JP5189953B2 - Manufacturing method of three-dimensional shaped object - Google Patents

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for a three-dimensional shaped object. More specifically, the present invention manufactures a three-dimensional shaped object in which a plurality of solidified layers are laminated and integrated by repeatedly performing formation of a solidified layer by irradiating a predetermined portion of the powder layer with a light beam. The present invention relates to a method and an apparatus therefor.

  Conventionally, a method of manufacturing a three-dimensional shaped object by irradiating a powder material with a light beam (generally referred to as “powder sintering lamination method”) is known. In such a method, “(i) by irradiating a predetermined portion of the powder layer with a light beam, the powder at the predetermined portion is sintered or melt-solidified to form a solidified layer, and (ii) of the obtained solidified layer A three-dimensional shaped article is manufactured by repeating the process of “laying a new powder layer on the top and irradiating the same with a light beam to form a solidified layer” (see Patent Document 1 or Patent Document 2). When a metal powder is used as the powder material, the obtained three-dimensional shaped object can be used as a mold or the like. When a resin powder is used as the powder material, the obtained three-dimensional shaped object is a plastic. It can be used as a model. According to such a manufacturing technique, it is possible to manufacture a complicated three-dimensional shaped object in a short time.

  In the powder sintering lamination method, a three-dimensional shaped object is manufactured in a chamber maintained in an inert atmosphere from the viewpoint of oxidation prevention and the like. Specifically, the three-dimensional shaped object is manufactured on a “modeling table” in the chamber or a “modeling plate arranged on the modeling table”. As shown in FIG. 1, when a three-dimensional modeled object is manufactured on a modeling plate 21 arranged on the modeling table 20, first, a powder layer 22 having a predetermined thickness t <b> 1 is first formed on the modeling plate 21. After the formation (see FIG. 1A), the solidified layer 24 is formed on the modeling plate 21 by irradiating a predetermined portion of the powder layer 22 with a light beam. Then, a new powder layer 22 is laid on the formed solidified layer 24 and irradiated again with a light beam to form a new solidified layer. When the solidified layer is repeatedly formed in this way, a three-dimensional shaped object in which a plurality of solidified layers 24 are laminated and integrated can be obtained (see FIG. 1B). Since the solidified layer corresponding to the lowest layer can be formed in a state of being adhered to the modeling plate surface, the “bottom surface of the three-dimensional modeled object” and “the modeling plate surface on which the three-dimensional modeled object is provided” In other words, they are joined together.

Here, since the three-dimensional shaped object is manufactured through the irradiation of the light beam, the three-dimensional shaped object is affected by heat from the light beam. Specifically, the irradiated portion of the powder layer is once melted to be in a molten state and then solidified to form a solidified layer. However, a shrinkage phenomenon may occur when the solidified layer is solidified. Although not bound by a specific theory, a shrinkage phenomenon occurs when the molten powder is cooled and solidified (see FIG. 2 (a)). On the other hand, the modeling plate that supports the solidified layer (that is, the three-dimensional modeled object) is a rigid body made of steel or the like, and is hardly affected by the heat of the light beam because it is away from the irradiation position of the light beam. As a result, a warping force (moment) is generated in the three-dimensional shaped object 24 on the modeling plate, and if it exceeds a certain limit, as shown in FIG. A phenomenon in which the shaped object is peeled off from the modeling plate 21 occurs. When the three-dimensional shaped object is peeled from the modeling plate 21, it is not desirable in that the desired three-dimensional shaped object cannot be manufactured. In other words, when the three-dimensional shaped object (ie, solidified layer) is warped and peeled, not only the shape accuracy of the obtained three-dimensional shaped object is lost, but also the solidified layer is caused by the solidified layer warping. A new powder layer cannot be laid on top with a predetermined thickness (for example, if the solidified layer warps larger than the thickness of the next powder layer, the powder layer cannot be laid uniformly).
JP-T-1-502890 JP 2000-73108 A

  The present invention has been made in view of such circumstances. That is, an object of the present invention is to provide a “three-dimensional shaped article manufacturing method” and a “three-dimensional shaped article manufacturing apparatus” that suppress the peeling phenomenon of the solidified layer (that is, the three-dimensional shaped article) as much as possible. That is.

In order to solve the above problems, in the present invention,
(I) irradiating a predetermined portion of the powder layer with a light beam (eg, a directional energy beam such as a laser beam) to sinter or melt and solidify the powder at the predetermined portion to form a solidified layer; and (ii) ) A three-dimensional shape in which a new powder layer is formed on the obtained solidified layer, and a step of forming a further solidified layer by irradiating a predetermined portion of the new powder layer with a light beam is repeated in the chamber. A manufacturing method of a model,
At least one recess is provided on the main surface of the modeling table or modeling plate on which the powder layer or the solidified layer is provided, and the bottom surface of the three-dimensional modeled object (or “bottom part of the three-dimensional modeled object” or “the concave part” There is provided a method for producing a three-dimensional shaped object, characterized in that a solidified portion ") of the three-dimensional shaped object formed inside" and the concave part are in contact with each other.

  The manufacturing method of the present invention is characterized in that at least one recess is provided on the main surface of the modeling table or modeling plate so as to be in contact with at least a part of the bottom surface of the three-dimensional modeled object. Have. More specifically, in the present invention, the solidified portion formed inside the concave portion is in contact (fitting / joining) with the concave portion, thereby supplementing the bonding force between the three-dimensional shaped object and the modeling plate. In other words, in the present invention, the bottom surface of the three-dimensional shaped object that is going to be warped in the manufacturing process is locally hooked by the concave portion, or the bottom surface and the concave portion of the three-dimensional shaped structure are locally fitted. By combining them, peeling of the three-dimensional shaped object is prevented (hereinafter, the effect provided by such a recess is also referred to as “hooking effect” or “anchor effect”).

  The “main surface” in the present specification substantially means a surface on which a three-dimensional shaped object (or a powder layer or a solidified layer) is provided among the surfaces included in the modeling table or the modeling plate. .

  In addition, the “bottom surface of the three-dimensional shaped object” in the present specification substantially means a surface in contact with the modeling table or the modeling plate, and corresponds to the above-described recess as well as a flat surface. A surface including a convex bottom surface portion that can be formed in this manner is also contemplated.

  Further, the “concave portion” in the present invention is intentionally provided on the main surface of the modeling table or the modeling plate in order to hook the bottom surface of the three-dimensional modeled object or to fit the bottom surface of the three-dimensional modeled object. It should be noted that it does not mean scratches that are inevitably or accidentally formed during the production of the shaping table or the shaping plate.

  In a preferable aspect, the bottom surface of the peripheral portion of the three-dimensional shaped object and the recess are in contact with each other during the manufacturing process. That is, the concave portion is provided on the modeling table or the modeling plate so as to be in contact with the bottom surface of the peripheral portion of the manufactured three-dimensional modeled article. From another viewpoint, the solidified layer is formed so that the peripheral portion of the three-dimensional shaped object is positioned in the recess. Thereby, the curvature up / peeling from the peripheral part of a three-dimensional shaped molded article can be prevented effectively.

In this invention, the "manufacturing apparatus of a three-dimensional shape molded article" for implementing the manufacturing method mentioned above is also provided. A manufacturing apparatus for such a three-dimensional shaped object is:
Powder layer forming means for forming a powder layer,
"Forming table" or "Modeling plate arranged on the forming table" on which the powder layer and / or solidified layer will be formed, and for irradiating the powder layer with a light beam so that the solidified layer is formed Comprising light beam irradiation means,
At least one recessed part is provided in the modeling object formation area of the main surface of a modeling table or a modeling plate, It is characterized by the above-mentioned.

  In a preferred aspect, the recess has a tapered shape that expands downward. In other words, the vertical cross section of the concave portion has a shape that gradually widens from the upward direction to the downward direction in the vertical direction (vertical direction). With such a tapered shape, the bottom surface of the three-dimensional shaped object can be more effectively “hooked”, and warping / peeling of the three-dimensional shaped object can be more reliably prevented.

  The concave portion of the modeling table or the modeling plate may have a groove shape. In this case, it is preferable that the groove-shaped recess has a form along the peripheral edge (edge) of the bottom surface of the three-dimensional shaped object. In such a case, a “hooking effect” can be provided to the entire peripheral edge of the bottom surface of the three-dimensional shaped object, and warping / peeling from the peripheral part of the three-dimensional shaped object can be more reliably prevented. Such a groove-shaped recess is also preferable in that the processing itself is easy.

  In the present invention, stress that can occur in the interior of the three-dimensional modeled object during manufacturing (particularly stress that can be generated when the three-dimensional modeled object shrinks as a whole) can be received by the concave portion of the modeling table or the modeling plate. . That is, it is possible to prevent the three-dimensional shaped object from warping by hooking at least a part of the bottom surface of the three-dimensional shaped object into the recess (or fitting them together). As a result, the three-dimensional shaped object (that is, the solidified layer) can be prevented from peeling from the modeling table surface or the modeling plate surface, so that a new powder layer can be laid on the solidified layer with a predetermined thickness. In addition, the shape accuracy of the finally obtained three-dimensional shaped object is also improved.

  That is, in the present invention, in addition to joining the three-dimensional shaped object (that is, the lowermost solidified layer) and the shaping table or the shaping plate, a hooking effect of the recess can be additionally provided. The joining state between the “shaped object” and the “modeling table surface or modeling plate surface” can be further strengthened, and the “debonding phenomenon of the object” can be effectively prevented.

  In addition, in order to obtain the shape accuracy of a three-dimensional shaped object in the prior art, it was necessary to design in advance assuming phenomena such as “warping” and “peeling”, but in the present invention, modeling is performed. The shape accuracy can be substantially increased by simply providing the recess in the member that supports the object. In other words, the present invention is very useful in that it is possible to omit such a design taking into account such a phenomenon that is difficult to predict by simple means.

  Hereinafter, the present invention will be described in more detail with reference to the drawings.

[Powder sintering lamination method]
First, the powder sintering lamination method as a premise of the production method of the present invention will be described. 1, 3, and 4 show the function and configuration of an optical modeling composite processing machine 1 that can perform the powder sintering lamination method. The optical modeling composite processing machine 1 includes “a powder layer forming means 2 for forming a powder layer by spreading a powder such as a metal powder and a resin powder with a predetermined thickness” and “in a modeling tank 29 whose outer periphery is surrounded by a wall 27. In FIG. 2, a modeling table 20 that moves up and down by cylinder drive ”,“ a modeling plate 21 that is arranged on the modeling table 20 and serves as a foundation of the modeling object ”, and“ light beam irradiation means 3 that irradiates the light beam L to an arbitrary position ” "The cutting means 4 which cuts the circumference | surroundings of a molded article" is mainly provided. As shown in FIG. 1, the powder layer forming means 2 includes “a powder table 25 that moves up and down by a cylinder drive in a powder material tank 28 whose outer periphery is surrounded by a wall 26” and “a powder layer 22 on a modeling plate. And a squeezing blade 23 "for forming. As shown in FIGS. 3 and 4, the light beam irradiation means 3 includes a “light beam oscillator 30 that emits a light beam L” and a “galvanomirror 31 that scans (scans) the light beam L onto the powder layer 22 (scanning). Optical system) ”. If necessary, the light beam irradiation means 3 has beam shape correction means (for example, a pair of cylindrical lenses and a rotation drive mechanism for rotating the lenses around the axis of the light beam) for correcting the shape of the light beam spot. And an fθ lens. The cutting means 4 mainly includes “a milling head 40 that cuts the periphery of the modeled object” and “an XY drive mechanism 41 that moves the milling head 40 to a cutting position” (see FIG. 4).

  The operation of the optical modeling complex machine 1 will be described in detail with reference to FIGS. 1 and 5. FIG. 5 shows an operation flow of the stereolithography combined processing machine.

  The operation of the optical modeling composite processing machine includes a powder layer forming step (S1) for forming the powder layer 22, a solidified layer forming step (S2) for forming the solidified layer 24 by irradiating the powder layer 22 with the light beam L, It is mainly composed of a cutting step (S3) for cutting the surface of the modeled object. In the powder layer forming step (S1), the modeling table 20 is first lowered by Δt1 (S11). Next, after raising the powder table 25 by Δt1, as shown in FIG. 1A, the squeezing blade 23 is moved in the direction of arrow A, and the powder (for example, “average particle size”) While “iron powder of about 5 μm to 100 μm” or “powder of nylon, polypropylene, ABS or the like having an average particle size of about 30 μm to 100 μm” is transferred onto the modeling plate 21 (S12), the powder is adjusted to a predetermined thickness Δt1. The layer 22 is formed (S13). Next, the process proceeds to a solidified layer forming step (S2), where a light beam L (for example, a carbon dioxide laser or an ultraviolet ray) is emitted from the light beam oscillator 30 (S21). (S22), the powder is melted and solidified to form a solidified layer 24 integrated with the modeling plate 21 (S23).

  The powder layer forming step (S1) and the solidified layer forming step (S2) are repeated until the thickness of the solidified layer 24 reaches a predetermined thickness obtained from the tool length of the milling head 40, and the solidified layer 24 is laminated (FIG. 1). (See (b)). In addition, the solidified layer newly laminated | stacked will be integrated with the solidified layer which comprises the already formed lower layer in the case of sintering or melt-solidification.

  When the thickness of the laminated solidified layer 24 reaches a predetermined thickness, the process proceeds to the cutting step (S3), and the milling head 40 is driven (S31). For example, when the tool (ball end mill) of the milling head 40 has a diameter of 1 mm and an effective blade length of 3 mm, a cutting process with a depth of 3 mm can be performed. Therefore, if Δt1 is 0.05 mm, 60 solidified layers are formed. At that time, the milling head 40 is driven. The milling head 40 is moved in the directions of the arrow X and the arrow Y by the XY drive mechanism 41, and the surface of the modeled object composed of the laminated solidified layer 24 is cut (S32). And when manufacture of a three-dimensional shape molded article has not ended yet, it will return to a powder layer formation step (S1). Thereafter, the solidified layer 24 is further laminated by repeating S1 to S3, thereby manufacturing a three-dimensional shaped object.

  The irradiation path of the light beam L in the solidified layer forming step (S2) and the cutting path in the cutting step (S3) are previously created from three-dimensional CAD data. At this time, a machining path is determined by applying contour line machining. For example, in the solidified layer forming step (S2), contour shape data of each cross section obtained by slicing STL data generated from a three-dimensional CAD model at an equal pitch (for example, 0.05 mm pitch when Δt1 is 0.05 mm) is used. .

[Production method of the present invention]
The manufacturing method of the present invention pays particular attention to “relaxation of internal stress that can occur in a three-dimensional shaped object” for the above-described powder sintering lamination method. That is, according to the present invention, as shown in FIG. 2B, a phenomenon in which a three-dimensional shaped object is warped and peeled off from a modeling plate or a modeling table due to internal stress is provided on the modeling plate surface or the modeling table surface. It has a feature in that it is suppressed by a concave portion (see FIG. 6).

  Assuming that the three-dimensional shaped object 24 is manufactured on the modeling plate 21 as shown in FIG. 7A, the “concave portion” referred to in the present invention is a concave portion formed on the main surface of the modeling plate 21. Which means practically. On the other hand, as shown in FIG. 7B, assuming that the three-dimensional shaped object 24 is directly manufactured on the modeling table 20, the “concave portion” is formed on the main surface of the modeling table 20. A substantially concave portion is meant.

  In the following description, “metal powder” is used as a powder (that is, a metal powder layer is used as a powder layer), and a three-dimensional shaped object is manufactured on a modeling plate under the condition that the solidified layer is a sintered layer. An embodiment will be described as an example.

  At least one recess is provided on the main surface of the modeling plate used in the manufacturing method of the present invention (that is, the surface with which the bottom surface of the three-dimensional modeled object is in contact). Specifically, a concave portion 60 is provided in a region 21a where a modeled object is formed, as shown in FIG. The shape of the recess 60 is not particularly limited, but as shown in FIG. 9, a cylindrical shape (FIG. 9A), a polygonal column shape (for example, a rectangular column shape (FIG. 9B)), a conical shape, etc. (FIG. 9 (c)), a truncated cone shape (FIG. 9 (d) and FIG. 9 (e)), etc. From the viewpoint of easy processing, a cylinder as shown in FIG. Although the shape is preferable, the number of the recesses may depend on the individual size, the bottom size of the modeled object, the main surface size of the modeled plate, etc., for example, a modeled object area 21a (width La: 100 mm as shown in FIG. , Width Lb: 100 mm) and the number of recesses (about 4 to 100) are assumed, the width Wa of the cylindrical recess shown in FIG. 9A is about 0.5 to 20 mm, and the depth Da Is about 0.5 to 10 mm, and the pitch of the recessed portion to be provided is Also, the shaped object area, although may depend like number of recesses sized or recess, the embodiment as shown in FIG. 10 (a) for example, is taken as an example, the pitch Lp of the recess may be about 10 to 80 mm.

  In addition, from the viewpoint of more effectively “hooking” the bottom surface of the three-dimensional shaped object to be warped or peeled off, it is preferable that the shape of the concave portion is a tapered shape extending downward. That is, it is preferable that the shape of the recess is as shown in FIG. Moreover, as shown in FIG.9 (f) and FIG. 11, after it becomes more than a certain depth, the form which spreads in a taper shape toward the downward direction may be sufficient. When the recess has a taper shape, the taper spread angle α as shown in the upper right of FIG. 9E is preferably about 1 ° to 45 °. When the recess has a taper shape, it may be in the form of a through hole as shown in FIG. 12 in that the recess itself can be easily processed.

  Since the three-dimensional shaped object in the manufacturing process may have a tendency to warp or peel off from the peripheral portion (see FIG. 2B), FIG. 10A to FIG. 10C. As shown, it is preferable to provide the recessed part 60 in the peripheral part of the molded article area 21a of a modeling plate. In particular, since the warping from the corner (corner portion) of the modeled object can be considered, the embodiment shown in FIG. Moreover, when providing a recessed part in the peripheral part of the molded article area 21a, the recessed part 60 may have a groove form entirely (refer FIG. 13). In such a case, when the three-dimensional shaped object is formed so that the bottom edge of the three-dimensional shaped object follows the groove-shaped recess, the “hook effect” is provided to the entire periphery of the three-dimensional shaped object. And warpage / peeling can be prevented more reliably. Incidentally, the groove-shaped recess is also advantageous in that the processing becomes easy. Exemplifying the size of the groove-shaped recess, the groove width Wb shown in FIG. 13 is about 0.5 to 10 mm, and the groove depth Db is about 0.5 to 10 mm.

  When providing a recessed part in the peripheral part of the modeling object area 21a of a modeling plate, you may form a lowermost solidified layer so that the bottom face of a three-dimensional shaped modeling object may contact | connect only at least one part of a recessed part. For example, the lowermost layer may be formed in an area indicated by 21b (area surrounded by a broken line) in FIG. 13A, and in particular, as shown in FIG. You may do it. Even in this case, the modeled object that warps upward toward the center is caught in the concave portion, so that the stress inside the modeled product is relieved and “peeling” is suppressed.

  The method of providing the concave portion on the modeling plate is not particularly limited, but cutting, electric discharge machining, laser machining, or the like can be used. Moreover, it is also possible to provide a concave portion on the surface of the modeling plate by using a dicer or a mechanical method such as drilling or sandblasting. In the case where a through-hole-shaped recess is provided, it is preferable to make it by machining such as a drill.

  Since the three-dimensional shaped object obtained by the manufacturing method of the present invention is integrally obtained in a state of being joined to the shaping plate, the “three-dimensional shaped object” and the “shaped plate” integrated as such are separated. It can be used as a product such as a mold without any problems. In such a case, it is desirable that the material of the modeling plate has high bondability with the three-dimensional modeled object (that is, the solidified layer to be formed). For example, in the case of using iron powder in the production of a three-dimensional shaped object, the modeling plate is preferably made of a material such as steel or stainless steel, and in the case of using a resin powder such as nylon in the production of a three-dimensional shaped object, The plate is preferably made of a material such as the same kind of resin (such as nylon). However, if necessary, the three-dimensional shaped object may be used separately from the modeling plate. In that case, the material of the modeling plate is a three-dimensional shaped object (that is, a solidified layer to be formed). It is desirable to have a low bondability. For example, when iron powder is used in the production of a three-dimensional shaped object, the modeling plate is preferably made of a high melting point material such as alumina or zirconia, and may be coated by thermal spraying or the like. In the case of using a resin powder such as nylon when manufacturing a three-dimensional shaped object, the modeling plate is preferably made of a material such as metal or ceramics such as alumina. After separating the three-dimensional modeled object from the modeling plate, “the convex part on the bottom of the modeled object that can be formed corresponding to the concave part” may be cut and removed as necessary. When the three-dimensional shaped object is separated from the modeling plate, as shown in FIG. 14, the contact area between the recess 60 and the molded object bottom 24 ′ formed therein may be reduced. This helps easy separation due to the “structural plane” rather than the “material plane”.

  Next, with reference to FIG. 15 and FIG. 16, the process of manufacturing a three-dimensional shape molded article on a modeling plate is demonstrated over time. Incidentally, the case where “metal powder” is used as the powder, the solidified layer is a sintered layer, and the modeling plate is made of a material having high bonding property to the solidified layer will be described as an example.

  First, as shown to Fig.15 (a), the modeling plate 21 provided with the recessed part 60 in the area | region in which a three-dimensional molded object is provided is prepared. Next, as shown in FIG. 15B, after filling the recess with the powder 19p, the powder 19p is irradiated with a light beam to sinter the powder to form a sintered portion 24p (FIG. 15). (See (c)). Due to the sintering, the sintered portion 24p can be joined to the concave surface. The formed sintered portion 24p may be cut as necessary (for example, in the case where the sintered portion 24p is formed so as to protrude from the concave portion, the modeling plate surface is flattened). It may be removed by cutting). Subsequently, as shown in FIG. 15 (d), a first metal powder layer 19a is formed on the modeling plate 21 so as to cover the sintered portion 24p, and the first sintering is performed by irradiating a predetermined portion with a light beam. The layer 24a is formed (see FIG. 15E). Due to the sintering, the first sintered layer 24a is joined to the modeling plate surface and integrated with the sintered portion 24p existing therebelow. Next, as shown in FIG. 15F, a second metal powder layer 19b is formed on the first sintered layer 24a, and a second sintered layer 24b is formed by irradiating a predetermined portion with a light beam ( (Refer FIG.15 (g)). Due to the sintering, the second sintered layer 24b is laminated and integrated with the first sintered layer 24a existing therebelow. Thereafter, the same operation is repeated to form the shape of the three-dimensional shaped object. In such a manufacturing process, as shown in FIG. 15G, a force (moment that warps inward) is applied to a three-dimensional shaped object composed of a plurality of sintered layers (24a, 24b, 24c...). ) Will occur, but due to the sintered portion 24a being joined or caught in the recess, a force to counteract it will occur as a reaction. That is, the phenomenon in which the three-dimensional shaped object is separated from the modeling plate is prevented by the recess.

  In the manufacturing process described above, the sintered portion 24p and the first sintered portion 24a are separately formed, but they may be integrally formed. Such an embodiment is shown in FIG. In this embodiment, as shown in FIG. 16B, the first metal powder layer 19a is formed on the modeling plate 21 so that the recess 60 is filled with powder. And as shown in FIG.16 (c), a light beam is irradiated so that not only the metal powder of the predetermined part of the 1st metal powder layer 19a but the metal powder with which the recessed part was sintered may be sintered. In general, when comparing the powder in the A region and the powder in the B region shown in FIG. 16B, the irradiation condition of the light beam is adjusted so that the irradiation energy density is larger for the powder in the B region. To do. By such irradiation, a sintered layer in which the sintered portion 24p and the first sintered layer 24a are integrated can be obtained. Subsequently, as shown in FIG. 16D, a second metal powder layer 19b is formed on the first sintered layer 24a, and a second sintered layer 24b is formed by irradiating a predetermined portion with a light beam. (See FIG. 16 (e)). Due to the sintering, the second sintered layer 24b is laminated and integrated with the first sintered layer 24a and the sintered portion 24p existing therebelow. Thereafter, the same operation is repeated to form the shape of the three-dimensional shaped object.

[Production apparatus of the present invention]
Next, an apparatus suitable for carrying out the production method of the present invention will be described (this will be described taking an example in which a metal powder is used as the powder and the solidified layer is a sintered layer). Such an apparatus comprises a powder layer forming means 2 for forming a metal powder layer, as shown in FIGS. 1, 3, 4, 7, and 8.
The “modeling table 20” or “modeling plate 21 arranged on the modeling table 20” on which the metal powder layer and / or the sintered layer is formed, and the metal powder layer so that the sintered layer is formed. Light beam irradiation means 3 for irradiating a light beam
Comprising
At least one concave portion 60 is provided in the modeling object forming region 21 a on the main surface of the modeling table 20 or the modeling plate 21. In such an apparatus, the concave portion 60 provided in the modeling object forming region on the main surface of the modeling plate 21 or the modeling table 20 relieves stress (moment) that may be generated in the sintered layer in the manufacturing process. It is possible to suppress the phenomenon that the shaped object is peeled off from the modeling plate or the modeling table. The “powder layer forming means 2”, “modeling table 20”, “modeling plate 21”, “light beam irradiating means 3”, “recessed portion 60” and the like including the operation of the apparatus have been described above. The description is omitted to avoid this.

  As mentioned above, although embodiment of this invention has been described, it has only illustrated the typical example of the application scope of this invention. Therefore, those skilled in the art will readily understand that the present invention is not limited thereto and various modifications can be made.

  For example, you may roughen the inner surface of the recessed part provided in a modeling plate. As a result, the frictional resistance between the bottom surface of the three-dimensional modeled object and the concave portion is increased, so that the bottom surface of the three-dimensional modeled product that is going to warp in the manufacturing process can be more reliably “hooked” by the concave part.

  In the above description, it is assumed that a modeling plate in which concave portions are formed in advance is used, but the present invention is not necessarily limited to this. For example, a flat modeling plate may be used, and the concave portion may be cut and used prior to the manufacture of the three-dimensional shaped object. More specifically, after the “unprocessed modeling plate having a flat surface” is arranged on the modeling table, a concave portion may be formed by performing a cutting process on a desired location using an optical modeling composite processing machine. After the concave portion is formed on the modeling plate, the powder layer / solidified layer is repeatedly formed in the same manner as described above to manufacture a three-dimensional modeled article. In the case where the concave portion is formed after using the “flat modeling plate”, it is advantageous in that “positioning” is not necessary. That is, in the case of using a modeling plate in which a concave portion is formed in advance, it is necessary to arrange the modeling plate on the modeling table in consideration of the position of the concave portion formed in advance, or a powder layer or a solidified layer However, in the case of using a flat modeling plate, the concave portion is formed after being placed on the modeling table, so that the concave portion can be arbitrarily and arbitrarily selected. Inconvenience due to the “predetermined formation position” can be avoided.

  In the above description, the “mode A (see FIG. 7A) for manufacturing the three-dimensional shaped object 24 on the modeling plate 21” is mainly exemplified, but “directly on the modeling table 20”. A person skilled in the art can easily understand that the aspect B (see FIG. 7B) for producing the three-dimensional shaped object 24 can have the same features and effects as the aspect A described so far. You can understand. That is, even if it manufactures directly on a modeling table, the peeling phenomenon of a modeling object can be prevented by providing a recessed part in it. Further, in the above-described embodiment, although there is a portion described taking as an example “mode C in which the powder layer is a metal powder layer and the solidified layer is a sintered layer”, “the powder layer is a resin powder layer” Thus, those skilled in the art will easily understand that even if the solidified layer is the mode D ”in which the hardened layer is a cured layer, it can have the same characteristics and effects as the mode C.

  Various articles | goods can be manufactured by implementing the manufacturing method of the three-dimensional shape molded article of this invention. For example, in the case of “when the powder layer is a metal powder layer and the solidified layer is a sintered layer”, the resulting three-dimensional shaped article is a plastic injection mold, press mold, die casting mold, casting mold. It can be used as a mold such as a mold or a forged mold. In addition, in “the powder layer is a resin powder layer and the solidified layer is a hardened layer”, the obtained three-dimensional shaped article can be used as a resin molded product.

Sectional view schematically showing the operation of the stereolithography combined processing machine Cross-sectional view schematically showing the phenomenon that three-dimensional shaped objects cause peeling The perspective view which showed typically the aspect by which the powder sintering lamination method is performed The perspective view which showed typically the structure of the optical shaping complex processing machine by which a powder sintering lamination method is implemented Flow chart of operation of stereolithography combined processing machine Schematic diagram conceptually showing the features of the present invention Sectional drawing which showed the aspect by which a molded article is manufactured typically Perspective view schematically showing modeling plate Schematic diagram showing various aspects of recesses Top view of modeling plate schematically showing various arrangements of recesses The perspective view which showed typically the modeling plate provided with the taper-shaped recessed part Cross-sectional view schematically showing a through-hole-shaped recess The perspective view which showed typically the modeling plate provided with the recessed part of a groove form The figure which showed typically the aspect with a small contact area of a recessed part and a molded article bottom part Sectional drawing which showed the process in the manufacturing method of this invention typically Sectional drawing which showed the process in the manufacturing method of this invention typically

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Optical modeling combined processing machine 2 Powder layer formation means 3 Light beam irradiation means 4 Cutting means 19 Powder / powder layer (For example, metal powder / metal powder layer or resin powder / resin powder layer)
19p Powder filled in recess (for example, metal powder or resin powder)
19a First powder layer (for example, first metal powder layer or first resin powder layer)
19b Second powder layer (for example, second metal powder layer or second resin powder layer)
20 Modeling table 21 Modeling plate 21a Modeling object formation area (modeling object area)
21b Modeling object formation area (modeling object area)
22 Powder layer (for example, metal powder layer or resin powder layer)
23 Blade for squeezing 24 Solidified layer (for example, sintered layer or hardened layer) or three-dimensional shaped product 24p obtained therefrom Solidified portion (for example, sintered portion or hardened portion)
24a First solidified layer (for example, first sintered layer or first hardened layer)
24b Second solidified layer (for example, second sintered layer or second hardened layer)
25 Powder table 26 Wall part 27 of powder material tank 27 Wall part 28 of modeling tank Powder material tank 29 Modeling tank 30 Light beam oscillator 31 Galvano mirror 40 Milling head 41 XY drive mechanism 50 Chamber 52 Light transmission window 60 Recess L Light beam

Claims (5)

(I) irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) a new powder on the obtained solidified layer. Forming a layer, irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer, a method for producing a three-dimensional shaped object,
A concave portion having a groove shape as a whole is provided on the main surface of the modeling table or modeling plate on which the powder layer or the solidified layer is provided ,
The solidified layer is formed so that a bottom edge of the manufactured three-dimensional shaped object is in contact with only a part of the recess in the groove shape, whereby the bottom edge is along the recess in the groove shape. A method for producing a three-dimensional shaped object, characterized in that it is provided . The three-dimensional shaped object according to claim 1, wherein the groove width Wb is 0.5 to 10 mm and the groove depth Db is 0.5 to 10 mm for the recess in the groove shape. Production method. A manufacturing apparatus for a three-dimensional shaped object,
Powder layer forming means for forming a powder layer,
A shaping table on which a powder layer and / or a solidified layer is to be formed or a shaping plate arranged on the shaping table, and
Light beam irradiation means for irradiating the powder layer with a light beam so as to form a solidified layer
Comprising
The main surface of the modeling table or modeling plate is provided with a recess having a groove shape as a whole,
The concave portion of the groove shape partially overlaps with the peripheral portion of the molded object forming region so that the bottom edge of the manufactured three-dimensional shape molded article contacts only a part of the concave portion of the groove shape. An apparatus for producing a three-dimensional shaped object, characterized in that The three-dimensional shaped object according to claim 3, wherein the groove width Wb is 0.5 to 10 mm and the groove depth Db is 0.5 to 10 mm for the recess in the groove shape. manufacturing device. 5. The three-dimensional shaped article manufacturing apparatus according to claim 3, wherein the concave portion has a tapered shape spreading downward.

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