Three-dimensional molding device and mold molding method

Abstract

The invention provides a three-dimensional molding apparatus and a mold molding method. The three-dimensional molding device (10) is used for carrying out stack molding, and is provided with: a stage (14); a discharge head (12) that laminates the thermoplastic molding material on the stage by heating and discharging the thermoplastic molding material; a squeegee (18) for laminating the mold material on the table by applying the slurry-like mold material; and a hardening promotion unit (22) for promoting hardening of the mold material laminated on the stage. As a result, a three-dimensional shaped object having a complex shape and low cost can be obtained.

Description

Technical Field

[0001] The invention relates to a three-dimensional modeling device and a casting mold modeling method. Background Art

[0002] Japanese Patent Application No. 4374575 discloses a molding method in which a resin model is set in a template and plaster is flowed into the template to form a plaster mold. Summary of the invention

[0003] In recent years, better modeling technology has been desired.

[0004] The purpose of the present invention is to solve the above-mentioned technical problems.

[0005] The first embodiment of the present invention is a three-dimensional modeling device for performing stacked modeling, the three-dimensional modeling device comprising: a work table; a discharge head, which stacks the thermoplastic modeling material on the work table by heating and discharging the thermoplastic modeling material; a scraper, which stacks the mold material on the work table by applying a slurry-like mold material; and a hardening promotion section, which is used to promote the hardening of the mold material stacked on the work table.

[0006] The second aspect of the present invention is a casting mold modeling method for molding a casting mold, the casting mold modeling method comprising: a step of performing stacking modeling on a molding object on a workbench by repeating a stacking process; and a step of obtaining a casting mold made of a hardened mold material by melting a thermoplastic molding material in the molding object and discharging the molten thermoplastic molding material, wherein the stacking process comprises: a first stacking step of stacking the thermoplastic molding material on the workbench by heating and discharging the thermoplastic molding material by a discharge head of a three-dimensional molding device; a second stacking step of applying the mold material in a slurry state by a scraper of the three-dimensional molding device, thereby stacking the mold material on the workbench; and a hardening promotion step of promoting the hardening of the mold material stacked on the workbench by a hardening promotion portion of the three-dimensional molding device.

[0007] According to the present invention, it is possible to provide a good three-dimensional modeling device and a casting mold modeling method.

[0008] The above-mentioned objects, features, and advantages will be easily understood from the following description of the embodiments described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a schematic diagram of a three-dimensional modeling device.

[0010] Figure 2A to Figure 2EThis is a schematic diagram for explaining a method of laminating a thermoplastic molding material and a mold material.

[0011] Figure 3 It is a flow chart of the mold modeling process. DETAILED DESCRIPTION

[0012] In recent years, there has been an increasing demand for three-dimensional modeling devices that can model complex shapes that are difficult to form in existing casting and forging technologies, and they are required to be widely used in mass production of metal parts. However, in general, the cost of metal materials used in three-dimensional modeling devices is higher than that of materials used for mass production. In addition, sometimes the mechanical strength of the modeling object is lower than that of the mass production manufacturing method, so it is dealt with by using auxiliary devices to manage the quality during the modeling process or delaying the modeling speed to improve the quality. Or, sometimes it is dealt with by using materials with different chemical compositions from the metal materials of the prior art. In addition, after the modeling is completed, it is necessary to remove the modeling aids or perform post-processing such as heat treatment. Therefore, the total modeling time until the modeling object with sufficient quality and mechanical strength is completed becomes longer. As mentioned above, due to the high material cost and long modeling time, there is a problem of increased cost of the modeling object. In addition, from the perspective of realizing a sustainable society, it is expected to develop more advanced technologies such as using reusable materials to model the modeling object.

[0013] A method is known in the prior art, in which a molded object made of a resin molding material that is cheaper than metal powder is embedded in a mold material such as gypsum used for casting, fired, and then cast. In this method, the process of molding the model and the process of embedding the molded object in the mold material are performed in different processes. According to the present invention, the state of the model after being embedded in the mold material can be molded in one process. In addition, the model and the mold part can be molded using relatively easy-to-obtain and cheap materials. Accordingly, a three-dimensional molding device is provided in the present invention, which can not only cast complex shapes that cannot be obtained by the molding method of the prior art, but also obtain a three-dimensional molded object cheaper than the prior art.

[0014] [One implementation method] [Structure of the three-dimensional modeling device] Figure 1: is a schematic diagram of the three-dimensional modeling device 10. The three-dimensional modeling device 10 of the present embodiment forms a model of a casting by stacking thermoplastic modeling materials. In addition, the three-dimensional modeling device 10 of the present embodiment forms a mold by stacking plaster as a mold material around the model of the casting. Hereinafter, a part molded by stacking thermoplastic modeling materials and stacking mold materials is sometimes referred to as a molded object. When the molded object is heated, the thermoplastic modeling material inside melts. The molten thermoplastic modeling material is discharged from the molded object, thereby completing a mold made of the mold material. Molten metal or the like flows into the mold, and after cooling, the mold is broken to take out the casting inside. It is desired that the discharged thermoplastic modeling material is used again to form a model of the casting.

[0015] The thermoplastic molding material may be a grease material such as a brazing material or a wax material. The thermoplastic molding material may also be a thermoplastic resin containing a plant resin such as polylactic acid. The mold material is preferably gypsum in a slurry state, but is not particularly limited thereto and can be appropriately selected.

[0016] The three-dimensional modeling device 10 includes a discharge head 12 , a work table 14 , a mold material supply unit 16 , a scraper 18 , a storage tank 20 , a hardening promotion unit 22 , and a control device 34 .

[0017] The discharge head 12 discharges the molten thermoplastic molding material to stack the thermoplastic molding material on the table 14. The mold material supply unit 16 supplies the slurry-like mold material to the auxiliary table 15. The scraper 18 spreads the mold material on the auxiliary table 15 to stack the mold material on the thermoplastic molding material, thereby stacking the mold material on the table 14.

[0018] The receiving tank 20 receives the thermoplastic molding material and the mold material stacked on the work table 14. The work table 14 can move in the up-down direction in the receiving tank 20. Each time a layer of the thermoplastic molding material and the mold material is stacked, the work table 14 moves downward.

[0019] The hardening promotion unit 22 includes a first temperature regulator 24, a second temperature regulator 26, and a blower 28. The first temperature regulator 24 is provided on the workbench 14. The first temperature regulator 24 may be a heater. The first temperature regulator 24 heats the thermoplastic molding material and the mold material stacked on the workbench 14 to promote the hardening of the mold material.

[0020] The first temperature regulator 24 controls the temperature of the heated thermoplastic molding material and the mold material to reach a predetermined temperature. For example, when the thermoplastic molding material is a wax material, a brazing material, or other grease material, the predetermined temperature is a temperature in the range of 30° C. to 60° C., but is not limited thereto, as long as it is below the melting temperature of the grease material.

[0021] In addition, when the thermoplastic molding material is a thermoplastic resin containing a plant resin such as polylactic acid, it is desirable to control the predetermined temperature to about 50° C. to 70° C. so that the resin melted and softened by the discharge head 12 is in close contact with the upper surface of the table 14. The predetermined temperature can be appropriately controlled according to the characteristics of the selected thermoplastic resin.

[0022] When the temperature of the thermoplastic molding material is too low, the contact angle of the thermoplastic molding material to the mold material becomes larger and the wettability decreases. Therefore, the thermoplastic molding material does not adhere to the mold material. On the other hand, when the temperature of the thermoplastic molding material is too high, the contact angle of the thermoplastic molding material to the mold material becomes smaller and the wettability becomes higher. Therefore, there is a concern that the thermoplastic molding material may penetrate into the mold material. By performing temperature control so that the temperatures of the thermoplastic molding material and the mold material reach a specified temperature, the hardening of the mold material can be promoted while maintaining the state in which the thermoplastic molding material is appropriately attached to the mold material. Therefore, the precision of the molded object can be improved.

[0023] The second temperature regulator 26 is provided on the side of the receiving groove 20. The second temperature regulator 26 includes an upper temperature regulator 30 and a lower temperature regulator 32. The upper temperature regulator 30 may be a heater. The lower temperature regulator 32 may also be a heater. The thermoplastic molding material stacked on the workbench 14 and the mold material stacked on the workbench 14 are heated by the upper temperature regulator 30 and the lower temperature regulator 32 to promote the hardening of the mold material. The upper temperature regulator 30 and the lower temperature regulator 32 are controlled so that the temperature of the heated thermoplastic molding material and the mold material reaches a predetermined temperature.

[0024] The amount of heat output from the lower temperature regulator 32 may be smaller than the amount of heat output from the upper temperature regulator 30. Thermoplastic molding material and mold material located below are more likely to retain heat than the thermoplastic molding material and mold material located above. Therefore, when the thermoplastic molding material located below is heated in the same manner as the thermoplastic molding material located above, there is a concern that the thermoplastic molding material may melt and infiltrate the mold material. By making the amount of heat output from the lower temperature regulator 32 lower than the amount of heat output from the upper temperature regulator 30, it is possible to suppress the thermoplastic molding material from infiltrating the mold material.

[0025] The lower temperature regulator 32 may also be a cooler. The lower temperature regulator 32 as a cooler may be used to cool the thermoplastic molding material and the mold material without heating them. Alternatively, the lower temperature regulator 32 may be provided to be capable of heating and cooling appropriately.

[0026] The fan 28 blows air toward the thermoplastic molding material and the mold material stacked on the workbench 14, thereby drying the thermoplastic molding material and the mold material. Thus, the hardening of the thermoplastic molding material and the mold material is promoted. The temperature of the air sent from the fan 28 may be higher than the temperature of the air around the fan 28. The temperature of the air sent from the fan 28 may also be lower than the temperature of the air around the fan 28. The temperature of the air sent from the fan 28 may also be the same as the temperature of the air around the fan 28.

[0027] The control device 34 controls the discharge head 12 , the mold material supply unit 16 , the scraper 18 , the first temperature regulator 24 , the second temperature regulator 26 , and the fan 28 .

[0028] The control device 34 has a computing unit 36 ​​and a storage unit 38. The computing unit 36 ​​is, for example, a processor such as a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit). The computing unit 36 ​​has a control unit 40. The control unit 40 is implemented by executing a program stored in the storage unit 38 in the computing unit 36. At least a part of the control unit 40 can also be implemented by an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field-Programmable Gate Array). At least a part of the control unit 40 can also be implemented by an electronic circuit including discrete devices. The discharge head 12, the mold material supply unit 16, the scraper 18, the first temperature regulator 24, the second temperature regulator 26 and the fan 28 are controlled by the control unit 40.

[0029] In addition, when the thermoplastic molding material and the mold material are changed, the optimal temperature control is appropriately performed by the control device 34. According to this, even when the thermoplastic molding material and the mold material are changed, the thermoplastic molding material and the mold material can be stacked in a state controlled at an appropriate temperature according to the characteristics of the thermoplastic molding material and the mold material. Therefore, the accuracy of the molded object can be maintained.

[0030] The storage unit 38 is a computer-readable storage medium. The storage medium is composed of a volatile memory not shown in the figure and a non-volatile memory not shown in the figure. Examples of volatile memory include RAM (Random Access Memory) and the like. Examples of non-volatile memory include ROM (Read Only Memory), flash memory and the like. Data and the like are stored in, for example, volatile memory. Programs, tables, mappings and the like are stored in, for example, non-volatile memory. At least a portion of the storage unit 38 may also be provided in the above-mentioned processor, integrated circuit and the like. At least a portion of the storage unit 38 may also be mounted on a device connected to the three-dimensional modeling apparatus 10 via a network.

[0031] [Layering method] Figure 2A to Figure 2E This is a schematic diagram for explaining the stacking method of thermoplastic molding material and mold material. Figure 2A As shown in FIG. 1 , the discharge head 12 discharges the thermoplastic molding material, and a layer of thermoplastic molding material is stacked. Figure 2B As shown, the mold material supply unit 16 supplies the mold material. Figure 2B In the present invention, the mold material is supplied to the stacked mold material, but it is also possible to Figure 1 The mold material is supplied to the auxiliary workbench 15 shown in FIG. Figure 2C As shown, the scraper 18 stretches the mold material and coats the mold material on top of the already coated mold material. Figure 2D As shown, the fan 28 blows air to the thermoplastic molding material and the mold material after the scraper 18 passes through, so as to dehumidify the thermoplastic molding material and the mold material. Figure 2E As shown, the mold material is laminated one layer at a time.

[0032] [Molding treatment] Figure 3 It is a flow chart of the mold modeling process.

[0033] In step S1, the control unit 40 of the control device 34 executes the first stacking step. Thereafter, the process proceeds to step S2. In the first stacking step, the control unit 40 controls the discharge head 12 to discharge the molten thermoplastic modeling material from the discharge head 12. Thus, the thermoplastic modeling material is stacked on the table 14.

[0034] In step S2, the control unit 40 controls the mold material supply unit 16 to supply the mold material to the sub-stage 15. Thereafter, the process proceeds to step S3.

[0035] In step S3, the control unit 40 performs the second lamination step. In the second lamination step, the control unit 40 controls the scraper 18 to apply the mold material by the scraper 18. Accordingly, the mold material is laminated on the workbench 14. After that, the process proceeds to step S4. By performing the lamination process based on steps S1 to S3, a layer of thermoplastic molding material and mold material is laminated. During the lamination process, the hardening acceleration step of accelerating the hardening of the mold material by the first temperature regulator 24, the second temperature regulator 26 and the fan 28 is continuously performed.

[0036] In step S4, the control unit 40 determines whether the stacking formation of the object is completed. If the control unit 40 determines that the stacking formation is completed, the process proceeds to step S5. If the control unit 40 determines that the stacking formation is not completed, the process returns to step S1.

[0037] In step S5, a heating step is performed. In the heating step, the modeled object formed by stacking the modeling is heated to melt the thermoplastic modeling material in the modeled object. The modeled object can be heated by the first temperature regulator 24 and the second temperature regulator 26. The modeled object can also be heated by other devices other than the three-dimensional modeling device 10. The heating step can also be implemented by the user.

[0038] In step S6, a removal step is performed. After this, the mold shaping process is completed. In the removal step, the molten thermoplastic molding material is discharged from the molded object. The removal step can also be implemented by the user. Accordingly, the mold is completed.

[0039] Regarding the above disclosed contents, the following supplementary notes are further disclosed.

[0040] (Note 1) A three-dimensional modeling device (10) for performing layered modeling, the three-dimensional modeling device comprising: a workbench (14); a discharge head (12) for heating and discharging the thermoplastic modeling material to layer the thermoplastic modeling material on the workbench; a scraper (18) for coating the mold material in a slurry state to layer the mold material on the workbench; and a hardening promotion section (22) for promoting the hardening of the mold material layered on the workbench. According to this structure, the mold material layered on the workbench can be well hardened. Therefore, according to this structure, a good three-dimensional modeling device can be provided.

[0041] (Note 2) According to the three-dimensional modeling device described in Supplementary Note 1, the hardening promotion unit may be a first temperature regulator (24) provided on the workbench, and the first temperature regulator heats the thermoplastic modeling material stacked on the workbench and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0042] (Note 3) According to the three-dimensional modeling device described in Supplement 1 or 2, the hardening promotion unit may be a blower (28) for sending out air, and the blower blows air to the thermoplastic modeling material and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0043] (Note 4) The three-dimensional modeling device according to Appendix 1 or 2 may include a receiving groove (20) for receiving the thermoplastic modeling material and the mold material stacked on the workbench, and the hardening promotion unit is a second temperature regulator (26) provided on the side of the receiving groove, and the second temperature regulator heats the thermoplastic modeling material and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0044] (Note 5) According to the three-dimensional modeling device of Supplementary Note 1 or 2, the thermoplastic modeling material is a grease containing a brazing material or a wax material, or a thermoplastic resin containing polylactic acid. According to this structure, the mold material stacked on the table can be cured well.

[0045] (Note 6) A casting mold forming method for forming a casting mold, the casting mold forming method comprising: a step of forming a molded object on a workbench by repeating a stacking process; and a step of obtaining a casting mold made of a hardened mold material by melting a thermoplastic molding material in the molded object and discharging the molten thermoplastic molding material, wherein the stacking process comprises: a first stacking step of stacking the thermoplastic molding material on the workbench by heating and discharging the thermoplastic molding material by a discharging head of a three-dimensional molding device; a second stacking step of stacking the mold material on the workbench by applying the mold material in a slurry state by a scraper of the three-dimensional molding device; and a hardening promotion step of promoting the hardening of the mold material stacked on the workbench by a hardening promotion section of the three-dimensional molding device. According to this structure, the mold material stacked on the workbench can be well hardened.

[0046] (Note 7) According to the casting molding method described in Supplementary Note 6, the hardening promotion section may be a first temperature regulator provided on the workbench, and in the hardening promotion step, the first temperature regulator heats the thermoplastic molding material stacked on the workbench and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0047] (Note 8) According to the casting molding method described in Supplementary Note 6 or 7, the hardening promotion part may be a blower that blows air, and in the hardening promotion step, the blower blows air to the thermoplastic molding material stacked on the workbench and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0048] (Note 9) According to the casting molding method described in Supplementary Note 6 or 7, the hardening promotion part may be a second temperature regulator, the second temperature regulator is provided on the side of a receiving groove for receiving the thermoplastic molding material and the mold material stacked on the workbench, and in the hardening promotion step, the second temperature regulator heats the thermoplastic molding material and the mold material stacked on the workbench. According to this structure, the mold material stacked on the workbench can be well hardened.

[0049] In addition, the present invention is not limited to the above-mentioned disclosure, and various structures can be adopted within the scope not departing from the gist of the present invention.

Claims

1. A three-dimensional modeling device (10) for performing layered modeling, characterized in that: have: Workbench (14); a discharge head (12) for stacking the thermoplastic molding material on the workbench by heating and discharging the thermoplastic molding material; a scraper (18) for laminating the mold material on the table by applying the mold material in a slurry state; and A hardening promoting portion (22) is used to promote the hardening of the mold material stacked on the workbench.

2. The three-dimensional modeling device according to claim 1, characterized in that: The hardening promotion unit is a first temperature regulator (24) provided on the workbench. The first temperature regulator heats the thermoplastic modeling material stacked on the table and the mold material stacked on the table.

3. The three-dimensional modeling device according to claim 1 or 2, characterized in that: The hardening promoting part is a fan (28) for delivering air. The blower blows air to the thermoplastic modeling material stacked on the workbench and the mold material stacked on the workbench.

4. The three-dimensional modeling device according to claim 1 or 2, characterized in that: A receiving groove (20) is provided, wherein the receiving groove (20) receives the thermoplastic molding material stacked on the workbench and the mold material stacked on the workbench, The hardening promoting part is a second temperature regulator (26) provided on the side of the receiving groove. The second temperature regulator heats the thermoplastic modeling material stacked on the table and the mold material stacked on the table.

5. The three-dimensional modeling device according to claim 1 or 2, characterized in that: The thermoplastic modeling material is grease containing solder and wax, or thermoplastic resin containing polylactic acid.

6. A casting mold forming method for forming a casting mold, characterized in that: have: The step of laminating the object on the workbench by repeating the laminating process; and a step of melting the thermoplastic molding material in the molding and discharging the molten thermoplastic molding material to obtain a casting mold made of a hardened mold material, Wherein, the stacking process has: a first stacking step of stacking the thermoplastic modeling material on the workbench by heating and discharging the thermoplastic modeling material through a discharge head of a three-dimensional modeling device; A second laminating step of laminating the mold material on the workbench by applying the mold material in a slurry state using a scraper of the three-dimensional modeling device; and The hardening promotion step promotes the hardening of the mold material stacked on the workbench by a hardening promotion unit of the three-dimensional modeling device.

7. The casting mold forming method according to claim 6, characterized in that: The hardening promotion unit is a first temperature regulator provided on the workbench. In the hardening acceleration step, the first temperature regulator heats the thermoplastic modeling material stacked on the table and the mold material stacked on the table.

8. The casting mold forming method according to claim 6 or 7, characterized in that: The hardening promotion part is a fan for sending out air. In the hardening accelerating step, the blower blows air to the thermoplastic modeling material stacked on the work table and the mold material stacked on the work table.

9. The casting mold forming method according to claim 6 or 7, characterized in that: The hardening promotion part is a second temperature regulator, and the second temperature regulator is provided on a side of a receiving groove for receiving the thermoplastic molding material stacked on the workbench and the mold material stacked on the workbench. In the hardening acceleration step, the second temperature regulator heats the thermoplastic modeling material stacked on the table and the mold material stacked on the table.

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