Molding system

Abstract

To provide a molding system that uses a molded object to form an appropriate structure.SOLUTION: A molding system comprises a molding device comprising an energy beam irradiation part that emits an energy beam and a material supply part that supplies molding material to the part irradiated by the energy beam, and a control device that controls the molding device to mold a molding object. The molding system molds a second object above a first object having a first space. The second object includes a first inclined part connected to the first object, a second inclined part connected to the first object, and a connection connected to the tip of the first inclined part and the tip of the second inclined part. The molding system molds the first inclined part and the second inclined part by successively molding a part of the first inclined part and a part of the second inclined part. A second space below the first inclined part and the second inclined part is connected to a first space, and the upper part of the second space is closed by the connection.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to, for example, the technical field of a modeling system that models a modeled object. [Background technology]

[0002] An example of a modeling system for modeling a modeled object is described in Patent Document 1. In such a modeling system, a technical challenge is to form an appropriate structure using the modeled object. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] US Patent Application Publication No. 2014 / 0197576 Summary of the Invention

[0004] According to a first aspect, a modeling system is provided that includes a modeling device having an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies modeling material to the portion irradiated with the energy beam, and a control device that controls the modeling device to model a modeled object, wherein a second object is modeled above a first object having a first space, the second object including a first inclined portion connected to the first object, a second inclined portion connected to the first object, and a connecting portion that connects to the tip of the first inclined portion and the tip of the second inclined portion, and the first inclined portion and the second inclined portion are modeled by sequentially modeling a portion of the first inclined portion and a portion of the second inclined portion, and a second space below the first inclined portion and the second inclined portion is connected to the first space, and the upper part of the second space is closed by the connecting portion.

[0005] According to a second aspect, there is provided a method for forming a model using a modeling device having an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies modeling material to the portion irradiated with the energy beam, the method including sequentially forming a portion of a first inclined portion connected to the first object and a portion of a second inclined portion connected to the first object in order to form a second object above a first object having a first space, and forming a connecting portion that connects an end of the first inclined portion and an end of the second inclined portion, wherein a second space below the first inclined portion and the second inclined portion is connected to the first space, and an upper portion of the second space is closed by the connecting portion.

[0006] According to a third aspect, there is provided a modeling system comprising an object mounting device on which a first object is placed, an energy beam irradiation unit that emits an energy beam, and a material supply unit that supplies modeling material to the portion irradiated with the energy beam, and which performs modeling on the first object, a position change device that changes the relative positional relationship between the modeling device and the object mounting device, and a control device that controls the modeling device and the position change device, wherein the position change device has a drive device that moves the object mounting device around a rotation axis, and which alternates between a first modeling operation performed using the modeling device in a first state in which the object mounting device is moved from a reference position in a first direction around the rotation axis, and a second modeling operation performed using the modeling device in a second state in which the object mounting device is moved from the reference position in a second direction around the rotation axis opposite to the first direction, thereby modeling a second object on the first object, including a first inclined portion modeled by the first modeling operation and a second inclined portion modeled by the second modeling operation.

[0007] According to a fourth aspect, a modeling apparatus includes an object mounting device on which a first object is mounted, an energy beam irradiation unit that emits an energy beam, and a material supply unit that supplies modeling material to a portion irradiated with the energy beam, and performs modeling on the first object, a position changing device that changes a relative positional relationship between the modeling device and the object mounting device, and a control device that controls the modeling device and the position changing device, and models a second object connecting a first region of the first object and a second region of the first object, and changes the relative positional relationship in order to model the second object. the position changing device changes the positional relationship so that the position relationship is a first relationship, and then irradiates the first region with the energy beam to form a first object that is a part of the second object on the first region, and the position changing device changes the positional relationship so that the positional relationship is a second relationship different from the first relationship, and then irradiates the first object with the energy beam to form a second object on the first object that constitutes a part of the second object and connects the first object to the second region.

[0008] The functions and other advantages of the present invention will become apparent from the following detailed description of the preferred embodiments. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a block diagram showing a system configuration of a modeling system according to the present embodiment. [Diagram 2] FIG. 2 is a cross-sectional view showing the structure of the modeling system of the present embodiment. [Diagram 3] FIG. 3 is a cross-sectional view showing a structure of the molding system of the present embodiment. [Figure 4] Each of Figs. 4(a) to 4(e) is a cross-sectional view showing a state in which a certain area on a workpiece is irradiated with modeling light and modeling material is supplied thereto. [Diagram 5] Each of Figures 5(a) to 5(c) is a cross-sectional view showing a process for fabricating a three-dimensional structure. [Figure 6]FIG. 6 is a perspective view showing the external appearance of a three-dimensional structure including a second object formed above a first object. [Figure 7] FIG. 7 is a plan view showing the top surface of a three-dimensional structure including a second object formed above a first object. [Figure 8] FIG. 8 is a cross-sectional view (particularly, a cross-sectional view taken along line AA' in FIG. 7) showing a cross section of a three-dimensional structure including a second object formed above a first object. [Figure 9] FIG. 9 is a cross-sectional view (particularly, a cross-sectional view taken along line BB' in FIG. 7) showing a cross section of a three-dimensional structure including a second object formed above a first object. [Figure 10] 10(a) and 10(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 11] FIG. 11 is a cross-sectional view showing a ramp member to be molded on a sidewall member. [Figure 12] FIG. 12 is an enlarged cross-sectional view showing the inclined member formed on the sidewall member. [Figure 13] Each of FIG. 13(a) and FIG. 13(b) is a cross-sectional view showing an example of a state of a stage for forming a tilt member. [Figure 14] FIG. 14 is a cross-sectional view showing the shaping light irradiated onto the side wall member in order to shape another inclined member after the whole of one inclined member has been shaped. [Figure 15] 15(a) and 15(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 16] 16(a) and 16(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 17] 17(a) to 17(d) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9, respectively. [Figure 18] FIG. 18 is a cross-sectional view showing a process for fabricating the three-dimensional structure shown in FIGS. [Figure 19]19(a) and 19(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 20] 20(a) and 20(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 21] FIG. 21 is a cross-sectional view showing a process for fabricating the three-dimensional structure shown in FIGS. [Figure 22] FIG. 22 is a cross-sectional view showing a process for fabricating the three-dimensional structure shown in FIGS. [Figure 23] 23(a) and 23(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 24] 24(a) and 24(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Diagram 25] 25(a) and 25(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 26] 26(a) and 26(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Figure 27] FIG. 27 is a cross-sectional view showing a process for fabricating the three-dimensional structure shown in FIGS. [Figure 28] FIG. 28 is a cross-sectional view showing a process for fabricating the three-dimensional structure shown in FIGS. [Figure 29] 29(a) and 29(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Diagram 30] 30(a) and 30(b) are cross-sectional views showing the process of fabricating the three-dimensional structure shown in FIGS. 6 to 9. FIG. [Diagram 31] FIG. 31 shows a schematic diagram of the movement direction of the target irradiation area EA by the scanning operation. [Diagram 32] FIG. 32 is a cross-sectional view showing a cross section of a three-dimensional structure including an outer wall member at a position where a support member is not formed. [Diagram 33] FIG. 33 is a cross-sectional view showing a cross section of a three-dimensional structure including an outer wall member at a position where a support member is formed. [Diagram 34] FIG. 34 is a cross-sectional view showing a three-dimensional structure including a roof member having a through hole formed therein. [Diagram 35] FIG. 35 is a cross-sectional view showing a three-dimensional structure including an outer wall member having a through hole formed therein. [Diagram 36] FIG. 36 is a cross-sectional view showing a process of forming an outer wall member having a through hole formed therein. [Figure 37] Figures 37(a) and 37(c) are each a cross-sectional view showing an example of the cross-sectional shape of a through hole formed in a roof member, and Figure 37(b) is a cross-sectional view showing an example of the cross-sectional shape of a through hole formed in an exterior wall member. [Figure 38] Each of Figures 38(a) and 38(b) is a cross-sectional view showing the base member. [Figure 39] FIG. 39 is a cross-sectional view showing a process of forming a three-dimensional structure in the fifth modified example. [Diagram 40] FIG. 40 is a cross-sectional view showing a process of forming a three-dimensional structure in the fifth modified example. [Diagram 41] FIG. 41 is a cross-sectional view showing a process of forming a three-dimensional structure in the fifth modified example. [Diagram 42] FIG. 42 is a cross-sectional view showing a process of forming a three-dimensional structure in the fifth modified example. [Diagram 43] FIG. 43 is a cross-sectional view showing a pipe. [Diagram 44] FIG. 44 is a cross-sectional view showing a curved pipe. [Diagram 45] FIG. 45 is a cross-sectional view showing a process of forming a partial pipe. [Figure 46] FIG. 46 is a cross-sectional view showing a process of forming a partial pipe. [Figure 47] FIG. 47 is a cross-sectional view showing a process of forming a partial pipe. [Figure 48] FIG. 48 is a cross-sectional view showing a process of forming a partial pipe. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of a modeling system will be described with reference to the drawings. Hereinafter, an embodiment of a modeling system will be described using a modeling system SYS that performs additive processing on a workpiece W, which is an example of an object, to form a model on the workpiece W. In particular, below, an embodiment of a modeling system will be described using a modeling system SYS that performs additive processing based on a laser metal deposition method (LMD). The additive processing based on the laser metal deposition method is an additive processing that melts a modeling material M supplied to the workpiece W with modeling light EL (i.e., an energy beam in the form of light) to form a model that is integrated with the workpiece W or that can be separated from the workpiece W.

[0011] Laser metal deposition (LMD) may also be called direct metal deposition, directed energy deposition, laser cladding, laser engineered net shaping, direct light fabrication, laser consolidation, shape deposition manufacturing, wire-feed laser deposition, gas through wire, laser powder fusion, laser metal forming, selective laser powder remelting, laser direct casting, laser powder deposition, laser additive manufacturing, and laser rapid forming.

[0012] In the following description, the positional relationship of various components constituting the modeling system SYS will be described using an XYZ Cartesian coordinate system defined by mutually orthogonal X-axis, Y-axis, and Z-axis. For convenience of explanation, the X-axis direction and the Y-axis direction are each assumed to be horizontal (i.e., a predetermined direction in a horizontal plane), and the Z-axis direction is assumed to be vertical (i.e., a direction perpendicular to the horizontal plane, essentially an up-down direction). Furthermore, the rotation directions (in other words, tilt directions) around the X-axis, Y-axis, and Z-axis are referred to as the θX direction, the θY direction, and the θZ direction, respectively. Here, the Z-axis direction may be the direction of gravity. Furthermore, the XY plane may be the horizontal direction.

[0013] (1) Structure of modeling system SYS First, the structure of the modeling system SYS of this embodiment will be described with reference to Fig. 1 to Fig. 3. Fig. 1 is a system configuration diagram showing the system configuration of the modeling system SYS of this embodiment. Fig. 2 and Fig. 3 are each a cross-sectional view that typically shows the structure of the modeling system SYS of this embodiment.

[0014] The modeling system SYS can model (in other words, form) a modeled object. In this embodiment, the modeled object may mean any object modeled by the modeling system SYS. For example, the modeling system SYS can model a three-dimensional structure ST (i.e., a three-dimensional object having a size in any of the three-dimensional directions, a solid object, in other words, an object having a size in the X-axis direction, the Y-axis direction, and the Z-axis direction) as an example of a modeled object. The modeling system SYS can model the three-dimensional structure ST on a workpiece W that serves as a base (i.e., a base material) for modeling the three-dimensional structure ST. In other words, the modeling system SYS performs modeling on the workpiece W. The modeling system SYS can model the three-dimensional structure ST by performing additional processing on the workpiece W. In the case where the workpiece W is a stage 31 described later, the modeling system SYS can model the three-dimensional structure ST on the stage 31. When the workpiece W is a mounted object, which is an object placed on the stage 31, the modeling system SYS can model a three-dimensional structure ST on the mounted object. In this case, the modeling system SYS may model a three-dimensional structure ST integrated with the mounted object. The operation of modeling a three-dimensional structure ST integrated with the mounted object is equivalent to the operation of adding a new structure to the mounted object. The existing structure may be, for example, an item that has a missing part and needs to be repaired. Alternatively, the modeling system SYS may model a three-dimensional structure ST that can be separated from the mounted object. The mounted object placed on the stage 31 may be another three-dimensional structure ST (i.e., an existing structure) modeled by the modeling system SYS. Note that FIG. 1 shows an example in which the workpiece W is an existing structure held by the stage 31. In the following, the explanation will be given using an example in which the workpiece W is an existing structure held by the stage 31.

[0015] As described above, the modeling system SYS can model a three-dimensional structure ST by the laser build-up welding method. In other words, the modeling system SYS can be said to be a 3D printer that models an object using additive manufacturing technology. The additive manufacturing technology may also be called rapid prototyping, rapid manufacturing, or additive manufacturing.

[0016] The modeling system SYS processes the modeling material M using the modeling light EL to model a three-dimensional structure ST. The modeling material M is a material that can be melted by irradiation with the modeling light EL of a predetermined intensity or higher. For example, at least one of a metallic material and a resinous material can be used as the modeling material M. However, other materials different from the metallic material and the resinous material may also be used as the modeling material M. The modeling material M is a powder or granular material. In other words, the modeling material M is a powdered granular material. However, the modeling material M does not have to be a powdered granular material. For example, at least one of a wire-shaped modeling material and a gaseous modeling material may be used as the modeling material M.

[0017] 1 to 3 , in order to model a three-dimensional structure ST, the modeling system SYS includes a material supply source 1, a modeling unit 2, a stage unit 3, a light source 5, a gas supply source 6, and a control device 7. The modeling unit 2 and the stage unit 3 may be housed in the internal space of a housing 8.

[0018] The material supply source 1 supplies the modeling material M to the modeling unit 2. The material supply source 1 supplies a desired amount of modeling material M according to a required amount so that the amount of modeling material M required per unit time for modeling a three-dimensional structure ST is supplied to the modeling unit 2.

[0019] The modeling unit 2 processes the modeling material M supplied from the material supply source 1 to model a three-dimensional structure ST. In order to model the three-dimensional structure, the modeling unit 2 includes a modeling head 21 and a head drive system 22. Furthermore, the modeling head 21 includes an irradiation optical system 211 and a material nozzle (i.e., a supply system that supplies the modeling material M) 212. The modeling head 21 may be referred to as a modeling device.

[0020] The irradiation optical system 211 is an optical system (e.g., a focusing optical system) for emitting the modeling light EL from the emission unit 213. Specifically, the irradiation optical system 211 is optically connected to the light source 5 that emits the modeling light EL via an optical transmission member 51 such as an optical fiber or a light pipe. The irradiation optical system 211 emits the modeling light EL propagated from the light source 5 via the optical transmission member 51. The irradiation optical system 211 irradiates the modeling light EL downward (i.e., toward the -Z side) from the irradiation optical system 211. A stage 31 is disposed below the irradiation optical system 211. When a workpiece W is placed on the stage 31, the irradiation optical system 211 irradiates the modeling light EL toward the workpiece W. For this reason, the irradiation optical system 211 may be referred to as an energy beam irradiation unit. Specifically, the irradiation optical system 211 can irradiate the modeling light EL to a target irradiation area EA that is set on or near the workpiece W as an area where the modeling light EL is irradiated (typically, condensed). Furthermore, the state of the irradiation optical system 211 can be switched between a state in which the target irradiation area EA is irradiated with the shaping light EL and a state in which the target irradiation area EA is not irradiated with the shaping light EL under the control of the control device 7. Note that the direction of the shaping light EL emitted from the irradiation optical system 211 is not limited to directly downward (i.e., coinciding with the -Z-axis direction), and may be, for example, a direction inclined at a predetermined angle with respect to the Z-axis.

[0021] The material nozzle 212 is formed with a supply outlet 214. The material nozzle 212 supplies (e.g., ejects, jets, spouts, or sprays) the modeling material M from the supply outlet 214. For this reason, the material nozzle 212 may be referred to as a material supply unit. The material nozzle 212 is physically connected to the material supply source 1, which is a supply source of the modeling material M, via the supply pipe 11 and the mixer 12. The material nozzle 212 supplies the modeling material M supplied from the material supply source 1 via the supply pipe 11 and the mixer 12. The material nozzle 212 may pressure-feed the modeling material M supplied from the material supply source 1 via the supply pipe 11. That is, the modeling material M from the material supply source 1 and the conveying gas (i.e., a pressure-feed gas, for example, an inert gas such as nitrogen or argon) may be mixed in the mixer 12 and then pressure-feed to the material nozzle 212 via the supply pipe 11. As a result, the material nozzle 212 supplies the modeling material M together with the conveying gas. As the gas for conveyance, for example, a purge gas supplied from the gas supply source 6 is used. However, as the gas for conveyance, a gas supplied from a gas supply source other than the gas supply source 6 may be used. Although the material nozzle 212 is depicted in a tube shape in FIG. 1, the shape of the material nozzle 212 is not limited to this shape. The material nozzle 212 supplies the modeling material M from the material nozzle 212 downward (i.e., toward the -Z side). The stage 31 is disposed below the material nozzle 212. When the workpiece W is mounted on the stage 31, the material nozzle 212 supplies the modeling material M toward the workpiece W or the vicinity of the workpiece W. The traveling direction of the modeling material M supplied from the material nozzle 212 is a direction inclined at a predetermined angle (as an example, an acute angle) with respect to the Z-axis direction, but may be the -Z side (i.e., directly below).

[0022] In this embodiment, the material nozzle 212 supplies the modeling material M to a portion irradiated with the modeling light EL from the irradiation optical system 211. That is, the material nozzle 212 supplies the modeling material M to a target irradiation area EA to which the irradiation optical system 211 irradiates the modeling light EL. For this reason, the material nozzle 212 and the irradiation optical system 211 are aligned so that a target supply area MA, which is set on or near the workpiece W as an area to which the material nozzle 212 supplies the modeling material M, coincides with (or at least partially overlaps with) the target irradiation area EA. The material nozzle 212 may supply the modeling material M to a molten pool MP (see FIG. 4, etc., which will be described later) formed by the modeling light EL emitted from the irradiation optical system 211. However, the material nozzle 212 may not supply the material to the molten pool MP. For example, the modeling system SYS may melt the modeling material M from the material nozzle 212 by the irradiation optical system 211 before the modeling material M reaches the workpiece W, and attach the molten modeling material M to the workpiece W.

[0023] The head drive system 22 moves the object-forming head 21. The head drive system 22 moves the object-forming head 21, for example, along at least one of the X-axis, the Y-axis, the Z-axis, the θX direction, the θY direction, and the θZ direction. In the example shown in FIG. 2 and FIG. 3, the head drive system 22 moves the object-forming head 21 along each of the X-axis, the Y-axis, and the Z-axis. In this case, the head drive system 22 may include a head drive system 22X, a head drive system 22Y, and a head drive system 22Z. The head drive system 22X moves the object-forming head 21 along the X-axis. The head drive system 22Y moves the object-forming head 21 along the Y-axis. The head drive system 22Z moves the object-forming head 21 along the Z-axis.

[0024] Head driving system 22Y includes Y guide member 221Y connected to support frame 224 installed on the bottom surface of housing 8 (or a base placed on the bottom surface of housing 8) via an anti-vibration device such as an air spring and extending along the Y axis, Y slide member 222Y movable along Y guide member 221Y, and a motor (not shown) for moving Y slide member 222Y. Head driving system 22X includes X guide member 221X connected to Y slide member 222Y and extending along the X axis, X slide member 222X movable along X guide member 221X, and a motor (not shown) for moving X slide member 222X. Head driving system 22Z includes Z guide member 221Z connected to X slide member 222X and extending along the Z axis, Z slide member 222Z movable along Z guide member 221Z, and a motor (not shown) for moving Z slide member 222Z. The object-forming head 21 is connected to the Z slide member 222Z. When the Y slide member 222Y moves along the Y guide member 221Y, the object-forming head 21 connected to the Y slide member 222Y via the head drive systems 22X and 22Z moves along the Y axis. When the X slide member 222X moves along the X guide member 221X, the object-forming head 21 connected to the X slide member 222X via the head drive system 22Z moves along the X axis. When the Z slide member 222Z moves along the Z guide member 221Z, the object-forming head 21 connected to the Z slide member 222Z moves along the Z axis.

[0025] When the head drive system 22 moves the object-modeling head 21, the relative positions of the object-modeling head 21, the stage 31, and the workpiece W placed on the stage 31 change. Therefore, the head drive system 22 may function as a position changing device for changing the relative positional relationship between the object-modeling head 21, the stage 31, and the workpiece W. Furthermore, when the relative positions of the object-modeling head 21, the stage 31, and the workpiece W change, the target irradiation area EA and the target supply area MA (and further, the molten pool MP) move relative to the workpiece W.

[0026] The stage unit 3 includes a stage 31 and a stage drive system 32 .

[0027] A workpiece W, which is an object, is placed on the stage 31. Specifically, the workpiece W is placed on a placement surface 311, which is at least a part of the upper surface of the stage 31. When a three-dimensional structure ST is formed on the workpiece W, the three-dimensional structure ST is placed on the stage 31 via the workpiece W. For this reason, the stage 31 may be referred to as an object placement device. The stage 31 is capable of supporting the workpiece W placed on the stage 31. When a three-dimensional structure ST is formed on the workpiece W, the stage 31 is capable of supporting the three-dimensional structure ST via the workpiece W. For this reason, the stage 31 may be referred to as a support device. The stage 31 may be capable of holding the workpiece W placed on the stage 31. In this case, the stage 31 may be equipped with at least one of a mechanical chuck, an electrostatic chuck, a vacuum chuck, and the like, in order to hold the workpiece W. Alternatively, the stage 31 may not be capable of holding the workpiece W placed on the stage 31. In this case, the workpiece W may be placed on the stage 31 in a clampless manner. The above-mentioned irradiation optical system 211 emits the modeling light EL during at least a portion of the period during which the workpiece W is placed on the stage 31. Furthermore, the above-mentioned material nozzle 212 supplies the modeling material M during at least a portion of the period during which the workpiece W is placed on the stage 31.

[0028] In this embodiment, the stage 31 includes a stage 31θX and a stage 31θZ. The reason why the stage 31 includes the stage 31θX and the stage 31θZ is to move the stage 31 along the θX direction and the θZ direction by a stage driving system 32 described later, as will be described in detail later. The workpiece W is placed on the stage 31θZ. For this reason, at least a part of the upper surface of the stage 31θZ is used as a mounting surface 311 on which the workpiece W is placed. The stage 31θX is movable along the θX direction by the stage driving system 32, as will be described later (i.e., rotatable around a rotation axis along the X-axis). The stage 31θZ is disposed in a recess formed in the stage 31θX so as to be rotatable around a rotation axis along the X-axis together with the stage 31θX in accordance with the rotation of the stage 31θX. As described below, stage 31θZ is disposed in a recess formed in stage 31θX so that it can be moved along the θZ direction by stage drive system 32 regardless of the rotation of stage 31θX (i.e., can rotate around a rotation axis along the Z axis). Note that the configuration of stage 31 is not limited to the configuration shown in Figures 2 and 3. As an example, stage 31θZ does not have to be disposed in a recess formed in stage 31θX.

[0029] The stage driving system 32 moves the stage 31. The stage driving system 32 moves the stage 31, for example, along at least one of the X-axis, Y-axis, Z-axis, θX direction, θY direction, and θZ direction. In the example shown in FIG. 2 and FIG. 3, the stage driving system 32 moves the stage 31 along each of the θX direction and the θZ direction. That is, the stage driving system 32 rotates the stage 31 around a rotation axis along the X-axis, and rotates the stage 31 around a rotation axis along the Z-axis. In this case, the stage driving system 32 may include a stage driving system 32θX and a stage driving system 32θZ. The stage driving system 32θX rotates the stage 31 (particularly, the stage 31θX) around a rotation axis along the X-axis. The stage driving system 32θZ rotates the stage 31 (particularly, the stage 31θZ) around a rotation axis along the Z-axis. The stage driving system 32θX includes a pair of rotating shafts 321θX rotatably connected to a pair of support frames 323 installed on the bottom surface of the housing 8 (or a base placed on the bottom surface of the housing 8) via an anti-vibration device such as an air spring, and a motor 322θX which is a driving device for rotating the pair of rotating shafts 321θX around a rotation axis along the X axis. The pair of rotating shafts 321θX extend along the X axis direction. The pair of rotating shafts 321θX are connected to the stage 31θX so as to sandwich the stage 31θX along the X axis direction. The stage driving system 32θZ includes a rotating shaft 321θZ which extends along the Z axis direction and is connected to the bottom surface of the stage 31θZ (specifically, the surface facing the stage 31θX), and a motor 322θZ which rotates the rotating shaft 321θZ around a rotation axis along the Z axis. When the pair of rotating shafts 321θX rotate, the stage 31θX rotates around a rotation axis along the X axis. As a result, the stage 31θZ supported by the stage 31θX (and further, the workpiece W supported by the stage 31θZ) also rotates about a rotation axis along the X-axis. When the rotating shaft 321θZ rotates, the stage 31θZ (and further, the workpiece W supported by the stage 31θZ) also rotates about a rotation axis along the Z-axis. Note that the stage 31 shown in FIGS. 2 and 3 has a double-supported structure in which the stage 31θX is supported from both sides by the support frame 323.However, the stage 31 may have a cantilever structure in which the stage 31θX is supported from one side by the support frame 323.

[0030] When the stage drive system 32 moves the stage 31, the relative positions of the object-modeling head 21 and the stage 31 and the workpiece W placed on the stage 31 change. For this reason, the stage drive system 32 may function as a position changing device for changing the relative positional relationship between the object-modeling head 21 and the stage 31 and the workpiece W. Furthermore, when the relative positions of the object-modeling head 21 and the stage 31 and the workpiece W change, the target irradiation area EA and the target supply area MA (and further, the molten pool MP) move relative to the workpiece W.

[0031] The operation of rotating the stage 31 around the rotation axis may be considered to be substantially equivalent to an operation of changing the attitude of the stage 31 (for example, changing the relative attitude of the stage 31 with respect to the object-forming head 21). For this reason, the stage drive system 32 may function as a position changing device for changing the relative positional relationships between the object-forming head 21 and each of the stage 31 and the workpiece W by changing the relative attitude of the stage 31 with respect to the object-forming head 21.

[0032] The light source 5 emits, for example, at least one of infrared light, visible light, and ultraviolet light as the shaping light EL. However, other types of light may be used as the shaping light EL. The shaping light EL may include multiple pulsed lights (i.e., multiple pulse beams). The shaping light EL may be laser light. In this case, the light source 5 may include a laser light source (for example, a semiconductor laser such as a laser diode (LD: Laser Diode). The laser light source may be a fiber laser, a CO2 laser, a YAG laser, an excimer laser, etc. However, the shaping light EL does not have to be laser light. The light source 5 may include any light source (for example, at least one of an LED (Light Emitting Diode) and a discharge lamp, etc.).

[0033] The gas supply source 6 is a supply source of a purge gas for purging the internal space of the housing 8. The purge gas includes an inert gas. Examples of the inert gas include nitrogen gas and argon gas. The gas supply source 6 supplies the purge gas to the internal space of the housing 8 through a supply pipe 61 that connects the gas supply source 6 and the housing 8. As a result, the internal space of the housing 8 becomes a space purged by the purge gas. The gas supply source 6 may be a cylinder that stores an inert gas such as nitrogen gas or argon gas. When the inert gas is nitrogen gas, the gas supply source 6 may be a nitrogen gas generator that generates nitrogen gas using the air as a raw material.

[0034] As described above, when the material nozzle 212 supplies the modeling material M together with the purge gas, the gas supply source 6 may supply the purge gas to the mixer 12 to which the modeling material M from the material supply source 1 is supplied. Specifically, the gas supply source 6 may be connected to the mixer 12 via a supply pipe 62 that connects the gas supply source 6 and the mixer 12. As a result, the gas supply source 6 supplies the purge gas to the mixer 12 via the supply pipe 62. In this case, the modeling material M from the material supply source 1 may be supplied (specifically, pumped) through the supply pipe 11 toward the material nozzle 212 by the purge gas supplied from the gas supply source 6 via the supply pipe 62. In other words, the gas supply source 6 may be connected to the material nozzle 212 via the supply pipe 62, the mixer 12, and the supply pipe 11. In that case, the material nozzle 212 supplies the modeling material M from the supply outlet 214 together with the purge gas for pumping the modeling material M.

[0035] The control device 7 controls the operation of the modeling system SYS. For example, the control device 7 may control the modeling unit 2 (e.g., at least one of the modeling head 21 and the head drive system 22) included in the modeling system SYS. For example, the control device 7 may control the stage unit 3 (e.g., the stage drive system 32) included in the modeling system SYS. As a result, the control device 7 may control at least one of the modeling unit 2 and the stage unit 3 to model a model (e.g., a three-dimensional structure ST).

[0036] The control device 7 may include, for example, a calculation device and a storage device. The calculation device may include, for example, at least one of a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit). The storage device may include, for example, a memory. The control device 7 functions as a device that controls the operation of the modeling system SYS by the calculation device executing a computer program. This computer program is a computer program for making the calculation device perform (i.e., execute) the operation to be performed by the control device 7, which will be described later. In other words, this computer program is a computer program for making the control device 7 function so as to make the modeling system SYS perform the operation to be described later. The computer program executed by the calculation device may be recorded in a storage device (i.e., a recording medium) included in the control device 7, or may be recorded in any storage medium (e.g., a hard disk or a semiconductor memory) built into the control device 7 or externally attachable to the control device 7. Alternatively, the calculation device may download the computer program to be executed from a device external to the control device 7 via a network interface.

[0037] The control device 7 may control the emission mode of the modeling light EL by the irradiation optical system 211. The emission mode may include, for example, at least one of the intensity of the modeling light EL and the emission timing of the modeling light EL. When the modeling light EL includes a plurality of pulsed lights, the emission mode may include, for example, at least one of the emission time of the pulsed light, the emission cycle of the pulsed light, and the ratio between the emission time of the pulsed light and the emission cycle of the pulsed light (so-called duty ratio). Furthermore, the control device 7 may control the movement mode of the modeling head 21 by the head driving system 22. The control device 7 may control the movement mode of the stage 31 by the stage driving system 32. The movement mode may include, for example, at least one of the movement amount, the movement speed, the movement direction, and the movement timing (movement time). Furthermore, the control device 7 may control the supply mode of the modeling material M by the material nozzle 212. The supply mode may include, for example, at least one of the supply amount (particularly, the supply amount per unit time) and the supply timing (supply time).

[0038] The control device 7 may not be provided inside the modeling system SYS. For example, the control device 7 may be provided as a server or the like outside the modeling system SYS. In this case, the control device 7 and the modeling system SYS may be connected by a wired and / or wireless network (or a data bus and / or a communication line). As the wired network, a network using a serial bus type interface represented by at least one of IEEE1394, RS-232x, RS-422, RS-423, RS-485, and USB may be used. As the wired network, a network using a parallel bus type interface may be used. As the wired network, a network using an interface compliant with Ethernet (registered trademark) represented by at least one of 10BASE-T, 100BASE-TX, and 1000BASE-T may be used. As the wireless network, a network using radio waves may be used. An example of a network using radio waves is a network compliant with IEEE802.1x (for example, at least one of wireless LAN and Bluetooth (registered trademark)). A network using infrared rays may be used as the wireless network. A network using optical communication may be used as the wireless network. In this case, the control device 7 and the modeling system SYS may be configured to be able to transmit and receive various information via the network. The control device 7 may also be able to transmit information such as commands and control parameters to the modeling system SYS via the network. The modeling system SYS may include a receiving device that receives information such as commands and control parameters from the control device 7 via the network. The modeling system SYS may include a transmitting device (i.e., an output device that outputs information to the control device 7) that transmits information such as commands and control parameters to the control device 7 via the network. Alternatively, a first control device that performs a part of the processing performed by the control device 7 may be provided inside the modeling system SYS, while a second control device that performs another part of the processing performed by the control device 7 may be provided outside the modeling system SYS.

[0039] As a recording medium for recording the computer program executed by the control device 7, at least one of CD-ROM, CD-R, CD-RW, flexible disk, MO, DVD-ROM, DVD-RAM, DVD-R, DVD+R, DVD-RW, DVD+RW, Blu-ray (registered trademark), and other optical disks, magnetic media such as magnetic tape, magneto-optical disk, semiconductor memory such as USB memory, and any other medium capable of storing a program may be used. The recording medium may include a device capable of recording a computer program (for example, a general-purpose device or a dedicated device in which a computer program is implemented in a state in which it can be executed in at least one of the forms of software and firmware). Furthermore, each process or function included in the computer program may be realized by a logical processing block realized in the control device 7 by the control device 7 (i.e., a computer) executing the computer program, or may be realized by hardware such as a predetermined gate array (FPGA, ASIC) provided in the control device 7, or may be realized in a form in which a logical processing block and a partial hardware module that realizes some elements of the hardware are mixed.

[0040] (2) Operation of modeling system SYS Next, the operation of the modeling system SYS will be described.

[0041] (2-1) Modeling operation First, a modeling operation (additive processing operation in this embodiment) for forming a three-dimensional structure ST will be described. As described above, the modeling system SYS performs modeling operation for forming a three-dimensional structure ST by performing additive processing on the workpiece W. Specifically, the modeling system SYS forms the three-dimensional structure ST by a laser build-up welding method. For this reason, the modeling system SYS may form the three-dimensional structure ST by performing an existing additive processing operation conforming to the laser build-up welding method. Below, an example of a modeling operation for forming a three-dimensional structure ST using the laser build-up welding method will be briefly described.

[0042] The modeling system SYS models a three-dimensional structure ST on a workpiece W based on three-dimensional model data (e.g., CAD (Computer Aided Design) data) of the three-dimensional structure ST to be modeled. Measurement data of a solid object measured by at least one of a measuring device (not shown) provided in the modeling system SYS and a three-dimensional shape measuring device provided separately from the modeling system SYS may be used as the three-dimensional model data. In order to model the three-dimensional structure ST, the modeling system SYS sequentially models, for example, a plurality of layered partial structures (hereinafter referred to as "structural layers") SL arranged along the Z-axis direction. For example, the modeling system SYS sequentially models a plurality of structural layers SL one by one based on data of a plurality of layers obtained by slicing a model of the three-dimensional structure ST along the Z-axis direction. As a result, a three-dimensional structure ST, which is a laminated structure in which a plurality of structural layers SL are stacked, is modeled. Hereinafter, a flow of operations for modeling a three-dimensional structure ST by sequentially modeling a plurality of structural layers SL one by one will be described.

[0043] First, the operation of forming each structure layer SL will be described with reference to FIG. 4(a) to FIG. 4(e). Under the control of the control device 7, the modeling system SYS moves at least one of the modeling head 21 and the stage 31 so that the target irradiation area EA is set in a desired area on the modeling surface MS corresponding to the surface of the workpiece W or the surface of the modeled structure layer SL. After that, the modeling system SYS irradiates the modeling light EL from the irradiation optical system 211 to the target irradiation area EA. At this time, the light collecting surface on which the modeling light EL is collected in the Z-axis direction may coincide with the modeling surface MS. Alternatively, the light collecting surface may deviate from the modeling surface MS in the Z-axis direction. As a result, as shown in FIG. 4(a), a molten pool (i.e., a pool of metal or the like melted by the modeling light EL) MP is formed on the modeling surface MS irradiated with the modeling light EL. Furthermore, under the control of the control device 7, the modeling system SYS supplies the modeling material M from the material nozzle 212. As a result, the modeling material M is supplied to the molten pool MP. The modeling material M supplied to the molten pool MP is melted by the modeling light EL irradiated onto the molten pool MP. Alternatively, the modeling material M supplied from the material nozzle 212 may be melted by the modeling light EL before reaching the molten pool MP, and the molten modeling material M may be supplied to the molten pool MP. Thereafter, when the modeling light EL is no longer irradiated onto the molten pool MP as at least one of the modeling head 21 and the stage 31 moves, the molten modeling material M in the molten pool MP is cooled and solidified (i.e., solidified). As a result, as shown in FIG. 4(c), a model made of the solidified modeling material M is deposited on the modeling surface MS.

[0044] The modeling system SYS repeats a series of modeling processes, including forming a molten pool MP by irradiating the modeling light EL, supplying the modeling material M to the molten pool MP, melting the supplied modeling material M, and solidifying the molten modeling material M, while moving the modeling head 21 relative to the modeling surface MS along at least one of the X-axis direction and the Y-axis direction, as shown in Fig. 4(d). Typically, the modeling system SYS repeats a scanning operation in which the modeling head 21 moves relative to the modeling surface MS along either the X-axis direction or the Y-axis direction while irradiating the modeling surface MS with the modeling light EL at a desired timing, and a stepping operation in which the modeling head 21 moves relative to the modeling surface MS along the other of the X-axis direction and the Y-axis direction without irradiating the modeling light EL to the modeling surface MS. In this case, during the period in which the scanning operation is being performed, the modeling system SYS irradiates the modeling light EL to an area on the modeling surface MS where a model is to be formed, while not irradiating the modeling light EL to an area on the modeling surface MS where a model is not to be formed. That is, the modeling system SYS irradiates the modeling light EL to the modeling surface MS at a timing according to the distribution of the area where the object is to be modeled while moving the target irradiation area EA along a predetermined movement trajectory on the modeling surface MS. Typically, the modeling system SYS repeats a scanning operation of moving the target irradiation area EA along either the X-axis direction or the Y-axis direction relative to the modeling surface MS while irradiating the target irradiation area EA with the modeling light EL at a desired timing, and a stepping operation of moving the target irradiation area EA along the other of the X-axis direction or the Y-axis direction relative to the modeling surface MS without irradiating the target irradiation area EA with the modeling light EL. As a result, the molten pool MP also moves on the modeling surface MS along a movement trajectory according to the movement trajectory of the target irradiation area EA. Specifically, the molten pool MP is sequentially formed on the modeling surface MS in the area along the movement trajectory of the target irradiation area EA where the modeling light EL is irradiated. As a result, as shown in FIG. 4(e), a structure layer SL corresponding to the object, which is an aggregate of the melted and then solidified modeling material M, is formed on the modeling surface MS. In other words, a structural layer SL (i.e., a structural layer SL having a shape corresponding to the movement trajectory of the molten pool MP in a planar view) corresponding to a collection of objects formed on the building surface MS in a pattern corresponding to the movement trajectory of the molten pool MP is formed.When the target irradiation area EA is set in an area where it is not desired to form an object, the modeling system SYS may irradiate the target irradiation area EA with the modeling light EL and stop the supply of the modeling material M. When the target irradiation area EA is set in an area where it is not desired to form an object, the modeling system SYS may supply the modeling material M to the target irradiation area EA and irradiate the target irradiation area EA with modeling light EL of an intensity that does not allow a molten pool MP to form.

[0045] The modeling system SYS repeatedly performs an operation for forming such a structure layer SL based on the three-dimensional model data under the control of the control device 7. Specifically, first, before performing an operation for forming the structure layer SL, the control device 7 slices the three-dimensional model data at a layer pitch to create slice data. The modeling system SYS performs an operation for forming the first structure layer SL#1 on the printing surface MS corresponding to the surface of the workpiece W based on the slice data corresponding to the structure layer SL#1. As a result, the structure layer SL#1 is formed on the printing surface MS as shown in FIG. 5(a). After that, the modeling system SYS sets the surface (i.e., the upper surface) of the structure layer SL#1 as a new printing surface MS, and then forms the second structure layer SL#2 on the new printing surface MS. In order to form the structure layer SL#2, the control device 7 first controls at least one of the head driving system 22 and the stage driving system 32 so that the printing head 21 moves along the Z axis relative to the stage 31. Specifically, the control device 7 controls at least one of the head driving system 22 and the stage driving system 32 to move the modeling head 21 toward the +Z side and / or move the stage 31 toward the -Z side so that the target irradiation area EA is set on the surface of the structure layer SL#1 (i.e., the new modeling surface MS). Thereafter, under the control of the control device 7, the modeling system SYS models the structure layer SL#2 on the structure layer SL#1 based on the slice data corresponding to the structure layer SL#2, in the same manner as the operation for modeling the structure layer SL#1. As a result, as shown in FIG. 5(b), the structure layer SL#2 is modeled. Thereafter, the same operation is repeated until all the structure layers SL constituting the three-dimensional structure ST to be modeled on the workpiece W are modeled. As a result, as shown in FIG. 5(c), the three-dimensional structure ST is modeled by a stacked structure in which a plurality of structure layers SL are stacked.

[0046] (2-2) Specific examples of modeling operations In this embodiment, the modeling system SYS may model a second object above a first object by performing the above-mentioned modeling operation. That is, the modeling system SYS may model a three-dimensional structure ST including the second object modeled above the first object. The modeling system SYS may model a three-dimensional structure ST including the first object and the second object modeled above the first object.

[0047] In this embodiment, when forming a second object above a first object, the modeling system SYS may form the second object such that a space is formed below the second object and the upper part of the space is closed (e.g., blocked). At this time, the modeling system SYS may form the second object above the first object having the first space (i.e., the first object in which the first space is formed) such that a second space is formed below the second object and the upper part of the second space is closed. At this time, the first space and the second space may be connected. At this time, the modeling system SYS may form a first space below the second object and close the upper part of the first space by forming the second object on the upper surface (typically a flat or convex surface) of the first object.

[0048] An example of a three-dimensional structure ST including a second object formed above a first object is shown in Figs. 6 to 9. Fig. 6 is a perspective view showing the appearance of a three-dimensional structure ST including a second object formed above a first object. Fig. 7 is a plan view showing the upper surface of a three-dimensional structure ST including a second object formed above a first object. Fig. 8 is a cross-sectional view (particularly, a cross-sectional view taken along line A-A' in Fig. 7) showing a cross section of a three-dimensional structure ST including a second object formed above a first object. Fig. 9 is a cross-sectional view (particularly, a cross-sectional view taken along line B-B' in Fig. 7) showing a cross section of a three-dimensional structure ST including a second object formed above a first object.

[0049] 6 to 9 show a three-dimensional structure ST including a base member BM, which is an example of a first object, and a roof member RM, which is an example of a second object, formed above the base member BM, as an example of a three-dimensional structure ST including a second object formed above the first object. Note that Figs. 6 to 9 show an example in which the three-dimensional structure ST is a turbine blade BL that constitutes the blades of a turbine. That is, Figs. 6 to 9 show a three-dimensional structure ST that can be used as a turbine blade BL. In other words, Figs. 6 to 9 show an example in which the shape of the three-dimensional structure ST corresponds to the shape of the turbine blade BL. Note that the turbine blade BL may be a moving blade or a stationary blade. However, the three-dimensional structure ST including the second object formed above the first object is not limited to the turbine blade BL. The three-dimensional structure ST including the second object formed above the first object may be an object other than the turbine blade BL (for example, an object used for a purpose other than use in a turbine).

[0050] As shown in Figs. 6 to 9, the three-dimensional structure ST has a shape extending along the longitudinal direction (the X-axis direction in the examples shown in Figs. 6 to 9). Since the three-dimensional structure ST is a turbine blade BL, the three-dimensional structure ST may be curved to have a bow-shaped shape in a plan view. In the examples shown in Figs. 6 to 9, the three-dimensional structure ST is curved in a plane along the XY plane so as to have a bow-shaped shape in the plane along the XY plane. Therefore, each of the base member BM and the roof member RM may also have a shape extending along the X-axis direction, and may be curved in a plane along the XY plane so as to have a bow-shaped shape in the plane along the XY plane.

[0051] The base member BM includes a bottom member BMC, a sidewall member BML, and a sidewall member BMR.

[0052] The bottom member BMC is, for example, a long plate-like member that extends to have a longitudinal direction (i.e., extends along the longitudinal direction). In the example shown in Fig. 6 to Fig. 9, the bottom member BMC has a longitudinal direction along the X-axis direction (for example, has a longitudinal direction in a direction substantially parallel to the rotation axis of the stage 31θX described above). However, since the three-dimensional structure ST is a turbine blade, the bottom member BMC may be curved to have a bow-shaped shape in a planar view. In the example shown in Fig. 6 to Fig. 9, the bottom member BMC may be curved in a plane along the XY plane to have a bow-shaped shape in a plane along the XY plane.

[0053] The sidewall member BML and the sidewall member BMR are formed on the bottom member BMC. The sidewall member BML and the sidewall member BMR may be formed along the outer edge of the bottom member BMC. In this case, the sidewall member BML, the sidewall member BMR, and the bottom member BMC may be formed as an integrated member (as a monolithic member). Specifically, the sidewall member BML may be formed along the outer edge of one side of the bottom member BMC (for example, the outer edge of the -Y side), and the sidewall member BMR may be formed along the outer edge of one side of the bottom member BMC (for example, the outer edge of the +Y side). For this reason, each of the sidewall members BML and BMR may be curved so as to have an arched shape in a plan view. In the examples shown in FIG. 6 to FIG. 9, each of the sidewall members BML and BMR may be curved in a plane along the XY plane so as to have an arched shape in a plane along the XY plane.

[0054] Each of the sidewall members BML and BMR extends upward so as to protrude from the bottom member BMC. The sidewall members BML and BMR may be formed so as to be connected in an annular shape in plan view (in the examples shown in Figs. 6 to 9, they are connected in an annular shape in a plane along the XY plane). As a result, the sidewall members BML and BMR may form a space BMsp (see Fig. 8) which is an example of a first space together with the bottom member BMC. That is, the sidewall members BML and BMR may protrude from the bottom member BMC and be connected in an annular shape in plan view so as to form a space BMsp surrounded by the sidewall members BML and BMR and the bottom member BMC (in other words, facing the sidewall members BML and BMR and the bottom member BMC).

[0055] The roof member RM includes a slope member RML and a slope member RMR.

[0056] The inclined member RML is a member connected to the side wall member BML. For example, the inclined member RML is formed on the side wall member BML. In this case, the inclined member RML may be formed along the side wall member BML. Therefore, the inclined member RML may be curved so as to have an arch shape in a plan view. In the examples shown in Figs. 6 to 9, the inclined member RML may be curved in a plane along the XY plane so as to have an arch shape in the plane along the XY plane.

[0057] The inclined member RML may be a plate-like member extending from the sidewall member BML. The inclined member RML may be a member extending from the sidewall member BML toward the upper side of the sidewall member BML. In particular, the inclined member RML may be a member extending in a direction inclined with respect to the sidewall member BML. For example, the inclined member RML may be a member extending in a direction inclined with respect to the upper surface BMLus of the sidewall member BML on which the inclined member RML is formed. In the example shown in FIG. 6 to FIG. 9, the upper surface BMLus of the sidewall member BML is a surface along the XY plane. Therefore, the inclined member RML may be a member extending in a direction inclined with respect to the XY plane. For example, the inclined member RML may be a member extending in a direction inclined with respect to the direction in which the sidewall member BML extends (i.e., protrudes). In the example shown in FIG. 6 to FIG. 9, the sidewall member BML is a member extending (i.e., protruding) in the Z-axis direction. Therefore, the inclined member RML may be a member extending in a direction inclined with respect to the Z-axis.

[0058] The inclined member RMR is a member connected to the side wall member BMR. For example, the inclined member RMR is formed on the side wall member BMR. In this case, the inclined member RMR may be formed along the side wall member BMR. Therefore, the inclined member RMR may be curved so as to have an arch shape in a plan view. In the examples shown in Figs. 6 to 9, the inclined member RMR may be curved in a plane along the XY plane so as to have an arch shape in the plane along the XY plane.

[0059] The inclined member RMR may be a plate-like member extending from the sidewall member BMR. The inclined member RMR may be a member extending from the sidewall member BMR toward the upper side of the sidewall member BMR. In particular, the inclined member RMR may be a member extending in a direction inclined with respect to the sidewall member BMR. For example, the inclined member RMR may be a member extending in a direction inclined with respect to the upper surface BMRus of the sidewall member BMR on which the inclined member RMR is formed. In the example shown in FIG. 6 to FIG. 9, the upper surface BMRus of the sidewall member BMR is a surface along the XY plane. Therefore, the inclined member RMR may be a member extending in a direction inclined with respect to the XY plane. For example, the inclined member RMR may be a member extending in a direction inclined with respect to the direction in which the sidewall member BMR extends (i.e., protrudes). In the example shown in FIG. 6 to FIG. 9, the sidewall member BMR is a member extending (i.e., protruding) in the Z-axis direction. Therefore, the inclined member RMR may be a member extending in a direction inclined with respect to the Z-axis.

[0060] A space RMsp (see FIG. 8), which is an example of a second space, may be formed below the inclined members RMR and RML. That is, the inclined members RMR and RML may be formed above the base member BM so that a space RMsp is formed below the inclined members RMR and RML that is partially surrounded by the inclined members RMR and RML (in other words, facing the inclined members RMR and RML). In this case, typically, the direction in which the inclined member RMR extends may be different from the direction in which the inclined member RML extends. For example, the direction in which the inclined member RMR extends may intersect with the direction in which the inclined member RML extends.

[0061] The space RMsp formed below the slope members RMR and RML may be connected to the space BMsp formed in the base member BM. In other words, the three-dimensional structure ST may have a space including the space BMsp and the space RMsp, which are surrounded by the base member BM and the roof member RM. The upper part of the space RMsp may be closed (in other words, it may be blocked or covered). Specifically, the upper part of the space RMsp may be closed by the slope members RML and RMR provided in the roof member RM. Note that the "space closed by the roof member RM" here may also mean the "space surrounded by the roof member RM".

[0062] In the case where the upper part of the space RMsp is closed by the roof member RM, the tip of the inclined member RML and the tip of the inclined member RMR may be connected. The tip of the inclined member RML may mean the other end (e.g., the upper end) of the inclined member RML located opposite to one end (e.g., the lower end) of the inclined member RML connected to the side wall member BML. The tip of the inclined member RMR may mean the other end (e.g., the upper end) of the inclined member RMR located opposite to one end (e.g., the lower end) of the inclined member RMR connected to the side wall member BMR. For example, as shown in Figs. 6 to 9, the roof member RM may include a connecting member RMC that connects the tip of the inclined member RML and the tip of the inclined member RMR. In other words, the roof member RM may be provided with a connecting member RMC that connects the tip of the inclined member RML and the tip of the inclined member RMR so that the upper part of the space RMsp is closed. In this case, the upper part of the space RMsp may be considered to be closed by the connecting member RMC. Alternatively, the tip of the slope member RML and the tip of the slope member RMR may be directly connected to each other, that is, the roof member RM does not necessarily have to include the connecting member RMC.

[0063] The roof member RM may further include a support member RMS. The support member RMS is a member for supporting the inclined portions RML and RMR. The support member RMS is, for example, a member for supporting the inclined portions RML and RMR from below. As an example, the support member RMS may be, for example, a plate-shaped member extending from below toward above so as to support the inclined portions RML and RMR from below.

[0064] The support member RMS is formed on the support member BMS provided on the base member BM. The support member BMS is a member that supports the support member RMS. For example, the support member BMS may be a member that supports the support member RMS from below. In this case, the support member RMS may be a member that extends upward from the support member BMS (i.e., from the support member BMS toward the sloped portions RML and RMR located above the support member BMS). The support member RMS may be a member that is connected to the support member BMS at its lower portion and connected to the sloped members RML and RMR at its upper portion.

[0065] The roof member RM may include multiple support members RMS at multiple discrete positions along the longitudinal direction of the roof member RM (i.e., the longitudinal direction in which the roof member RM extends). In this case, the base member BM may include multiple support members BMS at multiple discrete positions along the longitudinal direction of the base member BM (i.e., the longitudinal direction in which the base member BM extends). Note that Fig. 8 shows a cross section of the three-dimensional structure ST at a position where the support members BMS and RMS are not formed, and Fig. 9 shows a cross section of the three-dimensional structure ST at a position where the support members BMS and RMS are formed. Note that in the example shown in Figs. 6 to 7, the roof member RM has four support members RMS, but the number of support members RMS is not limited to four.

[0066] Next, the operation for forming a three-dimensional structure ST including a second object formed above a first object will be further described with reference to Figures 10 to 30. For convenience of explanation, the operation for forming the three-dimensional structure ST shown in Figures 6 to 9 will be described below. However, any three-dimensional structure ST including a second object formed above a first object may be formed by the operation described below.

[0067] First, as shown in Fig. 10(a) and Fig. 10(b), the modeling system SYS performs the above-mentioned modeling operation to model a base member BM on the workpiece W. Specifically, the modeling system SYS models a plurality of structure layers SL in order to model a base member BM composed of the plurality of structure layers SL on the workpiece W. Typically, the modeling system SYS first models a bottom member BMC, and then models a side wall member BML, a side wall member BMR, and a support member BMS on the bottom member BMC. At this time, the modeling system SYS may repeat a scanning operation of moving the target irradiation area EA along the longitudinal direction of the base member BM (e.g., the X-axis direction) while irradiating the target irradiation area EA with the modeling light EL at a desired timing, and a stepping operation of moving the target irradiation area EA along a direction intersecting the longitudinal direction of the base member BM (e.g., the Y-axis direction) without irradiating the target irradiation area EA with the modeling light EL. Note that Figure 10(a) shows a cross-section of the base member BM at a position where the support member BMS has not been formed, and Figure 10(b) shows a cross-section of the base member BM at a position where the support member BMS has been formed.

[0068] However, an already-modeled base member BM may be used. In this case, the modeling system SY does not need to model the base member BM. The already-modeled base member BM may be placed on the stage 31 as the workpiece W. The already-modeled base member BM may be a turbine blade, or may be a turbine blade that needs repair.

[0069] After the base member BM is modeled, the modeling system SYS performs the above-mentioned modeling operation to model a roof member RM on the base member BM. Specifically, the modeling system SYS models a roof member RM composed of a plurality of structural layers SL on the base member BM by sequentially modeling the plurality of structural layers SL. In other words, the modeling system SYS models a roof member RM composed of a plurality of structural layers SL and including slope members RML, slope members RMR, and support members RMS on the base member BM.

[0070] Here, as described above, the inclined member RML is inclined with respect to the sidewall member BML. Therefore, in order to model the inclined member RML in a state in which the upper surface BMLus of the sidewall member BML on which the inclined member RML is to be formed is a horizontal plane, the modeling system SYS needs to model an inclined portion RML extending from the upper surface BMLus along a direction inclined with respect to the gravity direction (i.e., a direction intersecting with the gravity direction corresponding to the Z-axis direction) as shown in FIG. 11 showing the inclined member RML to be modeled on the sidewall member BML. From another perspective, the modeling system SYS needs to model an inclined portion RML extending along a direction intersecting with the principal axis of the modeling light EL (specifically, an axis along the principal ray, and in the example shown in FIG. 11, an axis along the Z-axis). From yet another perspective, the modeling system SYS needs to model an inclined portion RML extending along a direction intersecting with the mounting surface 311 of the workpiece W on which the base member BM is mounted.

[0071] On the other hand, since the modeling system SYS models the three-dimensional structure ST by sequentially modeling a plurality of structural layers SL, there is a limit to the angle θL between the direction in which the inclined member RML extends and the direction of gravity. This is because, as shown in FIG. 12, which shows an enlarged view of the inclined member RML modeled on the sidewall member BML, the distance d between the end of one structural layer SL and the end of another structural layer SL modeled on the one structural layer SL in a direction intersecting the direction in which the plurality of structural layers SL are stacked (the Y-axis direction in the example shown in FIG. 12) cannot exceed the allowable upper limit distance dmax, and therefore the allowable upper limit angle θmax of the angle θL caused by the allowable upper limit distance dmax is determined. In other words, it is difficult for the modeling system SYS to model the inclined member RML that extends along a direction intersecting the direction of gravity at an angle exceeding the allowable upper limit angle θmax. For this reason, depending on the relationship between the direction of gravity and the direction in which the inclined member RML extends from the upper surface BMLus, it may be difficult for the modeling system SYS to appropriately model the inclined member RML. Incidentally, the "angle θL between the extension direction of the inclined member RML and the direction of gravity" referred to here may mean the smaller of the two angles (typically an acute angle) between the axis along the extension direction of the inclined member RML and the axis along the direction of gravity (the Z-axis in the example shown in FIG. 12).

[0072] Although a detailed description is omitted, the same can be said about the inclination member RMR extending in a direction intersecting the direction in which the inclination member RML extends.

[0073] Therefore, in the present embodiment, the modeling system SYS may, as necessary, before modeling the inclined member RML, rotate (i.e., move) the stage 31 from the reference position in the first direction around the rotation axis to set the state of the stage 31 to a state in which the angle θL between the extension direction of the inclined member RML and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax. Note that, as the reference position of the stage 31, a position of the stage 31 in a state in which the placement surface 311 is a horizontal plane may be used. In other words, before modeling the inclined member RML, the modeling system SYS may change the state of the stage 31 to a first state for modeling the inclined member RML, which is different from the third state for modeling the base member BM. Note that, as described above, when the stage 31 rotates, the relative positional relationship between the modeling head 21 and the stage 31 changes. Therefore, before printing the inclined member RML, the modeling system SYS may change the relative positional relationship between the modeling head 21 and the stage 31 to a first relationship for printing the inclined member RML, which is different from the third relationship for printing the base member BM. After that, the modeling system SYS may print the inclined member RML in a state where the angle θL between the extension direction of the inclined member RML and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax.

[0074] Similarly, the modeling system SYS may, as necessary, before modeling the tilted member RMR, rotate (i.e., move) the stage 31 from the reference position in a second direction around the rotation axis to set the state of the stage 31 to a state in which the angle θR between the extension direction of the tilted member RMR and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax. Note that the second direction, which is the rotation direction of the stage 31 before modeling the tilted member RMR, is typically the opposite direction to the first direction, which is the rotation direction of the stage 31 before modeling the tilted member RML, but may be the same direction. In other words, the modeling system SYS may change the state of the stage 31 to a second state, which is different from the third state for modeling the base member BM and the first state for modeling the tilted member RML and is for modeling the tilted member RMR, before modeling the tilted member RMR. Before modeling the inclined member RMR, the modeling system SYS may change the relative positional relationship between the modeling head 21 and the stage 31 to a second relationship for modeling the inclined member RMR, which is different from the third relationship for modeling the base member BM and the first relationship for modeling the inclined member RML. After that, the modeling system SYS may model the inclined member RMR in a state where the angle θR between the extension direction of the inclined member RMR and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax.

[0075] As an example, an example of the state of the stage 31 for forming the inclined members RML and BMR with an inclination angle θob of 45 degrees with respect to the mounting surface 311 under the condition that the allowable upper limit angle θmax is 15 degrees will be described with reference to Figures 13(a) and 13(b). Note that the inclination angle θob of the inclined member RML with respect to the mounting surface 311 may mean the smaller angle (typically an acute angle) of two angles between an axis along the normal line of the mounting surface 311 and an axis along the extension direction of the inclined member RML. The inclination angle θob of the inclined member RMR with respect to the mounting surface 311 may mean the smaller angle (typically an acute angle) of two angles between an axis along the normal line of the mounting surface 311 and an axis along the extension direction of the inclined member RMR.

[0076] FIG. 13(a) is a cross-sectional view showing an example of a state of the stage 31 for forming the inclined member RML. As shown in FIG. 13(a), the modeling system SYS may rotate the stage 31 around the X-axis in a first rotation direction from a reference position by “90 degrees-(upper limit angle θmax+inclination angle θob)” after forming the base member BM so that the longitudinal direction of the base member BM is the X-axis direction. In the example shown in FIG. 13(a), the modeling system SYS may rotate the stage 31 around the X-axis in a counterclockwise direction from a reference position by “90 degrees-(15 degrees+45 degrees)=30 degrees”. After that, the modeling system SYS may form the inclined member RML so that the inclined member RML extends along a direction in which the angle θL with respect to the gravity direction is equal to the upper limit angle θmax (i.e., 15 degrees). In this case, it may be considered that the modeling system SYS models the inclined member RML extending along a direction intersecting at least one of the direction of gravity, the principal axis of the modeling light EL, and the placement surface 311. As a result, the inclination angle of the modeled inclined member RML with respect to the placement surface 311 is 45 degrees.

[0077] 13(a), the modeling system SYS models the inclined member RML so that the angle θL is greater than zero degrees, but the modeling system SYS may also model the inclined member RML so that the angle θL is zero degrees (i.e., the inclined member RML extends along the direction of gravity). The modeling system SYS may also rotate the stage 31 around the X-axis in a first rotation direction from a reference position by a desired first rotation angle, and model the inclined member RML so that the inclination angle of the modeled inclined member RML with respect to the mounting surface 311 becomes the desired first angle.

[0078] FIG. 13(b) is a cross-sectional view showing an example of a state of the stage 31 for forming the inclined member RMR. As shown in FIG. 13(b), the modeling system SYS may rotate the stage 31 around the X-axis from the reference position by “90 degrees-(upper limit angle θmax+inclination angle θob)” in a second rotation direction opposite to the first rotation direction, after forming the base member BM so that the longitudinal direction of the base member BM is the X-axis direction. In the example shown in FIG. 13(b), the modeling system SYS may rotate the stage 31 around the X-axis from the reference position by “90 degrees-(upper limit angle θmax+inclination angle θob)” in a clockwise direction. After that, the modeling system SYS may form the inclined member RMR so that the inclined member RMR extends along a direction in which the angle θR with respect to the gravity direction is equal to the upper limit angle θmax. In this case, it may be considered that the modeling system SYS models the inclined member RMR extending along a direction intersecting at least one of the direction of gravity, the principal axis of the modeling light EL, and the placement surface 311. As a result, the inclination angle of the modeled inclined member RMR with respect to the placement surface 311 is 45 degrees.

[0079] 13(b), the modeling system SYS models the inclined member RMR so that the angle θR is greater than zero degrees, but the modeling system SYS may also model the inclined member RMR so that the angle θR is zero degrees (i.e., the inclined member RMR extends along the direction of gravity). The modeling system SYS may also rotate the stage 31 around the X-axis in a second rotation direction from the reference position by a desired second rotation angle, and model the inclined member RMR so that the inclination angle of the modeled inclined member RMR with respect to the mounting surface 311 becomes the desired second angle by modeling the inclined member RMR so that the inclination angle of the modeled inclined member RMR with respect to the mounting surface 311 becomes the desired second angle.

[0080] However, the modeling system SYS may not rotate the stage 31 from the reference position in the first direction around the rotation axis before modeling the inclined member RML. For example, if the angle θL between the extension direction of the inclined member RML and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax without rotating the stage 31, the modeling system SYS may not rotate the stage 31 from the reference position in the first direction around the rotation axis before modeling the inclined member RML. The modeling system SYS may model the inclined member RML on the base member BM placed on the stage 31 at the reference position. The modeling system SYS may model the inclined member RML under a condition in which the state of the stage 31 is in a third state for modeling the base member BM. The modeling system SYS may model the inclined member RML under a condition in which the relative positional relationship between the modeling head 21 and the stage 31 is in a third relationship for modeling the base member BM.

[0081] Similarly, the modeling system SYS may not rotate the stage 31 from the reference position in the second direction around the rotation axis before modeling the inclined member RMR. For example, if the angle θR between the extension direction of the inclined member RMR and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax without rotating the stage 31, the modeling system SYS may not rotate the stage 31 from the reference position in the second direction around the rotation axis before modeling the inclined member RMR. The modeling system SYS may model the inclined member RMR on a base member BM placed on the stage 31 at the reference position. The modeling system SYS may model the inclined member RMR under a condition in which the state of the stage 31 is in a third state for modeling the base member BM. The modeling system SYS may model the inclined member RMR under a condition in which the relative positional relationship between the modeling head 21 and the stage 31 is in a third relationship for modeling the base member BM.

[0082] In addition, in this embodiment, as described above, the inclined members RML and RMR extend in directions different from each other. In this case, when modeling of the other of the inclined members RML and RMR is started after the whole (or most) of one of the inclined members RML and RMR is modeled, the modeling light EL for modeling the other of the inclined members RML and RMR may be blocked by one of the inclined members RML and RMR. For example, FIG. 14 shows the modeling light EL irradiated to the side wall member BMR in order to model the inclined member RMR after the whole of the inclined member RML is modeled. As shown in FIG. 14, when an attempt is made to model the inclined member RMR that extends along a direction intersecting with the gravity direction at an angle smaller than the allowable upper limit angle θmax, the modeling light EL may be blocked by the already-modeled inclined member RML. As a result, the modeling system SYS may not be able to properly model the inclined member RMR.

[0083] Therefore, in this embodiment, an operation of alternately forming a modeled object including a part of the inclined member RML and a modeled object including a part of the inclined member RMR is repeated. That is, the modeling system SYS forms a roof member RM including the inclined members RML and RMR by sequentially forming a part of the inclined member RML and a part of the inclined member RMR. However, the modeling system SYS may form a roof member RM including the inclined members RML and RMR without sequentially forming a part of the inclined member RML and a part of the inclined member RMR. For example, the modeling system SYS may start forming the other of the inclined members RML and RMR after forming the whole (or most of) one of the inclined members RML and RMR. For example, in the case where the modeling light EL is not blocked by the already-formed inclined members RML and RMR, the modeling system SYS may start forming the other of the inclined members RML and RMR after forming the whole (or most of) one of the inclined members RML and RMR.

[0084] Below, the flow of operations in which the stage 31 is rotated from the reference position before printing each of the inclined members RML and RMR, and an object including a portion of the inclined member RML and an object including a portion of the inclined member RMR are alternately printed will be further explained with reference to Figures 15 to 30.

[0085] After the base member BM is formed, the modeling system SYS forms a part of the inclined member RML. In this case, as shown in Fig. 15(a) and Fig. 15(b), the modeling system SYS rotates the stage 31 from the reference position in a first direction around the rotation axis (e.g., the X-axis) before forming the inclined member RML. Note that Fig. 15(a) shows a cross section of the base member BM at a position where the support member BMS has not been formed, and Fig. 15(b) shows a cross section of the base member BM at a position where the support member BMS has been formed. Thereafter, as shown in Fig. 15(a), the modeling system SYS irradiates a region of the side wall member BML where a part of the inclined member RML is to be formed with modeling light EL in order to form a part of the inclined member RML. In addition, at the position where the support member BMS is being formed, the modeling system SYS irradiates modeling light EL to the area of ​​the side wall member BML where the inclined member RML is to be formed and the area of ​​the support member BMS where the support member RMS is to be formed, in order to form a part of the inclined member RML and a part of the support member RMS, as shown in Figure 15(b).

[0086] Even when printing a roof member RM, the modeling system SYS may repeat a scanning operation of moving the target irradiation area EA along a first direction (e.g., the longitudinal direction of the base member BM (e.g., the X-axis direction)) while irradiating the target irradiation area EA with modeling light EL at a desired timing, and a stepping operation of moving the target irradiation area EA along a second direction (e.g., a direction intersecting the longitudinal direction of the base member BM (e.g., the Y-axis direction)) without irradiating the target irradiation area EA with modeling light EL. For example, when the movement direction of the target irradiation area EA in the scanning operation coincides with a direction parallel to the rotation axis of the stage 31 (e.g., the X-axis), the modeling system SYS may perform a scanning operation of irradiating the side wall member BML and the support member BMS with modeling light EL while changing the relative positional relationship between the modeling head 21 and the stage 31 in the direction parallel to the rotation axis of the stage 31 (e.g., the X-axis direction). Alternatively, for example, when the movement direction of the target irradiation area EA in the scanning operation intersects with a direction parallel to the rotation axis of the stage 31 (e.g., the X-axis), the modeling system SYS may perform a scanning operation to irradiate the side wall member BML and the support member BMS with modeling light EL while simultaneously changing the relative positional relationship between the modeling head 21 and the stage 31 in a direction parallel to the rotation axis of the stage 31 (e.g., the X-axis direction) and the relative positional relationship between the modeling head 21 and the stage 31 in a direction perpendicular to the rotation axis of the stage 31 (e.g., the Y-axis direction).

[0087] As a result, at a position where the support member BMS is not formed (i.e., a position where the support member RMS does not need to be formed), a partial inclination member RMLp#1, which is a part of the inclination member RML, is formed on the side wall member BML as shown in Fig. 16(a). Also, at a position where the support member BMS is formed (i.e., a position where the support member RMS is formed), the partial inclination member RMLp#1 is formed on the side wall member BML, and a partial support member RMSp#11, which is a part of the support member RMS and is connected to the partial inclination member RMLp#1, is formed on the support member BMS as shown in Fig. 16(b).

[0088] The partial inclination member RMLp#1 may be a member composed of a single structural layer SL. The partial support member RMSp#11 formed together with the partial inclination member RMLp#1 may also be a member composed of a single structural layer SL. In this case, the modeling system SYS forms the partial inclination member RMLp#1 and the partial support member RMSp#11 by performing a modeling operation to model a single modeling layer SL. Alternatively, the partial inclination member RMLp#1 may be a member composed of a plurality of structural layers SL. The partial support member RMSp#11 formed together with the partial inclination member RMLp#1 may also be a member composed of a plurality of structural layers SL. In this case, the modeling system SYS forms the partial inclination member RMLp#1 and the partial support member RMSp#11 by performing a modeling operation to model a plurality of modeling layers SL. Incidentally, FIG. 16(a) and FIG. 16(b) show an example in which each of the partial inclination member RMLp#1 and the partial support member RMSp#11 is configured from a plurality of structural layers SL.

[0089] When the partial inclination member RMLp#1 and the partial support member RMSp#11 are composed of a plurality of structural layers SL, the number of scanning operations performed to form one structural layer SL may be different from the number of scanning operations performed to form another structural layer SL on one structural layer SL. For example, Fig. 17(a) to Fig. 17(d) are cross-sectional views showing the process of forming two structural layers SL constituting the partial inclination member RMLp#1. As shown in Fig. 17(a), when forming the first structural layer SL#1 on the upper surface BMLus of the side wall member BML, the modeling system SYS may set a part of the upper surface BMLus as the modeling surface MS and then perform a scanning operation to irradiate the modeling surface MS with the modeling light EL. The reason why a part of the upper surface BMLus, rather than the entire upper surface BMLus, is set as the modeling surface MS is that the upper and lower surfaces of the structural layer SL to be modeled are basically surfaces along a horizontal plane, while the upper surface BMLus on which the modeling surface MS is set is a surface that intersects with the horizontal plane. As a result, as shown in Fig. 17(b), the first structural layer SL#1 is formed on a part of the upper surface BMLus. Thereafter, as shown in Fig. 17(c), in order to form the second structural layer SL#2, the modeling system SYS may set the upper surface of the first structural layer SL#1 and another part of the upper surface BMLus as the modeling surface MS, and then perform a scanning operation to irradiate the modeling light EL onto the modeling surface MS. As a result, as shown in Fig. 17(d), the second structural layer SL#2 is formed on the upper surface of the first structural layer SL#1 and another part of the upper surface BMLus.

[0090] Here, when forming the second structural layer SL#2, the printing surface MS becomes wider in the direction intersecting the movement direction of the target irradiation area EA in the scanning operation (the X-axis direction in the example shown in FIG. 17(c)). Therefore, when forming the second structural layer SL#2, the number of scanning operations is greater than when forming the first structural layer SL#1. In the examples shown in FIG. 17(a) and FIG. 17(c), one scanning operation is performed when forming the first structural layer SL#1, and two scanning operations are performed when forming the second structural layer SL#2. In this way, if the number of scanning operations is adjusted, the structural layer SL can be appropriately printed even if the printing surface MS is set on a surface intersecting a horizontal plane.

[0091] Alternatively, the reason why the upper surface BMLus of the sidewall member BML on which the structure layer SL is formed becomes a surface intersecting with the horizontal plane is because the stage 31 rotates (i.e., moves) from the reference position after the base member BM is formed and before the inclined member RML is formed. Therefore, as shown in Fig. 18, the modeling system SYS may model the base member BM so that the upper surface BMLus of the sidewall member BML becomes a surface parallel to the horizontal plane in a state in which the stage 31 is rotated from the reference position to model the inclined member RML. For example, the modeling system SYS may model the base member BM at the stage of modeling the base member BM so that the upper surface BMLus of the sidewall member BML becomes a surface intersecting with the horizontal plane. In this case, the modeling system SYS may model the sidewall member BML whose upper surface BMLus becomes a surface intersecting with the horizontal plane by performing the above-mentioned modeling operation. Alternatively, the modeling system SYS may perform the above-described modeling operation to model the sidewall member BML whose upper surface BMLus is a surface parallel to the horizontal plane, and then remove a portion of the sidewall member BML to model the sidewall member BML whose upper surface BMLus is a surface intersecting the horizontal plane. For example, the modeling system SYS may remove a portion of the sidewall member BML by irradiating a portion of the sidewall member BML with modeling light EL.

[0092] After the partial inclined member RMLp#1 and the partial support member RMSp#11 are formed, the modeling system SYS forms a part of the inclined member RMR. In this case, as shown in Fig. 19(a) and Fig. 19(b), the modeling system SYS rotates the stage 31 from the reference position in a second direction around the rotation axis (e.g., the X-axis) before forming the inclined member RMR. Note that Fig. 19(a) shows a cross section of the base member BM at a position where the support member BMS has not been formed, and Fig. 19(b) shows a cross section of the base member BM at a position where the support member BMS has been formed. After that, as shown in Fig. 19(a), the modeling system SYS irradiates the modeling light EL to an area of ​​the side wall member BMR where a part of the inclined member RMR is to be formed, in order to form a part of the inclined member RMR. In addition, at the position where the support member BMS is being formed, the modeling system SYS irradiates modeling light EL to the area of ​​the side wall member BMR where the inclined member RMR is to be formed and the area of ​​the support member BMS where the support member RMS is to be formed, in order to form a part of the inclined member RMR and a part of the support member RMS, as shown in Figure 19(b).

[0093] As a result, at a position where the support member BMS is not formed (i.e., a position where the support member RMS does not need to be formed), a partial inclination member RMRp#1, which is a part of the inclination member RMR, is formed on the side wall member BMR, as shown in Fig. 20(a). Also, at a position where the support member BMS is formed (i.e., a position where the support member RMS is formed), the partial inclination member RMRp#1 is formed on the side wall member BMR, and a partial support member RMSp#12, which is a part of the support member RMS and is connected to the partial inclination member RMRp#1, is formed on the support member BMS, as shown in Fig. 20(b).

[0094] Note that the operation of forming the partial inclination member RMRp#1 may be the same as the operation of forming the partial inclination member RMLp#1. Therefore, the above description of the partial inclination member RMLp#1 can be used as a description of the partial inclination member RMRp#1 by replacing the term "partial inclination member RMLp#1" with the term "partial inclination member RMRp#1". Therefore, the description of the partial inclination member RMRp#1 will be omitted.

[0095] Furthermore, the operation of forming the partial support member RMSp#12 may be the same as the operation of forming the partial support member RMSp#11. Therefore, the above description of the partial support member RMSp#11 can be used as a description of the partial support member RMSp#12 by replacing the term "partial support member RMSp#11" with the term "partial support member RMSp#12." Therefore, the description of the partial support member RMSp#12 will be omitted.

[0096] After forming the partial tilt member RMRp#1 and the partial support member RMSp#12, the modeling system SYS forms a part of the support member RMS between the partial support member RMSp#11 and the partial support member RMSp#12. In this case, as shown in FIG. 21, before forming the support member RMS, the modeling system SYS rotates the stage 31 around the rotation axis (e.g., the X-axis) to return the stage 31 to the reference position. Thereafter, as shown in FIG. 21, the modeling system SYS irradiates the modeling light EL to an area of ​​the support member BMS where the support member RMS is to be formed, in order to form a part of the support member RMS. As a result, as shown in FIG. 22, a partial support member RMSp#13, which is a part of the support member RMS, is formed on the support member BMS. That is, the partial support member RMSp#13 located between the partial support member RMSp#11 and the partial support member RMSp#12 is formed on the support member BMS. The partial support member RMSp#13 is typically a member that connects the partial support member RMSp#11 and the partial support member RMSp#12. At least a part of the partial support member RMSp#13 may be formed on at least one of the partial support members RMSp#11 and #12. In this case, the modeling system SYS may irradiate the modeling light EL to at least a part of the partial support members RMSp#11 and #12 in order to model the partial support member RMSp#13.

[0097] After that, the modeling system SYS models a part of the inclined member RML on the partial inclined member RMLp#1. In this case, as shown in Fig. 23(a) and Fig. 23(b), the modeling system SYS rotates the stage 31 from the reference position in a first direction around the rotation axis (e.g., the X-axis) before modeling a part of the inclined member RML. Note that Fig. 23(a) shows a cross section of the base member BM at a position where the support member BMS has not been modeled, and Fig. 23(b) shows a cross section of the base member BM at a position where the support member BMS has been modeled. After that, as shown in Fig. 23(a), the modeling system SYS irradiates modeling light EL to an area of ​​the partial inclined member RMLp#1 where a part of the inclined member RML is to be modeled, in order to model a part of the inclined member RML. In addition, at the position where the support member BMS is being formed, the modeling system SYS also irradiates the modeling light EL to the area of ​​the partial support members RMSp#11 to #13 where a portion of the support member RMS is to be formed, in order to form a portion of the support member RMS on the partial support members RMSp#11 to #13, as shown in Figure 23(b).

[0098] As a result, as shown in Fig. 24(a), in a position where the support member BMS is not formed (i.e., a position where the support member RMS does not need to be formed), a partial tilt member RMLp#2 that is a part of the tilt member RML is formed on the partial tilt member RMLp#1. Also, as shown in Fig. 24(b), in a position where the support member BMS is formed (i.e., a position where the support member RMS is formed), a partial support member RMSp#21 that is a part of the support member RMS and is connected to the partial tilt member RMLp#2 is formed on at least a part of the partial support members RMSp#11 to #13.

[0099] Incidentally, the operation of forming the partial inclination member RMLp#2 may be similar to the operation of forming the partial inclination member RMLp#1. Therefore, the above-mentioned description of the partial inclination member RMLp#1 can be used as a description of the partial inclination member RMLp#2 by replacing the term "partial inclination member RMLp#1" with the term "partial inclination member RMLp#2". Therefore, the description of the partial inclination member RMLp#2 will be omitted. Incidentally, the movement amount (typically, rotation angle) of the stage 31 from the reference position when forming the partial inclination member RMLp#2 may be the same as or different from the movement amount (typically, rotation angle) of the stage 31 from the reference position when forming the partial inclination member RMLp#1.

[0100] Furthermore, the operation of forming the partial support member RMSp#21 may be the same as the operation of forming the partial support member RMSp#11. Therefore, the above description of the partial support member RMSp#11 can be used as a description of the partial support member RMSp#21 by replacing the term "partial support member RMSp#11" with the term "partial support member RMSp#21." Therefore, the description of the partial support member RMSp#21 will be omitted.

[0101] After the partial inclined member RMLp#2 and the partial support member RMSp#21 are formed, the modeling system SYS forms a part of the inclined member RMR. In this case, as shown in Fig. 25(a) and Fig. 25(b), the modeling system SYS rotates the stage 31 from the reference position in a second direction around the rotation axis (e.g., the X-axis) before forming the inclined member RMR. Note that Fig. 25(a) shows a cross section of the base member BM at a position where the support member BMS is not formed, and Fig. 25(b) shows a cross section of the base member BM at a position where the support member BMS is formed. After that, as shown in Fig. 25(a), the modeling system SYS irradiates the modeling light EL to an area of ​​the partial inclined member RMRp#1 where a part of the inclined member RMR is to be formed, in order to form a part of the inclined member RMR. In addition, at the position where the support member BMS is being formed, the modeling system SYS also irradiates the modeling light EL to the area of ​​the partial support members RMSp#11 to #13 where a portion of the support member RMS is to be formed, in order to form a portion of the support member RMS on the partial support members RMSp#11 to #13, as shown in Figure 25(b).

[0102] As a result, as shown in Fig. 26(a), in a position where the support member BMS is not formed (i.e., a position where the support member RMS does not need to be formed), a partial tilt member RMRp#2, which is a part of the tilt member RMR, is formed on the partial tilt member RMRp#1. Also, as shown in Fig. 26(b), in a position where the support member BMS is formed (i.e., a position where the support member RMS is formed), a partial support member RMSp#22, which is a part of the support member RMS and is connected to the partial tilt member RMRp#2, is formed on at least a part of the partial support members RMSp#11 to #13.

[0103] Note that the operation of forming the partial inclination member RMRp#2 may be similar to the operation of forming the partial inclination member RMRp#1. Therefore, the above-mentioned description of the partial inclination member RMRp#1 can be used as a description of the partial inclination member RMRp#2 by replacing the term "partial inclination member RMRp#1" with the term "partial inclination member RMRp#2". Therefore, the description of the partial inclination member RMRp#2 will be omitted. Note that the movement amount (typically, a rotation angle) of the stage 31 from the reference position when forming the partial inclination member RMRp#2 may be the same as or different from the movement amount (typically, a rotation angle) of the stage 31 from the reference position when forming the partial inclination member RMRp#1.

[0104] Furthermore, the operation of forming the partial support member RMSp#22 may be the same as the operation of forming the partial support member RMSp#12. Therefore, the above description of the partial support member RMSp#12 can be used as a description of the partial support member RMSp#22 by replacing the term "partial support member RMSp#12" with the term "partial support member RMSp#22." Therefore, the description of the partial support member RMSp#22 will be omitted.

[0105] After the partial tilt member RMRp#2 and the partial support member RMSp#22 are formed, the modeling system SYS forms a part of the support member RMS between the partial support member RMSp#21 and the partial support member RMSp#22. In this case, as shown in FIG. 27, before forming the support member RMS, the modeling system SYS rotates the stage 31 around the rotation axis (e.g., the X-axis) to return the stage 31 to the reference position. Thereafter, as shown in FIG. 28, the modeling system SYS irradiates the modeling light EL to an area where the support member RMS is to be formed in order to form a part of the support member RMS. As a result, as shown in FIG. 28, a partial support member RMSp#23, which is a part of the support member RMS, is formed. That is, the partial support member RMSp#23 located between the partial support member RMSp#21 and the partial support member RMSp#22 is formed. The partial support member RMSp#23 is typically a member that connects the partial support member RMSp#21 and the partial support member RMSp#22.

[0106] The operation of forming the partial support member RMSp#23 may be the same as the operation of forming the partial support member RMSp#13. Therefore, the above description of the partial support member RMSp#13 can be used as a description of the partial support member RMSp#23 by replacing the term "partial support member RMSp#13" with the term "partial support member RMSp#23." Therefore, the description of the partial support member RMSp#23 will be omitted.

[0107] The above similar operations are repeated until the formation of the tilt members RML, RMR, and support member RMS is completed. As a result, the tilt members RML, RMR, and support member RMS are formed on the base member BM as shown in Fig. 29(a) and Fig. 29(b). Note that Fig. 29(a) shows cross sections of the tilt members RML and RMR at a position where the support members BMS and RMS have not been formed, and Fig. 29(b) shows cross sections of the tilt members RML, RMR, and support member RMS at a position where the support members BMS and RMS have been formed.

[0108] After completing the modeling of the tilted members RML, the tilted members RMR, and the support member RMS, the modeling system SYS may model a connection member RMC that connects the tilted members RML and the tilted members RMR by performing the above-mentioned modeling operation. In this case, the modeling system SYS may rotate the stage 31 around a rotation axis (e.g., the X-axis) to return the stage 31 to a reference position before modeling the connection member RMC. However, if the stage 31 is already positioned at the reference position, the modeling system SYS does not need to rotate the stage 31. After that, as shown in Figures 29(a) and 29(b), the modeling system SYS sequentially irradiates at least a part of the tip RMLt of the tilted member RML with modeling light EL in order to model the connection member RMC. As a result, a molten pool MP is formed at least a part of the tip RMLt of the tilted member RML. Furthermore, the modeling system SYS sequentially irradiates at least a part of the tip RMRt of the tilted member RMR with modeling light EL. As a result, a molten pool MP is formed on at least a part of the tip RMRt of the tilt member RMR. At this time, a molten pool MP may be formed across at least a part of the tip RMLt of the tilt member RML and at least a part of the tip RMRt of the tilt member RMR. Alternatively, after a molten pool MP is formed on at least a part of either the tip RMLt of the tilt member RML or the tip RMRt of the tilt member RMR, a molten pool MP may be formed on at least a part of the other of the tip RMLt of the tilt member RML or the tip RMRt of the tilt member RMR.

[0109] As a result, as shown in Figures 30(a) and 30(b), a connecting member RMC that connects the tilt members RML and RMR is printed on the tilt members RML and RMR. As a result, the printing of the three-dimensional structure ST (e.g., a turbine blade BL) shown in Figures 6 to 9 is completed. Note that Figure 30(a) shows a cross section of the three-dimensional structure ST at a position where the support members BMS and RMS have not been printed, and Figure 30(b) shows a cross section of the three-dimensional structure ST at a position where the support members BMS and RMS have been printed.

[0110] In this embodiment, since the laser build-up welding method is used, each member is an integrated member (monolithic member), and therefore each member may be referred to as each portion.

[0111] (3) Technical effect As described above, when the modeling system SYS of this embodiment models the roof member RM including the slope members RML and RMR and the support member RMS on the base member BM, the modeling system SYS sequentially models the partial slope member RMLp that is a part of the slope member RML and the first partial support member RMSp that is a part of the support member RMS, the partial slope member RMRp that is a part of the slope member RMR and the second partial support member RMSp that is a part of the support member RMS, and the third partial support member RMSp that is a part of the support member RMS and is located between the first partial support member RMSp and the second partial support member RMSp. Therefore, the modeling system SYS can reduce the possibility of a technical problem (see FIG. 14) occurring in which the modeling light EL is blocked by a part of the already-modeled three-dimensional structure ST.

[0112] Furthermore, before printing the inclined member RML, the modeling system SYS rotates the stage 31 from the reference position in the first direction around the rotation axis, and then starts printing the inclined member RML. Therefore, the modeling system SYS can print the inclined member RML in a state where the angle θL between the extension direction of the inclined member RML and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax. In other words, the modeling system SYS can reduce the possibility of a technical problem (see FIG. 12) occurring in which the inclined member RML cannot be printed due to the constraint of the allowable upper limit angle θmax.

[0113] In the above description, the modeling system SYS sequentially models the partial inclination member RMLp and the first partial support member RMSp, the partial inclination member RMRp and the second partial support member RMSp, and the third partial support member RMSp located between the first partial support member RMSp and the second partial support member RMSp. However, the modeling system SYS does not need to model the third partial support member RMSp located between the first partial support member RMSp and the second partial support member RMSp. In this case, at least a part of the third partial support member RMSp may be modeled as a part of the first partial support member RMSp or the second partial support member RMSp. Alternatively, the modeling system SYS may sequentially model either one of the partial inclination members RMLp and RMRp and the partial support member RMSp, and the other of the partial inclination members RMLp and RMRp. In other words, the modeling system SYS does not need to model the partial support member RMSp together with the other of the partial tilt members RMLp and RMRp In other words, the modeling system SYS may model the entire support member RMS together with one of the tilt members RML and RMR.

[0114] In the above description, the three-dimensional structure ST includes the support member RMS. However, the three-dimensional structure ST does not have to include the support member RMS. In this case, the modeling system SYS may model the partial inclination member RMLp and the partial inclination member RMRp in this order.

[0115] (4) Variations Next, a modified example of the modeling system SYS will be described.

[0116] (4-1) First Modification As described above, in order to form a three-dimensional structure ST, the modeling system SYS repeats a scanning operation in which the target irradiation area EA is moved along either the X-axis direction or the Y-axis direction relative to the modeling surface MS while irradiating the target irradiation area EA with modeling light EL at the desired timing, and a stepping operation in which the target irradiation area EA is moved along the other of the X-axis direction or the Y-axis direction relative to the modeling surface MS without irradiating the target irradiation area EA with modeling light EL.

[0117] In a second modified example, the modeling system SYS may change the moving direction of the target irradiation area EA by the scanning operation. That is, the modeling system SYS may change the moving direction of the target irradiation area EA by the scanning operation from a first moving direction to a second moving direction different from the first moving direction.

[0118] The first moving direction may be the opposite direction to the second moving direction. As an example, when the target irradiation area EA moves along the X-axis direction by the scanning operation, the modeling system SYS may change the moving direction of the target irradiation area EA by the scanning operation from the first moving direction from the -X side to the +X side to the second moving direction from the +X side to the -X side at a desired timing, as shown in Fig. 31. Alternatively, the modeling system SYS may change the moving direction of the target irradiation area EA by the scanning operation from the second moving direction from the +X side to the -X side to the first moving direction from the -X side to the +X side at a desired timing.

[0119] The modeling system SYS may change the movement direction of the target irradiation area EA by the scanning operation so that the target irradiation area EA moves along a first movement direction by the scanning operation during a first period, and so that the target irradiation area EA moves along a second movement direction by the scanning operation during a second period different from the first period.

[0120] The first period may include a period for forming a first structural layer SL, and the second period may include a period for forming a second structural layer SL different from the first structural layer SL. In this case, the modeling system SYS may change a moving direction of the target irradiation area EA by the scanning operation so that the target irradiation area EA moves along the first moving direction by the scanning operation during the first period for forming the first structural layer SL, and the target irradiation area EA moves along the second moving direction by the scanning operation during the second period for forming the second structural layer SL. As a specific example, in order to form the first to Nth (N is an integer greater than or equal to 2) structural layers SL, the modeling system SYS may change the movement direction of the target irradiation area EA by the scanning operation so that during a first period in which the ith (i is an odd number greater than or equal to 1 and less than or equal to N) structural layer SL is formed, the target irradiation area EA moves along a first movement direction by the scanning operation, and during a second period in which the jth (j is an even number greater than or equal to 1 and less than or equal to N) structural layer SL is formed, the target irradiation area EA moves along a second movement direction by the scanning operation.

[0121] The first period may include a period for forming a first partially inclined member RMLp, and the second period may include a period for forming a second partially inclined member RMLp different from the first partially inclined member RMLp. In this case, the modeling system SYS may change a moving direction of the target irradiation area EA by the scanning operation so that the target irradiation area EA moves along the first moving direction by the scanning operation during the first period for forming the first partially inclined member RMLp, and the target irradiation area EA moves along the second moving direction by the scanning operation during the second period for forming the second partially inclined member RMLp. As a specific example, in order to form the first to Mth (where M is an integer greater than or equal to 2) partial inclined members RMLp, the modeling system SYS may change the movement direction of the target irradiation area EA by the scanning operation so that during a first period in which the ith (where i is an odd number greater than or equal to 1 and less than or equal to M) partial inclined member RMLp is formed, the target irradiation area EA moves along a first movement direction by the scanning operation, and during a second period in which the jth (where j is an even number greater than or equal to 1 and less than or equal to M) partial inclined member RMLp is formed, the target irradiation area EA moves along a second movement direction by the scanning operation.

[0122] The first period may include a period for forming a first partial inclination member RMRp, and the second period may include a period for forming a second partial inclination member RMRp different from the first partial inclination member RMRp. In this case, the modeling system SYS may change a moving direction of the target irradiation area EA by the scanning operation so that the target irradiation area EA moves along the first moving direction by the scanning operation during the first period for forming the first partial inclination member RMRp, and the target irradiation area EA moves along the second moving direction by the scanning operation during the second period for forming the second partial inclination member RMRp. As a specific example, in order to form the first to Lth (where L is an integer greater than or equal to 2) partial inclined members RMRp, the modeling system SYS may change the movement direction of the target irradiation area EA by the scanning operation so that during a first period in which the ith (where i is an odd number greater than or equal to 1 and less than or equal to L) partial inclined member RMRp is formed, the target irradiation area EA moves along a first movement direction by the scanning operation, and during a second period in which the jth (where j is an even number greater than or equal to 1 and less than or equal to L) partial inclined member RMRp is formed, the target irradiation area EA moves along a second movement direction by the scanning operation.

[0123] The first period may include a period for forming a first partial support member RMSp, and the second period may include a period for forming a second partial support member RMSp different from the first partial support member RMSp. In this case, the modeling system SYS may change a moving direction of the target irradiation area EA by the scanning operation so that the target irradiation area EA moves along the first moving direction by the scanning operation during the first period for forming the first partial support member RMSp, and the target irradiation area EA moves along the second moving direction by the scanning operation during the second period for forming the second partial support member RMSp. As a specific example, in order to form the first to Oth (where O is an integer greater than or equal to 2) partial support members RMSp, the modeling system SYS may change the movement direction of the target irradiation area EA by the scanning operation so that during a first period in which the ith (where i is an odd number greater than or equal to 1 and less than or equal to O) partial support member RMSp is formed, the target irradiation area EA moves along a first movement direction by the scanning operation, and during a second period in which the jth (where j is an even number greater than or equal to 1 and less than or equal to O) partial support member RMSp is formed, the target irradiation area EA moves along a second movement direction by the scanning operation.

[0124] In this way, when the moving direction of the target irradiation area EA is changeable, the possibility of a gap being generated between the support member RMS and the inclined members RML and RMR is reduced compared to when the moving direction of the target irradiation area EA is not changeable. In other words, the modeling accuracy of the roof member RM is improved. Therefore, in the first modification, the modeling system SYS can improve the modeling accuracy of the roof member RM while providing the above-mentioned effects.

[0125] (4-2) Second Modification In the above description, the modeling system SYS models a three-dimensional structure ST including a second object modeled above a first object by modeling a second object above the first object. In a second modified example, the modeling system SYS may model a three-dimensional structure ST including the second object modeled above the first object and the third object modeled around the second object by modeling a second object above the first object and modeling a third object around the second object.

[0126] As described above, the modeling system SYS models a three-dimensional structure ST (e.g., turbine blade BL) including a base member BM which is an example of a first object, and a roof member RM which is an example of a second object modeled above the base member BM. In the second modified example, a three-dimensional structure ST (e.g., turbine blade BL) may be modeled including the base member BM, the roof member RM, and an exterior wall member OM which is an example of a third object modeled around the roof member RM. In the three-dimensional structure ST in which the exterior wall member OA is modeled, the exterior wall member OA and the roof member RM may be an integrated member.

[0127] An example of a three-dimensional structure ST including an outer wall member OM is shown in Figures 32 and 33. Figure 32 is a cross-sectional view showing a cross-section of the three-dimensional structure ST including the outer wall member OM at a position where the support member RMS has not been formed. Figure 33 is a cross-sectional view showing a cross-section of the three-dimensional structure ST including the outer wall member OM at a position where the support member RMS has been formed.

[0128] 32 and 33, the outer wall member OM may be shaped so as to cover at least a portion of the roof member RM. In other words, the outer wall member OM may be shaped so as to cover at least a portion of the slope members RML, slope members RMR, and connection members RMC that constitute the roof member RM and are exposed to the outside.

[0129] The outer wall member OM may be a member for forming the outer shape of the three-dimensional structure ST into a predetermined shape. As an example, in the example shown in Fig. 32 and Fig. 33, the outer wall member OM is a member for forming the outer shape of the upper part of the three-dimensional structure ST (i.e., the shape of the upper surface of the three-dimensional structure ST) into a horizontal shape (i.e., a horizontal surface).

[0130] When the outer wall member OM is to be formed, the modeling system SYS may sequentially model a partial inclined member RMLp that is a part of the inclined member RML, a partial inclined member RMRp that is a part of the inclined member RMR, and a partial outer wall member that is a part of the outer wall member OM. That is, the modeling system SYS may repeat an operation of alternately forming the partial inclined member RMLp, the partial inclined member RMRp, and the partial outer wall member. In this case, as described above, it is possible to reduce the possibility of the technical problem (see FIG. 14) occurring that the modeling light EL is blocked by a part of the already-formed three-dimensional structure ST during the period in which the three-dimensional structure ST is being formed.

[0131] However, the modeling system SYS may model the inclined members RML and RMR and the outer wall member OM without sequentially modeling a part of the inclined member RML, a part of the inclined member RMR, and a part of the outer wall member OM. For example, the modeling system SYS may start modeling the outer wall member OM after modeling the whole (or most of) the inclined members RML and RMR.

[0132] (4-3) Third Modification In a third modified example, the modeling system SYS may model a three-dimensional structure ST (for example, a turbine blade BL) including a roof member RM in which a through-hole HA is formed.

[0133] An example of a three-dimensional structure ST including a roof member RM in which a through hole HA is formed is shown in Fig. 34. As shown in Fig. 34, the through hole HA may be formed in at least one of the slope members RML and RMR. In the example shown in Fig. 34, the through hole HA is formed in the slope member RMR. The through hole HA is a hole that penetrates the roof member RM (in the example shown in Fig. 34, the slope member RMR). The through hole HA may be a hole that connects the space outside the roof member RM (i.e., the space outside the three-dimensional structure ST) and the space RMsp inside the roof member RM.

[0134] When the outer wall member OM described in the second modified example is formed around the roof member RM in which the through hole HA is formed, a through hole HB may also be formed in the outer wall member OM as shown in Fig. 35. The through hole HB is a hole that penetrates the outer wall member OM. The through hole HB may be connected to the through hole HA. As a result, the space outside the roof member RM (i.e., the space outside the three-dimensional structure ST) and the space RMsp inside the roof member RM may be connected via the through holes HA and HB.

[0135] When an outer wall member OM in which a through hole HB is formed is to be formed, the modeling system SYS may rotate the stage 31 so that the extension direction of the through hole HB is aligned with the direction of gravity before forming the outer wall member OM, as shown in Fig. 36. Thereafter, the modeling system SYS may form the outer wall member OM in which a through hole HB is formed (particularly, a part of the outer wall member OM surrounding the through hole HB) in a state in which the extension direction of the through hole HB is aligned with (for example, parallel to) the direction of gravity. When the outer wall member OM is formed in this manner in a state in which the extension direction of the through hole HB is aligned with the direction of gravity, the modeling system SYS can form the outer wall member OM so that the shape of the cross section of the through hole HB (specifically, the cross section intersecting the extension direction of the through hole HB) has a desired shape.

[0136] Even when a roof member RM in which a through hole HA is formed is modeled, the modeling system SYS may model the roof member RM in which the through hole HA is formed (particularly, a part of the roof member RM surrounding the through hole HA) in a state in which the extension direction of the through hole HA is aligned (for example, parallel) with the direction of gravity. However, as described above, since the roof member RM includes the slope members RML and RMR, it is desirable that the angle θL between the extension direction of the slope member RML and the direction of gravity and the angle θR between the extension direction of the slope member RMR and the direction of gravity are equal to or less than the allowable upper limit angle θmax. Therefore, depending on the extension direction of the slope members RML and RMR, the modeling system SYS may not be able to model the roof member RM in which the through hole HA is formed in a state in which the extension direction of the through hole HA is aligned with the direction of gravity. In this case, the modeling system SYS may model the roof member RM in which the through hole HA is formed in a state in which the extension direction of the through hole HA is not aligned (for example, intersects) with the direction of gravity. On the other hand, when the roof member RM is formed in such a state that the extension direction of the through hole HA is not aligned with the direction of gravity, the modeling system SYS may not be able to form the roof member RM so that the cross section of the through hole HA (specifically, the cross section intersecting the extension direction of the through hole HA) has the desired shape. This is because the surface RMha (see FIG. 36) of the roof member RM facing the through hole HA (i.e., forming the through hole HA) is inclined with respect to the direction of gravity, and therefore molten metal etc. may sag due to gravity from the molten pool MP formed to form the surface RMha, resulting in a disruption of the shape of the through hole HA.

[0137] Even if the cross-sectional shape of the through hole HA formed in the roof member RM is not the desired shape, the modeling system SYS can model the exterior wall member OM so that the cross-sectional shape of the through hole HB formed in the exterior wall member OM covering the roof member RM is the desired shape. Specifically, the modeling system SYS can model the exterior wall member OM in which a through hole HB (see FIG. 37(b)) having a cross-sectional shape different from the cross-sectional shape of the through hole HA (see FIG. 37(a)). In other words, the modeling system SYS can model the exterior wall member OM so that the cross-sectional shape of the through hole HA on the surface of the roof member RM (specifically, the boundary surface between the roof member RM and the exterior wall member OM) is different from the cross-sectional shape of the through hole HB on the surface of the exterior wall member OM (specifically, the outer surface). As a result, there is a low possibility that a person viewing the three-dimensional structure ST will feel uncomfortable with the shape of the through hole HB that appears on the outer surface of the three-dimensional structure ST. Therefore, the modeling system SYS can model a three-dimensional structure ST having a desired appearance by modeling the outer wall member OM so that the cross-sectional shape of the through hole HB has a desired shape. Note that the cross-sectional shape of the through hole HA shown in Fig. 37(a) (e.g., a polygonal cross-sectional shape) is only an example, and for example, a through hole HA having a cross-sectional shape shown in Fig. 37(c) (e.g., a cross-sectional shape with a part of the outer shape being an arc) may be formed.

[0138] (4-4) Fourth Modification In a fourth modified example, after the base member BM is modeled and before the roof member RM is modeled, the modeling system SYS may perform processing to flatten the surface of the base member BM on which the roof member RM is to be formed. For example, since the sloped member RML is formed on the sidewall member BML of the base member BM, the modeling system SYS may perform processing to flatten the upper surface BMLus (see Figures 38(a) and 38(b)) of the sidewall member BML on which the sloped member RML is to be formed before modeling the sloped member RML. For example, since the sloped member RMR is formed on the sidewall member BMr of the base member BM, the modeling system SYS may perform processing to flatten the upper surface BMRus (see Figures 38(a) and 38(b)) of the sidewall member BMR on which the sloped member RMR is to be formed before modeling the sloped member RMR. For example, since the support member RMS is formed on the support member BMS of the base member BM, the printing system SYS may perform processing to flatten the upper surface BMSus (see Figure 38(b)) of the support member BMS on which the support member RMS is formed before printing the support member RMS.

[0139] The modeling system SYS may perform a process for flattening the surface of the base member BM by irradiating the surface of the base member BM with modeling light EL. For example, as shown in FIG. 38(a) and FIG. 38(b), the modeling system SYS may perform a process for flattening the upper surface BMLus of the sidewall member BML by irradiating the upper surface BMLus of the sidewall member BML with modeling light EL. For example, as shown in FIG. 38(a) and FIG. 38(b), the modeling system SYS may perform a process for flattening the upper surface BMRus of the sidewall member BMR by irradiating the upper surface BMRus of the sidewall member BMR with modeling light EL. For example, as shown in FIG. 38(b), the modeling system SYS may perform a process for flattening the upper surface BMSus of the support member BMS by irradiating the upper surface BMSus of the support member BMS with modeling light EL.

[0140] When the surface of the base member BM is irradiated with the shaping light EL, the metal or the like that constitutes the surface of the base member BM at least partially melts and then solidifies. As a result, the minute irregularities that existed on the surface of the base member BM may disappear due to the melting and solidification of the surface of the base member BM. Alternatively, the height of the minute irregularities that existed on the surface of the base member BM may become smaller due to the melting and solidification of the surface of the base member BM. For this reason, the surface of the base member BM irradiated with the shaping light EL is flatter than the surface of the base member BM before it was irradiated with the shaping light EL.

[0141] Alternatively, in addition to or instead of performing a process for flattening the surface of the base member BM after the base member BM is modeled, the modeling system SYS may perform a process for flattening the surface of the base member BM by modeling the base member BM with a relatively high modeling accuracy. For example, the modeling system SYS may model the base member BM with such a high modeling accuracy that it is possible to realize a state in which no minute irregularities exist on the surface of the base member BM. For example, the modeling system SYS may model the base member BM with such a high modeling accuracy that it is possible to realize a state in which the height of minute irregularities present on the surface of the base member BM does not exceed an upper limit value.

[0142] On the other hand, when the modeling accuracy of the base member BM increases, the time required for modeling the base member BM increases. This leads to a deterioration in the throughput for modeling the three-dimensional structure ST. Therefore, the modeling system SYS may model the first portion BM1 including the surface of the base member BM on which the roof member RM is to be formed with a modeling accuracy higher than the modeling accuracy when the second portion BM2 of the base member BM, which is different from the first portion BM1, is modeled. In other words, the modeling system SYS may lower the modeling accuracy of the second portion BM2 of the base member BM that does not include the surface of the base member BM on which the roof member RM is to be formed, compared with the modeling accuracy of the first portion BM1 of the base member BM that includes the surface of the base member BM on which the roof member RM is to be formed. As a result, the modeling system SYS can flatten the surface of the base member BM on which the roof member RM is to be formed while suppressing an increase in the time required for modeling the base member BM. As shown in Figures 38(a) and 38(b), a first portion BM1 of the base member BM including the surface on which the roof member RM is formed is typically a portion that is formed on a second portion BM2 of the base member BM that does not include the surface on which the roof member RM is formed.

[0143] When the process for flattening the surface of the base member BM is performed in this manner, the deviation between the actual position of the roof member RM molded on the base member BM and the designed position of the roof member RM is smaller than when the process for flattening the surface of the base member BM is not performed. As a result, the slope members RML and RMR constituting the roof member RM are more likely to be connected above it. This is because the positional deviation of the slope members RML and RMR connected above is relatively small.

[0144] (4-5) Fifth Modification In the above description, in order to form a three-dimensional structure ST in which the space RMsp below the roof member RM is closed, two slope members RML and RMR that are connected at the top are formed on the side wall members BML and BMR, respectively. On the other hand, in the fifth modified example, in order to form a three-dimensional structure ST in which the space RMsp below the roof member RM is closed, the following method may be adopted.

[0145] Specifically, first, as shown in Fig. 39, the modeling system SYS may perform a modeling operation to form a model on the side wall member BML of the base member BM by irradiating the side wall member BML with modeling light EL. As a result, as shown in Fig. 40, a model is formed on the side wall member BML. This model constitutes a roof member RM#1 that is a part of the roof member RM in the fifth modified example. In the following description, the roof member RM in the fifth modified example will be referred to as a "roof member RM'" to distinguish it from the above-mentioned roof member RM including the inclined members RML and RMR.

[0146] The roof member RM#1 may be a member composed of a single structural layer SL. Alternatively, the roof member RM#1 may be a member composed of multiple structural layers SL. In the example shown in Fig. 40, the roof member RM#1 is composed of multiple structural layers SL.

[0147] When modeling the roof member RM#1, the stage 31 may be located at a reference position. That is, the position of the stage 31 (typically, the rotation angle around the rotation axis) when modeling the roof member RM#1 may be the same as the position of the stage 31 when modeling the base member BM. However, when modeling the roof member RM#1, the stage 31 may be rotated around the rotation axis (for example, the X-axis) from the reference position.

[0148] After that, the modeling system SYS models the remaining roof member RM#2 of the roof member RM' other than the already-modeled roof member RM#1. Specifically, as shown in FIG. 41 , the modeling system SYS rotates the stage 31 from the reference position around a rotation axis (for example, a rotation axis along the X-axis). That is, by rotating the stage 31, the modeling system SYS changes the relative positional relationship between the modeling head 21 and the stage 31 from a first relationship for modeling the roof member RM#1 to a second relationship for modeling the roof member RM#2. In this case, for example, the modeling system SYS may rotate the stage 31 so that the direction from the side wall member BML to the side wall member BMR is aligned with the direction of gravity. For example, the modeling system SYS may rotate the stage 31 so that the direction from the roof member RM#1 modeled on the side wall member BML to the side wall member BMR is aligned with the direction of gravity. For example, the modeling system SYS may rotate the stage 31 by 90 degrees from the reference position around a rotation axis (eg, a rotation axis along the X-axis).

[0149] After that, as shown in Fig. 41, the modeling system SYS performs a modeling operation of forming an object on the roof member RM#1 by irradiating the roof member RM#1 with modeling light EL. As a result, as shown in Fig. 42, a model corresponding to the roof member RM#2 is formed on the roof member RM#1. At this time, the modeling system SYS repeats the modeling operation of forming an object on the roof member RM#1 until the roof member RM#2 is connected to the side wall member BMR. In other words, the modeling system SYS repeats the modeling operation of forming an object on the roof member RM#1 until the roof member RM#2 connects the roof member RM#1 and the side wall member BMR. At this time, the modeling system SYS may or may not change the position of the stage 31. In other words, the modeling system SYS may or may not rotate the stage 31 around a rotation axis (for example, a rotation axis along the X-axis).

[0150] 39 and 41, the angle formed by the main axis of the modeling light EL when modeling the roof member RM#2 and the axis along the direction from the side wall member BML to the side wall member BMR (i.e., the axis connecting the side wall member BML and the side wall member BMR, and the Z-axis in FIG. 41) may be smaller than the angle formed by the main axis of the modeling light EL when modeling the roof member RM#1 and the axis along the direction from the side wall member BML to the side wall member BMR (the Y-axis in FIG. 39). In other words, the modeling system SYS may rotate the stage 31 so that the angle formed by the main axis of the modeling light EL when modeling the roof member RM#2 and the axis along the direction from the side wall member BML to the side wall member BMR is smaller than the angle formed by the main axis of the modeling light EL when modeling the roof member RM#1 and the axis along the direction from the side wall member BML to the side wall member BMR.

[0151] As a result, as shown in Fig. 42, a roof member RM#2 is formed that connects the roof member RM#1 formed on the side wall member BML and the side wall member BMR. In other words, a roof member RM' is formed that connects the side wall member BML and the side wall member BMR. Even when the roof member RM' is formed in this manner, the space RMsp below the roof member RM' is closed by the roof member RM'. Therefore, the modeling system SYS can form a three-dimensional structure ST in which the space RMsp below the roof member RM' is closed, by using the method described in the fifth modified example.

[0152] In the example shown in Fig. 42, the modeling system SYS models a roof member RM#2 that extends in the direction of gravity. However, the modeling system SYS may also model a roof member RM#2 that extends in a direction that is at least partially inclined with respect to the direction of gravity. In this case, the modeling system SYS may model the roof member RM#2 in a state in which the angle between the extension direction of the roof member RM#2 and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax. The modeling system SYS may rotate the stage 31 around the rotation axis so that the angle between the extension direction of the roof member RM#2 and the direction of gravity is equal to or smaller than the allowable upper limit angle θmax, and then model the roof member RM#2.

[0153] (4-6) Sixth Modification As described above, in this embodiment, the modeling system SYS can rotate the stage 31 around a rotation axis (for example, a rotation axis along the X-axis corresponding to the horizontal direction). In this case, the modeling system SYS may model a pipe P including at least two pipes PP extending in different directions, as shown in FIG. 43 showing an example of a three-dimensional structure ST. In the example shown in FIG. 43, the pipe P includes a pipe PP#1 extending linearly along the Y-axis direction, a pipe PP#2 extending linearly along the X-axis direction, a pipe PP#3 extending linearly along the Y-axis direction, and a pipe PP#4 extending linearly along the XY-axis direction. In this case, the modeling system SYS may rotate the stage 31 so that the extension direction of each pipe PP is aligned with the direction of gravity (or the angle between the extension direction of each pipe PP and the direction of gravity is equal to or less than the allowable upper limit angle θmax), and then model each pipe PP.

[0154] Two pipes PP extending in different directions may be connected by a curved pipe PC for connecting the two pipes PP extending in different directions. In the example shown in Fig. 43, pipes PP#1 and PP#2 are connected by a pipe PC#1, pipes PP#2 and PP#3 are connected by a pipe PC#2, and pipes PP#3 and PP#4 are connected by a pipe PC#3.

[0155] In order to print a curved pipe PC, the printing system SYS may sequentially print a plurality of partial pipes PCp, each of which constitutes the pipe PC. For example, as shown in Fig. 44, the printing system SYS may further subdivide a pipe PC having a sector shape into a plurality of partial pipes PCp having smaller sector shapes, and sequentially print the plurality of partial pipes PCp.

[0156] In order to form each partial pipe PCp, the modeling system SYS may perform the above-mentioned modeling operation of sequentially forming a plurality of structural layers SL. For example, as shown in Fig. 45, the modeling system SYS may form a partial pipe PCp composed of a plurality of structural layers SL by forming the plurality of structural layers SL on a modeling surface MS so that the sizes of the plurality of structural layers SL along the XY plane (the size along the Y axis in the example shown in Fig. 45) gradually decrease. Thereafter, as shown in Fig. 46, the modeling system SYS may set a new modeling surface MS on the surface of the formed partial pipe PCp and form a new partial pipe PCp on the formed partial pipe PCp. At this time, the modeling system SYS may rotate the stage 31 so that the new modeling surface MS becomes a horizontal plane.

[0157] Alternatively, in order to form each partial pipe PCp, for example, as shown in FIG. 47, the modeling system SYS may form a partial pipe PCp composed of a plurality of structural layers SL on a modeling surface MS so that the size of the plurality of structural layers SL along the XY plane (in the example shown in FIG. 47, the size along the Y axis) gradually increases and then gradually decreases, thereby forming a partial pipe PCp. In this case, the stage 31 may be rotated so that the center line CL of the fan shape formed by the partial pipe PCp (for example, a line connecting the midpoint of the inner arc and the midpoint of the outer arc) becomes horizontal. Thereafter, as shown in FIG. 48, the modeling system SYS may set a new modeling surface MS on the surface of the formed partial pipe PCp and form a new partial pipe PCp on the formed partial pipe PCp. In this case, the modeling system SYS can form the pipe PC with high accuracy, compared to the case where the pipe PC is formed by the method shown in FIG. 46 to FIG. 47.

[0158] (4-7) Other variations In the above description, the modeling system SYS processes the workpiece W by irradiating the workpiece W with the modeling light EL. However, the modeling system SYS may process the workpiece W by irradiating the workpiece W with an arbitrary energy beam. In this case, the modeling system SYS may be provided with a beam irradiation device capable of irradiating an arbitrary energy beam in addition to or instead of the light source 5 and the irradiation optical system 211. Examples of the arbitrary energy beam include at least one of a charged particle beam and an electromagnetic wave. Examples of the charged particle beam include at least one of an electron beam and an ion beam.

[0159] (5) Additional Notes The following supplementary notes are further disclosed regarding the above-described embodiment. [Appendix 1] A modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam; a control device that controls the modeling device to model a modeled object; Equipped with A second object is formed above the first object; the second object includes a first inclined portion connected to the first object, a second inclined portion connected to the first object, and a connecting portion connected to a tip of the first inclined portion and a tip of the second inclined portion, The first inclined portion and the second inclined portion are formed by sequentially forming a part of the first inclined portion and a part of the second inclined portion, A space below the first inclined portion and the second inclined portion faces the first object, The upper part of the space is closed by the connection part. Molding system. [Appendix 2] A molten portion is formed at a tip of the first inclined portion and a tip of the second inclined portion, and the connection portion is formed by supplying the molding material to the molten portion. 3. The modeling system of claim 2. [Appendix 3] forming a third object around the second object; The second object and the third object are formed by sequentially forming a part of the first inclined portion, a part of the second inclined portion, and a part of the third object. 3. The modeling system according to claim 1 or 2. [Appendix 4] The third object includes an outer wall member for forming an outer shape of a structure including the second object into a predetermined shape by covering at least a part of a surface of the second object. 4. The modeling system of claim 3. [Appendix 5] The upper profile of the structure is horizontal. 5. The modeling system of claim 4. [Appendix 6] the second object includes a first support portion connected to the first inclined portion and a second support portion connected to the second inclined portion; The second object is formed by sequentially forming a part of the first inclined portion and a part of the first support portion, a part of the second inclined portion and a part of the second support portion, and a part of a third support portion between the first support portion and the second support portion. 6. The modeling system of claim 1. [Appendix 7] The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with the direction of gravity. 7. The modeling system of claim 1. [Appendix 8] The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting a main axis of the energy beam. 8. The modeling system of claim 1. [Appendix 9] a support device for supporting a structure including the second object to be modeled by the modeling device, The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with an upper surface of the support device. 9. The modeling system of any one of claims 1 to 8. [Appendix 10] The structure including the second object is a turbine blade. 10. The modeling system of any one of claims 1 to 9. [Appendix 11] A modeling method for forming a model by a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, the method comprising: In order to model a second object above a first object, modeling a part of a first inclined portion connected to the first object and modeling a part of a second inclined portion connected to the first object are performed in sequence; forming a connection portion that is connected to a tip end of the first inclined portion and a tip end of the second inclined portion; Including, a space below the first inclined portion and the second inclined portion faces the first object, The upper part of the space is closed by the connection part. Modeling method. [Appendix 12] A turbine blade that is shaped by a shaping device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a shaping material to a portion irradiated with the energy beam, A first sloped portion that connects to the first object; A second sloped portion that connects to the first object; a connection portion that connects a tip of the first inclined portion and a tip of the second inclined portion; an outer wall member for covering the first inclined portion, the second inclined portion, and a part of the connection portion to form an outer shape into a predetermined shape; a space below the first inclined portion and the second inclined portion faces the first object; The upper part of the space is closed by the connection part. Turbine blade. [Appendix 13] A modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam; a control device that controls the modeling device to model a modeled object; Equipped with A second object is formed above the first object; the second object includes a first inclined portion connected to the first object and a second inclined portion connected to the first object; the control device controls the molding device to mold the first inclined portion and the second inclined portion by sequentially molding a portion of the first inclined portion and a portion of the second inclined portion; The space below the first inclined portion and the second inclined portion faces the first object, and the upper part of the space is closed. Molding system. [Appendix 14] A modeling method for forming a model by a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, the method comprising: forming a second object above the first object; forming the second object includes sequentially forming a part of a first inclined portion connected to the first object and a part of a second inclined portion connected to the first object; A second space below the first inclined portion and the second inclined portion faces the first object, and an upper portion of the second space is closed. Modeling method. [Appendix 15] A turbine blade that is shaped by a shaping device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a shaping material to a portion irradiated with the energy beam, A first sloped portion that connects to the first object; A second sloped portion that connects to the first object; an outer wall member for covering a part of the first inclined portion and the second inclined portion to form an outer shape into a predetermined shape; Equipped with A space below the first inclined portion and the second inclined portion faces the first object, The upper part of the space is closed. Turbine blade. [Appendix 16] A modeling method for forming a model by a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, the method comprising: In order to form a second object above a first object having a first space, forming a part of a first inclined portion connected to the first object and forming a part of a second inclined portion connected to the first object in sequence; forming a connection portion that is connected to a tip end of the first inclined portion and a tip end of the second inclined portion; Including, a second space below the first inclined portion and the second inclined portion is connected to the first space, The upper part of the second space is closed by the connecting portion. Modeling method. [Appendix 17] A turbine blade that is shaped by a shaping device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a shaping material to a portion irradiated with the energy beam, a first inclined portion connected to a first object having a first space; A second sloped portion that connects to the first object; a connection portion that connects a tip of the first inclined portion and a tip of the second inclined portion; an outer wall member for covering the first inclined portion, the second inclined portion, and a part of the connection portion to form an outer shape into a predetermined shape; a second space below the first inclined portion and the second inclined portion is connected to the first space, The upper part of the second space is closed by the connecting portion. Turbine blade. [Appendix 18] A modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam; a control device that controls the modeling device to model a modeled object; Equipped with forming a second object above a first object having a first space; the second object includes a first inclined portion connected to the first object and a second inclined portion connected to the first object; the control device controls the molding device to mold the first inclined portion and the second inclined portion by sequentially molding a portion of the first inclined portion and a portion of the second inclined portion; A second space below the first inclined portion and the second inclined portion is connected to the first space, and an upper portion of the second space is closed. Molding system. [Appendix 19] A modeling method for forming a model by a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, the method comprising: forming a second object above a first object having a first space; forming the second object includes sequentially forming a part of a first inclined portion connected to the first object and a part of a second inclined portion connected to the first object; A second space below the first inclined portion and the second inclined portion is connected to the first space, and an upper portion of the second space is closed. Modeling method. [Appendix 20] A turbine blade that is shaped by a shaping device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a shaping material to a portion irradiated with the energy beam, a first inclined portion connected to a first object having a first space; A second sloped portion that connects to the first object; an outer wall member for covering a part of the first inclined portion and the second inclined portion to form an outer shape into a predetermined shape; Equipped with a second space below the first inclined portion and the second inclined portion is connected to the first space, The upper part of the second space is closed. Turbine blade.

[0160] At least a part of the components of each of the above-mentioned embodiments can be appropriately combined with at least a part of other components of each of the above-mentioned embodiments. Some of the components of each of the above-mentioned embodiments may not be used. In addition, to the extent permitted by law, the disclosures of all publications and U.S. patents cited in each of the above-mentioned embodiments are incorporated by reference into the present description.

[0161] The present invention is not limited to the above-described embodiments, but may be modified as appropriate within the scope that does not contradict the gist or concept of the invention that can be read from the claims and the entire specification, and molding systems involving such modifications are also included in the technical scope of the present invention. [Explanation of symbols]

[0162] 2 Modeling equipment 21 Sculpted head 22 Head drive system 3. Stage Equipment 31, 31θX, 31θZ stage 32 Stage drive system 7 Control Device Double work EL Shaped Light ST 3D structure BL Turbine Blade BM Base material BML, BMR sidewall members BMS support member RM Roofing Materials RML, RMR sloped members RMS Support Member RMC connection material

Claims

1. a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam; a control device that controls the modeling device to model a modeled object; Equipped with A second object is formed above a first object having a first space; the second object includes a first inclined portion connected to the first object, a second inclined portion connected to the first object, and a connecting portion connected to a tip of the first inclined portion and a tip of the second inclined portion, The first inclined portion and the second inclined portion are formed by sequentially forming a part of the first inclined portion and a part of the second inclined portion, a second space below the first inclined portion and the second inclined portion is connected to the first space, The upper part of the second space is closed by the connecting portion. Molding system.

2. A molten portion is formed at a tip of the first inclined portion and a tip of the second inclined portion, and the connection portion is formed by supplying the molding material to the molten portion. The molding system of claim 1 .

3. forming a third object around the second object; The second object and the third object are formed by sequentially forming a part of the first inclined portion, a part of the second inclined portion, and a part of the third object. The molding system according to claim 1 or 2.

4. The third object includes an outer wall member for forming an outer shape of a structure including the second object into a predetermined shape by covering at least a part of a surface of the second object. The molding system of claim 3 .

5. The upper profile of the structure is horizontal. The molding system of claim 4 .

6. the second object includes a first support portion connected to the first inclined portion and a second support portion connected to the second inclined portion; The second object is formed by sequentially forming a part of the first inclined portion and a part of the first support portion, a part of the second inclined portion and a part of the second support portion, and a part of a third support portion between the first support portion and the second support portion. The molding system according to any one of claims 1 to 5.

7. The first inclined portion extends in a first direction, The second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with the direction of gravity. The molding system according to any one of claims 1 to 6.

8. The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting a main axis of the energy beam. The molding system according to any one of claims 1 to 7.

9. a support device for supporting a structure including the second object to be modeled by the modeling device, The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with an upper surface of the support device. The molding system according to any one of claims 1 to 8.

10. The structure including the second object is a turbine blade. The molding system according to any one of claims 1 to 9.

11. a modeling apparatus including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam; a control device that controls the modeling device to model a modeled object; Equipped with A second object is formed above the first object; the second object includes a first inclined portion and a second inclined portion; A space is formed below the first inclined portion and the second inclined portion, and an upper portion of the space is closed. Molding system.

12. a support device that supports a structure including an object to be formed by the modeling device; and a position changing device that changes a relative positional relationship between the modeling device and the supporting device; Further comprising: The first inclined portion is formed after the position change device changes the positional relationship so that the positional relationship becomes a first relationship, and the second inclined portion is formed after the position change device changes the positional relationship so that the positional relationship becomes a second relationship different from the first relationship. The molding system of claim 11 .

13. Before the second object is modeled, the first object is modeled in a state in which the positional relationship is a third relationship different from the first relationship and the second relationship. The molding system of claim 12.

14. the second object includes a first support portion connected to the first inclined portion and a second support portion connected to the second inclined portion; After the position changing device changes the positional relationship so that the positional relationship becomes a first relationship, a part of the first inclined portion and a part of the first support portion are shaped; After the position changer changes the positional relationship to a second relationship different from the first relationship, a part of the second inclined portion and a part of the second support portion are shaped; After the position changer changes the positional relationship to a third relationship different from the first relationship and the second relationship, a third support portion is formed between a part of the first support portion and a part of the second support portion. The molding system according to any one of claims 11 to 13.

15. the second object includes a connection portion that connects a tip of the first inclined portion and a tip of the second inclined portion, A molten portion is formed at a tip of the first inclined portion and a tip of the second inclined portion, and the connection portion is formed by supplying the molding material to the molten portion. The molding system according to any one of claims 11 to 14.

16. forming a third object around the second object; The second object and the third object are formed by sequentially forming a part of the first inclined portion, a part of the second inclined portion, and a part of the third object. The molding system according to any one of claims 11 to 15.

17. The third object includes an outer wall member for forming an outer shape of a structure including the second object into a predetermined shape by covering at least a part of a surface of the second object. The molding system of claim 16.

18. The upper profile of the structure is horizontal. The molding system of claim 17.

19. the second object includes a first support portion connected to the first inclined portion and a second support portion connected to the second inclined portion; The second object is formed by sequentially forming a part of the first inclined portion and a part of the first support portion, a part of the second inclined portion and a part of the second support portion, and a part of a third support portion between the first support portion and the second support portion.

19. The molding system of any one of claims 11 to 18.

20. The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with the direction of gravity.

20. The molding system of claim 11 .

21. The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting a main axis of the energy beam.

21. The molding system of any one of claims 11 to 20.

22. a support device for supporting a structure including the second object to be modeled by the modeling device, The first inclined portion extends in a first direction, the second inclined portion extends in a second direction intersecting the first direction, The first direction and the second direction are directions intersecting with an upper surface of the support device.

22. The molding system of any one of claims 11 to 21.

23. an object placement device on which a first object is placed; a modeling device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, and performs modeling on the first object; a position change device that changes a relative positional relationship between the modeling device and the object placement device; and a control device for controlling the molding device and the position changing device; Equipped with the position changing device has a drive device that moves the object mounting device around a rotation axis; A first modeling operation is performed by using the modeling device in a first state in which the object mounting device is moved from the reference position in a first direction around the rotation axis, and a second modeling operation is performed by using the modeling device in a second state in which the object mounting device is moved from the reference position in a second direction around the rotation axis opposite to the first direction, thereby forming a second object on the first object, the second object including a first inclined portion formed by the first modeling operation and a second inclined portion formed by the second modeling operation. Molding system.

24. the first modeling includes changing, by the position changing device, the position relationship between the object placement device and the modeling device in the first state in a direction parallel to the rotation axis; The second modeling includes changing the positional relationship between the object placement device and the modeling device in the second state in a direction parallel to the rotation axis, by using the position changing device. The molding system of claim 23.

25. the first modeling includes simultaneously changing, by the position changing device, the positional relationship between the object placement device and the modeling device in the first state in a direction parallel to the rotation axis and the positional relationship between the object placement device and the modeling device in a direction perpendicular to the rotation axis; The second modeling includes simultaneously changing, by the position changing device, the positional relationship between the object placement device and the modeling device in the second state in a direction parallel to the rotation axis and the positional relationship between the object placement device and the modeling device in a direction perpendicular to the rotation axis.

25. The molding system of claim 23 or 24.

26. After completing the first and second modeling operations, the object mounting device is returned to the reference position, and a molten portion including a part of the tip of the first inclined portion and a part of the tip of the second inclined portion adjacent to the part of the tip of the first inclined portion is formed by irradiating the energy beam, and a connection portion connecting the tip of the first inclined portion and the tip of the second inclined portion is modeled as a part of the second object by supplying the modeling material to the molten portion.

26. The molding system of any one of claims 23 to 25.

27. The first object has a longitudinal direction parallel to the axis of rotation.

27. The molding system of any one of claims 23 to 26.

28. an object placement device on which a first object is placed; a modeling device including an energy beam irradiation unit that emits an energy beam and a material supply unit that supplies a modeling material to a portion irradiated with the energy beam, and performs modeling on the first object; a position change device that changes a relative positional relationship between the modeling device and the object placement device; and a control device for controlling the molding device and the position changing device; Equipped with forming a second object connecting a first region of the first object and a second region of the first object; To build the second object, after the position changing device changes the positional relationship so that the positional relationship becomes a first relationship, irradiating the first area with the energy beam, thereby forming a first object, which is a part of the second object, on the first area; After the position changing device changes the positional relationship so that the positional relationship becomes a second relationship different from the first relationship, the energy beam is irradiated onto the first object, thereby forming, on the first object, a second object that constitutes a part of the second object and connects the first object to the second region. Molding system.

29. the first relationship is a positional relationship in which an angle between an axis connecting the first region and the second region and a principal axis of the energy beam is a first angle; The second relationship is a positional relationship in which the angle is a second angle smaller than the first angle.

30. The molding system of claim 28.

30. The position change device changes the positional relationship by changing the relative attitude of the object placement device with respect to the molding device.

30. The molding system of any one of claims 23 to 29.

31. the modeling apparatus irradiates the first object with an energy beam while moving an irradiation position of the energy beam with respect to the first object along a predetermined direction; A moving direction of the irradiation position in a first period for forming a part of the second object is different from a moving direction of the irradiation position in a second period for forming another part of the second object.

31. The molding system of any one of claims 1 to 30.

32. A moving direction of the irradiation position in the first period is opposite to a moving direction of the irradiation position in the second period.

32. The molding system of claim 31.

33. the first period includes a period for forming a first object that constitutes a part of the two objects, The second period includes a period for forming a second object that constitutes another part of the two objects and is different from the first object.

33. The molding system of claim 31 or 32.

34. The second object having a through hole is formed. The molding system according to any one of claims 1 to 33.

35. The through hole is a first through hole, forming a third object around the second object, the third object having a second through hole that covers at least a part of a surface of the second object and is connected to the first through hole; A shape of the first through hole at the boundary between the second object and the third object is different from a shape of the second through hole at the surface of the third object.

35. The molding system of claim 34.

36. an object placement device on which the first object is placed; a position change device that changes a relative positional relationship between the modeling device and the object placement device; Further comprising: After the position changer changes the positional relationship so that a predetermined relationship is established in which a direction in which the second through-hole extends and a direction of gravity are aligned, a part of the third object is modeled.

36. The molding system of claim 34 or 35.

37. irradiating a first region of the first object with the energy beam to melt at least a portion of the first region, and after at least a portion of the melted first region has solidified, irradiating the first region with the energy beam to form a portion of the second object on the first region; by irradiating a second region of the first object with the energy beam, at least a portion of the second region is melted, and after at least a portion of the melted second region is solidified, by irradiating the second region with the energy beam, another portion of the second object is formed on the second region.

37. The molding system of any one of claims 1 to 36.

38. After the first object is formed, the second object is formed on the first object; After a portion of the first object is modeled with a first modeling accuracy, a remaining portion of the first object including a surface on which the second object is to be modeled is modeled with a second modeling accuracy higher than the first modeling accuracy.

38. The molding system of any one of claims 1 to 37.

39. The structure including the second object is a turbine blade.

39. The molding system of any one of claims 1 to 38.

Images