔９ａに充填された粉末材料１が硬化する際に、該粉末材料１の凝縮による盛り上がり変形は、上側の貫通孔９ｂで逃がされ吸収されるので、各シート材料８間での密着性を向上させることができる。
【００４４】
又、該実施形態において、図１０に示す如く、上下層の両シート材料８間で連通する貫通孔９ｂ，９ａと連通しない貫通孔９ｃとを共に配設しても良い。この場合には、連通する両貫通孔９ｂ，９ａでシート材料８間の位置決めを行うことができ、連通しない貫通孔９ｃでシート材料８間の接着強度を高めることができる。
【００４５】
又、該実施形態において、図１１に示す如く、シート材料８間で連通する貫通孔９の孔径を、各シート材料８の層間で相違させても良い。この場合、上下の貫通孔９ｃ，９ａが大径に形成され、中程の貫通孔９ｂが小径に形成されている。又、図１２に示す如く、上下層の両シート材料８間で連通する貫通孔９ｂ，９ａの各開口端縁に各々面取り加工を施しても良い。これ等の場合には、シート材料８の重ね合わせ方向で、各シート材料８が相互により剥がれ難くなって、各シート材料８間での接着強度を向上させることができる。
【００４６】
又、該実施形態において、図１３に示す如く、シート材料８間で連通する各貫通孔９をテーパ孔状に形成しても良い。この場合、図１３（ａ）に示す如く、粉末材料１が充填硬化される下側の貫通孔９ａと、逃がし孔とされる上側の貫通孔９ｂとを、共に同じ傾斜で同じ大きさののテーパ孔状に形成しても良く、又、図１３（ｂ）に示す如く、多数層にわたって連通する各貫通孔９を、全て同じ傾斜で同じ大きさのテーパ孔状に形成しても良く、又、図１３（ｃ）に示す如く、多数層にわたって連通する各貫通孔９を、相互に傾斜が連続するよう順次その大きさを変化させてテーパ孔状に形成し、このように連通形成された複数の貫通孔９を複数組み相互に相反するテーパにして配設しても良い。これ等の場合には、シート材料８の重ね合わせ方向で、各シート材料８が相互により剥がれ難くなって、各シート材料８間での接着強度を向上させることができると共に、位置決め作業も容易となる。
【００４７】
図１４は、本発明の請求項１、４に対応する更に別の実施形態を示し、該実施形態の三次元形状物製造法においては、各シート材料８の厚みを埋設用部材３の外側面の傾斜Ｋがきつくなる部位（傾斜Ｋが鉛直方向に近くなる部位）では厚く、同傾斜Ｋが緩くなる部位（傾斜Ｋが水平方向に近くなる部位）では薄くなるように変化設定するものである。この場合、図１５（ａ）に示す如く、傾斜Ｋが鉛直方向に近くなる部位でシート材料８を厚くすることにより、その積層数は少なくなり、又、図１５（ｂ）に示す如く、傾斜Ｋが水平方向に近くなる部位でシート材料８を薄くすることにより、その端部で発生する段差は小さくなる。
【００４８】
したがって、この場合は特に、埋設用部材３の外側面の傾斜Ｋがきつくなる部位では、シート材料８の厚みが厚くなるように変化設定されて、該シート材料８の積層枚数は削減されるので、造形時間の更なる短縮化を図ることができる。逆に、埋設用部材３の外側面の傾斜Ｋが緩くなる部位では、シート材料８の厚みが薄くなるように変化設定されて、該シート材料８の端部で発生する段差は小さくなるので、造形物の水平に近い表面を滑らかに仕上げることができる。
【００４９】
又、該実施形態の三次元形状物製造法において、図１６（ａ）に示す如く、シート材料８を各層ごとで一体に形成しその厚みを均一としても良く、又、図１６（ｂ）に示す如く、シート材料８を特定の部位でその複数層を一体に形成しその厚みを相違させても良い。なお、それ以外は、上記図３に示した実施形態と同様に構成されて同様の工程となっており、同上記実施形態におけると同様の作用効果が奏される。
【００５０】
図１７は、本発明の請求項１に対応する更に別の実施形態を示し、該実施形態の三次元形状物製造法においては、シート材料８の間に粉末材料１が固化される粉末固化層10を介設形成するものである。この場合、粉末固化層10はシート材料８の代わりに配設されるもので、その上下両側のシート材料８を強固に接合させる。
【００５１】
したがって、この場合は特に、シート材料８による積層面が微細で複雑な形状となる場合、例えば、切り抜き形状が複雑であったり、独立した輪郭線の島が多く発生する場合に、同シート材料８に代えてその部位に粉末材料１が固化される粉末固化層１０を介設形成することにより、該粉末固化層１０を簡単に正確な位置に形成して、複雑な形状となる造形物の製造にも容易に対応することができる。
【００５２】
又、該実施形態の三次元形状物製造法において、図１８に示す如く、複数の粉末固化層１０を介設してこれ等の厚みを相違させることができる。この場合、厚い粉末固化層１０を得るためには、粉末材料１の塗布及び硬化を複数回繰り返して行えば良く簡単で、シート材料８の厚みを変えるに比して容易であり、特別な機構や装置も不要となる。なお、それ以外は、上記図３に示した実施形態と同様に構成されて同様の工程となっており、同上記実施形態におけると同様の作用効果が奏される。
【００５３】
図１９は、本発明の請求項１に対応する更に別の実施形態を示し、該実施形態の三次元形状物製造法においては、埋設用部材３の外側面が各シート材料８の間で階段状となり、該階段状の凹部に粉末材料１をその上面が同階段傾斜に略沿ったテーパー状となるように充填して硬化させるものである。この場合には、図２０に示す如く、段差が大きくなっていたものが、図２１に示す如く、階段傾斜Ｋに沿って段差が小さくなる。ここで、図２０、２１の各（ａ）は全体形状を示し、各（ｂ）はビーム12を照射して粉末材料１を硬化させる状態の要部を示し、各（ｃ）は同粉末材料１が硬化された硬化層２を示している。
【００５４】
したがって、この場合は特に、階段状となる埋設用部材３の外側面が、該階段状の凹部に充填して硬化される粉末材料１により同階段傾斜Ｋに略沿ったテーパー状となるので、造形物の表面を滑らかに仕上げることができる。しかも、ここで、磨き仕上げされるときには、削り取り量が削減されて仕上げ時間の短縮化を図ることができる。
【００５５】
又、該実施形態の三次元形状物製造法においては、加振装置を採用することによって、階段状の凹部に粉末材料１をその上面がテーパー状となるように充填することができる。例えば、図２２に示す如く、粉末材料１を充填後にプレート５を上昇させてこれに振動を付与し、不要な粉末材料１を振り落としてその上面をテーパー状となすことができる。この場合、図２２（ａ）に示す如く、プレート５を所定位置に降下させた状態で、周壁体４で囲まれたスペース７内に粉末材料１を充填し、次に、図２２（ｂ）に示す如く、同プレート５を最上位にまで上昇させてこれを振動させ、不要な粉末材料１を振り落としてその上面をテーパー状となし、続いて、図２２（ｃ）に示す如く、同プレート５を所定位置に降下させこの状態で、最上層のシート材料８の周辺付近の粉末材料１にのみビーム１２を照射して硬化層２を形成する。なお、それ以外は、上記図３に示した実施形態と同様に構成されて同様の工程となっており、同上記実施形態におけると同様の作用効果が奏される。
【００５６】
又、本発明の三次元形状物製造法においては、レーザや指向性エネルギービーム等の光ビームを照射することで、粉末材料１が焼結により硬化されると共にシート材料８は所定形状に切断されるのであるが、このように、光ビームを採用することで、ピンポイント的に局部加熱を行うことができ、シート材料８に熱による悪影響を与えることなくこれを切断することができ、その際、輪郭線形状に合わせて自由に且つ正確に同光ビームを走査することができる。
【００５７】
又、本発明の三次元形状物製造法において、シート材料８の切断形状は、図２３に示す如く、箱形状の造形物を製作する場合、同シート材料８の端縁部分に粉末材料１が充填されるスペースが形成されるように形成する。すなわち、最下層のシート材料８は造形物に合致する形状（必要寸法Ａ）で良いが、その上の他のシート材料８はその端縁部分に粉末材料１の充填量を考慮したスペース（充填部寸法Ｂ）が確保されるよう若干小さく切断する。この場合には、各シート材料８の端縁部分が確実に接着されて、必要寸法Ａを有する所定の箱形状となる造形物を高精度で得ることができる。
【００５８】
又、図２４に示す如く、シート材料８による積層面に独立した輪郭線の島部１４が発生する場合、該島部１４とその他の部分とを結合する連結部１５が備わった形状に同シート材料８を切断形成する。この場合、シート材料８の積層接合後、或いは、造形物の製作完了後に、図２４（ａ）（ｄ）に示す如く、前記連結部１５を切断除去するものである。それ故、この場合には、切断形成したシート材料８を搬送する際、図２４（ｂ）に示す如く、島部１４が連結部１５でその他の部分と一体化されていて、容易に搬送することができ、又、図２４（ｃ）に示す如く、同シート材料８を積層接合する際にも、島部１４が連結部１５でその他の部分と一体化されていて、その位置決め作業を容易に行うことができる。
【００５９】
又、本発明の三次元形状物製造法において、シート材料８の位置決めは、例えば、図２５に示す如く、シート材料８をその周辺に位置決め辺部１６が備わった形状に切断形成し、該位置決め辺部１６を位置決めピン１７に当接させることによって行うことができる。この場合、図２５（ｂ）に示す如く、シート材料８は二辺の直角に配置される位置決め辺部１６が島部１４と共にその他の部分と連結部１５を介して結合された形状に切断形成され、図２５（ｃ）に示す如く、両位置決め辺部１６を少なくとも三つの位置決めピン１７に当接させることにより同シート材料８は位置決め設置されて積層接合され、最終的には、図２５（ａ）に示す如く、全ての連結部１５及び位置決め辺部１６が切断除去される。なお、位置決めピン１７は、例えば、プレート５上に突設される。
【００６０】
又、本発明の三次元形状物製造法においては、図２６に示す如く、シート材料８の位置決めを行うこともできる。すなわち、この場合には、シート材料８をその全周に位置決め辺部１６が備わった形状に切断形成し、該位置決め辺部１６を周壁体４の内壁面に当接させることによって、同シート材料８の位置決めを行うものである。ここでは、図２６（ａ）に示す如く、シート材料８はその全周を包囲するように配される位置決め辺部１６が島部１４と共にその他の部分と連結部１５を介して結合された形状に切断形成され、図２６（ｂ）に示す如く、位置決め辺部１６の外側縁を周壁体４の内壁面に当接させることにより同シート材料８は位置決め設置されて積層接合される。なお、最終的には、全ての連結部１５及び位置決め辺部１６が切断除去される。
【００６１】
上記図２５、２６に示した如く、シート材料８の位置決めを行うと、該位置決め作業が容易となり、粉末材料１を充填する領域が小さくなって該粉末材料１の量も少なくて済み、その結果として、高精度の造形物を得ることができる。
【００６２】
又、本発明の三次元形状物製造法においては、図２７に示す如く、プッシャ可動装置１８から進退自在に突出されるプッシャ１９を、シート材料８の外縁部分に当接させることで、同シート材料８の位置決めを行うこともできる。ここで、図２７（ａ）は位置決め時の状態を示し、図２７（ｂ）は位置決め解除状態を示している。又、図２８に示す如く、ピン可動装置装置２０から進退自在に突出される可動ピン２１を、各シート材料８に穿設される位置決め用孔２２に挿通係合させることで、同各シート材料８の位置決めを行うこともできる。ここで、図２８（ａ）は位置決め時の状態を示し、図２８（ｂ）は位置決め解除状態を示している。このように、シート材料８の位置決めを行うと、光ビーム照射がシート材料８の輪郭線部に沿って正確に走査され、各シート材料８間の接着が良好に行われて接着強度が向上され、造形精度の向上を期待できるようになる。
【００６３】
又、本発明の三次元形状物製造法において、シート材料８の位置決めが、各シート材料８に穿設される位置決め用孔２２に可動ピン２１を挿通係合させることで行われる場合には、図２９に示す如く、可動ピン２１をプレート５上に立設してこれと共に可動されるようになしても良い。この場合、シート材料８の位置決めが容易に行われながら、図２９（ａ）（ｂ）に示す工程及びビーム１２を粉末材料１に照射して硬化層２を形成する工程が繰り返され、最終的に図２９（ｃ）に至って造形物が完成し、その際、前記可動ピン２１は埋設用部材３の一部として造形物内に埋設形成される。
【００６４】
又、本発明の三次元形状物製造法において、シート材料８の位置決めが、各シート材料８に穿設される位置決め用孔２２に可動ピン２１を挿通係合させることで行われる場合、図３０に示す如く、可動ピン２１の先端部分をかしめたり（かしめ膨大部２３）、図３１（ａ）に示す如く、上層のシート材料８の位置決め用孔２２に粉末材料１を充填し、これを硬化させて可動ピン２１の先端部分と結合させたり（結合硬化部２４）、その際、図３１（ｂ）に示す如く、同上層のシート材料８の位置決め用孔２２を面取り形状に形成したり（面取り部２５）することができる。この場合には、シート材料８が可動ピン２１から抜け外れ難くなって、各シート材料８の積層方向における強度アップが図られる。
【００６５】
又、このように、シート材料８の位置決めが、各シート材料８に穿設される位置決め用孔２２に可動ピン２１を挿通係合させることで行われるような場合には、図３２（ａ）に示す如く、可動ピン２１が全シート材料８に連通挿入されるようになしても、或いは、図３２（ｂ）に示す如く、複数の可動ピン２１が上下の両シート材料８間ごとで挿通されるようになしても良いものである。
【００６６】
又、本発明の三次元形状物製造法において、シート材料８の位置決めが、各シート材料８に穿設される位置決め用孔２２に可動ピン２１を挿通係合させることで行われる場合に、図３３に示す如く、可動ピン２１を下層のシート材料８の上面に突出形成し、同可動ピン２１が上層のシート材料８の位置決め用孔２２に挿入係合されるようになすこともできる。
【００６７】
この場合、図３３（ａ）に示す如く、下層のシート材料８の上面に粉末材料１を塗布し、図３３（ｂ）に示す如く、該粉末材料１の一部にビーム１２をスポット状に照射し硬化させて可動ピン２１を形成し、図３３（ｃ）に示す如く、未硬化で残存する粉末材料１を除去して同可動ピン２１を下層のシート材料８の上面から突出させ、図３３（ｄ）に示す如く、前記下層のシート材料８の上に上層のシート材料８を積層して、その際、該上層のシート材料８の位置決め用孔２２に前記可動ピン２１を挿入係合させて両シート材料８を相互に位置決めし、その後は、図３３（ｅ）（ｆ）に示す如く、別途の粉末材料１を充填し、上層のシート材料８の周辺付近の同粉末材料１にビーム１２を照射して硬化層２を形成し、これ等の工程を繰り返して造形物が完成される。
【００６８】
したがって、この場合には、可動ピン２１を予め別途に設置形成する手間が省かれ、該可動ピン２１の形状や大きさを位置決め用孔２２に対応させて自由に設定することができ、シート材料８を積層する工程の中で簡単に各シート材料８の積層方向における強度アップを図ることができる。
【００６９】
又、本発明の三次元形状物製造法においては、図３４、３５に示す如く、位置決め用リブ２６を下層のシート材料８の上面に突出形成して、同位置決め用リブ２６に上層のシート材料８の外辺部分を当接させることで、両シート材料８を相互に位置決めすることもできる。
【００７０】
この場合、図３４（ａ）に示す如く、下層のシート材料８の上面に粉末材料１を塗布し、図３４（ｂ）に示す如く、該粉末材料１の一部にビーム１２を線状に照射し硬化させて位置決め用リブ２６を形成し、図３４（ｃ）、図３５（ａ）に示す如く、未硬化で残存する粉末材料１を除去して同位置決め用リブ２６を下層のシート材料８の上面から突出させ、図３４（ｄ）、図３５（ｂ）に示す如く、前記下層のシート材料８の上に上層のシート材料８を積層して、その際、該上層のシート材料８の対向する外辺部分の一辺を前記位置決め用リブ２６に当接させて両シート材料８を相互に位置決めし、その後は、図３４（ｅ）（ｆ）、図３５（ｃ）に示す如く、別途の粉末材料１を充填し、上層のシート材料８の前記外辺部分の他辺付近の同粉末材料１にビーム１２を照射して硬化層２を形成し、これ等の工程を繰り返して造形物が完成される。
【００７１】
したがって、この場合にも、位置決め用リブ２６を予め別途に設置形成する手間が省かれ、該位置決め用リブ２６の形状や大きさを自由に設定することができ、シート材料８を積層する工程の中で簡単に各シート材料８の積層方向における強度アップを図ることができる。
【００７２】
なお、本発明の三次元形状物製造法においては、図３６（ａ）（ｂ）に示す如く、上層のシート材料８の下面に突起２７を突出形成し、該突起２７を下層のシート材料８の上面に食い込み状に係合させることで、両シート材料８を相互に位置決めすることもできる。この場合、図３７に示す如く、ポンチを上下昇降させる加工機２８を具備し、該加工機２８のポンチを上層のシート材料８上に下降押圧させることで、該上層のシート材料８の下面に突出形成される突起２７が下層のシート材料８の上面に食い込み係止されるようになしても良い。
【００７３】
又、本発明の三次元形状物製造法においては、図３８、３９に示す如く、所定の粉末材料１が全て焼結により硬化された後の最終工程として、造形物の上面に機械加工を施しても良い。この場合における全工程について、図３８、図３９の（ａ）〜（ｅ）の工程順に説明する。
まず、図３８（ａ）、図３９（ａ）に示す如く、ロール状に巻き取られた金属製のシート材料８を繰り出してこれにビーム１２を照射し、貫通孔９（スルーホールのような接着用の共通孔）を形成すると共に輪郭線で所定形状に切断する。次に、所定形状に切断されたシート材料８を周壁体４で囲まれたプレート５上に設置し、図３８（ｂ）〜（ｄ）、図３９（ｂ）〜（ｄ）に示す如く、図７に示した実施形態におけると同様に、複数の貫通孔９が穿設された前記シート材料８の上から、該シート材料８の周辺と各貫通孔９内とに粉末材料１を充填し、同シート材料８の上からビーム１２を照射して、該シート材料８の周辺及び各貫通孔９内に充填された前記粉末材料１を硬化させる。これ等の工程が二回繰り返されて、二層構造の造形物が完成される。
【００７４】
なお、この場合、ビーム１２はレーザ照射装置Ａより照射され、粉末材料１は材料供給装置Ｂによって供給充填され、該粉末材料１は同ビーム１２が照射されることにより焼結硬化して、シート材料８の貫通孔９及び輪郭線部分を接着するものである。又、図３８（ｅ）、図３９（ｅ）に示す如く、最終工程として、造形物の上面に機械加工が施されるものであり、この場合、粉末材料１の硬化部分（貫通孔９内及び周辺の硬化層２）が造形物の上面から突出しており、該突出部分が加工装置Ｃによって切削除去される。
【００７５】
【発明の効果】
上述の如く、本発明の請求項１記載の三次元形状物製造法によると、高強度な造形物を製造することができ、埋設用部材の周辺付近のみの粉末材料を層構成として順次に硬化させるだけで良いので、複雑な形状であってもその造形時間の短縮化を図ることができ、粉末材料の硬化時の収縮による変形も防止されて、高精度な造形物を製造することができる。
【００７７】
又、本発明の請求項１記載の三次元形状物製造法によると、複雑な形状の造形物であっても、埋設用部材をシート材料の積層一体化により形成することで、簡単に製造することができる。
【００７８】
しかも、本発明の請求項１記載の三次元形状物製造法によると、シート材料を予め積層一体化して形成しておく必要がなく、埋設用部材を簡単に形成することができ、同埋設用部材は粉末材料の充填の際に邪魔になることもない。
【００７９】
又、本発明の請求項２記載の三次元形状物製造法によると、特に、貫通孔に充填される粉末材料の硬化によって、シート材料間の結合強度が向上されると共に粉末材料硬化時の熱影響による各シート材料の変形も防止され、造形物の高強度化、高精度化を図ることができる。
【００８０】
又、本発明の請求項３記載の三次元形状物製造法によると、特に、シート材料間で連通した貫通孔に充填される粉末材料の硬化によって、各シート材料は相互に位置決めされて横ズレなく結合され、造形物の更なる高強度化、高精度化を図ることができる。
【００８１】
又、本発明の請求項４記載の三次元形状物製造法によると、特に、埋設用部材の外側面の傾斜がきつくなる部位では、シート材料は厚くなりその積層枚数が削減されて、造形時間の更なる短縮化を図ることができ、同傾斜が緩くなる部位では、シート材料は薄くなりその端部で発生する段差が小さくなって、造形物の水平に近い表面を滑らかに仕上げることができる。
【図面の簡単な説明】
【図１】本発明の一参考例である三次元形状物製造法を示し（ａ）〜（ｅ）各々その製造過程における概略断面図。
【図２】別の参考例である三次元形状物製造法を示し（ａ）〜（ｅ）各々その製造過程における概略断面図。
【図３】本発明の一実施形態である三次元形状物製造法を示し（ａ）〜（ｅ）各々その製造過程における概略断面図。
【図４】同実施形態である三次元形状物製造法におけるシート材料の積層方法を例示する概略断面図。
【図５】同実施形態である三次元形状物製造法におけるシート材料の別の積層方法を例示し（ａ）〜（ｄ）各々その積層過程における概略断面図。
【図６】別の実施形態である三次元形状物製造法を示し（ａ）〜（ｄ）各々その製造過程における概略断面図。
【図７】更に別の実施形態である三次元形状物製造法を示す概略断面図。
【図８】同実施形態である三次元形状物製造法におけるシート材料の積層態様を例示する（ａ）（ｂ）各々異なる積層態様の概略断面図。
【図９】本発明の三次元形状物製造法におけるシート材料の積層態様を例示する概略断面図。
【図１０】本発明の三次元形状物製造法におけるシート材料の別の積層態様を例示する概略断面図。
【図１１】本発明の三次元形状物製造法におけるシート材料の更に別の積層態様を例示する概略断面図。
【図１２】本発明の三次元形状物製造法におけるシート材料の更に別の積層態様を例示する概略断面図。
【図１３】本発明の三次元形状物製造法におけるシート材料の更に別の積層態様を例示する図面で、（ａ）〜（ｃ）各々異なる積層態様の概略断面図。
【図１４】更に別の実施形態である三次元形状物製造法を示す概略断面図。
【図１５】同実施形態である三次元形状物製造法を説明するための（ａ）（ｂ）各々概略断面図。
【図１６】同実施形態である三次元形状物製造法におけるシート材料の積層態様を例示する（ａ）（ｂ）各々異なる積層態様の概略断面図。
【図１７】更に別の実施形態である三次元形状物製造法を示す概略断面図。
【図１８】同実施形態である三次元形状物製造法におけるシート材料の別の積層態様を示す概略断面図。
【図１９】更に別の実施形態である三次元形状物製造法を示す概略断面図。
【図２０】同実施形態である三次元形状物製造法を説明するための比較形態を示し（ａ）はその概略断面図、（ｂ）（ｃ）はその製造過程を示す要部拡大断面図。
【図２１】同実施形態である三次元形状物製造法を示し（ａ）はその概略断面図、（ｂ）（ｃ）はその製造過程を示す要部拡大断面図。
【図２２】同実施形態である三次元形状物製造法における粉末材料の充填硬化方法を示し（ａ）〜（ｃ）各々その充填硬化過程における概略断面図。
【図２３】本発明の三次元形状物製造法におけるシート材料の切断形状を例示する概略断面図。
【図２４】本発明の三次元形状物製造法におけるシート材料の別の切断形状を例示する図面で、（ａ）（ｂ）はその各々異なる状態での概略平面図、（ｃ）（ｄ）はその各々異なる状態での概略断面図。
【図２５】本発明の三次元形状物製造法におけるシート材料の位置決め方法を例示する図面で、（ａ）〜（ｃ）各々その異なる状態での概略平面図。
【図２６】本発明の三次元形状物製造法におけるシート材料の別の位置決め方法を例示する図面で、（ａ）はその概略平面図、（ｂ）はその概略断面図。
【図２７】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）（ｂ）各々その異なる状態での概略側面図。
【図２８】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）（ｂ）各々その異なる状態での概略断面図。
【図２９】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）〜（ｃ）各々その位置決め過程における概略断面図。
【図３０】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する概略断面図。
【図３１】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）（ｂ）各々異なる方法態様の概略断面図。
【図３２】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）（ｂ）各々異なる方法態様の概略断面図。
【図３３】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）〜（ｆ）各々その位置決め過程における概略断面図。
【図３４】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）〜（ｆ）各々その位置決め過程における概略断面図。
【図３５】同シート材料の位置決め方法を示す（ａ）〜（ｃ）各々その位置決め過程における概略平面図。
【図３６】本発明の三次元形状物製造法におけるシート材料の更に別の位置決め方法を例示する図面で、（ａ）（ｂ）各々異なる形状態様の概略断面図。
【図３７】同シート材料の位置決め方法における設備を例示する概略側面図。
【図３８】本発明の三次元形状物製造法における最終の機械加工をも含めた全工程を例示する図面で、（ａ）〜（ｅ）各々その各工程における概略断面図。
【図３９】同全工程を示す（ａ）〜（ｅ）各々その各工程における概略斜視図。
【図４０】従来例である三次元形状物製造法を示し（ａ）はその全体斜視図、（ｂ）は要部斜視図。
【符号の説明】
１粉末材料
２硬化層
３埋設用部材
４周壁体
５プレート
６上端部
７スペース
８シート材料
９貫通孔
１０粉末固化層[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a three-dimensional object by obtaining a three-dimensional object by sequentially forming a cured layer in which a powder material is cured.
[0002]
[Prior art]
Conventionally, as shown in FIG. 40, there has been known a method for manufacturing a three-dimensional object in which a cured layer 2 in which a powder material 1 is cured is sequentially laminated to obtain a three-dimensional object. This is disclosed in Japanese Patent No. 2620353 as a "method of manufacturing parts by selective sintering", in which a powder material 1 made of an inorganic material such as a metal or an organic material such as a resin is deposited. There, a light beam (laser beam 12) such as a laser or a directional energy beam is irradiated and hardened to form a hardened layer 2, and the hardened layers 2 are sequentially laminated to form a three-dimensional shaped object. .
[0003]
In this case, as shown in FIG. 40 (a), the powder material 1 is supplied from the hopper 29 into the surrounding structure 30, and the laser beam 12 is selectively applied to a predetermined portion from above as shown in FIG. 40 (b). Irradiation is performed, and this is repeated to form the cured layer 2 in a laminated manner. The laser beam 12 is illuminated from a laser head 31, and its traveling path is operated so as to be changed in direction by a scanning system 33 including a prism 32. Is selectively irradiated. Therefore, in this case, a molded article having a complicated shape can be manufactured relatively easily.
[0004]
[Problems to be solved by the invention]
However, in the above-mentioned conventional technology, the packing density of the powder material 1 is low and the density after irradiation and curing does not reach 100%. Therefore, the strength of the manufactured modeled product is lower than the original mechanical strength of the material. There was a problem that it became weak. In addition, there is a problem that a step of scanning with the laser beam 12 is required to form the hardened layer 2, and furthermore, the amount of scanning data within the contour of the modeled object is large, so that the modeling time is prolonged. In addition, since the powder material 1 shrinks when it hardens, the hardened layer 2 is deformed, so that there is a problem that it is not possible to manufacture a molded article with high accuracy.
[0005]
The present invention has been invented in order to solve all the problems in the above-described conventional technology, and the problem is that a three-dimensional object capable of easily manufacturing a high-strength, high-precision molded object having a complicated shape. An object of the present invention is to provide a method for manufacturing a shaped article.
[0006]
[Means for Solving the Problems]
The method for producing a three-dimensional object according to claim 1 of the present invention is a method for obtaining a three-dimensional object by sequentially forming a cured layer in which a powder material is cured, in which a burying member is installed. A method of filling a powder material around the embedding member, curing the powder material in the vicinity of the embedding member so as to be integrated therewith, and sequentially forming a hardened layer by lamination It is.
[0007]
Therefore, in this case, by forming the embedding member firmly at high density, it is possible to manufacture a molded article having high strength as a whole. Moreover, it is only necessary to sequentially cure the powder material in the vicinity of the buried member only in the form of a layer, and in this case, the amount of scanning data for scanning with the beam for curing is reduced within the contour line of the modeled object, and the scanning is performed. The time is shortened, and the molding time can be shortened even for a complicated shape. In addition, since the amount of the powder material to be hardened is reduced, deformation due to shrinkage during hardening is also prevented, and a high-precision molded article can be manufactured.
[0008]
Also in this case In the above, the embedding member is placed on a plate surrounded by the peripheral wall, and the plate is sequentially lowered from the upper end of the peripheral wall by a dimension corresponding to the thickness of the hardened layer, and is surrounded by the peripheral wall. The powdered material is filled into the space at each drop of the plate and cured. May .
[0009]
By doing this As the embedded member is lowered by the dimension corresponding to the thickness of the hardened layer and the hardened layer is sequentially formed around the lower portion, the powder material can be easily filled every time after the hardening. The setting of the distance of the beam for irradiating the wafer becomes easy, and the optimum manufacturing equipment can be obtained.
[0010]
Also, Claims of the invention 1 The three-dimensional shape manufacturing method described of In the method for manufacturing a three-dimensionally shaped article, the embedding member is formed by laminating and integrating sheet materials.
[0011]
Therefore, in this case, in particular, even a shaped object having a complicated shape can be easily manufactured by forming the embedding member embedded therein by lamination and integration of the sheet material.
[0012]
Moreover, Claims of the invention 1 The three-dimensional shape manufacturing method described of In the method for manufacturing a three-dimensionally shaped object, each time a cured layer is formed, each sheet material is sequentially stacked and disposed to form an embedding member.
[0013]
Therefore, in this case, in particular, it is not necessary to laminate and integrate the sheet materials in advance, and each time each cured layer is formed, each sheet material is sequentially laminated and installed, thereby simplifying the embedding member. The embedding member does not hinder the filling of the powder material.
[0014]
Claims of the invention 2 The method for producing a three-dimensional object according to the claim 1 In the method for manufacturing a three-dimensionally shaped article described above, a powder material is filled in a through hole formed in each sheet material to be laminated, and the sheet materials are combined by curing the powder material. Things.
[0015]
Accordingly, in this case, particularly, the sheet materials are bonded by the hardening of the powder material filled in the through holes, so that the bonding strength between the sheet materials is improved, and the sheet material is deformed due to the heat effect during the hardening of the powder material. Is also prevented, and it is possible to achieve higher strength and higher accuracy of the modeled object.
[0016]
Claims of the invention 3 The method for producing a three-dimensional object according to the claim 2 In the method for manufacturing a three-dimensionally-shaped object described above, a through hole is communicated between the sheet materials.
[0017]
Therefore, in this case, in particular, since the sheet materials are combined by the curing of the powder material filled in the through-holes communicating between the sheet materials, the sheet materials are positioned with respect to each other and combined without lateral displacement, and the modeled object is formed. Can be further enhanced in strength and accuracy.
[0018]
Claims of the invention 4 The method for producing a three-dimensional object according to the claim 1 In the method for manufacturing a three-dimensionally shaped object described above, the thickness of each sheet material is changed and set so as to be thick at a portion where the inclination of the outer surface of the embedding member is steep and thin at a portion where the inclination is gentle. Things.
[0019]
Accordingly, in this case, particularly, in a portion where the inclination of the outer surface of the embedding member is steep, the thickness of the sheet material is changed and set so as to be thicker, the number of stacked sheet materials is reduced, and the molding time is further reduced. Can be achieved. Conversely, at a portion where the inclination of the outer surface of the embedding member becomes gentle, the thickness of the sheet material is changed and set so as to be thin, and the step generated at the end of the sheet material becomes small, and the shape of the molded object is almost horizontal. The surface can be finished smoothly.
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. Reference example Indicates that Reference example Is a manufacturing method of obtaining a three-dimensional shaped object by sequentially forming a cured layer 2 in which the powder material 1 is hardened to obtain a three-dimensional shaped object. A method of filling the powder material 1 around the burying member 3 and curing the powder material 1 so as to be integrated with the burying member 3 in the vicinity of the burying member 3 and sequentially forming a hardened layer 2 in a laminated manner. Is the law.
[0025]
The Reference example In the method for producing a three-dimensionally shaped object, the embedding member 3 is placed on a plate 5 surrounded by the peripheral wall body 4, and the plate 5 corresponds to the thickness of the hardened layer 2 from the upper end 6 of the peripheral wall body 4. The powder material 1 is successively lowered by the dimension L, and the space 7 surrounded by the peripheral wall 4 is filled with the powder material 1 every time the plate 5 is lowered and hardened.
[0026]
In this case, as shown in FIG. 1 (a), the embedding member 3 is previously set on the plate 5, and as shown in FIG. 1 (b), the plate 5 is moved by a dimension L corresponding to the thickness of the hardened layer 2. As shown in FIG. 1 (c), the powder material 1 is filled in the space 7 surrounded by the peripheral wall body 4 formed by this. Here, a slider 11 is provided around the plate 5 so as to slide in close contact with the inner surface of the peripheral wall 4, and a space 7 from which the powder material 1 does not leak is defined from the upper end 6 of the peripheral wall 4. (Dimension L).
[0027]
Next, as shown in FIG. 1D, only the powder material 1 in the vicinity of the embedding member 3 is irradiated with the beam 12 to be cured, and at this time, the cured layer 2 where the powder material 1 is cured is embedded. It is also integrated and integrated with the outer surface of the member 3 for use. Here, a light beam such as a laser or a directional energy beam is irradiated as the beam 12, and the powder material 1 is cured by sintering. The powder material 1 is made of an inorganic material such as a metal or an organic material such as a resin, and only necessary portions are selectively sintered by the beam 12 to be efficiently and surely hardened. The material of the burying member 3 is preferably the same material as the powder material 1 because the powder material 1 is hardened and bonded and integrated with the burying member 3, and the burying member 3 has high density and high strength. Although it is formed, another material which is inexpensive and has high strength may be employed.
[0028]
The steps of FIG. 1B to FIG. 1D are repeated, and finally a model is completed as shown in FIG. In this case, a metal part, a mold, and the like can be manufactured by curing and laminating the powder material 1 made of a metal, and a resin part can be manufactured using the powder material 1 made of a resin. Mixed shaped objects and parts can also be manufactured.
[0029]
Therefore, Reference example In the method for manufacturing a three-dimensionally shaped object described above, by forming the burying member 3 at a high density and firmly, it is possible to manufacture a molded article having high strength as a whole. In addition, it is only necessary to sequentially cure the powder material 1 in the vicinity of the burying member 3 only in a layer configuration, and at this time, the amount of scanning data for scanning the beam 12 for curing is small within the contour line of the modeled object. As a result, the scanning time is shortened, and the shaping time of a complicated shape can be reduced. In addition, since the amount of the powder material 1 to be hardened is reduced, deformation due to shrinkage during hardening is also prevented, and a highly accurate molded article can be manufactured.
[0030]
Also, Reference example In the method of manufacturing a three-dimensionally shaped article described above, the embedded member 3 is lowered by the dimension L corresponding to the thickness of the hardened layer 2 and the hardened layers 2 are sequentially laminated around the embedded member 3. Can be easily filled with the powder material 1 and the distance setting of the beam 12 irradiating the powder material 1 can be easily performed, so that optimum manufacturing equipment can be provided. Moreover, in this case, since the plate 5 is lowered from the upper end portion 6 of the peripheral wall body 4 by the dimension L corresponding to the thickness of the hardened layer 2, the powder material 1 is reduced to the thickness of the dimension L. Filled exactly the right amount.
[0031]
FIG. 2 shows another embodiment of the present invention. Reference example Indicates that Reference example In the method for producing a three-dimensionally shaped object, the sheet material 8 is laminated and integrated to form the burying member 3. In this case, the sheet material 8 is made of an inorganic material or an organic material, and is stacked and integrated in advance and placed on the plate 5.
[0032]
Therefore, in this case, in particular, even a shaped object having a complicated shape can be easily manufactured by forming the embedding member 3 embedded therein by stacking and integrating the sheet material 8. In addition, other than that is shown in FIG. Reference example And the same steps Reference example The same operation and effect as those described above are obtained.
[0033]
FIG. 3 shows the claims of the present invention. 1 Corresponding to one An embodiment is shown, and in the method for manufacturing a three-dimensionally shaped article according to the embodiment, each of the sheet materials 1 is sequentially stacked and placed before each of the cured layers 2 is formed to form the embedding member 3. It is. In this case, the sheet material 8 is cut into a predetermined size and shape, and the thickness dimension thereof is formed substantially equal to the dimension L corresponding to the thickness of the hardened layer 2. Before lowering the plate 5 by the dimension L, Although the sheet material 8 is placed on the plate 5, the sheet material 8 may be placed on the plate 5 after the plate 5 is lowered, that is, as shown in FIGS. 3 (a) and 3 (b). The steps may be interchanged.
[0034]
Therefore, in this case, in particular, it is not necessary to laminate and integrate the sheet materials 8 in advance to form the embedding member 3, and each time each of the cured layers 2 is formed, the respective sheet materials 8 are sequentially laminated and installed. Thus, the burying member 3 can be easily formed, and the burying member 3 does not hinder the filling of the powder material 1. In addition, since the burying member 3 does not protrude upward from the filled powder material 1, there is no hindrance to the work of curing the powder material 1 irradiating the beam 12. In addition, other than that is shown in FIG. Reference example And the same steps Reference example The same operation and effect as those described above are obtained.
[0035]
Also, each of the above Reference example, In the embodiment, as shown in FIG. 4, the powder material 1 is filled in a region excluding the upper region from the lower layer. That is, the powder material 1 is filled around the contour of the sheet material 8, and the powder material 1 is not interposed between the sheet materials 8. In this case, the gap between the end faces of each sheet material 8 is closed by the hardened layer 2 of the powder material 1 and firmly adhered to prevent the sheet material 8 from being turned up and deformed from the same end face. , The influence of thermal distortion and the like is small, and a high-precision molded object can be obtained.
[0036]
Also, each of the above Reference example, In the embodiment, as shown in FIG. 5, the powder material 1 is applied and interposed between the sheet materials 8, and the powder material 1 between the sheet materials 8 is melted or sintered so that the respective sheet materials 8 are interconnected. It is also possible to join them. In this case, as shown in FIGS. 5 (a) and 5 (b), the powder material 1 is applied to the surface of the lower layer sheet material 8 to form a powder adhesive layer 13, and as shown in FIG. An upper sheet material 8 is placed on the layer 13, and as shown in FIG. 5D, a beam 12 such as a laser is radiated from above the upper sheet material 8 through the sheet material 8, whereby the powder The adhesive layer 13 is melted or sintered, and the upper and lower sheet materials 8 are bonded to each other by the powder adhesive layer 13.
[0037]
Therefore, in this case, the adhesive strength between the sheet materials 8 is improved, and the mechanical strength of the modeled object can be enhanced. Further, in this case, the powder material 1 having a lower melting point than the sheet material 8 is used, whereby the sheet material 8 can be formed without being damaged by the thermal influence of the beam 12. A highly accurate model can be obtained without causing deformation of the material 8.
[0038]
FIG. 6 shows a first embodiment of the present invention. , 2 Corresponding to Another In the method for manufacturing a three-dimensionally shaped object according to the embodiment, the powder material 1 is filled into the through holes 9 formed in the respective sheet materials 8 to be laminated, and the powder material 1 is cured. The sheet materials 8 are combined with each other. In this case, as shown in FIGS. 6 (a) and 6 (b), the powder material 1 is put on the periphery of the sheet material 8 and in each through hole 9 from above the sheet material 8 in which a plurality of through holes 9 are formed. As shown in FIG. 6C, the sheet material 8 is irradiated with a beam 12 such as a laser or the like from above the sheet material 8 to cure the powder material 1 filled around the sheet material 8 and in each through hole 9. Let it. The steps of FIG. 6A to FIG. 6C are repeated, and finally the model is completed as shown in FIG.
[0039]
Therefore, in this case, in particular, since the sheet materials 8 are bonded by the curing of the powder material 1 filled in the through-holes 9, the bonding strength between the sheet materials 8 is improved, and at the same time as the powder material 1 is cured. Deformation of each sheet material 8 due to thermal influence is also prevented, and it is possible to achieve higher strength and higher precision of the modeled object. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.
[0040]
FIG. 7 shows claims 1 to 5 of the present invention. 3 Is shown, and in the method for manufacturing a three-dimensionally shaped article according to this embodiment, the through holes 9 are communicated between the sheet materials 8. In this case, the through holes 9 communicate with all the sheet materials 8, and the communicated through holes 9 are provided at a plurality of locations.
[0041]
Therefore, in this case, in particular, the respective sheet materials 8 are bonded by the curing of the powder material 1 filled in the through holes 9 communicating between the sheet materials 8, so that the respective sheet materials 8 are positioned with respect to each other and do not shift laterally. By being combined, it is possible to further increase the strength and accuracy of the modeled object. Except for this, the configuration is the same as that of the embodiment shown in FIG. 6 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.
[0042]
In this embodiment, as shown in FIG. 8, the through holes 9 can be formed so as to be inclined and communicate with each other. In this case, the through holes 9 may be alternately inclined in different directions for each layer of the sheet material 8 as shown in FIG. 8A, or a plurality of layers of the sheet material 8 as shown in FIG. The through-holes 9 may be alternately inclined in different directions every 8. In this case, the sheet materials 8 are less likely to be separated from each other in the direction in which the sheet materials 8 are superimposed, and it is possible to further increase the strength of the modeled object.
[0043]
In this embodiment, as shown in FIG. 9, the upper through-holes 9b of both through-holes 9 communicating between the upper and lower sheet materials 8 are filled with the lower through-holes 9a. An escape hole may be used. In this case, when the powder material 1 filled in the lower through-hole 9a hardens, the bulging deformation due to the condensation of the powder material 1 is released and absorbed by the upper through-hole 9b. Adhesion between the sheet materials 8 can be improved.
[0044]
In this embodiment, as shown in FIG. 10, through-holes 9b and 9a communicating between both upper and lower sheet materials 8 and through-holes 9c not communicating with each other may be provided. In this case, the positioning between the sheet materials 8 can be performed by the communicating two through holes 9b and 9a, and the bonding strength between the sheet materials 8 can be increased by the non-communicating through holes 9c.
[0045]
Further, in this embodiment, as shown in FIG. 11, the hole diameter of the through hole 9 communicating between the sheet materials 8 may be different between the layers of each sheet material 8. In this case, the upper and lower through holes 9c and 9a are formed with a large diameter, and the middle through hole 9b is formed with a small diameter. In addition, as shown in FIG. 12, chamfering may be applied to each opening edge of the through holes 9b and 9a communicating between the upper and lower sheet materials 8. In these cases, the sheet materials 8 are less likely to peel off from each other in the direction in which the sheet materials 8 are overlapped, and the adhesive strength between the sheet materials 8 can be improved.
[0046]
In this embodiment, as shown in FIG. 13, each through-hole 9 communicating between the sheet materials 8 may be formed in a tapered shape. In this case, as shown in FIG. 13 (a), the lower through-hole 9a filled and hardened with the powder material 1 and the upper through-hole 9b, which is a relief hole, have the same inclination and the same size. As shown in FIG. 13 (b), each through hole 9 communicating over multiple layers may be formed in a tapered hole shape with the same inclination and the same size. Further, as shown in FIG. 13 (c), the through holes 9 communicating with each other over a large number of layers are formed in a tapered shape by changing the size of the through holes 9 so that the inclinations are continuous with each other. Alternatively, a plurality of through-holes 9 may be provided in a mutually opposing taper. In these cases, the sheet materials 8 are less likely to peel off from each other in the direction in which the sheet materials 8 are overlapped, so that the adhesive strength between the sheet materials 8 can be improved, and the positioning operation can be facilitated. Become.
[0047]
FIG. 14 shows a first embodiment of the present invention. , 4 In the method for manufacturing a three-dimensionally shaped article according to this embodiment, the thickness of each sheet material 8 is set so that the slope K of the outer surface of the embedding member 3 is steep (the slope K is vertical). In this case, the change is set so as to be thick at a portion closer to the direction (portion closer to the horizontal direction) and to be thin at a portion where the slope K is gentler (portion where the slope K is closer to the horizontal direction). In this case, as shown in FIG. 15A, by increasing the thickness of the sheet material 8 at a position where the inclination K is close to the vertical direction, the number of layers is reduced, and as shown in FIG. By reducing the thickness of the sheet material 8 at a position where K is close to the horizontal direction, the step generated at the end portion is reduced.
[0048]
Therefore, in this case, particularly, at a portion where the inclination K of the outer surface of the embedding member 3 is steep, the thickness of the sheet material 8 is changed and set so as to increase, and the number of stacked sheet materials 8 is reduced. Further, the molding time can be further reduced. Conversely, at a portion where the inclination K of the outer surface of the burying member 3 becomes gentle, the thickness of the sheet material 8 is changed and set so as to be thin, and the step generated at the end of the sheet material 8 becomes small. The surface near the horizontal of the modeled object can be finished smoothly.
[0049]
In the method for manufacturing a three-dimensionally shaped article according to the present embodiment, as shown in FIG. 16A, the sheet material 8 may be integrally formed for each layer so as to have a uniform thickness. As shown, a plurality of layers of the sheet material 8 may be integrally formed at a specific portion and the thickness thereof may be different. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.
[0050]
FIG. 17 shows the claims of the present invention. 1 In the three-dimensional shape manufacturing method according to this embodiment, a powder solidified layer 10 in which the powder material 1 is solidified is formed between the sheet materials 8. In this case, the powder solidified layer 10 is provided in place of the sheet material 8, and the upper and lower sheet materials 8 are firmly joined.
[0051]
Therefore, in this case, particularly, when the lamination surface of the sheet material 8 has a fine and complicated shape, for example, when the cutout shape is complicated or when islands with independent contour lines are generated many, the sheet material 8 has the same shape. Instead of this, a solidified powder layer 10 where the powder material 1 is solidified is formed at the site, so that the solidified powder layer 10 can be easily formed at an accurate position to produce a shaped article having a complicated shape. Can be easily handled.
[0052]
Further, in the method for manufacturing a three-dimensionally shaped article according to the present embodiment, as shown in FIG. 18, a plurality of solidified powder layers 10 can be provided to make the thicknesses different. In this case, in order to obtain a thick powder solidified layer 10, it is only necessary to repeat the application and curing of the powder material 1 a plurality of times, which is simpler than changing the thickness of the sheet material 8, and a special mechanism is used. And devices are not required. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.
[0053]
FIG. 19 shows the claims of the present invention. 1 In the method of manufacturing a three-dimensional object according to this embodiment, the outer surface of the embedding member 3 has a step-like shape between the sheet materials 8, and the step-like concave portion has powder. The material 1 is filled and hardened so that the upper surface thereof has a tapered shape substantially along the same slope. In this case, the step becomes larger as shown in FIG. 20, but becomes smaller along the step slope K as shown in FIG. 21. Here, each (a) of FIGS. 20 and 21 shows the entire shape, each (b) shows a main part in a state where the powder material 1 is cured by irradiating the beam 12, and each (c) shows the same powder material. Reference numeral 1 denotes a cured layer 2 that has been cured.
[0054]
Therefore, in this case, in particular, the outer surface of the embedding member 3 having the step shape has a tapered shape substantially along the same step slope K by the powder material 1 which fills and hardens the step-shaped recess. The surface of the modeled object can be finished smoothly. In addition, when polishing is performed, the amount of shaving is reduced, and the finishing time can be shortened.
[0055]
Further, in the method for manufacturing a three-dimensionally shaped object according to the present embodiment, the stepped concave portion can be filled with the powder material 1 so that the upper surface thereof is tapered by employing the vibration device. For example, as shown in FIG. 22, after filling the powder material 1, the plate 5 is raised to apply vibration to the plate 5, and unnecessary powder material 1 is shaken off to form a tapered upper surface. In this case, as shown in FIG. 22A, with the plate 5 lowered to a predetermined position, the powder material 1 is filled in the space 7 surrounded by the peripheral wall 4, and then, FIG. As shown in FIG. 22, the plate 5 is raised to the uppermost position and vibrated, and the unnecessary powder material 1 is shaken off to form a tapered upper surface. Subsequently, as shown in FIG. The plate 5 is lowered to a predetermined position, and in this state, the beam 12 is irradiated only on the powder material 1 near the periphery of the uppermost sheet material 8 to form the hardened layer 2. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.
[0056]
Further, in the method for manufacturing a three-dimensionally shaped object of the present invention, by irradiating a light beam such as a laser or a directional energy beam, the powder material 1 is hardened by sintering, and the sheet material 8 is cut into a predetermined shape. However, by employing the light beam in this way, local heating can be performed pinpointly, and the sheet material 8 can be cut without adversely affecting the sheet material 8. The light beam can be freely and accurately scanned in accordance with the contour shape.
[0057]
In the method for producing a three-dimensionally shaped object according to the present invention, the cut shape of the sheet material 8 is as shown in FIG. It is formed so that a space to be filled is formed. That is, the lowermost sheet material 8 may have a shape (required dimension A) conforming to the modeled object, but the other sheet material 8 on the lower edge layer may have a space (filling space) at its edge portion in consideration of the filling amount of the powder material 1. Cut slightly smaller to ensure the part size B). In this case, the edge portion of each sheet material 8 is securely bonded, so that a shaped article having a required dimension A and having a predetermined box shape can be obtained with high accuracy.
[0058]
Further, as shown in FIG. 24, when an island portion 14 having an independent contour line is generated on the lamination surface of the sheet material 8, the sheet is formed into a shape having a connecting portion 15 for connecting the island portion 14 and other portions. The material 8 is cut and formed. In this case, after the lamination and joining of the sheet material 8 or after the production of the modeled object is completed, as shown in FIGS. 24A and 24D, the connecting portion 15 is cut and removed. Therefore, in this case, when the cut and formed sheet material 8 is transported, as shown in FIG. 24B, the island portion 14 is integrated with the other portions at the connecting portion 15 and is easily transported. Further, as shown in FIG. 24 (c), when the sheet materials 8 are laminated and joined, the island portion 14 is integrated with the other portions at the connecting portion 15, so that the positioning operation is easy. Can be done.
[0059]
In the method for manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed, for example, by cutting the sheet material 8 into a shape having positioning sides 16 around the sheet material 8 as shown in FIG. This can be performed by bringing the side portion 16 into contact with the positioning pin 17. In this case, as shown in FIG. 25B, the sheet material 8 is cut and formed into a shape in which the positioning sides 16 arranged at right angles to the two sides are joined to the other parts via the connecting parts 15 together with the islands 14. Then, as shown in FIG. 25 (c), the sheet material 8 is positioned and installed by laminating both the positioning side portions 16 against at least three positioning pins 17, and finally, as shown in FIG. As shown in a), all the connecting portions 15 and the positioning side portions 16 are cut and removed. The positioning pins 17 are provided, for example, on the plate 5.
[0060]
In the method for manufacturing a three-dimensionally shaped object according to the present invention, the sheet material 8 can be positioned as shown in FIG. That is, in this case, the sheet material 8 is cut into a shape having a positioning side 16 on the entire periphery thereof, and the positioning side 16 is brought into contact with the inner wall surface of the peripheral wall body 4 to thereby obtain the sheet material 8. 8 is performed. Here, as shown in FIG. 26 (a), the sheet material 8 has a shape in which the positioning side portions 16 arranged so as to surround the entire periphery thereof are joined together with the island portion 14 and other portions via the connecting portion 15. As shown in FIG. 26B, the outer edge of the positioning side 16 is brought into contact with the inner wall surface of the peripheral wall body 4 so that the sheet material 8 is positioned and installed to be laminated and joined. Finally, all the connecting portions 15 and the positioning side portions 16 are cut and removed.
[0061]
As shown in FIGS. 25 and 26, when the positioning of the sheet material 8 is performed, the positioning operation is facilitated, the area to be filled with the powder material 1 is reduced, and the amount of the powder material 1 can be reduced. As a result, a high-precision modeled object can be obtained.
[0062]
In the method for manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIG. 27, a pusher 19 protruding from a pusher movable device 18 to be able to advance and retreat is brought into contact with an outer edge portion of the sheet material 8 so that the sheet The positioning of the material 8 can also be performed. Here, FIG. 27A shows a state at the time of positioning, and FIG. 27B shows a state of releasing the positioning. Further, as shown in FIG. 28, the movable pins 21 projecting and retractable from the movable pin device 20 are inserted into and engaged with the positioning holes 22 formed in the respective sheet materials 8 so that the respective sheet materials can be engaged. 8 can also be performed. Here, FIG. 28A shows a state at the time of positioning, and FIG. 28B shows a state of releasing the positioning. When the positioning of the sheet material 8 is performed as described above, the light beam irradiation is accurately scanned along the contour of the sheet material 8, the bonding between the sheet materials 8 is performed well, and the bonding strength is improved. Thus, improvement in the molding accuracy can be expected.
[0063]
Further, in the method for manufacturing a three-dimensionally shaped object of the present invention, when the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 and engaging the same. As shown in FIG. 29, the movable pin 21 may be erected on the plate 5 so as to be movable therewith. In this case, while the positioning of the sheet material 8 is easily performed, the steps shown in FIGS. 29A and 29B and the step of irradiating the powder material 1 with the beam 12 to form the hardened layer 2 are repeated. 29 (c), the molded object is completed. At this time, the movable pin 21 is embedded in the molded object as a part of the embedding member 3.
[0064]
In the method of manufacturing a three-dimensionally shaped article according to the present invention, when the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8, FIG. As shown in FIG. 31, the tip of the movable pin 21 is swaged (swaging portion 23), and as shown in FIG. 31 (a), the powder material 1 is filled into the positioning holes 22 of the upper layer sheet material 8 and hardened. Then, the movable pin 21 is coupled to the tip portion (the coupling hardened portion 24). At this time, as shown in FIG. 31B, the positioning hole 22 of the sheet material 8 in the upper layer is formed into a chamfered shape ( The chamfer 25) can be performed. In this case, the sheet material 8 does not easily come off from the movable pins 21 and the strength of each sheet material 8 in the stacking direction is increased.
[0065]
When the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 as shown in FIG. As shown in FIG. 32, the movable pins 21 may be inserted in communication with all the sheet materials 8 or, as shown in FIG. 32B, a plurality of movable pins 21 may be inserted between the upper and lower sheet materials 8. It may be made to be done.
[0066]
Further, in the method for manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 so as to be engaged. As shown in FIG. 33, the movable pin 21 may be formed so as to protrude from the upper surface of the lower sheet material 8 so that the movable pin 21 is inserted into and engaged with the positioning hole 22 of the upper sheet material 8.
[0067]
In this case, as shown in FIG. 33 (a), the powder material 1 is applied to the upper surface of the lower sheet material 8, and as shown in FIG. 33 (b), the beam 12 is spotted on a part of the powder material 1. The movable pin 21 is formed by irradiating and curing, and as shown in FIG. 33C, the uncured and remaining powder material 1 is removed, and the movable pin 21 is projected from the upper surface of the sheet material 8 of the lower layer. As shown in FIG. 33 (d), the upper layer sheet material 8 is laminated on the lower layer sheet material 8, and at this time, the movable pins 21 are inserted and engaged with the positioning holes 22 of the upper layer sheet material 8. Then, both sheet materials 8 are positioned with respect to each other, and thereafter, as shown in FIGS. 33 (e) and (f), a separate powder material 1 is filled, and the same powder material 1 around the periphery of the upper layer sheet material 8 is added. The cured layer 2 is formed by irradiating the beam 12, and these steps are repeated. The shaped object is completed.
[0068]
Therefore, in this case, the work of separately setting and forming the movable pin 21 in advance is omitted, and the shape and size of the movable pin 21 can be freely set corresponding to the positioning holes 22, and the sheet material can be freely set. In the step of laminating the sheet materials 8, the strength of each sheet material 8 in the laminating direction can be easily increased.
[0069]
In the method for manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIGS. 34 and 35, positioning ribs 26 are formed so as to protrude from the upper surface of the lower sheet material 8, and the upper positioning sheet 26 By contacting the outer peripheral portions of the sheet materials 8, the two sheet materials 8 can be positioned relative to each other.
[0070]
In this case, as shown in FIG. 34 (a), the powder material 1 is applied to the upper surface of the lower sheet material 8, and as shown in FIG. 34 (b), the beam 12 is linearly applied to a part of the powder material 1. Irradiation and curing are performed to form positioning ribs 26, and as shown in FIGS. 34 (c) and 35 (a), the uncured and remaining powder material 1 is removed and the positioning ribs 26 are replaced with the lower sheet material. As shown in FIGS. 34 (d) and 35 (b), an upper sheet material 8 is laminated on the lower sheet material 8, and at this time, the upper sheet material 8 is laminated. The two sides of the sheet material 8 are positioned with respect to each other by bringing one side of the outer side portion of the sheet member into contact with the positioning rib 26, and thereafter, as shown in FIGS. 34 (e), (f) and 35 (c), A separate powder material 1 is filled and the same powder near the other side of the outer side portion of the upper sheet material 8 is used. By irradiating a beam 12 to the material 1 to form a cured layer 2, the shaped object is completed by repeating this such steps.
[0071]
Therefore, also in this case, the trouble of separately installing and forming the positioning ribs 26 in advance can be omitted, the shape and size of the positioning ribs 26 can be freely set, and the step of laminating the sheet material 8 can be performed. The strength of each sheet material 8 in the laminating direction can be easily increased.
[0072]
In the method for manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIGS. 36 (a) and (b), a projection 27 is formed on the lower surface of the upper sheet material 8, and the projection 27 is formed on the lower sheet material 8. The two sheet materials 8 can be positioned relative to each other by bitingly engaging the upper surface of the sheet material. In this case, as shown in FIG. 37, a processing machine 28 for vertically moving the punch up and down is provided, and the punch of the processing machine 28 is pressed down onto the upper sheet material 8 so that the lower surface of the upper sheet material 8 is formed. The protruding projection 27 may be engaged with the upper surface of the lower sheet material 8 and locked.
[0073]
In the method of manufacturing a three-dimensional object according to the present invention, as shown in FIGS. 38 and 39, as a final step after all of the predetermined powder material 1 is hardened by sintering, the upper surface of the object is machined. May be. All steps in this case will be described in the order of the steps (a) to (e) in FIGS.
First, as shown in FIGS. 38 (a) and 39 (a), a metal sheet material 8 wound up in a roll is fed out and irradiated with a beam 12, and the through hole 9 (such as a through hole) is formed. A common hole for bonding) is formed and cut into a predetermined shape along the contour line. Next, the sheet material 8 cut into a predetermined shape is placed on the plate 5 surrounded by the peripheral wall 4, and as shown in FIGS. 38 (b) to (d) and FIGS. 39 (b) to (d), As in the embodiment shown in FIG. 7, the powder material 1 is filled into the periphery of the sheet material 8 and the inside of each through hole 9 from above the sheet material 8 in which the plurality of through holes 9 are formed. A beam 12 is irradiated from above the sheet material 8 to harden the powder material 1 filled around the sheet material 8 and in the through holes 9. These steps are repeated twice to complete a two-layer structure.
[0074]
In this case, the beam 12 is irradiated from the laser irradiation device A, the powder material 1 is supplied and filled by the material supply device B, and the powder material 1 is sintered and hardened by the irradiation of the beam 12 to form a sheet. The through hole 9 of the material 8 and the contour line are bonded. As shown in FIGS. 38 (e) and 39 (e), the upper surface of the model is machined as a final step. In this case, the hardened portion of the powder material 1 (in the through hole 9) is formed. And the surrounding hardened layer 2) protrude from the upper surface of the modeled object, and the protruding portion is cut and removed by the processing device C.
[0075]
【The invention's effect】
As described above, according to the method of manufacturing a three-dimensional object according to claim 1 of the present invention, a high-strength modeled object can be manufactured, and the powder material only around the periphery of the burying member is sequentially cured as a layer structure. Since it is only necessary to perform the process, it is possible to shorten the molding time even for a complicated shape, to prevent deformation due to shrinkage of the powder material during curing, and to produce a highly accurate molded product. .
[0077]
Claims of the present invention 1 According to the described three-dimensional shape manufacturing method , Even a molded article having a complicated shape can be easily manufactured by forming the embedding member by laminating and integrating sheet materials.
[0078]
Moreover Claims of the present invention 1 According to the described three-dimensional shape manufacturing method , There is no need to laminate and integrate the sheet material in advance, and the embedding member can be easily formed, and the embedding member does not hinder the filling of the powder material.
[0079]
Claims of the present invention 2 According to the described three-dimensional shape manufacturing method, in particular, by curing the powder material filled in the through-holes, the bonding strength between the sheet materials is improved, and the deformation of each sheet material due to the thermal effect at the time of curing the powder material is also improved. Thus, the strength and accuracy of the molded object can be improved.
[0080]
Claims of the present invention 3 According to the method for manufacturing a three-dimensional object described above, the sheet materials are positioned with respect to each other and bonded without lateral displacement, particularly by hardening of the powder material filled in the through holes communicating between the sheet materials, and the shaped object is further updated. Higher strength and higher precision can be achieved.
[0081]
Claims of the present invention 4 According to the method of manufacturing a three-dimensional object described above, especially in a part where the outer surface of the burying member has a steep inclination, the sheet material is thickened and the number of stacked sheets is reduced, thereby further shortening the molding time. The sheet material becomes thinner at the portion where the inclination becomes gentle, and the step generated at the end becomes small, so that the surface near the horizontal of the modeled object can be smoothly finished.
[Brief description of the drawings]
FIG. 1 shows one embodiment of the present invention. Reference example FIGS. 3A to 3E are schematic cross-sectional views illustrating a method of manufacturing a three-dimensionally shaped object.
FIG. 2 shows another Reference example FIGS. 3A to 3E are schematic cross-sectional views illustrating a method of manufacturing a three-dimensionally shaped object.
FIG. 3 One of the present invention 3A to 3E are schematic cross-sectional views illustrating a method of manufacturing a three-dimensionally shaped object according to an embodiment, respectively.
FIG. 4 is a schematic cross-sectional view illustrating a method for laminating sheet materials in the method for manufacturing a three-dimensionally shaped object according to the embodiment.
FIGS. 5A to 5D are schematic cross-sectional views showing another example of a method of laminating sheet materials in the method of manufacturing a three-dimensionally shaped article according to the embodiment, in which FIGS.
FIG. 6 Another FIGS. 3A to 3D are schematic cross-sectional views illustrating a method of manufacturing a three-dimensionally shaped object according to the embodiment.
FIG. 7 is a schematic cross-sectional view illustrating a method of manufacturing a three-dimensionally shaped object according to still another embodiment.
FIGS. 8A and 8B are schematic cross-sectional views illustrating different lamination modes of a sheet material in the method for manufacturing a three-dimensionally shaped object according to the embodiment.
FIG. 9 is a schematic cross-sectional view illustrating a lamination mode of a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention.
FIG. 10 is a schematic cross-sectional view illustrating another laminating mode of a sheet material in the method for producing a three-dimensionally shaped article of the present invention.
FIG. 11 is a schematic cross-sectional view illustrating still another laminating aspect of a sheet material in the method for producing a three-dimensionally shaped article of the present invention.
FIG. 12 is a schematic cross-sectional view illustrating still another lamination mode of a sheet material in the method for producing a three-dimensionally shaped article of the present invention.
FIGS. 13A to 13C are diagrams illustrating still another laminating aspect of the sheet material in the method for producing a three-dimensionally shaped article according to the present invention, wherein FIGS.
FIG. 14 is a schematic cross-sectional view showing a method of manufacturing a three-dimensionally shaped object according to still another embodiment.
FIGS. 15A and 15B are schematic cross-sectional views illustrating a method for manufacturing a three-dimensionally shaped object according to the same embodiment.
16A and 16B are schematic cross-sectional views illustrating different lamination modes of the sheet material in the method of manufacturing a three-dimensionally shaped article according to the same embodiment.
FIG. 17 is a schematic cross-sectional view showing a method for manufacturing a three-dimensionally shaped object according to still another embodiment.
FIG. 18 is a schematic cross-sectional view showing another laminating mode of the sheet material in the three-dimensionally shaped article manufacturing method according to the embodiment.
FIG. 19 is a schematic cross-sectional view showing a method for manufacturing a three-dimensionally shaped object according to still another embodiment.
20A and 20B are comparative cross-sectional views illustrating a method for manufacturing a three-dimensionally shaped object according to the same embodiment, in which FIG. 20A is a schematic cross-sectional view, and FIGS. .
21 (a) is a schematic cross-sectional view showing a method for manufacturing a three-dimensionally shaped article according to the same embodiment, and FIGS. 21 (b) and (c) are enlarged cross-sectional views of essential parts showing the manufacturing process.
FIGS. 22A to 22C are schematic cross-sectional views showing a method of filling and curing a powder material in a method of manufacturing a three-dimensionally shaped article according to the same embodiment, respectively, in the filling and curing process.
FIG. 23 is a schematic cross-sectional view illustrating a cut shape of a sheet material in the method for producing a three-dimensionally shaped article of the present invention.
FIG. 24 is a view illustrating another cut shape of the sheet material in the method of manufacturing a three-dimensionally shaped article of the present invention, wherein (a) and (b) are schematic plan views in different states, respectively, and Is a schematic cross-sectional view in a different state.
FIGS. 25A to 25C are views illustrating a method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, and are schematic plan views in different states of FIGS.
26A and 26B are diagrams illustrating another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention, wherein FIG. 26A is a schematic plan view, and FIG.
FIGS. 27A and 27B are diagrams illustrating still another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, wherein FIGS.
FIGS. 28A and 28B are diagrams illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, wherein FIGS.
FIGS. 29A to 29C are diagrams illustrating still another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, and are schematic cross-sectional views in the respective positioning processes.
FIG. 30 is a schematic cross-sectional view illustrating still another method for positioning a sheet material in the method for producing a three-dimensionally shaped article of the present invention.
FIGS. 31A and 31B are diagrams illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article of the present invention, wherein FIGS.
FIGS. 32A and 32B are diagrams illustrating still another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, wherein FIGS.
FIG. 33 is a view illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, and is a schematic cross-sectional view in the respective positioning steps (a) to (f).
FIG. 34 is a view illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, and is a schematic cross-sectional view in each of (a) to (f) of the positioning process.
35 (a) to (c) are schematic plan views showing a positioning process of the sheet material in each positioning process.
FIG. 36 is a view illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, wherein (a) and (b) are schematic cross-sectional views showing different shapes.
FIG. 37 is a schematic side view illustrating equipment in the sheet material positioning method.
FIGS. 38A to 38E are schematic cross-sectional views illustrating all steps including final machining in the method for manufacturing a three-dimensionally shaped article of the present invention; FIGS.
FIGS. 39A to 39E are schematic perspective views showing all the steps, in each of the steps.
FIGS. 40A and 40B show a conventional example of a method for manufacturing a three-dimensionally shaped article, wherein FIG. 40A is an overall perspective view, and FIG.
[Explanation of symbols]
1 powder materials
2 Hardened layer
3 Buried members
4 Perimeter wall
5 plates
6 Upper end
7 spaces
8 Sheet material
9 Through hole
10 Solidified powder layer

Claims

A three-dimensionally shaped article manufacturing method for obtaining a three-dimensionally shaped article by sequentially forming a cured layer in which a powder material is cured to obtain a three-dimensionally shaped article, in which an embedding member is installed, and a powder is formed around the embedding member. This is a method of manufacturing a three-dimensional object in which a material is filled, the powder material is cured so as to be integrated therewith in the vicinity of the embedding member, and a cured layer is sequentially formed by lamination. Forming a burying member, and in this case, each time each of the hardened layers is formed, each sheet material is sequentially laminated and installed to form a burying member . Manufacturing method.

The powder material was filled in the through hole formed in the sheet material to be laminated, three-dimensional shaped article produced according to claim 1, wherein the coupling the same each sheet material by curing the powder material Law.

3. The method for producing a three-dimensionally shaped article according to claim 2 , wherein the through holes communicate with each other between the sheet materials.

Thick at the site where the slope becomes tight outer surface of the burying member the thickness of each sheet material, three-dimensional shaped article produced according to claim 1, wherein the change set to be thin at the site where the slope becomes loose Law.