Laser unit and laser irradiation method

Abstract

To provide a molding apparatus and a molding method for a powder laminate that efficiently manufacture desired products.SOLUTION: A molding apparatus 1 for a powder laminate includes: a plurality of molding stages 11; a stage transport mechanism 12; and a plurality of lifting control mechanisms 17. The molding stages 11 have main surfaces on which powder, which is an object to be processed, can be loaded. The stage transport mechanism 12 transports the plurality of molding stages 11 in a proceeding direction in a processing area A11 having a plurality of processing zones in which the plurality of molding stages are arranged along the proceeding direction of the process. The plurality of lifting control mechanisms 17 control a height of each of the plurality of molding stages 11 in the processing area A11.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a laser unit and a laser irradiation method. [Background technology]

[0002] A powder additive manufacturing device spreads a powder bed of material powder such as metal or resin, irradiates the powder bed with a laser to melt and solidify the powder, and stacks it to obtain a three-dimensional object.

[0003] For example, Patent Document 1 discloses a technique for repeating the following steps (a), (b), (c) and (d) as a manufacturing procedure for a metal 3D printer. (a) Fill a powder supply tank with a mixed powder consisting of a base metal powder and a corresponding heterogeneous nucleus particle, and create a vacuum in the chamber. (b) Lower the modeling table by one layer pitch, raise the powder supply layer by one layer pitch, and then spread the mixed powder on the modeling table with a blade. (c) By irradiating a laser, one layer of the mixed powder is preheated, melted, and solidified. Since only the base metal powder melts and solidifies, the heterogeneous nucleus particles act as nuclei for solidification during heterogeneous nucleation, resulting in the crystallization of equiaxed crystals and the refinement of crystal grains. (d) Layer the mixed powder on the model by one layer pitch, and irradiate a laser to preheat, melt, and solidify the mixed powder. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2017-222899 A Summary of the Invention [Problem to be solved by the invention]

[0005] In powder additive manufacturing, a batch system is adopted in which a single device performs the above-mentioned different processes one by one in sequence to manufacture the desired product. However, technology to improve productivity in powder additive manufacturing methods is desired.

[0006] The present disclosure has been made to solve such problems, and provides a powder additive manufacturing apparatus and the like that efficiently manufactures desired products. [Means for solving the problem]

[0007] The powder additive manufacturing apparatus according to the present disclosure has a plurality of modeling stages, a stage transport mechanism, and a plurality of lift control mechanisms. The modeling stage has a main surface on which powder, which is the object to be processed, can be loaded. The stage transport mechanism transports the plurality of modeling stages in the proceeding direction in a processing area having a plurality of processing zones in which the plurality of modeling stages are arranged along the proceeding direction of the process. The plurality of lift control mechanisms control the heights of the plurality of modeling stages in the processing area.

[0008] The modeling method disclosed herein is a modeling method carried out by a powder additive manufacturing device that has a plurality of modeling stages each having a main surface on which powder, which is the object to be processed, can be loaded, and that continuously models objects in a processing area in which the plurality of modeling stages are arranged along the direction in which the process progresses. In step (a), the powder rapid prototyping apparatus transports, in a proceeding direction of the process, the plurality of modeling stages arranged along the proceeding direction of the process. In step (b), the powder rapid prototyping apparatus lowers each of the multiple modeling stages. In step (c), the powder rapid prototyping apparatus spreads the powder on each of the multiple modeling stages. In step (d), the powder rapid prototyping apparatus irradiates the powder spread on the multiple modeling stages with laser light. The powder rapid prototyping apparatus repeats steps (a) to (d) as step (e). Effect of the Invention

[0009] According to the present disclosure, it is possible to provide a powder additive manufacturing apparatus and a powder additive manufacturing method that efficiently manufactures a desired product. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a side view of a powder rapid prototyping apparatus according to an embodiment. [Diagram 2] FIG. 1 is a top view of a powder rapid prototyping apparatus according to an embodiment. [Diagram 3] 2 is a side view showing an example of the configuration of an optical block in the powder rapid prototyping apparatus 1. FIG. [Figure 4] FIG. 13 is a diagram showing the layout of horizontal guides in the machining area. [Diagram 5] 11A and 11B are diagrams for explaining the configuration of a connecting portion and a lift control mechanism. [Figure 6] FIG. 2 is a diagram for explaining a configuration of a modeling stage. [Figure 7] FIG. [Figure 8] 1 is a flowchart showing a modeling method performed by the powder additive manufacturing apparatus. [Figure 9] FIG. 1 is a first diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 10] FIG. 2 is a second diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 11] FIG. 11 is a third diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 12] FIG. 4 is a fourth diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 13] FIG. 5 is a fifth diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 14] FIG. 6 is a sixth diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 15] FIG. 7 is a seventh diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 16] FIG. 8 is an eighth diagram for explaining the operation of the powder rapid prototyping apparatus. [Figure 17]FIG. 9 is a ninth diagram for explaining the operation of the powder rapid prototyping apparatus. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The present invention will be described below through the embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. In addition, not all of the configurations described in the embodiments are necessarily essential as means for solving the problems. For clarity of explanation, the following description and drawings are omitted and simplified as appropriate. In each drawing, the same elements are given the same reference numerals, and duplicate explanations are omitted as necessary.

[0012] <Embodiment Mode> First, an overview of the powder additive manufacturing apparatus according to the present embodiment will be described with reference to FIG. 1 and FIG. 2. FIG. 1 is a side view of the powder additive manufacturing apparatus according to the embodiment. FIG. 2 is a top view of the powder additive manufacturing apparatus according to the embodiment. The powder additive manufacturing apparatus 1 according to the present embodiment is a type of so-called 3D printer, and produces a product having a desired three-dimensional shape by forming and stacking thinly sliced ​​two-dimensional layers one by one based on three-dimensional design data. The powder additive manufacturing apparatus 1 according to the present embodiment is a continuous modeling apparatus that continuously produces products by performing different processes in parallel in multiple processing zones. Note that some components are omitted in FIG. 1 and FIG. 2 for ease of understanding.

[0013] The powder rapid prototyping apparatus 1 has a preheating area A10, a processing area A11, and a discharge area A12. The preheating area A10 is located before the processing area A11 and preheats a modeling stage on which powder is spread.

[0014] The processing area A11 is an area where the powder is processed to manufacture a desired three-dimensional object by each of the above-mentioned components fulfilling their respective functions. The processing area A11 includes four processing zones (first processing zone A111, second processing zone A112, third processing zone A113, and fourth processing zone A114) as shown in FIG. 2. A modeling stage is installed in each of the four processing zones, and different processes are performed on the installed modeling stage. More specifically, in the four processing zones, the powder additive manufacturing apparatus 1 forms a powder bed and irradiates the formed powder bed with laser light. As the modeling stage passes through the four processing zones in sequence, a modeled block containing a manufactured product is generated on the modeling stage. The discharge area A12 is an area where the modeled block that has passed through the processing area A11 is transported and discharged.

[0015] The following describes each component of the powder rapid prototyping apparatus 1. The powder rapid prototyping apparatus 1 has a modeling block 10, a partition control block 20, a powder supply block 30, and a light source block 40 as its main components.

[0016] For convenience of explaining the positional relationship of the components, a right-handed Cartesian coordinate system is used in Fig. 1. Also, in Fig. 2 and subsequent figures, when a Cartesian coordinate system is used, the X-axis, Y-axis, and Z-axis directions in Fig. 1 coincide with the X-axis, Y-axis, and Z-axis directions in these Cartesian coordinate systems, respectively.

[0017] (Modeling block 10) The main components of the shaping block 10 include a shaping stage 11, a stage transport mechanism 12, a connecting portion 13, a horizontal guide 16, a lift control mechanism 17, and side plates 18.

[0018] The modeling stage 11 has a rectangular main surface on which powder, which is the object to be processed, can be loaded. The modeling stage 11 is engaged with a stage transport mechanism 12 via a connecting portion 13, and is transported by the stage transport mechanism 12. The modeling stage 11 is configured so that the main surface faces upward in the processing area A11.

[0019] The stage transport mechanism 12 supports a plurality of modeling stages 11 via connectors 13, and transports the modeling stages 11 sequentially in the process proceeding direction. The process proceeding direction is the direction from the negative side of the X-axis to the positive side of the X-axis in Figures 1 and 2. The stage transport mechanism 12 mainly comprises a transport unit 121 and a transport drive unit 122.

[0020] The transport unit 121 is configured in a ring shape and supports the modeling stage 11 along the ring. The transport unit 121 is driven by a transport drive unit 122. As a result, the transport unit 121 circulates in a ring shape to transport the modeling stage 11. The transport unit 121 is, for example, a chain or belt configured in a ring shape.

[0021] The transport drive unit 122 includes a motor for driving the transport unit, and engages with the transport unit 121 to circulate the transport unit 121 in a circular manner. There may be one transport drive unit 122, or there may be multiple transport drive units. The stage transport mechanism 12 shown in FIG. 1 has a transport drive unit 122 at each of the right and left ends of the transport unit 121. As shown in FIG. 1, the transport drive unit 122 is configured to rotate right (i.e., rotate clockwise) around an axis parallel to the X-axis. As a result, the transport drive unit 122 transports the upper side of the transport unit 121 from left to right. The transport drive unit 122 also transports the lower side of the transport unit 121 from right to left. In addition to the above-mentioned configuration, the stage transport mechanism 12 may include a guide member for regulating the movement of the transport unit 121 or for assisting the operation of the transport drive unit 122. The transport drive units 122 shown in the figure may be one that drives and the other that is driven.

[0022] The transport unit 121 in this embodiment is configured to circulate along a vertical plane. More specifically, the transport unit 121 shown in FIG. 1 circulates in a ring shape along the YZ plane, which is a vertical plane. The transport unit 121 also has a substantially elliptical shape with circular parts at the left and right ends. Furthermore, the stage transport mechanism 12 is arranged so that the height of the transport unit 121 in the processing area A11 decreases from the upstream side to the downstream side of the process. In the case of the example shown in FIG. 1, the transport unit 121 is transported from left to right by the transport drive unit 122 in the processing area A11. Therefore, the upstream side of the process in the processing area A11 is the left side of the figure, and the downstream side of the process is the right side of the figure. Therefore, the transport unit 121 shown in FIG. 1 decreases from the upper left to the lower right.

[0023] The horizontal guide 16 extends in the processing area A11 in the traveling direction across two adjacent processes, and guides one engaged modeling stage 11 in the horizontal direction. The horizontal guide 16 may be configured, for example, as a linear guide. The modeling block 10 has a plurality of horizontal guides 16 in the processing area A11. The plurality of horizontal guides 16 are arranged in a cascade or staircase shape along the conveying section 121 that extends at an angle.

[0024] The lifting control mechanism 17 is arranged at each process in the processing area A11, and supports the modeling stage 11 transported to the process where it is arranged. The lifting control mechanism 17 also controls the height of the modeling stage 11 that it supports in order to form a powder bed in the powder supply block 30. Furthermore, after the powder spread on the modeling stage 11 is irradiated with the laser light, the lifting control mechanism 17 lowers the modeling stage 11 to a position where the modeling stage 11 can engage with the horizontal guide 16 located below the modeling stage 11.

[0025] The side plate 18 has a surface that contacts the side of the modeling stage 11 along the travel direction in the processing area A11. The side plate 18 supports the powder spread on the modeling stage 11 by contacting the side of the modeling stage 11. The side plate 18 in this embodiment extends across a plurality of adjacent processing sections, and its upper end is formed horizontally and fixed so that its position does not change. Therefore, the height from the main surface of the modeling stage 11 transported by the stage transport mechanism 12 to the upper end of the side plate 18 differs for each of the four processing sections. That is, the side plate 18 contacts the side of the modeling stage 11 along the travel direction in the processing area A11, and is erected so that the height from the main surface of the modeling stage 11 to the upper end can be changed. The side plate 18 also supports the powder supply block 30 at its upper end.

[0026] (Partition control block 20) The partition control block 20 controls the arrangement of a plurality of partitions 21 by working in conjunction with the modeling block 10. The partition control block 20 has the partitions 21, a partition transport mechanism 22, a partition transport belt 23, and a linear guide 24.

[0027] The partition plate 21 is a plate-like member extending in the vertical direction, and is erected in the processing area A11 along a direction perpendicular to the traveling direction of the modeling stage 11 and in contact with the side of the modeling stage 11. The partition plate 21 moves in conjunction with the movement of the modeling stage 11 while remaining interposed between adjacent modeling stages 11 in the processing area A11. As a result, the partition plate 21 supports the powder spread on the modeling stage 11. In other words, the main surface of the modeling stage 11 is supported on all four sides by the side plates 18 and the partition plate 21 described above. In other words, the side plates 18 and the partition plate 21 form a frame on the main surface of the modeling stage 11.

[0028] The partition plate 21 is supported by a linear guide 24 so as to be movable linearly in the vertical direction. As a result, the partition plate 21 is arranged in a stepped manner in the processing area A11, and follows the movement of the modeling stage 11 which is transported while being processed in the traveling direction.

[0029] The partition conveying mechanism 22 is a cylindrical rotating member having a central axis in the vertical direction. The partition conveying mechanism 22 engages with the partition conveying belt 23 and supports the movement of the partition conveying belt 23. Specifically, the partition conveying mechanism 22 shown in FIG. 2 engages with the inside of the circular portions at both ends of the elliptical partition conveying belt 23. The partition conveying mechanism 22 may include a drive unit for actively circulating the partition conveying belt 23. Alternatively, the partition conveying mechanism 22 may not include a drive unit and may be configured to be linked to and driven by the shaping block 10.

[0030] The partition plate conveying belt 23 is formed in a ring shape along a horizontal plane (i.e., the XY plane) and is supported by the partition plate conveying mechanism 22 so as to be circulable. A plurality of linear guides 24 are fixed to the outer periphery of the partition plate conveying belt 23. The partition plate conveying belt 23 shown in Fig. 2 has an elliptical shape extending in the left-right direction, and the partition plate conveying mechanism 22 engages with the inside of the circular portions at the left and right ends. The shape of the partition plate conveying belt 23 is not limited to the elliptical shape shown in Fig. 2.

[0031] The linear guide 24 has a rail portion and a movable portion. The rail portion is fixed to the partition plate conveying belt 23 so as to be parallel in the vertical direction. The movable portion holds the partition plate 21 so as to be movable in the vertical direction.

[0032] The above describes the partition control block 20. As described above, the partition control block 20 supports a plurality of partitions 21 that are capable of moving linearly independently in the vertical direction. The partition control block 20 also has a partition transport mechanism 22 that transports the partitions 21 so as to circulate in a circular manner along a horizontal plane.

[0033] The partition conveying mechanism 22 conveys the partition 21 along the moving direction in the processing area A11, and conveys the partition 21 in a direction different from the moving direction after the partition 21 leaves the processing area A11. The partition conveying mechanism 22 also links the partition 21 to the movement of the modeling stage 11 in the processing area A11.

[0034] (Powder feed block 30) The powder supply block 30 mainly comprises a recoater 31 and supply powder 32. The recoater 31 is a member for spreading the supply powder 32 over the modeling stage 11. The recoater 31 generally has a blade-like or roller-like shape. As shown in FIG. 2, the recoater 31 is disposed, for example, on the upper surface of the side plate 18 at the side of the modeling stage 11, and reciprocates in a direction (Y direction) perpendicular to the traveling direction (X-axis direction) of the modeling stage 11.

[0035] The supply powder 32 is a powder that is spread on the modeling stage 11 by the recoater 31. The supply powder 32 is supplied between the recoater 31 and the modeling stage 11 by a predetermined powder supplying device. The predetermined powder supplying device is, for example, a device that causes a preset amount of powder stored below to be movably raised by the recoater 31. The predetermined powder supplying device may also be, for example, a device that supplies a preset amount of powder by dropping it from above onto the surface between the recoater 31 and the modeling stage 11.

[0036] As described above, the multiple recoaters 31 spread the supply powder 32 in parallel on each of the multiple modeling stages 11 in the processing area A11. The recoaters 31 also perform reciprocating motion in a direction perpendicular to the traveling direction (Y direction in FIG. 2). In this way, the recoaters 31 spread the supply powder 32 on the modeling stages 11.

[0037] (Light source block 40) 1 irradiates laser light onto the powder spread by the recoater 31 in each processing section of the processing region A11. In this way, the light source block 40 melts and solidifies the powder into a desired shape.

[0038] The above describes the outline of the powder rapid prototyping apparatus 1. In the above example, the powder rapid prototyping apparatus 1 has four processing zones (first processing zone A111 to fourth processing zone A114) in the processing zone A11. However, the number of processing zones in the processing zone A11 is not limited to four. The processing zone A11 may have two or more processing zones.

[0039] Next, a configuration example of the light source block 40 will be described with reference to Fig. 3. Fig. 3 is a side view showing a configuration example of the optical block in the powder rapid prototyping apparatus 1. Fig. 3 shows a state in which powder beds 90 are spread over the modeling stages 11 installed for each processing section in the processing area A11. Fig. 3 also shows a state in which the light source block 40 irradiates laser light onto the multiple powder beds 90 to manufacture products 91.

[0040] The light source block 40 shown in Fig. 3 mainly comprises a laser oscillator 41, a semi-reflective mirror 42, a total reflective mirror 43, and a galvano unit 44. The laser oscillator 41 is, for example, a laser oscillator that outputs a carbon dioxide gas laser. The semi-reflective mirror 42 reflects a part of the input laser light and transmits the remaining laser light. The total reflective mirror 43 reflects the input laser light.

[0041] The galvano unit 44 includes a mirror that reflects the input laser light at a predetermined angle and a galvano motor that drives the mirror. With this configuration, the galvano unit 44 irradiates the input laser light onto a powder bed 90 spread on the main surface of the modeling stage 11, melts and solidifies the powder into a desired shape, and forms a product 91.

[0042] The light source block 40 combines a plurality of semi-reflective mirrors 42 and a total reflective mirror 43 to branch and supply the laser light generated by one laser oscillator 41 to the galvano units 44 provided in each of the plurality of processing zones. With this configuration, the light source block 40 can suppress the variation in the laser power irradiated to the plurality of different processing zones.

[0043] Next, the arrangement of the horizontal guide will be described with reference to Fig. 4. Fig. 4 is a diagram showing the arrangement of the horizontal guide in the processing area. Fig. 4 shows a part of the conveying section 121 and a plurality of horizontal guides 16 fixed above the conveying section 121. In Fig. 4, the conveying section 121 is conveyed from left to right. That is, the left side of Fig. 4 is the upstream side of the process, and the right side of Fig. 4 is the downstream side of the process.

[0044] As shown in the figure, the horizontal guide 16 extends in the traveling direction across two adjacent machining zones in the machining area A11. The horizontal guide 16 also has a horizontal guide groove 160. The modeling stage 11 removably engages with the horizontal guide groove 160 of the horizontal guide 16. When the modeling stage 11 engages with the horizontal guide groove 160, the horizontal guide 16 guides the engaged modeling stage 11 to the adjacent machining zone.

[0045] In addition, the horizontal guide 16 is arranged such that the upstream portion of the second horizontal guide arranged downstream of the process is disposed below the downstream portion of the first horizontal guide arranged upstream of the process. Specifically, for example, a first horizontal guide 161 and a second horizontal guide 162 are disposed in the first processing area A111. The right side (downstream portion) of the first horizontal guide 161 is disposed in the first processing area A111. In addition, the left side (upstream portion) of the second horizontal guide 162 is disposed below the first horizontal guide 161 in the first processing area A111. The first horizontal guide 161 and the second horizontal guide 162 have a distance of height H10 between them.

[0046] Next, the connecting portion 13 and the lifting control mechanism 17 will be described with reference to Fig. 5. Fig. 5 is a diagram for explaining the configuration of the connecting portion and the lifting control mechanism. The left side of Fig. 5 shows a state in which the connecting portion 13, in which the second connecting portion 15 is bent, connects the modeling stage 11 and the transport portion 121. The center of Fig. 5 shows a state in which the connecting portion 13 connects the modeling stage 11 and the transport portion 121 when the transport portion 121 extends obliquely in the processing area A11. The right side of Fig. 5 shows a state in which the modeling stage 11 is lowered while being supported by the lifting control mechanism 17.

[0047] First, the connecting portion 13 will be described. The connecting portion 13 that connects the transport portion 121 and the modeling stage 11 has a first connecting portion 14 and a second connecting portion 15. One end of the first connecting portion 14 engages with the modeling stage 11 on the upstream side of the modeling stage 11, and the other end engages with the transport portion 121, thereby connecting the modeling stage 11 and the transport portion 121. The first connecting portion 14 mainly includes a first connecting shaft 141 and a first guide groove 142. The first connecting shaft 141 engages with the transport portion 121. The first connecting portion 14 is supported by the transport portion 121 so as to be rotatable about the first connecting shaft 141. The first guide groove 142 is a guide groove, and supports the guide shaft 112 protruding from the side of the modeling stage 11 so as to be linearly movable.

[0048] The second connecting part 15 has one end which engages with the modeling stage 11 on the downstream side of the modeling stage 11 and the other end which engages with the transport part 121, thereby connecting the modeling stage 11 and the transport part 121. The second connecting part 15 mainly includes a second connecting shaft 151, a second guide groove 152, and a joint part 153. The second connecting shaft 151 engages with the transport part 121.

[0049] The second connecting part 15 is supported by the transport part 121 so as to be rotatable around the second connecting shaft 151. The second guide groove 152 is a guide groove, and supports the guide shaft 112 protruding from the side of the modeling stage 11 so as to be capable of linear motion. The joint part 153 is a joint provided between the second connecting shaft 151 and the second guide groove 152, and is configured so that the shape of the second connecting part 15 can be changed to either a bent state or a straight state. The second connecting part 15 may be provided with a locking mechanism for maintaining the bent state or the straight state.

[0050] As shown on the left side of the figure, when the transport unit 121 extends horizontally, the connecting unit 13 bends the joint 153 of the second connecting unit 15. Also, as shown in the center of the figure, when the transport unit 121 extends obliquely, the connecting unit 13 is in an extended state in which the joint 153 is not bent. In this way, by changing the state of the second connecting unit 15 according to the extension direction of the transport unit 121, the connecting unit 13 can keep the orientation of the modeling stage 11 parallel to the horizontal plane whether the transport unit 121 extends horizontally or obliquely. Also, as shown on the right side of the figure, the connecting unit 13 is configured to be able to lower the dimension of the height H10 while maintaining the orientation of the modeling stage 11 parallel to the horizontal plane. With the above-mentioned configuration, the connecting unit 13 connects to each of the transport unit 121 and the modeling stage 11 in the processing area A11 so that the relative positional relationship in the vertical direction can be changed.

[0051] Next, the lift control mechanism 17 will be described. The lift control mechanism 17 mainly comprises a lift motor 171, a drive shaft 172, and a lift block 173. The lift motor 171 rotates the drive shaft 172, which has a spiral groove, in a desired direction. The drive shaft 172 is a shaft that is rotated by the lift motor 171, and is engaged with the drive shaft 172. The lift block 173 is engaged with the drive shaft 172, and supports the lower part of the modeling stage 11.

[0052] For example, when the lifting motor 171 rotates the drive shaft 172 to the right, the lifting control mechanism 17 raises the lifting block 173. Also, when the lifting motor 171 rotates the drive shaft 172 to the left, the lifting control mechanism 17 lowers the lifting block 173. In this way, when the lifting block 173 supports the modeling stage 11, the lifting control mechanism 17 controls the height of the modeling stage 11 in accordance with the above-mentioned movement.

[0053] With the above-mentioned configuration, the lifting control mechanism 17 is arranged to be able to move up and down between the first horizontal guide 16 (e.g., the first horizontal guide 161 in FIG. 4) arranged on the upstream side of the process in the processing area and the second horizontal guide 16 (e.g., the second horizontal guide 162 in FIG. 4) arranged on the downstream side. In this way, the lifting control mechanism 17 lowers the modeling stage 11 that has been detached from the first horizontal guide 16 so that it can engage with the second horizontal guide 16.

[0054] Next, the configuration of the modeling stage 11 will be described with reference to Fig. 6. Fig. 6 is a diagram for explaining the configuration of the modeling stage. In Fig. 6, two modeling stages 11 are shown on the left and right sides, interposed between two opposing horizontal guides 16. Each modeling stage 11 is shown partially see-through for ease of understanding. The modeling stage 11 includes a plunger 111 and a guide shaft 112.

[0055] The plunger 111 drives the guide shaft 112 to advance or retract it in the axial direction. The modeling stage 11 has two plungers 111 arranged at a distance in the front-rear direction on each side (side in the Y direction), totaling four. The guide shafts 112 driven by the plungers 111 engage with the first connecting portion 14 and the second connecting portion 15, respectively.

[0056] The modeling stage 11 shown on the left side of Fig. 6 is in a state in which the four plungers 111 each have their guide shaft 112 extended. When the guide shafts 112 are extended by the plungers 111, they engage with the horizontal guide grooves 160 of the horizontal guide 16. In this case, the modeling stage 11 is guided by the horizontal guide 16 and can move in the horizontal direction while maintaining a posture in which the main surface is parallel to the horizontal plane. On the other hand, in this case, the modeling stage 11 is restrained by the horizontal guide grooves 160 and cannot move in the vertical direction.

[0057] The modeling stage 11 shown on the right side of Fig. 6 is in a state in which the four plungers 111 are retracting the guide shafts 112. The guide shafts 112 are removed from the horizontal guide grooves 160 by being retracted by the plungers 111. In this case, the modeling stage 11 is guided by the first connecting portion 14 and the second connecting portion 15 and can move in the vertical direction. Note that in this case, as indicated by the dotted lines on the right side of Fig. 6, the modeling stage 11 is supported from below by the lift control mechanism 17 and moves in the vertical direction.

[0058] This concludes the description of the configuration of the modeling stage 11. As described above, the modeling stage 11 in this embodiment is detachably engaged with the horizontal guide 16. In this way, the powder rapid prototyping apparatus 1 controls the positions and attitudes of the multiple modeling stages 11.

[0059] Next, the partition control block will be described with reference to Fig. 7. Fig. 7 is a perspective view of the partition control block. When the partition control block 20 shown in Fig. 7 is observed from above, the partition conveying belt 23 circulates counterclockwise. A plurality of linear guides 24 are fixed to the outer periphery of the partition conveying belt 23 along the vertical direction. The linear guide 24 has a partition 21 that is capable of moving linearly in the vertical direction. The partition conveying belt 23 circulates in response to the movement of the modeling stage 11. As a result, the partition 21 moves in conjunction with the modeling stage 11.

[0060] The modeling stage 11 passes between two opposing side plates 18. At this time, the distance between the two side plates 18 is W18. The modeling stage 11 passing through the distance W18 has a width W11. Here, the width W11 is large enough to pass through the distance W18 without rattling. The partition plate 21 has a width W21 as a dimension of a portion in contact with the modeling stage 11. Here, the width W11 of the modeling stage 11 and the width W21 of the partition plate 21 are approximately the same. Therefore, the powder bed 90 formed in the processing area A11 is sequentially transported in the process proceeding direction while being surrounded and supported by the side plates 18 and the partition plate 21.

[0061] The powder processed in the processing area A11 forms a powder block 92 in the shape of a rectangular prism. When the powder block 92 passes through the processing area A11, it is transported to the discharge area A12. In the discharge area A12, there is no side plate 18, and the partition plate 21 on the downstream side of the process moves along the partition plate conveying belt 23 and is therefore separated from the modeling stage 11. Therefore, in the discharge area A12, the powder block 92 is in contact with the partition plate 21 on the upstream side of the process, but the other surrounding surfaces are not supported. Then, when the modeling stage 11 and the partition plate 21 move further in the traveling direction from this state, the partition plate 21 moves while rotating in the direction of the arrow A21 along the partition plate conveying belt 23. Then, the powder block 92 is pushed out by the rotating partition plate 21 in a direction different from the traveling direction of the modeling stage 11. In this way, the partition plate 21 has the function of discharging the processed powder block 92 in the discharge area A12.

[0062] Next, the processing executed by the powder additive manufacturing apparatus 1 will be described with reference to Fig. 9. Fig. 9 is a flowchart showing a modeling method executed by the powder additive manufacturing apparatus. The flowchart shown in Fig. 9 shows processing executed by the powder additive manufacturing apparatus 1 in the processing area A11. The modeling method according to the present disclosure is a modeling method executed by a powder additive manufacturing apparatus that has a plurality of modeling stages each having a main surface on which powder, which is an object to be processed, is able to be loaded, and that successively models objects in the processing area where the plurality of modeling stages are arranged along the process progression direction.

[0063] First, in step (a), the powder rapid prototyping apparatus 1 transports, in the proceeding direction, a plurality of modeling stages 11 arranged along the proceeding direction of the process (step S11).

[0064] Next, in step (b), the powder rapid prototyping apparatus 1 lowers each of the multiple modeling stages 11 (step S12).

[0065] Next, in step (c), the powder rapid prototyping apparatus 1 spreads powder on each of the multiple modeling stages 11 (step S13).

[0066] Next, in step (d), the powder rapid prototyping apparatus 1 irradiates the powder spread on the multiple modeling stages 11 with laser light (step S14).

[0067] Next, the powder rapid prototyping apparatus 1 determines whether or not steps (b) to (d) have been performed a predetermined number of times (step S15). That is, the powder rapid prototyping apparatus 1 performs steps (b) to (d) a predetermined number of times. The predetermined number of times may be once or may be two or more times. If it is not determined that steps (b) to (d) have been performed a predetermined number of times (step S15: NO), the powder rapid prototyping apparatus 1 returns to step S12 and performs step (b). On the other hand, if it is determined that steps (b) to (d) have been performed a predetermined number of times (step S15: YES), the powder rapid prototyping apparatus 1 proceeds to step S16.

[0068] Next, the powder rapid prototyping apparatus 1 determines whether or not to end the series of processes (step S16). In other words, if the powder rapid prototyping apparatus 1 does not determine to end the series of processes (step S16: NO), it repeats steps (a) to (d) as step (e). Then, if the powder rapid prototyping apparatus 1 determines to end the series of processes (step S16: YES), it ends the series of processes. The series of processes may be ended, for example, when a user indicates that the process should be stopped or when powder has not been supplied to spread the powder bed.

[0069] The above describes the processes executed by the powder rapid prototyping apparatus 1. According to the above-described powder rapid prototyping method, a desired product can be efficiently manufactured.

[0070] Next, the above-mentioned powder additive manufacturing method will be described with a specific example. Fig. 9 is a first diagram for explaining the operation of the powder additive manufacturing apparatus. In Fig. 9, the modeling stage 11 shown by a solid line is located in the preheating area A10. In the following description, in order to focus on the operation of one modeling stage 11, the one modeling stage 11 of interest is shown by a solid line, and the other modeling stages 11, etc. are shown by dotted lines. Also, for ease of understanding, the configuration is appropriately omitted.

[0071] The modeling stage 11, indicated by a solid line in Fig. 9, is transported by the stage transport mechanism 12 from the preheating area A10 to the processing area A11 (step (a)). At this time, the guide shaft 112 is engaged with the horizontal guide groove 160. Therefore, the modeling stage 11 is transported to the first processing area A111 while its main surface is maintained horizontal. At this point, the joint portion 153 of the second connecting portion 15 that engages with the modeling stage 11 is in a bent state.

[0072] Fig. 10 is the second diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 10, the modeling stage 11 has reached the first processing area A111. At this point, the guide shaft 112 is engaged with the horizontal guide groove 160. In addition, the second connecting portion 15 has changed from a bent state to an extended state.

[0073] When the modeling stage 11 reaches the first processing area A111, the lifting control mechanism 17 installed in the first processing area A111 lifts the lifting block 173 to support the modeling stage 11. Note that the lifting control mechanism 17 may start lifting the lifting block 173 before the modeling stage 11 reaches the first processing area A111.

[0074] Fig. 11 is a third diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 11, the modeling stage 11 is supported by the lift control mechanism 17. Also, the guide shaft 112 is detached from the horizontal guide 16. Therefore, the modeling stage 11 is in a state where it can move in the vertical direction. From this point, the lift block 173 is lowered. Therefore, the modeling stage 11 is lowered together with the lift block 173 along the first guide groove 142 and the second guide groove 152.

[0075] Fig. 12 is a fourth diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 12, the modeling stage 11 is lowered by a height H11 from the position shown in Fig. 11 (step (b)). The height H11 corresponds to the thickness of the powder bed to be generated later.

[0076] Fig. 13 is a fifth diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 13, a powder bed 90 is spread over the main surface of the modeling stage 11 (step (c)), and laser light is irradiated from the galvano unit 44 (step (d)). When processing of the powder bed with the laser light is completed, the lift control mechanism 17 again lowers to height H11 (step (b)). Then, the galvano unit 44 irradiates the powder bed with laser light (steps (c), (d)). The powder rapid prototyping apparatus 1 repeats this process a predetermined number of times.

[0077] Fig. 14 is a sixth diagram for explaining the operation of the powder rapid prototyping apparatus. The modeling stage 11 shown in Fig. 14 is in a state where steps (b) to (d) have been repeated a predetermined number of times. After this, the lift control mechanism 17 moves the modeling stage 11 to a position where the guide shaft 112 can engage with the horizontal guide groove 160 in order to engage the modeling stage 11 with the horizontal guide 16 on the downstream side of the process.

[0078] Fig. 15 is a seventh diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 15, the modeling stage 11 is in a state in which the guide shaft 112 is engaged with the horizontal guide groove 160. Therefore, after this, the stage transport mechanism 12 drives the transport part 121 to transport the modeling stage 11 from the first processing area A111 to the second processing area A112 in order to proceed to the next process (process (a)).

[0079] Fig. 16 is an eighth diagram for explaining the operation of the powder rapid prototyping apparatus. In Fig. 16, the modeling stage 11 is transported to the second processing area A112. After this, the modeling stage 11 disengages from the horizontal guide 16. The modeling stage 11 is further lowered by the lift control mechanism 17 (step (b)). Then, the powder supply block 30 generates a powder bed on the main surface of the modeling stage 11 (step (c)). Then, the galvano unit 44 irradiates the powder bed with laser light (step (d)).

[0080] FIG. 17 is a ninth diagram for explaining the operation of the powder additive manufacturing apparatus. In FIG. 17, the modeling stage 11 is in a state where a predetermined process has been performed in the second processing area A112. Therefore, in the second processing area A112, a powder bed is further layered on the modeled object formed in the first processing area A111 on the modeling stage 11, and a modeled object is further formed by the laser light. When the process in the second processing area A112 is completed, the modeling stage 11 is transported to the third processing area A113, and the same process is repeated. Also, as shown in FIG. 17, processing is performed in parallel in each processing area. Therefore, the powder additive manufacturing apparatus 1 can continuously manufacture desired products.

[0081] Although the powder additive manufacturing apparatus 1 has been described above, the powder additive manufacturing apparatus 1 according to the embodiment is not limited to the above-mentioned configuration. For example, the transport unit 121 of the stage transport mechanism 12 may circulate along a horizontal plane instead of circulating along a vertical plane. Furthermore, the lift control mechanism 17 may not be fixed to each processing section, but may move in the direction of travel in conjunction with the modeling stage 11. Furthermore, the transport unit 121 may transport the lift control mechanism 17.

[0082] The side plates 18 may not be fixed to the processing area A11, but may be configured to be movable up and down in association with each of the modeling stages 11. The partition plate 21 may not be controlled by the partition plate control block 20, but may engage with the modeling stage 11 and be transported together with the modeling stage 11. The light source block 40 may not generate laser light by branching one laser light source, but may have a respective light source for each processing area.

[0083] As described above, according to the embodiment, it is possible to provide a powder rapid prototyping apparatus and a powder rapid prototyping method that efficiently manufacture a desired product.

[0084] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0085] 1 Powder additive manufacturing equipment 10 Modeling Blocks 11 Modeling Stage 12 Stage transport mechanism 13 Connecting part 14 1st connection part 15 2nd connection part 16 Horizontal guide 17 Lifting control mechanism 18 Side Panel 20 Partition control block 21 Partition 22 Partition plate transport mechanism 23 Partition conveyor belt 24 Linear guide 30 Powder Feed Block 31 Recoater 32 Feeding powder 40 Light source block 41 Laser oscillator 42 Semi-reflective mirror 43 Total Reflection Mirror 44 Galvano Unit 90 powder bed 91 products 92 Powder Block 111 Plunger 112 Guide shaft 121 Conveyor 122 Conveyor drive unit 141 1st connection shaft 142 First guide groove 151 2nd connection shaft 152 Second guide groove 153 Joints 160 Horizontal guide groove 171 Lift motor 172 Drive shaft 173 Lifting Block A11 Machining area

Claims

1. A laser unit for use in a powder additive manufacturing apparatus having a plurality of processing zones, A laser oscillator for outputting laser light; A plurality of mirrors that split the input laser beam according to a plurality of processing areas to generate a plurality of split laser beams; A plurality of galvanometer units that simultaneously irradiate the plurality of generated split laser beams onto a workpiece, which is a powder spread in each of a plurality of processing zones; Equipped with Laser unit.

2. The plurality of mirrors include a semi-reflective mirror that reflects a portion of the input laser light and transmits the remaining laser light; a total reflection mirror that reflects the input laser light, The semi-reflective mirror and the total reflective mirror are combined to generate a plurality of split laser beams having substantially equal laser powers.

2. The laser unit according to claim 1.

3. A laser irradiation method for powder additive manufacturing having a plurality of processing zones, comprising: A step of outputting a laser beam from a laser oscillator; A step of branching an input laser beam according to a plurality of processing zones to generate a plurality of branched laser beams; A step of simultaneously irradiating the generated plurality of branched laser beams onto a processing object, which is a powder spread in each of a plurality of processing zones; Equipped with Laser irradiation method.

4. In the step of generating a plurality of split laser beams, a semi-reflective mirror that reflects a portion of the input laser light and transmits the remaining laser light; A total reflection mirror that reflects the input laser light is combined to generate a plurality of branched laser light beams having approximately equal laser powers. The laser irradiation method according to claim 3.

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