Three-dimensional shaping apparatus and three-dimensional shaping method

Abstract

In a three-dimensional shaping device (1), a control unit (5) repeats the following operations: by controlling a material holding unit (3) and an optical head (2) on the basis of design data of a shaped object, a shaping material (91) is supplied onto a mounting table (341), and a multi-point beam is scanned in a predetermined scanning direction on a layer (92) to be drawn, which is a surface layer of the supplied shaping material (91), and the layer (92) to be drawn is drawn. The pattern is drawn by melting the shaping material (91) in the region irradiated with the light. In the design data, a non-drawing region not instructed to be drawn includes a narrow non-drawing region whose size in the scanning direction is equal to or less than a correction threshold value. Then, by means of the control by the control unit, light irradiation is suppressed in a narrow-portion-adjacent region adjacent to the narrow non-drawing region, among the drawing regions indicated to be drawn in the design data, and the narrow-portion-adjacent region is adjacent to the narrow non-drawing region. As a result, a shaped object can be formed with high precision.

Description

Technical Field

[0001] The present invention relates to technologies related to three-dimensional modeling.

[0002] References to related applications

[0003] This application claims the priority benefit of Japanese patent application JP2022-151022 filed on September 22, 2022, and all disclosed contents of that application are incorporated into this application. Background Art

[0004] In recent years, SLS (Selective Laser Sintering) type three-dimensional shaping devices have been used. This three-dimensional shaping device irradiates a shaping material such as resin powder or metal powder with a modulated laser beam to melt and solidify the shaping material, thereby performing three-dimensional shaping.

[0005] For example, in a powder bed type 3D modeling device, resin powder is spread thinly in layers on a building platform, and a laser beam is scanned on the resin powder layer with a galvo-mirror (also called a galvanometer), thereby melting the powder resin in the laser beam irradiation area. And, this action is repeated to stack and solidify the molten resin powder, thereby making a model. In a powder bed type 3D modeling device, the resin powder on the building platform is usually heated to a prescribed preheating temperature that is several to more than ten degrees Celsius lower than the melting point of the resin powder, and the resin powder maintained at the preheating temperature is irradiated with a laser beam (Japanese Patent Publication No. 2021-509094 (Document 1)).

[0006] However, in the resin powder layer on the build platform, the temperature of the laser beam irradiation area (i.e., the drawing area) rises, causing heat diffusion to the non-drawing area around the drawing area. In addition, near the boundary between the drawing area and the non-drawing area, the light amount of the laser beam gradually changes, so the light amount at the end of the non-drawing area is not 0. Therefore, in a fine non-drawing area sandwiched between two drawing areas, the resin powder may melt unintentionally due to the influence of heat diffusion from the drawing area and the light amount at the end of the drawing area, and the dimensional accuracy of the object may be reduced.

[0007] In addition, in the build platform, when new resin powder is supplied to a resin powder layer on which a pattern is drawn (hereinafter also referred to as a "drawn layer"), the temperature directly above the drawing area and the surrounding area of ​​the drawn layer in the new resin powder layer is sometimes higher than the prescribed preheating temperature. Therefore, when a laser beam is irradiated directly above the drawing area in the new resin powder layer, unintended melting of the resin powder may occur around the laser beam irradiated area. In particular, as described above, the possibility of unintended melting of the resin powder becomes high in a fine non-drawing area sandwiched between two drawing areas. Summary of the invention

[0008] The present invention is directed to a three-dimensional shaping device, and its purpose is to form a shape with high precision.

[0009] A first aspect of the present invention is a three-dimensional shaping device, comprising: a material holding unit having a stage for holding a powdered shaping material, and a material supply unit for supplying the shaping material to the stage; an optical head for modulating and scanning a multi-spot light beam on the shaping material on the stage, wherein the multi-spot light beam is composed of a plurality of light spots arranged in a straight line along a predetermined arrangement direction; and a control unit for repeatedly performing the following actions: controlling the material holding unit and the optical head according to design data of the shaping object, thereby supplying the shaping material to the stage, and On the surface layer, i.e., the layer to be drawn, the multi-point light beam is scanned along a specified scanning direction to melt the forming material in the area irradiated with light, thereby drawing a pattern. The non-drawing area that is not indicated for drawing in the design data includes: a narrow non-drawing area whose size is below a correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the stage, and the up and down directions perpendicular to the stage. The control unit controls to suppress light irradiation in the following areas: an area adjacent to the narrow non-drawing area in the drawing area indicated for drawing in the design data.

[0010] According to the present invention, a shaped object can be formed with high precision.

[0011] A second aspect of the present invention is a three-dimensional shaping device according to the first aspect, wherein the one direction of the narrow non-drawing area is the width direction. When one or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are located on the narrow non-drawing area, the narrow non-drawing point group and two correction point groups adjacent to the narrow non-drawing point group on both sides of the arrangement direction are set to be inactive under the control of the control unit.

[0012] Mode 3 of the present invention is based on the three-dimensional shaping device of Mode 1, wherein the plurality of light spots can be gray-scale adjusted. The one direction of the narrow non-drawing area is the width direction. When one or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are located on the narrow non-drawing area, the narrow non-drawing point group is set to be inactive under the control of the control unit, and in two correction point groups adjacent to both sides of the arrangement direction of the narrow non-drawing point group, the light intensity of the two or more light spots included in each correction point group is adjusted to increase as the distance from the narrow non-drawing point group is along the arrangement direction.

[0013] A fourth aspect of the present invention is a three-dimensional shaping device according to the first aspect (or any one of the first to third aspects), wherein the one direction of the narrow non-drawing area is the scanning direction. Under the control of the control unit, one or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when located on the narrow non-drawing area, and the narrow non-drawing point group is also set to be inactive when located on correction areas adjacent to both sides of the narrow non-drawing area in the scanning direction.

[0014] Mode 5 of the present invention is based on the three-dimensional shaping device of Mode 1 (it can also be any one of Modes 1 to 3), and the plurality of light spots can be gray-scale adjusted. The one direction of the narrow non-drawing area is the scanning direction. Through the control of the control unit, one or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when located on the narrow non-drawing area, and when the narrow non-drawing point group is located on a correction area adjacent to both sides of the narrow non-drawing area in the scanning direction, the light intensity of the narrow non-drawing point group is adjusted to increase as it moves away from the narrow non-drawing area along the scanning direction.

[0015] Mode 6 of the present invention is based on the three-dimensional shaping device of Mode 1 (or any one of Modes 1 to 5), wherein the one direction of the narrow non-drawing area is the up-down direction. Under the control of the control unit, one or more light points among the plurality of light points that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when located on the narrow non-drawing area in a drawing target layer including the narrow non-drawing area, and the narrow non-drawing point group is also set to be inactive when located above the narrow non-drawing area in a drawing target layer including an upper drawing area adjacent to the upper side of the narrow non-drawing area.

[0016] Mode 7 of the present invention is based on the three-dimensional modeling device of Mode 1 (it can also be any one of Modes 1 to 5), and the multiple light spots can be grayscale adjusted. The one direction of the narrow non-drawing area is the up-down direction. Through the control of the control unit, one or more light spots among the multiple light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when they are located on the narrow non-drawing area in the drawing object layer including the narrow non-drawing area, and the light intensity of the narrow non-drawing point group is adjusted to increase as it goes up when the narrow non-drawing point group is located above the narrow non-drawing area in the multiple drawing object layers including the upper drawing area adjacent to the upper side of the narrow non-drawing area.

[0017] Aspect 8 of the present invention is the three-dimensional shaping apparatus according to any one of aspects 1 to 7, wherein the three-dimensional shaping apparatus further comprises: a temperature measuring unit that measures the temperature distribution of the upper surface of the shaping material on the mounting table. The correction threshold is variable, and as the temperature of the area corresponding to the non-drawing area measured by the temperature measuring unit becomes high, the correction threshold becomes smaller.

[0018] The present invention is also directed to a three-dimensional forming method. A ninth aspect of the present invention is a three-dimensional forming method, comprising the following steps: a) a step of supplying a powdered forming material onto a stage; b) a step of modulating a multi-spot light beam on a surface layer, i.e., a drawing target layer, of the forming material supplied onto the stage according to design data of the object, and scanning along a predetermined scanning direction, wherein the multi-spot light beam is composed of a plurality of light spots arranged in a straight line along a predetermined arrangement direction; and c) repeating the steps a) and b). The non-drawing area not indicated for drawing in the design data includes a narrow non-drawing area whose size is less than a correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the stage, and the vertical direction perpendicular to the stage, and in the step b), light irradiation is suppressed in the following area: an area adjacent to the narrow non-drawing area in the drawing area indicated for drawing in the design data.

[0019] The above-mentioned object and other objects, features, aspects and advantages will become more apparent from the following detailed description of the present invention with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a diagram showing the structure of a three-dimensional modeling apparatus according to one embodiment.

[0021] Figure 2 It is a diagram showing the structure of the control unit.

[0022] Figure 3 It is a block diagram showing the functions of the control unit.

[0023] Figure 4 This is a diagram showing the process of forming an object in a three-dimensional forming device.

[0024] Figure 5 It is a three-dimensional image of a shape.

[0025] Figure 6 It is a cross-sectional view of the object.

[0026] Figure 7 It is a cross-sectional view of the object.

[0027] Figure 8 It is a diagram showing light quantity distribution and the like when a pattern is drawn in a three-dimensional shaping apparatus according to a comparative example.

[0028] Fig. 9 This is a diagram showing light quantity distribution and the like when a pattern is drawn in a three-dimensional object creation apparatus using the first correction method.

[0029] Fig.10 It is a diagram showing light amount distribution and the like when a pattern is drawn in a three-dimensional object forming apparatus using the second correction method.

[0030] Fig.11 It is a three-dimensional image of a shape.

[0031] Fig.12 It is a cross-sectional view of the object.

[0032] Fig.13 It is a diagram showing light quantity distribution and the like when a pattern is drawn in a three-dimensional object forming apparatus using the third correction method.

[0033] Fig.14 It is a diagram showing light amount distribution and the like when a pattern is drawn in a three-dimensional object forming apparatus using the fourth correction method.

[0034] Fig.15 It is a three-dimensional image of a shape.

[0035] Fig.16 It is a longitudinal cross-sectional view of the object.

[0036] Fig.17 It is a diagram showing light amount distribution and the like when a pattern is drawn in a three-dimensional shape forming apparatus using the fifth correction method.

[0037] Fig.18 It is a diagram showing light amount distribution and the like when a pattern is drawn in a three-dimensional shape forming apparatus using the sixth correction method. DETAILED DESCRIPTION

[0038] Figure 1It is a diagram showing the structure of a three-dimensional modeling apparatus 1 according to one embodiment of the present invention. Figure 1 The illustrated three-dimensional shaping device 1 is a SLS (Selective Laser Sintering) type three-dimensional shaping device, which performs three-dimensional shaping by irradiating a powdered shaping material with a modulated laser beam to melt the shaping material and then solidify it. The shaping material is, for example, resin, metal, engineering plastic or ceramic. The shaping material can include a variety of materials. In this embodiment, the shaping material is a powdered synthetic resin.

[0039] The three-dimensional shaping apparatus 1 includes an optical head 2, a material holding unit 3, a temperature measuring unit 4, and a control unit 5. The material holding unit 3 is disposed below the optical head 2 and holds a powdered shaping material 91. Figure 1 In FIG. 1 , the material holding portion 3 is represented by a longitudinal section, and the forming material 91 is marked with parallel oblique lines. The optical head 2 modulates a laser beam on the forming material 91 held by the material holding portion 3 and scans it. The light irradiated from the optical head 2 to the forming material 91 is a multi-spot beam consisting of a plurality of light spots arranged in a straight line along a predetermined arrangement direction. The temperature measuring portion 4 measures the temperature of the forming material 91 held in the material holding portion 3. The control portion 5 controls the optical head 2, the material holding portion 3, and the temperature measuring portion 4.

[0040] The material holding portion 3 has a shaping portion 31 and a material supply portion 32. The shaping portion 31 has a first cylinder 33 and a first piston 34. The first cylinder 33 is a tubular member extending in the up-down direction. The shape of the internal space of the first cylinder 33 when viewed from above is, for example, roughly rectangular. The first piston 34 is a member accommodated in the internal space of the first cylinder 33. The first piston 34 can move in the up-down direction in the internal space of the first cylinder 33. The first piston 34 has a roughly flat-plate-shaped mounting platform 341 that is roughly perpendicular to the up-down direction and a support column 342 that supports the mounting platform 341 from below. The shape of the mounting platform 341 when viewed from above is roughly the same as the shape of the internal space of the first cylinder 33 when viewed from above.

[0041] In the shaping section 31, a three-dimensional space surrounded by the inner side surface of the first cylinder 33 and the upper surface of the mounting table 341 is a shaping space 30 for performing three-dimensional shaping. In the shaping space 30, a powdered shaping material 91 is held on the mounting table 341. That is, the three-dimensional shaping apparatus 1 is a powder bed type three-dimensional shaping apparatus.

[0042] The forming section 31 includes a heater 35 for heating the forming material 91 on the mounting table 341. The heater 35 applies energy to the forming material 91 on the mounting table 341 substantially uniformly, thereby raising the temperature of the forming material 91 to a temperature lower than the melting point and maintaining the temperature. Figure 1In the example shown, the heater 35 includes a first heater 351 and a second heater 352. The first heater 351 is a substantially flat electric heater provided on the upper portion of the mounting table 341. The first heater 351 is, for example, built into the mounting table 341 and provided to cover substantially the entire surface of the mounting table 341 in a plan view. The second heater 352 is a halogen lamp which is separately arranged above the mounting table 341 and irradiates light toward the mounting table 341. The structure and arrangement of the heater 35 are not limited to the above-described structure and arrangement, and various modifications may be made.

[0043] The material supply unit 32 includes a second cylinder 35, a second piston 36, and a scraper 37. The second cylinder 35 is a tubular member extending in the up-down direction, and is disposed adjacent to the side of the first cylinder 33. The shape of the internal space of the second cylinder 35 when viewed from above is, for example, substantially rectangular. The second piston 36 is a member accommodated in the internal space of the second cylinder 35. The second piston 36 can move in the up-down direction in the internal space of the second cylinder 35. The shape of the second piston 36 when viewed from above is substantially the same as the internal space of the second cylinder 35.

[0044] In the material supply section 32, a three-dimensional space surrounded by the inner side surface of the second cylinder 35 and the upper surface of the second piston 36 serves as a storage space for storing a predetermined molding material 91 to be supplied to the molding section 31. The scraper 37 is a rod-shaped (e.g., substantially cylindrical) or plate-shaped member that crosses the upper opening of the second cylinder 35 and extends in the horizontal direction. The scraper 37 can move in the horizontal direction along the upper end surface of the second cylinder 35.

[0045] In the material holding section 3, when the forming material 91 is supplied onto the mounting table 341, the first piston 34 of the forming section 31 descends a predetermined distance. As a result, the upper surface of the forming material 91 on the mounting table 341 is located at a position lower than the upper end surface of the first cylinder 33. On the other hand, in the material supply section 32, the second piston 36 ascends a predetermined distance, and the forming material 91 in the second cylinder 35 is lifted upward. In addition, the scraper 37 moves from the second cylinder 35 to the first cylinder 33, and thereby the forming material 91 protruding upward from the upper end surface of the second cylinder 35 is supplied to the forming space 30 of the forming section 31. The upper surface of the forming material 91 held in the forming space 30 is located at a height substantially the same as the upper end surface of the first cylinder 33.

[0046] The optical head 2 includes a laser light source 21, an illumination optical system 221, a light modulator 222, a first projection optical system 223, a scanning unit 23, and a second projection optical system 224. The laser light source 21 emits a laser beam to the optical device 22. The laser light source 21 is, for example, a fiber laser light source. In addition, the type of the laser light source 21 can be changed in various ways. In addition, the wavelength of the laser beam emitted from the laser light source 21 is appropriately set to match the type of the forming material 91.

[0047] The illumination optical system 221, the light modulator 222, and the first projection optical system 223 modulate the laser beam from the laser light source 21 into a modulated beam and irradiate the modulated beam to the scanning unit 23. The second projection optical system 224 guides the multi-spot beam from the scanning unit 23 to the forming material 91 on the mounting table 341. The illumination optical system 221, the first projection optical system 223, and the second projection optical system 224 each have an optical element such as a plurality of lenses.

[0048] The illumination optical system 221, for example, shapes the laser beam from the laser light source 21 into a roughly rectangular shaped beam that is longer in one direction (hereinafter referred to as the "long axis direction") and guides it to the light modulator 222. In other words, the cross-sectional shape of the shaped beam is a roughly rectangular shape that is long in the long axis direction and short in the short axis direction perpendicular to the long axis direction. The long axis direction and the short axis direction are directions perpendicular to the direction of travel of the shaped beam (i.e., the optical axis direction). In addition, the cross-sectional shape of the shaped beam refers to the shape of the shaped beam in a plane perpendicular to the direction of travel of the shaped beam. The cross-sectional shape of the shaped beam can also be understood as a roughly straight line extending along the long axis direction.

[0049] The light modulator 222 modulates the shaped light beam from the illumination optical system 221 into a modulated light beam and guides it to the projection optical system 223. As the light modulator 222, for example, a type of PLV (Planar Light Valve), namely, LPLV (Liner Planar Light Valve) is used. The modulated light beam is a multi-point light beam consisting of a plurality of light points arranged in a straight line along the long axis direction. Grayscale adjustment (i.e., adjustment of the light intensity of the outgoing light) can be performed in each light point of the multi-point light beam. In addition, the light modulator 222 does not necessarily need to be an LPLV, and may have other structures.

[0050] The scanning unit 23 reflects the modulated light beam (i.e., the multi-spot light beam) from the first projection optical system 223, and scans the forming material 91 in the forming space 30 of the material holding unit 3 via the second projection optical system 224. The scanning unit 23 includes, for example, a relay lens 231 and a galvo scanner 232. The galvo scanner 232 is a scanning mechanism including a galvo mirror 233 and a galvo motor (not shown). In the scanning unit 23, the galvo mirror 233 is rotated by the galvo motor, thereby changing the traveling direction of the multi-spot light beam reflected by the galvo mirror 233. As a result, the multi-spot light beam irradiated onto the forming material 91 is scanned in a scanning direction inclined relative to the long axis direction of the multi-spot light beam (e.g., perpendicular to the long axis direction).

[0051] exist Figure 1In the example shown, the left-right direction in the figure is the above-mentioned scanning direction parallel to the mounting table 341. Figure 1 The direction perpendicular to the paper surface is the width direction (ie, the arrangement direction of the plurality of light spots in the multi-spot light beam) perpendicular to the scanning direction and parallel to the mounting table 341. In addition, the scanning unit 23 does not necessarily need to have a galvanometer scanner, and may have other structures.

[0052] The temperature measuring unit 4 measures the temperature distribution of the upper surface of the forming material 91 on the mounting table 341. The temperature measuring unit 4 is, for example, an infrared thermal imaging camera that can capture substantially the entire upper surface of the forming material 91 on the mounting table 341. The measurement result (for example, a captured image) of the temperature measuring unit 4 is transmitted to the control unit 5.

[0053] Figure 2 : is a diagram showing the structure of the control unit 5. The control unit 5 is a general computer having a processor 51, a memory 52, an input / output unit 53, and a bus 54. The bus 54 is a signal circuit connecting the processor 51, the memory 52, and the input / output unit 53. The memory 52 stores various information. The memory 52 reads out and stores, for example, a program product, i.e., a program 59, which is pre-stored in a storage medium 50. The storage medium 50 is, for example, a USB memory or a CD-ROM. The processor 51 performs various processes (for example, numerical calculations) using the memory 52, etc., according to the above-mentioned program 59, etc. stored in the memory 52. ​​The input / output unit 53 has: a keyboard 55 and a mouse 56 for accepting inputs from an operator, and a display 57 for displaying outputs from the processor 51, etc. The input / output unit 53 also has a sending unit 58 for sending outputs from the processor 51, etc.

[0054] Figure 3 5 is a block diagram showing functions realized by the control unit 5 executing the above-mentioned program 59. As functions realized by the control unit 5, the three-dimensional modeling device 1 has a storage unit 501, a correction unit 502, and a drawing control unit 503. The storage unit 501 is mainly realized by the memory 52, and stores design data of the modeling object formed by the three-dimensional modeling device 1 and the temperature distribution of the modeling material 91 measured by the temperature measuring unit 4. The correction unit 502 and the drawing control unit 503 are mainly realized by the processor 51. The correction unit 502 corrects the design data of the modeling object. The drawing control unit 503 controls the material holding unit 3 and the optical head 2, etc.

[0055] Next, refer to Figure 4The formation process of the object in the three-dimensional modeling device 1 is described. In the three-dimensional modeling device 1, first, the design data for forming a predetermined three-dimensional object is stored in the storage unit 501 of the control unit 5 (step S11). The design data is a set of data (hereinafter also referred to as "cross-sectional data") representing the cross section obtained by slicing the object in the vertical direction at a predetermined thickness. The cross-sectional data is data representing the shape of a part equivalent to one layer when the object is divided into a plurality of layers stacked in the vertical direction.

[0056] Next, the correction unit 502 corrects the design data to generate drawing data (step S12). The drawing data generated in step S12 is stored in the storage unit 501. The correction of the design data in step S12 will be described in detail later.

[0057] Next, the material holding unit 3 is controlled by the drawing control unit 503, thereby supplying the powdered forming material 91 to the mounting table 341 (step S13). The forming material 91 on the mounting table 341 is preheated by the heater 35 and is heated to a temperature lower than the melting point of the forming material 91 and higher than the crystallization point (i.e., crystallization temperature) of the forming material 91. For example, in the case of using a resin powder with a melting point of 185°C and a crystallization point of 150°C as the forming material 91, the temperature of the forming material 91 on the mounting table 341 is maintained at a temperature higher than 150°C and lower than 185°C (for example, about 173°C). As a result, the forming material 91 on the mounting table 341 is maintained in a powder state without melting. In addition, the molten forming material 91 on the mounting table 341 is maintained in a molten state without solidifying.

[0058] Then, the optical head 2 is controlled by the drawing control unit 503, so that the multi-spot light beam is modulated using the drawing data and scanned in the scanning direction in the surface layer of the forming material 91 supplied to the mounting table 341 (hereinafter, also referred to as the "drawing target layer 92") (step S14). As a result, the temperature of the forming material 91 in the area irradiated with light in the drawing target layer 92 rises to a forming temperature above the melting point (for example, about 220°C), and the forming material 91 in the area melts, and a pattern (that is, a pattern composed of the melted forming material 91) is drawn on the drawing target layer 92.

[0059] In addition, the pattern depiction in step S14 can be performed by a single-pass depiction in which the multi-point light beam scans only once in the scanning direction, or by a multi-pass depiction in which the multi-point light beam repeatedly scans in the scanning direction and steps in the width direction (i.e., the sub-scanning direction).

[0060] In the drawing target layer 92, heat is diffused from the forming material 91 melted in the region irradiated with light to the forming material 91 around the region. As a result, the temperature of the forming material 91 in the region irradiated with light decreases, but the temperature of the forming material 91 in the drawing target layer 92 is maintained at a temperature higher than the crystallization point by the heater 35, so that the forming material 91 in the region is maintained in a molten state.

[0061] When the pattern drawing of the drawing target layer 92 is completed, it is confirmed whether the formation of the object is completed (step S15). If the formation of the object is not completed, the process returns to step S13, and a new drawing target layer 92 is formed by supplying a new forming material 91 on the layer of the forming material 91 on which the pattern is drawn on the mounting table 341 (step S13). Then, a multi-spot light beam is scanned on the new drawing target layer 92 to draw the pattern of the molten forming material 91 (step S14).

[0062] As described above, in the pattern drawn in step S14, the forming material 91 is maintained in a molten state, and in the pattern drawn in the previous step S14, the forming material 91 is also maintained in a molten state. In this way, in the three-dimensional forming apparatus 1, the forming material 91 in a molten state is stacked, so that when solidified, a forming object with a high bonding force in the stacking direction (i.e., the vertical direction) is formed.

[0063] In the three-dimensional shaping device 1, steps S13 and S14 are repeated until the formation of the shaping object is completed. During the repetition of steps S13 and S14, the heating of the shaping material 91 by the heater 35 continues, and when the repetition of steps S13 and S14 ends, the heating of the shaping material 91 by the heater 35 also ends. Thus, the shaping material 91 maintained in a molten state in the above-mentioned pattern is cooled to below the crystallization point and solidified, and a three-dimensional shaping object composed of the solidified shaping material 91 is formed.

[0064] Next, the formation of the object in the three-dimensional modeling apparatus 1 and the formation of the object in the three-dimensional modeling apparatus of the comparative example are compared, and the correction of the design data in the above-mentioned step S12 is described. The three-dimensional modeling apparatus of the comparative example has a structure substantially the same as that of the three-dimensional modeling apparatus 1, but when forming the object, the correction of the design data in step S12 is not performed. That is, in the three-dimensional modeling apparatus of the comparative example, in step S14, the drawing of the drawing target layer 92 is performed using the uncorrected design data.

[0065] Figure 53D diagrams showing a predetermined object 81 formed by the three-dimensional forming apparatus 1 and the three-dimensional forming apparatus of the comparative example. The object 81 is substantially rectangular, and a first groove 811 and a second groove 812 are provided on the upper surface of the object 81. The first groove 811 and the second groove 812 are substantially linear grooves extending parallel to the above-mentioned scanning direction, and are provided to cover the entire length of the object 81 in the scanning direction. The depths of the first groove 811 and the second groove 812 are the same, and are smaller than the height of the object 81. The width direction of the first groove 811 is smaller than the width direction of the second groove 812.

[0066] Figure 6 Yes means Figure 5 FIG. 8 is a diagram of a cross section 813 of the structure 81 at the position of VI-VI. Figure 7 Yes means Figure 5 FIG. 814 is a diagram of a cross section 814 of a structure 81 at the position VII-VII in FIG. The cross-sectional data corresponding to the cross sections 813 and 814 are included in the above-mentioned design data (i.e., the design data before correction). In the cross section 813, the entire rectangular area corresponding to the structure 81 is the drawing area 815 indicated to be drawn in the design data. Figure 6 In FIG. 8 , the drawing area 815 is marked with parallel oblique lines.

[0067] In the cross section 814, the rectangular bands corresponding to the first groove 811 and the second groove 812 in the rectangular area directly above the drawing area 815 in the cross section 813 are non-drawing areas 816 and 817 that are not indicated for drawing in the design data. In addition, the rectangular area on the left side of the non-drawing area 816, the rectangular area between the non-drawing area 816 and the non-drawing area 817, and the rectangular area on the right side of the non-drawing area 817 are drawing areas 815a, 815b, and 815c that are indicated for drawing in the design data. Figure 7 In FIG. 8 , parallel oblique lines are marked on the drawing areas 815 a , 815 b , and 815 c .

[0068] exist Figure 7 In the example shown, the size of the non-drawing area 816 corresponding to the first groove 811 in the width direction (i.e., the left-right direction in the figure) is less than a predetermined correction threshold. In addition, the size of the non-drawing area 817 corresponding to the second groove 812 in the width direction is greater than the correction threshold (i.e., the correction threshold in the width direction). In the following description, the non-drawing area 816 is also referred to as a "narrow non-drawing area 816". That is, in Figure 7 In the example shown, the non-drawing areas 816 and 817 include a small non-drawing area 816 .

[0069] Figure 8814 is a diagram showing the light quantity distribution when a pattern corresponding to the cross section 814 is drawn in the three-dimensional shaping device of the comparative example. Figure 8 The figure marked with the symbol (a) (hereinafter also referred to as Figure 8 (a) is a diagram showing a pattern on the design data (ie, a design pattern) in the cross section 814. Figure 8 (b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated onto the image forming target layer 92 . Figure 8 In (b), the horizontal axis represents the width direction, and the vertical axis represents the light amount. Figure 8 (c) indicates that the irradiated Figure 8 (b) is a diagram showing the temperature distribution in the drawing target layer 92 of the multi-spot light beam having the light quantity distribution shown. Figure 8 In (c), the horizontal axis represents the width direction, and the vertical axis represents the temperature of the forming material 91 in the drawing target layer 92 . Figure 8 (d) is a diagram showing an actually drawn pattern (ie, a drawing pattern) in the cross section 814 .

[0070] In the three-dimensional modeling apparatus of the comparative example, as described above, no correction is performed on the design data. Figure 8 As shown in (b), the areas with the same width as the design pattern drawing areas 815a, 815b, 815c are set as ON (activated) areas 711a, 711b, 711c where the points of the multi-point light beam are lit. In addition, the areas with the same width as the design pattern non-drawing areas 816, 817 are set as OFF (inactivated) areas 712, 713 where the points of the multi-point light beam are extinguished. Figure 8 As shown by the solid line in (c), in the ON regions 711a, 711b, and 711c, the temperature of the forming material 91 in the drawing object layer 92 rises to a predetermined forming temperature (eg, 220°C) higher than the melting point (eg, 185°C) of the forming material 91.

[0071] like Figure 8 As shown in (b), the light quantity distribution in the ON region 711a is a roughly rectangular distribution. In addition, the light quantity does not suddenly become 0 outside the end portion in the width direction of the ON region 711a, but gradually decreases as it moves away from the ON region 711a. In the following description, the light quantity generated outside the end portion in the width direction of the ON region 711a due to the light in the light spot of the ON region 711a is also referred to as "end light quantity". The same is true for the ON regions 711b and 711c.

[0072] In the OFF region 713 corresponding to the non-drawing region 817 having a relatively large width direction, the light quantity at both ends in the width direction is slightly increased by the light quantity at the ends of the adjacent ON regions 711b and 711c on both sides. In addition, in the OFF region 713, heat diffusion also occurs from the ON regions 711b and 711c. Therefore, Figure 8 As shown by the solid line in (c), the temperature of the forming material 91 in the OFF region 713 is slightly higher than the preheating temperature (eg, 173° C.).

[0073] On the other hand, in the OFF area 712 corresponding to the narrow non-drawing area 816 having a smaller size in the width direction, as shown in FIG. Figure 8 As shown in (b), the light quantity is accumulated at the ends of the adjacent ON areas 711a and 711b on both sides, so the light quantity is greater than that of the OFF area 713 corresponding to the non-drawing area 817. In addition, in the OFF area 712, the heat diffused from the ON areas 711a and 711b is also superimposed. Figure 8 As indicated by the solid line in (c), the temperature of the forming material 91 in the OFF region 712 is higher than the temperature of the forming material 91 in the OFF region 713 .

[0074] Then, due to the heat diffusion from the ON regions 711a, 711b, and 711c over time, Figure 8 As shown by the double-dashed line in (c), the temperature of the forming material 91 in the ON regions 711a, 711b, and 711c decreases, while the temperature of the forming material 91 in the OFF regions 712 and 713 increases. As a result, the temperature of the forming material 91 in the OFF region 712 becomes higher than the melting point (e.g., 185°C), and the forming material 91 may melt in the OFF region 712 unintentionally. As a result, Figure 8 As shown in (d), in the actual drawing pattern, the narrow non-drawing area 816 disappears between the drawing area 815a and the drawing area 815b, or the width of the narrow non-drawing area 816 is smaller than the designed value. In addition, the temperature of the forming material 91 in the OFF area 713 does not rise to the melting point, so the forming material 91 does not melt in the OFF area 713. Therefore, the non-drawing area 817 exists between the drawing area 815b and the drawing area 815c.

[0075] On the other hand, in the three-dimensional modeling apparatus 1 of the present embodiment, in the above-mentioned step S12, the correction unit 502 (see Figure 3 ) performs design data correction to generate drawing data, and adjusts the drawing target layer 92 (refer to Figure 1 ) to distribute the light intensity of the multi-point light beams irradiated, thereby suppressing the unintended melting of the forming material 91.

[0076] Fig. 9 It is a diagram showing light quantity distribution and the like when a pattern corresponding to the cross section 814 is drawn in the three-dimensional shaping apparatus 1 . Fig. 9 (a) is a diagram showing a pattern on the design data in the cross section 814 (ie, a design pattern), and Figure 8 The same as shown in (a). Fig. 9 (b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated onto the image forming target layer 92 . Fig. 9 In (b), the horizontal axis represents the width direction, and the vertical axis represents the light amount. Fig. 9 (c) indicates that the irradiated Fig. 9 (b) is a diagram showing the temperature distribution in the drawing target layer 92 of the multi-spot light beam having the light quantity distribution shown. Fig. 9 In (c), the horizontal axis represents the width direction, and the vertical axis represents the temperature of the forming material 91 in the drawing target layer 92 . Fig. 9 (d) is a diagram showing an actually drawn pattern (ie, a drawing pattern) in the cross section 814 .

[0077] In the three-dimensional modeling apparatus 1, the design data is corrected by the correction unit 502, such as Fig. 9 As shown in (b), the width of the OFF area 715 corresponding to the narrow non-drawing area 816 is greater than Figure 8 The width of the OFF area 712 shown in (b) is larger in the width direction (i.e., the width of the narrow non-drawing area 816 in the design pattern). Specifically, the boundary between the ON area 714a corresponding to the drawing area 815a of the design pattern and the OFF area 715 is larger than that of the ON area 714a corresponding to the drawing area 815a of the design pattern. Figure 8 The boundary between the ON area 711a and the OFF area 712 shown in (b) is moved to the left. The boundary between the ON area 714b and the OFF area 715 corresponding to the drawing area 815b of the design pattern is smaller than that of the ON area 714b and the OFF area 715. Figure 8 The boundary between the ON region 711b and the OFF region 712 shown in (b) moves to the right.

[0078] That is, in the three-dimensional shaping device 1, the irradiation of light to the area adjacent to the narrow non-drawing area 816 in the drawing areas 815a and 815b (hereinafter also referred to as the "narrow portion adjacent area 818") is suppressed. In other words, the cumulative light amount per unit area in the narrow portion adjacent area 818 is lower than the cumulative light amount per unit area in the drawing areas 815a and 815b except for the narrow portion adjacent area 818. Fig. 9 In (a), each narrow portion adjacent region 818 is indicated by being surrounded by a two-dot chain line.

[0079] The above-mentioned correction of the light quantity distribution is achieved in the following manner: one or more light spots (hereinafter also referred to as "narrow non-drawing point group") among the multiple light spots of the multi-point light beam that pass through the narrow non-drawing area 816 are set to be inactive (hereinafter referred to as OFF) when located on the narrow non-drawing area 816, and two light spot groups adjacent to the narrow non-drawing point group on both sides in the width direction (hereinafter also referred to as "correction point group") are also set to OFF.

[0080] When the narrow non-drawing point group includes two or more light spots, the two or more light spots are arranged continuously in the arrangement direction of the plurality of light spots in the multi-spot light beam. Each calibration point group includes one or two or more light spots. When each calibration point group includes two or more light spots, the two or more light spots are arranged continuously in the above-mentioned arrangement direction. Preferably, the number of light spots included in each calibration point group increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller. In addition, there are no other light spots between each calibration point group and the narrow non-drawing point group.

[0081] In the three-dimensional modeling apparatus 1, the light quantity distribution of the multi-spot light beams irradiated to the image drawing target layer 92 is as follows: Fig. 9 The correction is performed as shown in (b), thereby suppressing the accumulation of light at the ends of the adjacent ON areas 714a and 714b on both sides in the OFF area 715 corresponding to the narrow non-drawing area 816. In addition, in the OFF area 715, the superposition of heat diffused from the ON areas 714a and 714b is also suppressed.

[0082] Therefore, the temperature of the forming material 91 in the OFF region 715 is as follows: Fig. 9 As shown in the solid line in (c), although it rises to a certain extent compared with the preheating temperature (for example, 173°C), there is no Figure 8 In addition, after the heat diffusion from the ON regions 714a and 714b occurs over time, as shown by the double-dashed line, the temperature of the forming material 91 in the widthwise central portion of the OFF region 715 is lower than the melting point (e.g., 185°C), and the temperature of the forming material 91 in the widthwise end portions of the OFF region 715 is higher than the melting point. Therefore, in the widthwise central portion of the OFF region 715, the temperature of the forming material 91 is higher than the melting point. Figure 8 Unlike the OFF region 712 shown in (c), the forming material 91 does not melt. On the other hand, the forming material 91 melts as intended at both ends in the width direction of the OFF region 715.

[0083] In the three-dimensional modeling device 1, the ON / OFF of the light points other than the above-mentioned calibration point group in the multi-point light beam (for example, ON / OFF in the OFF area 716 and the ON area 714c corresponding to the non-drawing area 817 and the drawing area 815c) is the same as that of the three-dimensional modeling device of the comparative example. Therefore, the melting of the modeling material 91 in the drawing areas 815a, 815b, and 815c is carried out according to the design data, and in the non-drawing area 817, the modeling material 91 is not melted according to the design data. As a result, Fig. 9 As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on the drawing target layer 92 with high accuracy.

[0084] In the three-dimensional modeling apparatus 1, the method for correcting the design data in step S12 is not limited to the above method (hereinafter also referred to as "first correction method"), and various changes can be made. The second correction method will be described below.

[0085] Fig.10 It is a diagram showing light quantity distribution and the like when a pattern corresponding to the cross section 814 is drawn in the three-dimensional object creation apparatus 1 using the second correction method. Fig.10 (a) is a diagram showing a pattern on the design data in the cross section 814 (ie, a design pattern), and Fig. 9 The same as shown in (a). Fig.10 (b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated to the drawing target layer 92 based on the drawing data generated by the second correction method. Fig.10 In (b), the horizontal axis represents the width direction, and the vertical axis represents the light amount. Fig.10 (c) indicates that the irradiated Fig.10 (b) is a diagram showing the temperature distribution in the drawing target layer 92 of the multi-spot light beam having the light quantity distribution shown. Fig.10 In (c), the horizontal axis represents the width direction, and the vertical axis represents the temperature of the forming material 91 in the drawing target layer 92 . Fig.10 (d) is a diagram showing an actually drawn pattern (ie, a drawing pattern) in the cross section 814 .

[0086] In the three-dimensional modeling apparatus 1 using the second correction method, the correction unit 502 performs correction of the design data, such as Fig.10As shown in (b), on both sides of the width direction of the OFF region 718 corresponding to the narrow non-drawing region 816, the boundary between the ON regions 717a, 717b corresponding to the drawing regions 815a, 815b of the design pattern and the OFF region 718 is tapered. Specifically, the amount of light at the end of the OFF region 718 side in the ON region 717a gradually decreases as it approaches the OFF region 718. In addition, the amount of light at the end of the OFF region 718 side in the ON region 717b gradually decreases as it approaches the OFF region 718. The width of the OFF region 718 (i.e., Fig.10 The width of the area where the light intensity does not change significantly around 0 in (b) is Figure 8 The width of the OFF region 718 shown in (b) is the same as that of the OFF region 712 (ie, the width of the narrow non-drawing region 816 in the design pattern). In addition, the width of the OFF region 718 may be larger than the width of the OFF region 712 or smaller than the width of the OFF region 712.

[0087] That is, in the three-dimensional modeling apparatus 1 using the second correction method, the irradiation of light to the narrow portion adjacent region 818 in the drawing areas 815a and 815b is suppressed in a similar manner to the three-dimensional modeling apparatus 1 using the first correction method. In other words, the accumulated light amount per unit area in the narrow portion adjacent region 818 is lower than the accumulated light amount per unit area in the drawing areas 815a and 815b except for the narrow portion adjacent region 818. Fig.10 In (a), each narrow portion adjacent region 818 is indicated by being surrounded by a two-dot chain line.

[0088] The above-mentioned correction of the light quantity distribution is achieved in the following manner: a narrow non-drawing point group among the multiple light spots of the multi-point light beam is set to OFF when located on the narrow non-drawing area 816, and in two correction point groups adjacent to each other on both sides of the width direction of the narrow non-drawing point group, the light intensity of the two or more light spots contained in each correction point group is adjusted to increase as it moves away from the narrow non-drawing point group along the above-mentioned arrangement direction.

[0089] In the case where the narrow non-drawing point group includes more than two light spots, the two or more light spots are arranged continuously in the above-mentioned arrangement direction. Each correction point group includes more than two light spots arranged continuously in the arrangement direction. In each correction point group, the light intensity of the light spot farthest from the narrow non-drawing point group in the width direction can be substantially the same as the light intensity of the light spot corresponding to the area other than the narrow portion adjacent area 818 in the drawing area 815a, 815b. Preferably, the number of light spots included in each correction point group increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller. As a result, the gradient of the light quantity distribution in the area corresponding to the narrow portion adjacent area 818 becomes gentle. In addition, there are no other light spots between each correction point group and the narrow non-drawing point group.

[0090] In the three-dimensional shaping apparatus 1 using the second correction method, Fig.10 The light quantity distribution of the multi-point light beam irradiated to the drawing object layer 92 is corrected as shown in (b), and in the OFF area 718 corresponding to the narrow non-drawing area 816, the light quantity accumulation at the ends of the ON areas 717a and 717b adjacent to each other on both sides in the width direction is suppressed. In addition, in the OFF area 718, the heat superposition diffused from the ON areas 717a and 717b is also suppressed. Therefore, Fig.10 As shown by the solid line in (c), although the temperature of the forming material 91 in the OFF region 718 rises to a certain extent from the preheating temperature (e.g., 173°C), it does not rise to the melting point (e.g., 185°C) of the forming material 91 as shown by the double-dashed line after heat diffusion occurs from the ON regions 717a and 717b over time. Figure 8 Unlike the OFF region 712 shown in (c), the forming material 91 does not melt. In addition, even if the forming material 91 melts to some extent in the OFF region 718, it is still different from the OFF region 718 shown in (c). Figure 8 The melting of the forming material 91 in the OFF region 712 shown in (c) is also suppressed. On the other hand, in the regions of the ON regions 717a and 717b adjacent to the OFF region 718, the melting of the forming material 91 occurs as intended.

[0091] In the three-dimensional modeling apparatus 1 using the second calibration method, the ON / OFF of the light points other than the above-mentioned calibration point group in the multi-point light beam (for example, ON / OFF in the OFF area 719 and the ON area 717c corresponding to the non-drawing area 817 and the drawing area 815c) is the same as that of the three-dimensional modeling apparatus 1 using the first calibration method. Therefore, the melting of the modeling material 91 in the drawing areas 815a, 815b, and 815c is performed according to the design data, and in the non-drawing area 817, the modeling material 91 is not melted according to the design data. As a result, Fig.10As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on the drawing target layer 92 with high accuracy.

[0092] Next, the third and fourth correction methods used in step S12 are described. Fig.11 1 is a three-dimensional diagram showing a predetermined object 82 formed by the three-dimensional forming apparatus 1 using the third and fourth correction methods. The object 82 is substantially rectangular, and a groove 821 is provided on the upper surface of the object 82. The groove 821 is a substantially linear groove extending parallel to the width direction, and is provided over the entire width direction of the object 82. The size of the groove 821 in the scanning direction is equal to Figure 5 The first grooves 811 shown have substantially the same size in the width direction.

[0093] Fig.12 Yes means Fig.11 FIG. 8 is a diagram of a cross section 824 of the object 82 at the position XII-XII in FIG. The cross-sectional data corresponding to the cross section 824 is included in the above-mentioned design data (i.e., the design data before correction). In the cross section 824, the rectangular band area corresponding to the groove 821 is a non-drawing area 826 that is not indicated to be drawn in the design data. Fig.12 In the example shown, the size of the non-drawing area 826 in the scanning direction is below a prescribed correction threshold, and in the following description, the non-drawing area 826 is also referred to as a "narrow non-drawing area 826". In addition, the correction threshold (i.e., the correction threshold in the scanning direction) may be the same as or different from the correction threshold in the width direction described above. In the cross section 824, the rectangular areas on both sides of the narrow non-drawing area 826 in the scanning direction are the drawing areas 825a and 825b indicated to be drawn in the design data. Fig.12 In FIG. 8 , parallel oblique lines are marked on the drawing areas 825a and 825b.

[0094] In the three-dimensional modeling device of the comparative example that does not perform design data correction, all the light points of the multi-point light beam are lit during the drawing of the drawing area 825a, and all the light points are extinguished only when the multi-point light beam is located in the narrow non-drawing area 826, and all the light points are lit again during the drawing of the drawing area 825b. Figure 8 The narrow non-drawing area 816 shown is substantially the same, and unintended melting of the forming material 91 may occur in the narrow non-drawing area 826 .

[0095] In contrast, in the three-dimensional modeling device 1 using the third and fourth correction methods, the correction unit 502 corrects the design data to generate drawing data, and adjusts the light intensity distribution of the multi-point light beam irradiated to the drawing object layer 92 according to the drawing data, thereby suppressing the unintended melting of the modeling material 91.

[0096] Fig.13 It is a diagram showing the light intensity distribution and the like when a pattern corresponding to the cross section 824 is drawn in the three-dimensional modeling apparatus 1 using the third correction method. Fig.13 (a) is a diagram showing a part of a pattern on design data (ie, a design pattern) in a cross section 824 . Fig.13 (b) is a graph showing the light amount distribution of the multi-spot light beams irradiated to the drawing target layer 92 based on the drawing data generated by the third correction method. Fig.13 In (b), the vertical axis represents the scanning direction, and the horizontal axis represents the light amount. Fig.13 (c) indicates that the irradiated Fig.13 (b) is a diagram showing the temperature distribution in the drawing target layer 92 of the multi-spot light beam having the light quantity distribution shown. Fig.13 In (c), the vertical axis represents the scanning direction, and the horizontal axis represents the temperature of the forming material 91 in the image forming target layer 92 . Fig.13 (d) is a diagram showing a portion of the actually drawn pattern (ie, the drawn pattern) in the cross section 824 .

[0097] In the three-dimensional modeling apparatus 1 using the third correction method, the correction unit 502 performs the correction of the design data, such as Fig.13 As shown in (b), the width of the OFF area 725 corresponding to the narrow non-drawing area 826 in the scanning direction is greater than Fig.13 Specifically, the width of the narrow non-drawing area 826 in the design pattern shown in (a) is larger in the scanning direction. Specifically, the boundary between the ON area 724a and the OFF area 725 corresponding to the drawing area 825a of the design pattern is wider than the boundary between the drawing area 825a and the narrow non-drawing area 826. Fig.13 In addition, the boundary between the ON area 724b and the OFF area 725 corresponding to the drawing area 825b of the design pattern is closer to the lower side (i.e., the front side in the scanning direction) than the boundary between the drawing area 825b and the small non-drawing area 826. Fig.13 Move to the upper side (i.e., the inner side in the scanning direction).

[0098] That is, in the three-dimensional modeling apparatus 1 using the third correction method, the irradiation of light to the area adjacent to the narrow non-drawing area 826 in the drawing areas 825a and 825b (hereinafter also referred to as the "correction area 828") is suppressed. In other words, the cumulative light amount per unit area in the correction area 828 is lower than the cumulative light amount per unit area in the drawing areas 825a and 825b other than the correction area 828. Fig.13 In (a), each correction region 828 is indicated by being surrounded by a two-dot chain line.

[0099] The above-mentioned correction of the light quantity distribution is achieved in the following manner: one or more light spots (hereinafter also referred to as "narrow non-drawing point group") among the multiple light spots of the multi-point light beam that pass through the narrow non-drawing area 826 are set to OFF when they are located on the narrow non-drawing area 826, and are also set to OFF when the narrow non-drawing point group is located on the correction area 828 adjacent to both sides of the narrow non-drawing area 826 in the scanning direction.

[0100] When the narrow non-drawing point group includes two or more light spots, the two or more light spots are arranged continuously in the arrangement direction of the plurality of light spots in the multi-point light beam. In addition, in the above example, the narrow non-drawing point group includes all the light spots of the multi-point light beam. In addition, the narrow non-drawing area 826 and each correction area 828 are continuous in the scanning direction, and there is no other area between the narrow non-drawing area 826 and each correction area 828 in the scanning direction. Preferably, the width of each correction area 828 in the scanning direction increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller.

[0101] In the three-dimensional shaping apparatus 1 using the third correction method, Fig.13 The light quantity distribution of the multi-spot light beam irradiated to the drawing target layer 92 is corrected as shown in (b) of FIG. 1 , and the light quantity accumulation at the ends of the adjacent ON regions 724a and 724b on both sides of the scanning direction is suppressed in the OFF region 725 corresponding to the narrow non-drawing region 826. In addition, the heat superposition diffused from the ON regions 724a and 724b is also suppressed in the OFF region 725. Therefore, as Fig.13 As shown by the solid line in (c), although the temperature of the forming material 91 in the OFF region 725 rises to a certain extent from the preheating temperature (e.g., 173°C), it does not rise as much as the temperature rise in the three-dimensional forming apparatus of the comparative example. In addition, after the heat diffusion from the ON regions 724a and 724b occurs over time, as shown by the double-dashed lines, the temperature of the forming material 91 in the central portion in the scanning direction of the OFF region 725 is lower than the melting point (e.g., 185°C), and the temperature of the forming material 91 in the two end portions in the scanning direction of the OFF region 725 is above the melting point. Therefore, in the central portion in the scanning direction of the OFF region 725, unlike the three-dimensional forming apparatus of the comparative example, the forming material 91 does not melt. On the other hand, at the two end portions in the scanning direction of the OFF region 725, the forming material 91 melts as intended.

[0102] In the three-dimensional shaping apparatus 1 using the third calibration method, the shaping material 91 in the drawing areas 825a and 825b is melted according to the design data. Fig.13 As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on the drawing target layer 92 with high accuracy.

[0103] Fig.14 It is a diagram showing light amount distribution and the like when a pattern corresponding to the cross section 824 is drawn in the three-dimensional object forming apparatus 1 using the fourth correction method. Fig.14 (a) is a diagram showing a portion of a pattern on the design data (ie, a design pattern) in the cross section 824, and Fig.13 The same as shown in (a). Fig.14 (b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated to the drawing target layer 92 based on the drawing data generated by the fourth correction method. Fig.14 In (b), the vertical axis represents the scanning direction, and the horizontal axis represents the light amount. Fig.14 (c) indicates that the irradiated Fig.14 (b) is a diagram showing the temperature distribution in the drawing target layer 92 of the multi-spot light beam having the light quantity distribution shown. Fig.14 In (c), the vertical axis represents the scanning direction, and the horizontal axis represents the temperature of the forming material 91 in the drawing target layer 92 . Fig.14 (d) is a diagram showing a portion of the actually drawn pattern (ie, the drawn pattern) in the cross section 824 .

[0104] In the three-dimensional modeling apparatus 1 using the fourth correction method, the correction unit 502 performs the correction of the design data, such as Fig.14 As shown in (b), on both sides of the width direction of the OFF area 728 corresponding to the narrow non-drawing area 826, the boundary between the ON areas 727a, 727b corresponding to the drawing areas 825a, 825b of the design pattern and the OFF area 728 is tapered. Specifically, the amount of light at the end of the ON area 727a on the OFF area 728 side gradually decreases as it approaches the OFF area 728. In addition, the amount of light at the end of the ON area 727b on the OFF area 728 side gradually decreases as it approaches the OFF area 728. The width of the OFF area 728 is the same as the width of the narrow non-drawing area 826 in the design pattern. In addition, the width of the OFF area 728 may be larger than the width of the narrow non-drawing area 826, or may be smaller than the width of the narrow non-drawing area 826.

[0105] That is, in the three-dimensional modeling apparatus 1 using the fourth correction method, the irradiation of light to the correction area 828 in the drawing areas 825a and 825b is suppressed in a similar manner to the three-dimensional modeling apparatus 1 using the third correction method. In other words, the cumulative light amount per unit area in the correction area 828 is lower than the cumulative light amount per unit area in the drawing areas 825a and 825b other than the correction area 828. Fig.14In (a), each correction area 828 is surrounded by a two-dot chain line. Each correction area 828 corresponds to two or more light spots of the multi-spot light beam. The cumulative light amount per unit area of ​​the light spot farthest from the narrow non-drawing area 826 in the scanning direction among the two or more light spots of the correction area 828 can be substantially the same as the cumulative light amount per unit area in the drawing areas 825a and 825b other than the correction area 828.

[0106] The above-mentioned correction of the light quantity distribution is achieved in the following manner: the narrow non-drawing point group among the multiple light spots of the multi-point light beam is set to OFF when located on the narrow non-drawing area 826, and when located on the correction area 828, the light intensity of each light spot in the narrow non-drawing point group is adjusted to increase as it moves away from the narrow non-drawing area 826 along the scanning direction.

[0107] In the case where the narrow non-drawing point group includes more than two light spots, the two or more light spots are continuously arranged in the arrangement direction of the plurality of light spots in the multi-point light beam. In addition, in the above example, the narrow non-drawing point group includes all the light spots of the multi-point light beam. In addition, the narrow non-drawing area 826 is continuous with each correction area 828 in the scanning direction, and there is no other area between the narrow non-drawing area 826 and each correction area 828 in the scanning direction. Preferably, the width of each correction area 828 in the scanning direction increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller. As a result, the gradient of the light quantity distribution in the correction area 828 becomes gentle.

[0108] In the three-dimensional shaping apparatus 1 using the fourth correction method, as Fig.14 By correcting the light quantity distribution of the multi-spot light beams irradiated to the drawing target layer 92 as shown in (b), in the OFF area 728 corresponding to the narrow non-drawing area 826, the light quantity accumulation at the ends of the adjacent ON areas 727a and 727b on both sides of the scanning direction is suppressed. In addition, in the OFF area 728, the heat superposition diffused from the ON areas 727a and 727b is also suppressed. Therefore, Fig.14As shown by the solid line in (c), although the temperature of the forming material 91 in the OFF region 728 rises to a certain extent compared to the preheating temperature (e.g., 173°C), after the heat diffusion from the ON regions 727a and 727b occurs over time, it does not rise to the melting point (e.g., 185°C) of the forming material 91 as shown by the double-dashed line. Therefore, in the OFF region 728, unlike the three-dimensional forming apparatus of the comparative example, the forming material 91 does not melt. In addition, even if the forming material 91 melts to some extent in the OFF region 728, it is suppressed compared to the melting of the forming material 91 in the three-dimensional forming apparatus of the comparative example. On the other hand, in the region of the ON regions 727a and 727b adjacent to the OFF region 728, the forming material 91 melts as intended.

[0109] In the three-dimensional shaping apparatus 1 using the fourth correction method, the shaping material 91 in the drawing areas 825a and 825b is melted according to the design data in substantially the same manner as in the three-dimensional shaping apparatus 1 using the third correction method. Fig.14 As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on the drawing target layer 92 with high accuracy.

[0110] Next, the fifth and sixth correction methods used in step S12 are described. Fig.15 1 is a three-dimensional diagram showing a predetermined object 83 formed by the three-dimensional forming apparatus 1 using the fifth and sixth correction methods. The object 83 is substantially rectangular, and a groove 831 is provided on the left side of the object 83. The groove 831 is a substantially linear groove extending parallel to the above-mentioned scanning direction, and is provided to cover the entire length of the object 83 in the scanning direction. The size of the groove 831 in the vertical direction is Figure 5 The first grooves 811 shown have substantially the same size in the width direction. The size of the groove 831 in the width direction is larger than the size of the groove 831 in the vertical direction.

[0111] Fig.16 Yes means Fig.15 FIG. 8 is a diagram of a longitudinal section 834 of a structure 83 at a position XVI-XVI in FIG. In the longitudinal section 834, a rectangular band-shaped area corresponding to the groove 831 is a non-drawing area 836 that is not indicated to be drawn in the design data. Fig.16In the example shown, the size of the non-drawing area 836 in the up-down direction is below a prescribed correction threshold, and in the following description, the non-drawing area 836 is also referred to as a "narrow non-drawing area 836". In addition, the correction threshold (i.e., the correction threshold in the up-down direction) may be the same as or different from the correction threshold in the scanning direction and the correction threshold in the width direction described above. In the longitudinal section 834, the rectangular areas on both sides of the narrow non-drawing area 836 in the up-down direction are the drawing areas 835a and 835b indicated for drawing in the design data. Fig.16 In FIG. 8 , parallel oblique lines are marked on the drawing areas 835a and 835b.

[0112] In the three-dimensional modeling apparatus of the comparative example that does not perform correction of the design data, the light spot for drawing the longitudinal section 834 among the above-mentioned multi-spot light beams is lit during drawing of the drawing target layer 92 corresponding to the drawing area 835a, extinguished during drawing of the drawing target layer 92 corresponding to the narrow non-drawing area 836, and lit again during drawing of the drawing target layer 92 corresponding to the drawing area 835b. Therefore, when the area just above the narrow non-drawing area 836 in the drawing area 835b is drawn, the unintended melting of the modeling material 91 may occur in the narrow non-drawing area 836 due to heat or the like diffused downward from the area just above.

[0113] In contrast, in the three-dimensional modeling device 1 using the fifth and sixth correction methods, the correction unit 502 performs design data correction to generate drawing data, and adjusts the light intensity distribution of the multi-point light beam irradiated to the drawing object layer 92 based on the drawing data, thereby suppressing the unintended melting of the modeling material 91.

[0114] Fig.17 It is a diagram showing light amount distribution and the like when rendering corresponding to the longitudinal section 834 is performed in the three-dimensional object shaping apparatus 1 using the fifth correction method. Fig.17 (a) is a diagram showing a pattern on the design data (ie, a design pattern) in the vertical section 834 . Fig.17 (b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated onto each drawing target layer 92 in the vertical section 834 based on the drawing data generated by the fifth correction method. Fig.17 In (b), the vertical axis represents the up and down direction, and the horizontal axis represents the light amount. Fig.17 (c) is a diagram showing temperature distribution in a plurality of drawing target layers 92 corresponding to the longitudinal section 834 . Fig.17 In (c), the vertical axis represents the up-down direction, and the horizontal axis represents the temperature of the forming material 91 in each drawing target layer 92 . Fig.17 (d) is a diagram showing an actual drawn pattern (ie, a drawn pattern) in the longitudinal section 834 .

[0115] In the three-dimensional modeling apparatus 1 using the fifth correction method, the correction of the design data performed by the correction unit 502 is as follows: Fig.17 As shown in (b), the width of the OFF area 735 corresponding to the narrow non-drawing area 836 in the vertical direction is greater than Fig.17 Specifically, the width of the narrow non-drawing area 836 in the design pattern shown in (a) is larger in the vertical direction. Specifically, the boundary between the ON area 734b and the OFF area 735 corresponding to the drawing area 835b of the design pattern is wider than the boundary between the drawing area 835b and the narrow non-drawing area 836. Fig.17 In addition, the boundary between the ON area 734a and the OFF area 735 corresponding to the drawing area 835a and the boundary between the drawing area 835a and the small non-drawing area 836 are located at the same position in the vertical direction.

[0116] That is, in the three-dimensional modeling device 1 using the fifth correction method, the irradiation of light to the area adjacent to the narrow non-drawing area 836 in the drawing area 835b located on the upper side of the narrow non-drawing area 836 (hereinafter also referred to as the "upper drawing area 838") is suppressed. In other words, the cumulative light amount per unit area in the upper drawing area 838 is reduced compared to the cumulative light amount per unit area in the drawing area 835b other than the upper drawing area 838. Fig.17 In (a), the upper drawing area 838 is surrounded by a double-dashed line. The upper drawing area 838 may be provided only in one drawing object layer 92 adjacent to the upper side of the drawing object layer 92 including the narrow non-drawing area 836, or may be provided over a plurality of drawing object layers 92 adjacent to the upper side of the drawing object layer 92 including the narrow non-drawing area 836.

[0117] The correction of the above-mentioned light quantity distribution is achieved in the following manner: one or more light spots (hereinafter also referred to as a "narrow non-drawing point group") among the multiple light spots of the multi-point light beam that pass through the narrow non-drawing area 836 are set to OFF when they are located on the narrow non-drawing area 836 in the drawing object layer 92 including the narrow non-drawing area 836, and the narrow non-drawing point group is also set to OFF when it is located above the narrow non-drawing area 836 in the drawing object layer 92 including the upper drawing area 838.

[0118] In the case where the narrow non-drawing point group includes more than two light spots, the two or more light spots are continuously arranged in the arrangement direction of the multiple light spots in the multi-point light beam. In addition, in the above example, the narrow non-drawing point group is composed of a plurality of light spots located at the left end of the width direction of the multi-point light beam. In addition, the narrow non-drawing area 836 and the upper drawing area 838 are continuous in the up and down scanning direction, and there is no other area (i.e., other drawing object layer 92) between the narrow non-drawing area 836 and the upper drawing area 838 in the up and down direction. The drawing object layer 92 including the upper drawing area 838 can be one layer or a plurality of layers continuous in the up and down direction. Preferably, the number of drawing object layers 92 including the upper drawing area 838 increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller.

[0119] In the three-dimensional shaping apparatus 1 using the fifth correction method, as Fig.17 As shown in (b) of FIG. 8 , the light quantity distribution of the multi-point light beams irradiated to the plurality of drawing target layers 92 corresponding to the longitudinal section 834 is corrected, thereby suppressing excessive heat transfer from the ON area 734b corresponding to the upper drawing area 838 to the OFF area 735 corresponding to the narrow non-drawing area 836. Fig.17 As shown by the solid line in (c), although the temperature of the forming material 91 in the OFF region 735 rises to a certain extent from the preheating temperature (e.g., 173°C), it does not rise as much as the temperature in the three-dimensional forming apparatus of the comparative example. In addition, after the heat diffusion from the ON region 734b occurs over time, as shown by the double-dashed line, the temperature of the forming material 91 in the lower part of the OFF region 735 is lower than the melting point (e.g., 185°C), and the temperature of the forming material 91 in the upper part of the OFF region 735 is higher than the melting point. Therefore, in the lower part of the OFF region 735, unlike the three-dimensional forming apparatus of the comparative example, the forming material 91 does not melt. On the other hand, in the upper part of the OFF region 735, the forming material 91 melts as intended.

[0120] In the three-dimensional shaping apparatus 1 using the fifth correction method, the shaping material 91 in the drawing areas 835a and 835b is melted according to the design data. Fig.17 As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on a plurality of drawing target layers 92 stacked in the vertical direction with high accuracy.

[0121] Fig.18 It is a diagram showing light amount distribution and the like when rendering corresponding to the longitudinal section 834 is performed in the three-dimensional object creation apparatus 1 using the sixth correction method. Fig.18 (a) is a diagram showing a pattern on the design data (ie, a design pattern) in the vertical section 834 . Fig.18(b) is a graph showing the light quantity distribution of the multi-spot light beams irradiated onto each drawing target layer 92 in the vertical section 834 based on the drawing data generated by the sixth correction method. Fig.18 In (b), the vertical axis represents the up and down direction, and the horizontal axis represents the light amount. Fig.18 (c) is a diagram showing temperature distribution in a plurality of drawing target layers 92 corresponding to the longitudinal section 834 . Fig.18 In (c), the vertical axis represents the up-down direction, and the horizontal axis represents the temperature of the forming material 91 in each drawing target layer 92 . Fig.18 (d) is a diagram showing an actual drawn pattern (ie, a drawn pattern) in the longitudinal section 834 .

[0122] In the three-dimensional modeling apparatus 1 using the sixth correction method, the correction of the design data performed by the correction unit 502 is as follows: Fig.18 As shown in (b), the boundary between the ON area 737b corresponding to the design pattern drawing area 835b and the OFF area 738 is tapered on the upper side of the OFF area 738 corresponding to the narrow non-drawing area 836. Specifically, the amount of light at the end of the ON area 737b on the OFF area 738 side gradually decreases as it approaches the OFF area 738. The width of the OFF area 738 is Fig.18 The width of the OFF region 738 may be larger or smaller than the width of the small non-drawing region 836. In addition, the boundary between the ON region 737a corresponding to the drawing region 835a and the OFF region 738 is located at the same position in the vertical direction as the boundary between the drawing region 835a and the small non-drawing region 836.

[0123] That is, in the three-dimensional modeling apparatus 1 using the sixth correction method, the irradiation of light to the upper drawing area 838 adjacent to the narrow non-drawing area 836 in the drawing area 835b located on the upper side of the narrow non-drawing area 836 is suppressed, similarly to the three-dimensional modeling apparatus 1 using the fifth correction method. In other words, the cumulative light amount per unit area in the upper drawing area 838 is lower than the cumulative light amount per unit area in the drawing area 835b other than the upper drawing area 838. Fig.18 In (a), the upper drawing area 838 is surrounded by a two-dot chain line.

[0124] The upper drawing area 838 is provided to cover a plurality of drawing target layers 92 adjacent to the upper side of the drawing target layer 92 including the narrow non-drawing area 836. In the uppermost drawing target layer 92 in the upper drawing area 838, the integrated light amount per unit area in the upper drawing area 838 may be substantially the same as the integrated light amount per unit area in the drawing area 835b excluding the upper drawing area 838.

[0125] The correction of the above-mentioned light quantity distribution is achieved in the following manner: when the small non-drawing point group among the multiple light spots of the multi-point light beam is located on the narrow non-drawing area 836 in the drawing object layer 92 including the narrow non-drawing area 836, it is set to OFF, and when the narrow non-drawing point group is located above the narrow non-drawing area 836 in the multiple drawing object layers 92 including the upper drawing area 838, the light intensity of the narrow non-drawing point group is adjusted to increase as it moves upward.

[0126] In the case where the narrow non-drawing point group includes more than two light spots, the two or more light spots are continuously arranged in the arrangement direction of the multiple light spots in the multi-point light beam. In addition, in the above example, the narrow non-drawing point group is composed of a plurality of light spots located at the left end of the width direction of the multi-point light beam. In addition, the narrow non-drawing area 836 and the upper drawing area 838 are continuous in the up and down scanning directions, and there is no other area (i.e., other drawing object layers 92) between the narrow non-drawing area 836 and the upper drawing area 838 in the up and down directions. Preferably, the number of drawing object layers 92 including the upper drawing area 838 increases as the difference between the melting point and the crystallization point of the forming material 91 becomes smaller. As a result, the gradient of the light quantity distribution in the upper drawing area 838 becomes gentle.

[0127] In the three-dimensional modeling apparatus 1 using the sixth correction method, by Fig.18 As shown in (b) of FIG. 8 , the light quantity distribution of the multi-point light beams irradiated to the plurality of drawing target layers 92 corresponding to the longitudinal section 834 is corrected to suppress excessive heat transfer from the ON area 737b corresponding to the upper drawing area 838 to the OFF area 738 corresponding to the narrow non-drawing area 836. Therefore, the temperature of the forming material 91 in the OFF area 738 is as follows: Fig.18As shown by the solid line in (c), although it rises to a certain extent from the preheating temperature (for example, 173°C), after the heat diffusion occurs from the ON region 737b over time, it does not rise to the melting point (for example, 185°C) of the forming material 91 as shown by the double-dashed line. Therefore, in the OFF region 738, unlike the three-dimensional forming apparatus of the comparative example, the forming material 91 does not melt. In addition, even if the forming material 91 melts to some extent in the OFF region 738, it is suppressed compared with the melting of the forming material 91 in the three-dimensional forming apparatus of the comparative example. On the other hand, in the region of the ON region 737b adjacent to the OFF region 738, the forming material 91 melts as intended.

[0128] In the three-dimensional shaping apparatus 1 using the sixth correction method, the shaping material 91 in the drawing areas 835a and 835b is melted according to the design data in substantially the same manner as in the three-dimensional shaping apparatus 1 using the fifth correction method. Fig.18 As shown in (d), compared with the three-dimensional modeling apparatus of the comparative example, it is possible to perform pattern drawing on a plurality of drawing target layers 92 stacked in the vertical direction with high accuracy.

[0129] In the three-dimensional modeling device 1 using the above-mentioned first to sixth correction methods, the correction threshold (i.e., the correction threshold in the width direction, the correction threshold in the scanning direction, and the correction threshold in the up and down direction) can be a variable threshold that is changed according to the measurement results of the temperature measuring unit 4.

[0130] For example, in Figure 6 When the pattern corresponding to the cross section 813 shown is drawn from the lower side to the upper side in the figure (i.e., from the near front side to the inner side in the scanning direction), in the layer of the new forming material 91 supplied to the layer of the forming material 91 corresponding to the cross section 813 (i.e., the drawn layer), the temperature on the inner side in the scanning direction is sometimes higher, and the temperature on the near front side in the scanning direction is sometimes lower due to heat diffusion from the lower layer. When such a temperature difference occurs, the drawing of the new forming material 91 layer is different from the drawing of the new forming material 91 layer. Figure 7 In the case of the pattern corresponding to the cross-section 814 shown, the undesirable melting of the forming material 91 in the narrow non-drawing area 816 is more likely to occur on the inner side in the scanning direction (i.e., the upper side in the figure) than on the front side in the scanning direction (i.e., the lower side in the figure).

[0131] Therefore, in the three-dimensional shaping apparatus 1 using the first and second correction methods, after drawing the pattern corresponding to the cross section 813 and before drawing the pattern corresponding to the cross section 814, the temperature distribution of the upper surface of the shaping material 91 on the mounting table 341 is measured by the temperature measuring unit 4. The temperature distribution measured by the temperature measuring unit 4 is, for example, the temperature distribution of the upper surface of the predetermined shaping target layer 92 (that is, the layer of the shaping material 91 newly supplied to the already drawn layer) in which the pattern corresponding to the cross section 814 is drawn. Alternatively, the temperature distribution of the upper surface of the shaping target layer 92 in which the pattern corresponding to the cross section 813 is drawn can be measured by the temperature measuring unit 4.

[0132] Then, in the correction unit 502, the above-mentioned correction threshold (i.e., the correction threshold in the width direction) is changed according to the temperature in the area corresponding to the non-drawing area 816, 817 measured by the temperature measuring unit 4. This temperature is the temperature of the predetermined area that becomes the non-drawing area 816, 817 when drawing the pattern corresponding to the cross section 814, and is hereinafter also referred to as the "non-drawing area temperature". In the correction unit 502, as the non-drawing area temperature increases, the correction threshold decreases. Therefore, when the non-drawing area temperature is low, it is difficult to judge the non-drawing area as a small non-drawing area, and when the non-drawing area temperature is high, it is easy to judge the non-drawing area as a small non-drawing area.

[0133] For example, as described above, when the temperature of the pattern corresponding to the cross section 813 is low on the lower side in the figure and high on the upper side in the figure, in the pattern corresponding to the cross section 814, the lower side area in the figure in the non-drawing area 816 is not determined as a small non-drawing area, and only the upper side area in the figure in the non-drawing area 816 is determined as a small non-drawing area. In this case, the correction of the first or second correction method is performed only on the upper side area in the figure in the non-drawing area 816, and the correction is not performed on the lower side area in the figure in the non-drawing area 816. As a result, the pattern drawing for the drawing target layer 92 can be performed with higher accuracy.

[0134] In the three-dimensional shaping apparatus 1 using the third and sixth correction methods, the non-drawing areas 826 and 836 (see Fig.12 as well as Fig.16 ) becomes higher, and the correction threshold (i.e., the correction threshold in the scanning direction and the correction threshold in the up-down direction) becomes smaller. Thus, the pattern drawing for the drawing target layer 92 can be performed with higher accuracy.

[0135] In the three-dimensional modeling apparatus 1 using the first to sixth correction methods, the degree of suppression of irradiation of light to the region adjacent to the narrow non-drawing regions 816, 826, 836 (i.e., the narrow portion adjacent region 818, the correction region 828, and the upper side drawing region 838) in the drawing regions 815a, 815b, 825a, 825b, 835b can be changed according to the measurement result of the temperature measuring unit 4 (i.e., according to the temperature of the drawn layer). Thus, the pattern drawing can be performed on the drawing target layer 92 with higher accuracy.

[0136] For example, in the three-dimensional image forming apparatus 1 using the first correction method, the width of the OFF region 715 corresponding to the narrow non-drawing region 816 in the width direction increases as the temperature of the drawn layer increases. In the three-dimensional image forming apparatus 1 using the second correction method, the gradient of the light quantity distribution in the region corresponding to the narrow portion adjacent region 818 in the ON regions 717a and 717b becomes gentler as the temperature of the drawn layer increases, and the width of the narrow portion adjacent region 818 in the width direction increases.

[0137] In the three-dimensional image forming apparatus 1 using the third correction method, the width in the scanning direction of the OFF region 725 corresponding to the narrow non-drawing region 826 increases as the temperature of the drawn layer increases. In the three-dimensional image forming apparatus 1 using the fourth correction method, the gradient of the light quantity distribution in the region corresponding to the correction region 828 among the ON regions 727a and 727b becomes gentler as the temperature of the drawn layer increases, and the width in the scanning direction of the correction region 828 increases.

[0138] In the three-dimensional image forming apparatus 1 using the fifth correction method, the width of the OFF region 735 corresponding to the narrow non-drawing region 836 in the vertical direction increases as the temperature of the drawn layer increases. In the three-dimensional image forming apparatus 1 using the sixth correction method, the gradient of the light quantity distribution in the region corresponding to the upper drawing region 838 in the ON region 737b becomes gentler as the temperature of the drawn layer increases, and the width of the upper drawing region 838 in the vertical direction increases.

[0139] As described above, the three-dimensional formation device 1 includes: a material holding unit 3, an optical head 2, and a control unit 5. The material holding unit 3 includes a stage 341 for holding a powdered formation material 91, and a material supply unit 32 for supplying the formation material 91 onto the stage 341. The optical head 2 modulates and scans a multi-spot light beam on the formation material 91 on the stage 341, wherein the multi-spot light beam is composed of a plurality of light spots arranged linearly along a predetermined arrangement direction. The control unit 5 repeatedly performs the following operations: the material holding unit 3 and the optical head 2 are controlled according to the design data of the formation object 81, 82, 83, thereby supplying the formation material 91 onto the stage 341, and scanning the multi-spot light beam along a predetermined scanning direction on the surface layer of the supplied formation material 91, i.e., the drawing target layer 92, so that the formation material 91 in the area irradiated with light is melted to draw a pattern.

[0140] The non-drawing regions 816, 817, 826, 836 not instructed to draw in the design data include narrow non-drawing regions 816, 826, 836 whose size is less than the correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the mounting table 341, and the up-down direction perpendicular to the mounting table 341. Furthermore, the control of the control unit 5 suppresses light irradiation of the following regions: the regions adjacent to the narrow non-drawing regions 816, 826, 836 (in the above example, the narrow portion adjacent region 818, the correction region 828, and the upper side drawing region 838) among the drawing regions 815a, 815b, 815c, 825a, 825b, 835a, 835b instructed to draw in the design data.

[0141] As described above, this can suppress the unintended melting of the forming material 91 in the narrow non-drawing regions 816, 826, 836. As a result, even when the formed objects 81, 82, 83 include the narrow non-drawing regions 816, 826, 836, the formed objects 81, 82, 83 can be formed with high precision.

[0142] As described above, the one direction of the narrow non-drawing area 816 is the width direction. Preferably, when one or more light spots among the plurality of light spots that pass through the narrow non-drawing area 816, i.e., the narrow non-drawing point group, are located on the narrow non-drawing area 816, the narrow non-drawing point group and two correction point groups adjacent to the narrow non-drawing point group on both sides of the arrangement direction are set to OFF (inactive) by the control of the control unit 5. Thus, the object 81 including the narrow non-drawing area 816 with a small width in the width direction can be formed with high precision.

[0143] As described above, the one direction of the narrow non-drawing area 816 is the width direction. Preferably, the plurality of light spots of the multi-spot light beam can be gray-scale adjusted. In addition, preferably, when one or more light spots among the plurality of light spots that pass through the narrow non-drawing area 816, i.e., the narrow non-drawing point group, are located on the narrow non-drawing area 816, the narrow non-drawing point group is set to OFF by the control of the control unit 5. More preferably, when the narrow non-drawing point group is located on the narrow non-drawing area 816, the light intensity of the two or more light spots included in each correction point group in the two correction point groups adjacent to both sides of the arrangement direction of the narrow non-drawing point group is adjusted to increase as the distance from the narrow non-drawing point group is increased along the arrangement direction. Thus, a shape 81 including a narrow non-drawing area 816 with a small width in the width direction can be formed with high precision.

[0144] As described above, the one direction of the narrow non-drawing area 826 is the scanning direction. Preferably, under the control of the control unit 5, one or more light spots among the multiple light spots of the multi-spot light beam that pass through the narrow non-drawing area 826, i.e., the narrow non-drawing point group, are set to OFF when located on the narrow non-drawing area 826. In addition, preferably, under the control of the control unit 5, the narrow non-drawing point group is also set to OFF when located on the correction area 828 adjacent to both sides of the narrow non-drawing area 826 in the scanning direction. Thus, the object 82 including the narrow non-drawing area 826 with a small width in the scanning direction can be formed with high precision.

[0145] As described above, the one direction of the narrow non-drawing area 826 is the scanning direction. Preferably, the plurality of light spots of the multi-spot light beam can be gray-scale adjusted. In addition, preferably, through the control of the control unit 5, one or more light spots among the plurality of light spots that pass through the narrow non-drawing area 826, i.e., the narrow non-drawing point group, are set to OFF when located on the narrow non-drawing area 826. More preferably, through the control of the control unit 5, when the narrow non-drawing point group is located on the correction area 828 adjacent to both sides of the narrow non-drawing area 826 in the scanning direction, the light intensity of the narrow non-drawing point group is adjusted to increase as it moves away from the narrow non-drawing area 826 in the scanning direction. Thus, it is possible to form a shape 82 including a narrow non-drawing area 826 with a small width in the scanning direction with high precision.

[0146] As described above, the one direction of the narrow non-drawing area 836 is the up-down direction. Preferably, under the control of the control unit 5, when one or more light spots among the plurality of light spots of the multi-spot light beam that pass through the narrow non-drawing area 836 are located on the narrow non-drawing area 836 in the drawing target layer 92 including the narrow non-drawing area 836, the narrow non-drawing point group is turned off. In addition, preferably, under the control of the control unit 5, when the narrow non-drawing point group is located above the narrow non-drawing area 836 in the drawing target layer 92 including the upper drawing area 838 adjacent to the upper side of the narrow non-drawing area 836, the narrow non-drawing point group is also turned off. Thus, the object 83 including the narrow non-drawing area 836 with a small width in the up-down direction can be formed with high precision.

[0147] As described above, the one direction of the narrow non-drawing area 836 is the up-down direction. Preferably, the plurality of light spots of the multi-spot light beam can be gray-scale adjusted. In addition, preferably, through the control of the control unit 5, when one or more light spots, i.e., the narrow non-drawing point group, among the plurality of light spots of the multi-spot light beam that pass through the narrow non-drawing area 836 are located on the narrow non-drawing area 836 in the drawing object layer 92 including the narrow non-drawing area 836, are set to OFF. More preferably, through the control of the control unit 5, when the narrow non-drawing point group is located above the narrow non-drawing area 836 in the plurality of drawing object layers 92 including the upper drawing area 838 adjacent to the upper side of the narrow non-drawing area 836, the light intensity of the narrow non-drawing point group is adjusted to increase toward the upper side. Thus, it is possible to form a shape 83 including a narrow non-drawing area 836 with a small width in the up-down direction with high precision.

[0148] As described above, it is preferred that the three-dimensional shaping apparatus 1 further includes: a temperature measuring unit 4 that measures the temperature distribution of the upper surface of the shaping material 91 on the mounting table 341. In addition, it is preferred that the above-mentioned correction threshold is variable, and as the temperature in the area corresponding to the non-drawing area 816, 817, 826, 836 measured by the temperature measuring unit 4 becomes high, the correction threshold becomes smaller. As a result, it is possible to appropriately suppress the unintended melting of the shaping material 91 in the narrow non-drawing area 816, 826, 836. As a result, even when the shaping objects 81, 82, 83 include the narrow non-drawing area 816, 826, 836, it is possible to form the shaping objects 81, 82, 83 with higher accuracy.

[0149] The above-mentioned three-dimensional shaping method has the following steps: a step of supplying a powdered shaping material 91 onto a mounting table 341 (step S13); a step of modulating a multi-point light beam on a surface layer of the shaping material 91 supplied onto the mounting table 341, i.e., a drawing object layer 92, and scanning the surface layer along a prescribed scanning direction according to the design data of the shaped object (step S14), wherein the multi-point light beam is composed of a plurality of light spots arranged in a straight line in a prescribed arrangement direction; and a step of repeating steps S13 and S14 (step S15).

[0150] The non-drawing regions 816, 817, 826, 836 for which drawing is not instructed in the design data include narrow non-drawing regions 816, 826, 836 whose size is less than the correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the stage 341, and the up-down direction perpendicular to the stage 341. Then, in step S14, light irradiation is suppressed in the following regions: the regions adjacent to the narrow non-drawing regions 816, 826, 836 (in the above example, the narrow portion adjacent region 818, the correction region 828, and the upper side drawing region 838) among the drawing regions 815a, 815b, 815c, 825a, 825b, 835a, 835b for which drawing is instructed in the design data.

[0151] As described above, this can suppress the unintended melting of the forming material 91 in the narrow non-drawing regions 816, 826, 836. As a result, even when the formed objects 81, 82, 83 include the narrow non-drawing regions 816, 826, 836, the formed objects 81, 82, 83 can be formed with high precision.

[0152] The three-dimensional object creation apparatus 1 and the three-dimensional object creation method described above can be modified in various ways.

[0153] For example, the above-mentioned step S13 (supplying the forming material 91 onto the mounting table 341) may be performed in parallel with the step S12 (correcting the design data), or may be performed before the step S12.

[0154] In step S12, the design data may be corrected by various methods other than the first to sixth correction methods described above.

[0155] The above-mentioned small non-drawing areas 816, 826, 836 may have sizes in two or more directions of the scanning direction, the width direction, and the up-down direction that are less than the correction threshold in each direction. In this case, the above-mentioned correction may be performed in each of the two or more directions.

[0156] In the three-dimensional object creation apparatus 1, it is not always necessary for the temperature measurement unit 4 to measure the temperature distribution. When the temperature distribution measurement is not performed, the temperature measurement unit 4 can be omitted from the three-dimensional object creation apparatus 1.

[0157] The configurations in the above-described embodiment and various modifications may be appropriately combined as long as they do not contradict each other.

[0158] Although the invention has been described and illustrated in detail, the above description is illustrative and not restrictive, and therefore, it can be said that many modifications and aspects are possible without departing from the scope of the invention.

[0159] Explanation of symbols

[0160] 13 Three-dimensional sculpture installation

[0161] 2 Optical head

[0162] 3 Material holding unit

[0163] 4 Temperature measurement unit

[0164] 5. Control Unit

[0165] 32 Material Supply Department

[0166] 81, 82, 83 Shapes

[0167] 91 Molding materials

[0168] 92 Drawing Object Layer

[0169] 341 Loading table

[0170] 815a, 815b, 815c, 825a, 825b, 835a, 835b depict areas

[0171] 816, 826, 836 Small non-depicted areas

[0172] 818 Narrow area adjacent to the

[0173] 828 Calibration Area

[0174] 838 Upper side drawing area

[0175] Steps S11 to S15.

Claims

1. A three-dimensional shaping device, characterized in that: have: A material holding portion having a mounting table for holding a powdered forming material and a material supplying portion for supplying the forming material to the mounting table; an optical head that modulates and scans a multi-spot light beam on the forming material on the mounting table, wherein the multi-spot light beam is composed of a plurality of light spots arranged in a straight line along a predetermined arrangement direction; and The control unit repeatedly performs the following actions: controlling the material holding unit and the optical head according to the design data of the object to supply the forming material to the mounting table, and scanning the multi-spot light beam along a predetermined scanning direction on the surface layer of the supplied forming material, i.e., the drawing target layer, so that the forming material in the area irradiated with the light is melted to draw a pattern, The non-drawing area not instructed to be drawn in the design data includes a small non-drawing area having a size below a correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the stage, and the up-down direction perpendicular to the stage, Through the control of the control unit, light irradiation is suppressed on a region adjacent to the narrow non-drawing region in the drawing region in which drawing is instructed in the design data.

2. The three-dimensional shaping device according to claim 1, characterized in that: The one direction of the narrow non-drawing area is the width direction, When more than one light spot among the multiple light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, is located on the narrow non-drawing area, the narrow non-drawing point group and two correction point groups adjacent to the narrow non-drawing point group on both sides of the arrangement direction are set to be inactive under the control of the control unit.

3. The three-dimensional shaping device according to claim 1, characterized in that: The plurality of light spots can be gray-scale adjusted, The one direction of the narrow non-drawing area is the width direction, When one or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are located on the narrow non-drawing area, the control unit controls the control unit to: The small non-rendering point group is set to be inactive, In two correction point groups adjacent to the narrow non-drawing point group on both sides of the arrangement direction, the light intensity of two or more light spots included in each correction point group is adjusted to increase with increasing distance from the narrow non-drawing point group in the arrangement direction.

4. The three-dimensional shaping device according to any one of claims 1 to 3, characterized in that: The one direction of the narrow non-drawing area is the scanning direction, Through the control of the control unit, One or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when located on the narrow non-drawing area. The narrow non-drawing point group is also set to be inactive when it is located in the correction area adjacent to both sides of the narrow non-drawing area in the scanning direction.

5. The three-dimensional shaping device according to any one of claims 1 to 3, characterized in that: The plurality of light spots can be gray-scale adjusted, The one direction of the narrow non-drawing area is the scanning direction, Through the control of the control unit, One or more light spots among the plurality of light spots that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are set to be inactive when located on the narrow non-drawing area. When the narrow non-drawing point group is located on a correction area adjacent to both sides of the narrow non-drawing area in the scanning direction, the light intensity of the narrow non-drawing point group is adjusted to increase with increasing distance from the narrow non-drawing area in the scanning direction.

6. The three-dimensional shaping device according to any one of claims 1 to 5, characterized in that: The one direction of the narrow non-drawing area is the up-down direction, Through the control of the control unit, When one or more light points among the plurality of light points that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are located on the narrow non-drawing area in the drawing target layer including the narrow non-drawing area, they are set to be inactive. The narrow non-drawing point group is also deactivated when it is located above the narrow non-drawing area in the drawing target layer including the upper drawing area adjacent to the upper side of the narrow non-drawing area.

7. The three-dimensional shaping device according to any one of claims 1 to 5, characterized in that: The plurality of light spots can be gray-scale adjusted, The one direction of the narrow non-drawing area is the up-down direction, Through the control of the control unit, When one or more light points among the plurality of light points that pass through the narrow non-drawing area, i.e., a narrow non-drawing point group, are located on the narrow non-drawing area in the drawing target layer including the narrow non-drawing area, they are set to be inactive. When the small non-drawing point group is located above the narrow non-drawing area in a plurality of drawing target layers including an upper drawing area adjacent to the upper side of the narrow non-drawing area, the light intensity of the small non-drawing point group is adjusted to increase upward.

8. The three-dimensional shaping device according to any one of claims 1 to 7, characterized in that: The three-dimensional shaping apparatus further comprises: a temperature measuring unit for measuring the temperature distribution of the upper surface of the shaping material on the mounting table; The correction threshold is variable, and becomes smaller as the temperature in the region corresponding to the non-drawing region measured by the temperature measuring unit becomes higher.

9. A three-dimensional shaping method, characterized in that: It has the following processes: a) supplying a powdered forming material onto a mounting table; b) a step of modulating a multi-spot light beam on a surface layer, i.e., a drawing target layer, of a forming material supplied to the mounting table and scanning the multi-spot light beam along a predetermined scanning direction according to design data of the formed object, wherein the multi-spot light beam is composed of a plurality of light spots arranged in a straight line along a predetermined arrangement direction; and c) repeating the steps a) and b), The non-drawing area not instructed to be drawn in the design data includes a small non-drawing area having a size below a correction threshold in one of the scanning direction, the width direction perpendicular to the scanning direction and parallel to the stage, and the up-down direction perpendicular to the stage, In the step b), light irradiation is suppressed from reaching a region adjacent to the narrow non-drawing region in the drawing region in which drawing is instructed in the design data.

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