Molding data creation device, three-dimensional laminate molding system and three-dimensional laminate molding method

Abstract

To achieve molding of one entire cross-sectional shape in appropriate molding conditions even if shape elements having contradicting appropriate molding conditions are included in the cross-sectional shape.SOLUTION: A molding data creation device creates molding data for controlling an operation of a three-dimensional laminate molding device configured to melt cross-sectional shapes of respective layers by irradiation of beams to mold an article. The molding data creation device includes: a region division part configured to conduct processing for dividing a cross-sectional shape cut out from three-dimensional shape data of an article into a fine region and a coarse region; and a condition application part configured to apply different molding conditions respectively to the fine region and the coarse region divided by the region division part to generate the molding data.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a modeling data creation device, a three-dimensional additive manufacturing system, and a three-dimensional additive manufacturing method. [Background technology]

[0002] Powder bed fusion is known as one of the molding methods for forming an object. The powder bed fusion is a molding method in which a beam is selectively irradiated onto the surface of a powder layer (hereinafter also referred to as the "molding surface") formed by spreading powder to a predetermined thickness, thereby melting and solidifying a cross-sectional shape of the object to be molded. In the powder bed fusion method, the molding plate is lowered in sequence each time the powder of each layer is melted and solidified, thereby stacking the powder layers one by one to form an object (part, etc.). A three-dimensional additive manufacturing device employing the powder bed fusion method is described in Patent Document 1, for example.

[0003] The operation of the three-dimensional additive manufacturing device is controlled according to an operation sequence program (hereinafter also referred to as "modeling data") that is prepared in advance based on three-dimensional shape data. Three-dimensional shape data is data that specifies the three-dimensional shape of an object generated by three-dimensional CAD (Computer-Aided Design) or the like. The modeling data is created by a computer device (hereinafter referred to as a "modeling data creation device") incorporating a program generally called CAM (Computer Aided Manufacturing) software, using three-dimensional shape data of the object to be modeled. CAM software can be executed by any computer.

[0004] The CAM software process in the modeling data creation device first cuts out the cross-sectional shapes of each layer at intervals of one layer's thickness from the input three-dimensional shape data. Next, the modeling conditions for melting the cross-sectional shapes of each layer are determined. The modeling data is the result of applying the modeling conditions to the cross-sectional shapes of each layer and outputting the results as an electronic file. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2019-7065 A Summary of the Invention [Problem to be solved by the invention]

[0006] In conventional modeling data creation devices, only one modeling condition could be applied to one cross-sectional shape. Therefore, when shape elements for which appropriate modeling conditions are contradictory are mixed in one cross-sectional shape, the modeling data created by the conventional modeling data creation device has a problem that the entire cross-sectional shape cannot be modeled under appropriate modeling conditions. Therefore, for example, when modeling conditions that are excellent in shape reproducibility but slow in modeling speed are applied to one cross-sectional shape, modeling may take more time than necessary. In addition, when modeling conditions that enable high-speed modeling but poor in shape reproducibility are applied to one cross-sectional shape, shape reproducibility may be reduced in a part of the cross-sectional shape.

[0007] An object of the present invention is to provide a technique capable of forming an entire cross-sectional shape under appropriate forming conditions even when shape elements having conflicting appropriate forming conditions are mixed in one cross-sectional shape. [Means for solving the problem]

[0008] The modeling data creation device of the present invention is a modeling data creation device that creates modeling data to control a three-dimensional additive manufacturing device that melts the cross-sectional shape of each layer by irradiating it with a beam to form an object, and is equipped with an area division unit that performs processing to divide the cross-sectional shape cut out from the three-dimensional shape data of the object into fine areas and coarse areas, and a condition application unit that applies different modeling conditions to the fine areas and coarse areas divided by the area division unit to generate modeling data.

[0009] The three-dimensional additive manufacturing system of the present invention is a three-dimensional additive manufacturing system comprising a three-dimensional additive manufacturing device that melts the cross-sectional shape of each layer by irradiating it with a beam to form an object, and a modeling data creation device that creates modeling data for controlling the three-dimensional additive manufacturing device, wherein the modeling data creation device comprises an area division unit that performs processing to divide the cross-sectional shape cut out from the three-dimensional shape data of the object into fine areas and coarse areas, and a condition application unit that applies different modeling conditions to the fine areas and coarse areas divided by the area division unit to generate modeling data, and the three-dimensional additive manufacturing device models the object in accordance with the modeling data.

[0010] The three-dimensional additive manufacturing method of the present invention is a three-dimensional additive manufacturing method in which the cross-sectional shape of each layer is melted by irradiating it with a beam to form an object, in which the cross-sectional shape cut out from the three-dimensional shape data of the object is divided into fine regions and coarse regions, and different manufacturing conditions are applied to the fine regions and the coarse regions to form the object. Effect of the Invention

[0011] According to the present invention, even when shape elements having conflicting suitable modeling conditions are mixed in one cross-sectional shape, the entire cross-sectional shape can be modeled under suitable modeling conditions. [Brief description of the drawings]

[0012] [Figure 1] 1 is a side view showing a schematic configuration of a three-dimensional additive manufacturing apparatus according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a block diagram showing an example of the configuration of a control system of a three-dimensional additive manufacturing apparatus according to an embodiment of the present invention. [Diagram 3] 4 is a flowchart showing a procedure of a processing operation of a three-dimensional additive manufacturing apparatus according to an embodiment of the present invention. [Figure 4] FIG. 1 is a diagram illustrating an example of the configuration of a three-dimensional additive manufacturing system according to an embodiment of the present invention. [Diagram 5] 1 is a block diagram showing an example of the configuration of a modeling data creating apparatus according to an embodiment of the present invention; [Figure 6]FIG. 11 is a diagram showing an example of setting beam scanning conditions. [Figure 7] FIG. 13 is a diagram showing an example of setting beam irradiation conditions in the case of a charged particle beam. [Figure 8] FIG. 13 is a diagram showing an example of setting beam irradiation conditions in the case of a laser beam. [Figure 9] 11 is a flowchart illustrating an example of a processing procedure of a modeling data creating apparatus. [Figure 10] FIG. 13 is a diagram showing an example of a cross-sectional shape that is a target for region division. [Figure 11] FIG. 13 is a diagram (part 1) for explaining the fine region identification process. [Figure 12] FIG. 11 is a diagram (part 2) for explaining the fine region identification process. [Figure 13] FIG. 11 is a diagram (part 3) for explaining the fine region identification process; [Figure 14] FIG. 11 is a fourth diagram for explaining the fine region identification process; [Figure 15] FIG. 5 is a diagram for explaining the fine region identification process; [Figure 16] FIG. 13 is a diagram (part 1) for explaining the coarse region identifying process. [Figure 17] FIG. 11 is a diagram (part 2) for explaining the coarse region identifying process. [Figure 18] FIG. 11 is a diagram (part 3) for explaining the coarse region identifying process; [Figure 19] FIG. 5 is a diagram for explaining the coarse region identifying process; [Figure 20] FIG. 1 is a diagram (part 1) showing an example of division of a cross-sectional shape. [Figure 21] 13A and 13B are diagrams illustrating an example of scanning lines generated by a first synthesis process. [Figure 22] 13A and 13B are diagrams illustrating examples of scanning lines generated by a second synthesis process. [Diagram 23] FIG. 11 is a diagram showing a first example of generating scanning lines in the vicinity of the contour line of a cross-sectional shape. [Figure 24] FIG. 13 is a diagram showing a first example of generating scanning lines in the vicinity of the contour line of a cross-sectional shape. [Diagram 25] FIG. 2 is a diagram (part 2) showing an example of division of a cross-sectional shape. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In this specification and the drawings, elements having substantially the same functions or configurations are given the same reference numerals, and duplicated descriptions are omitted as appropriate. In addition, the following description and drawings are examples for explaining the present invention, and may be omitted or simplified for convenience of explanation. Each component may be singular or plural unless otherwise limited. In addition, the position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc., in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

[0014] Fig. 1 is a side view showing a schematic configuration of a three-dimensional additive manufacturing apparatus according to an embodiment of the present invention. In the following description, in order to clarify the shapes and positional relationships of the various parts of the three-dimensional additive manufacturing apparatus, the left-right direction in Fig. 1 is defined as the X direction, the depth direction in Fig. 1 as the Y direction, and the up-down direction in Fig. 1 as the Z direction. The X direction, Y direction, and Z direction are mutually orthogonal. Moreover, the X direction and Y direction are parallel to the horizontal direction, and the Z direction is parallel to the vertical direction.

[0015] As shown in FIG. 1, the three-dimensional additive manufacturing apparatus 10 includes a vacuum chamber 12, a beam irradiation device 14, a powder coating device 16, a modeling table 18, a modeling box 20, a collection box 21, a modeling plate 22, an inner base 24, and a plate moving device 26. The three-dimensional additive manufacturing apparatus 10 models an article (hereinafter, also referred to as a "modeled object") by the above-mentioned powder bed fusion method. In this embodiment, the case where the beam irradiated to the surface of the powder layer is a charged particle beam, more specifically, an electron beam, is taken as an example for explanation. However, the beam is not limited to a charged particle beam, and may be, for example, a laser beam. When a laser beam is adopted, it is not necessary to evacuate the chamber.

[0016] The vacuum chamber 12 is a chamber for creating a vacuum state by exhausting the air inside the chamber with a vacuum pump (not shown). The vacuum chamber 12 corresponds to a modeling chamber that forms a space for modeling a three-dimensional object 38. The modeling chamber forms a space for modeling a three-dimensional object.

[0017] The beam irradiation device 14 is a device that irradiates the surface of the powder layer 32a, i.e., the forming surface 32b, with an electron beam 15. The electron beam 15 is an example of a charged particle beam. The beam irradiation device 14 has an electron gun 141 that is a source of the electron beam 15, a converging lens 142 that converges the electron beam 15 generated by the electron gun 141, and a deflection device 143 that deflects the electron beam 15.

[0018] The converging lens 142 is configured using a converging coil, and converges the electron beam 15 by a magnetic field generated by the converging coil. The size of the electron beam 15 on the printing surface 32b can be adjusted by the converging lens 142. The deflection device 143 is configured using a deflection coil, and deflects the electron beam 15 by a magnetic field generated by the deflection coil. Scanning of the electron beam 15 on the printing surface 32b is achieved by the deflection device 143.

[0019] The powder coating device 16 is a device that coats the metal powder 32, which is the raw material of the molded object 38, on the molding plate 22 to form a powder layer 32a. The metal powder 32 is an example of a powder that is the raw material of the molded object 38. The powder coating device 16 has a hopper 16a, a powder dropper 16b, and a squeegee 16c. The hopper 16a is a container for storing powder. The powder dropper 16b is a device that drops the powder stored in the hopper 16a onto the molding table 18. The squeegee 16c is a long member that is long in the Y direction. The squeegee 16c moves horizontally on the molding plate 22 from one end side to the other end side of the molding table 18 to spread the metal powder 32. As a result, the powder layer 32a is formed on the molding plate 22. The squeegee 16c is provided so as to be movable in the X direction in order to spread the metal powder 32 over the entire surface of the molding table 18.

[0020] The modeling table 18 is arranged horizontally inside the vacuum chamber 12. The modeling table 18 is arranged below the powder coating device 16. The center of the modeling table 18 is open. The shape of the opening of the modeling table 18 is circular or angular (e.g., rectangular) when viewed from above.

[0021] The modeling box 20 is a box that supports the inner base 24 so that it can move up and down. The modeling box 20 forms a space for stacking the metal powder 32 applied by the powder application device 16 on the inner base 24. The upper end of the modeling box 20 is connected to the edge of the opening of the modeling table 18. The lower end of the modeling box 20 is connected to the bottom wall of the vacuum chamber 12.

[0022] The recovery box 21 is a box for recovering metal powder 32 that is supplied in excess of the amount of metal powder 32 that is supplied onto the modeling table 18 by the powder coating device 16. The recovery box 21 is provided on each side in the X direction.

[0023] The shaping plate 22 is a plate for forming a shaped object 38 using the metal powder 32. The shaped object 38 is formed by stacking on the shaping plate 22. The shaping plate 22 is formed to be circular or angular in plan view to match the opening shape of the shaping table 18. The shaping plate 22 is connected (grounded) to the inner base 24 by an earth wire 34 so as not to be in an electrically floating state. The inner base 24 is held at a GND (ground) potential. The metal powder 32 is spread over the shaping plate 22 and the inner base 24.

[0024] The inner base 24 is provided so as to be movable in the vertical direction (Z direction). The shaping plate 22 moves vertically together with the inner base 24. The inner base 24 has outer dimensions larger than those of the shaping plate 22. The inner base 24 slides vertically along the inner surface of the shaping box 20. A sealing member 36 is attached to the outer periphery of the inner base 24. The sealing member 36 is a member that maintains slidability and airtightness between the outer periphery of the inner base 24 and the inner surface of the shaping box 20. The sealing member 36 is made of a material that is heat-resistant and elastic.

[0025] The plate moving device 26 is a device that moves the shaping plate 22 and the inner base 24 in the up-down direction. The plate moving device 26 includes a shaft 26a and a drive mechanism unit 26b. The shaft 26a is connected to the lower surface of the inner base 24. The drive mechanism unit 26b includes a motor and a power transmission mechanism (not shown), and moves the shaping plate 22 and the inner base 24 together with the shaft 26a in the up-down direction by driving the power transmission mechanism using the motor as a drive source. The power transmission mechanism is configured by, for example, a rack-and-pinion mechanism, a ball screw mechanism, or the like.

[0026] FIG. 2 is a block diagram showing an example of the configuration of a control system of a three-dimensional additive manufacturing apparatus according to an embodiment of the present invention. 2, the control unit 50 is configured by a computer including a processor 50a such as a CPU (Central Processing Unit) and a storage unit 50b such as a ROM (Read Only Memory), a RAM (Random Access Memory), a HDD (Hard Disk Drive), and an SSD (Solid State Drive). The control unit 50 centrally controls the operation of the three-dimensional additive manufacturing apparatus 10 by having the processor read out a program written in advance in the ROM into the RAM and execute it. The control unit 50 also controls the operation of the entire three-dimensional additive manufacturing apparatus 10 according to modeling data, which will be described later. The beam irradiation device 14, the powder coating device 16, and the plate moving device 26 are connected to the control unit 50 as objects to be controlled.

[0027] The beam irradiation device 14 irradiates the electron beam 15 based on a control command given from the control unit 50. At that time, the control unit 50 controls the electron beam 15 via the electron gun 141, the convergent lens 142, and the deflection device 143. For example, the control unit 50 controls the beam current amount of the electron beam 15 via the beam irradiation device 14. The control unit 50 also controls the spot size of the electron beam 15 via the convergent lens 142. The spot size of the electron beam 15 is the size of the electron beam 15 on the printing surface 32b. The control unit 50 also controls the deflection angle and deflection speed of the electron beam 15 via the deflection device 143. The deflection angle of the electron beam 15 is a control parameter that determines the irradiation position of the electron beam 15. The deflection speed of the electron beam 15 is a control parameter that determines the scanning speed of the electron beam 15. The scanning speed of the electron beam 15 can be rephrased as the moving speed of the electron beam 15. The moving speed of the electron beam 15 can also be expressed as (the reciprocal of) the residence time during which the electron beam 15 passes through a unit length section on the scanning path.

[0028] The plate moving device 26 moves the shaping plate 22 and the inner base 24 based on a control command given from the control unit 50. The powder coating device 16 applies metal powder 32 onto the shaping plate 22 based on a control command given from the control unit 50 to form a powder layer 32a. The operations of the hopper 16a, powder dropper 16b, and squeegee 16c of the powder coating device 16 are controlled by the control unit 50.

[0029] <Operation of 3D additive manufacturing device> 3 is a flowchart showing the procedure of the processing operation of the three-dimensional additive manufacturing apparatus according to one embodiment of the present invention. The processing operation shown in this flowchart is performed under the control of the control unit 50.

[0030] Before the start of modeling, the periphery of the modeling plate 22, except for the upper surface of the modeling plate 22, is covered with the metal powder 32. In addition, the upper surface of the modeling plate 22 is disposed at approximately the same height as the upper surface of the metal powder 32 spread on the modeling table 18.

[0031] (Plate heating process) First, the beam irradiation device 14 operates based on a control command given from the control unit 50 to heat the modeling plate 22 (step S1). In step S1, the beam irradiation device 14 irradiates the shaping plate 22 with the electron beam 15. As a result, the shaping plate 22 is heated to a temperature at which the metal powder 32 is pre-sintered by heat transfer from the shaping plate 22 when the metal powder 32 is laid thereon.

[0032] (Plate lowering process) Next, the plate moving device 26 operates based on a control command given from the control unit 50 to lower the modeling plate 22 by a predetermined amount (step S2). In step S2, the plate moving device 26 lowers the inner base 24 by a predetermined amount so that the upper surface of the shaping plate 22 is slightly lower than the upper surface of the metal powder 32 spread on the shaping table 18. At this time, the shaping plate 22 is lowered by a predetermined amount together with the inner base 24. This predetermined amount (hereinafter, also referred to as "ΔZ") corresponds to the thickness of one layer when the shaped object 38 is shaped by stacking.

[0033] (Powder coating process) Next, the powder coating device 16 operates based on a control command given from the control unit 50 to coat the metal powder 32 onto the shaping plate 22 to form a powder layer 32a (step S3). In step S3, the powder coating device 16 drops the metal powder 32 supplied from the hopper 16a to the powder dropper 16b onto the modeling table 18 using the powder dropper 16b, and then moves the squeegee 16c in the X direction to spread the metal powder 32 on the modeling plate 22. At this time, the metal powder 32 is spread on the modeling plate 22 to a thickness equivalent to ΔZ. As a result, a powder layer 32a is formed on the modeling plate 22. In addition, excess metal powder 32 is collected in the collection box 21.

[0034] (Preheating process) Next, the beam irradiation device 14 operates based on a control command given from the control unit 50 to preheat the powder layer 32a on the modeling plate 22 (step S4). In this preheating step S4, the powder layer 32a is preheated to pre-sinter the metal powder 32. The preheating step S4 is performed before the main sintering step S5, which will be described later. In this way, the preheating step performed before the main sintering step is also called a powder heat step. In FIG. 1, the reference character E1 indicates an unsintered region where the unsintered metal powder 32 exists, and the reference character E2 indicates a pre-sintered region where the pre-sintered metal powder 32 exists.

[0035] (Main sintering process) Next, the beam irradiation device 14 operates based on a control command given from the control unit 50, thereby melting and solidifying the metal powder 32 to perform main sintering (step S5). In step S5, the metal powder 32 provisionally sintered as described above is melted and solidified by irradiation with the electron beam 15, thereby final sintering the metal powder 32 as a provisionally sintered body. In step S5, the control unit 50 sets the cross-sectional shape of a layer cut out from the three-dimensional shape data of the target object 38 as a melting target region, and controls the beam irradiation device 14 in accordance with the molding data associated with the cross-sectional shape. As a result, the melting target region represented by the two-dimensional cross-sectional shape of the metal powder 32 on the molding plate 22 is melted by irradiation with the electron beam 15. The metal powder 32 melted by irradiation with the electron beam 15 solidifies after the electron beam 15 has passed. As a result, the first layer of the molded object is formed.

[0036] (Plate lowering process) Next, the plate moving device 26 operates based on a control command given from the control unit 50 to lower the modeling plate 22 by a predetermined amount (ΔZ) (step S6). In step S6, the plate moving device 26 lowers the modeling plate 22 and the inner base 24 by ΔZ.

[0037] (First pre-heating step) Next, the beam irradiation device 14 preheats the powder layer 32a on the modeling plate 22 based on a control command given by the control unit 50 (step S7). In this first preheating step S7, the powder layer 32a, which has been subjected to the main sintering step in the previous layer, is preheated in preparation for spreading the metal powder 32 of the next layer. As a result, the powder layer 32a is heated to a degree that the metal powder 32 of the next layer is pre-sintered by heat transfer from the powder layer 32a when it is spread. This preheating step S7 may be performed after the main sintering step S5 described above or after the main sintering step S10 described below. In this way, the preheating step performed after the main sintering step is also called an afterheating step.

[0038] (Powder coating process) Next, the powder coating device 16 operates based on a control command given from the control unit 50 to coat the metal powder 32 onto the shaping plate 22 to form a powder layer 32a (step S8). In step S8, the powder coating device 16 operates in the same manner as in step S3 above. As a result, on the shaping plate 22, the second layer of metal powder 32 is spread over the sintered body formed by the first layer of metal powder 32, forming a powder layer 32a.

[0039] (Second pre-heating process) Next, the beam irradiation device 14 operates based on a control command given from the control unit 50 to preheat the metal powder 32 forming the second powder layer 32a (step S9). This preheating step S9 is performed before the main sintering step 10 described below. Therefore, this preheating step S9 is also called a powder heat step. In step S9, the beam irradiation device 14 operates in the same manner as in step S4 above, whereby the metal powder 32 forming the second powder layer 32a is pre-sintered.

[0040] (Main sintering process) Next, the beam irradiation device 14 operates based on a control command given from the control unit 50, thereby melting and solidifying the metal powder 32 forming the second powder layer 32a to perform main sintering (step S10). In step S10, the beam irradiation device 14 operates in the same manner as in step S5 above, thereby forming a second-layer object.

[0041] Next, the control unit 50 checks whether or not the formation of the target object 38 has been completed (Step S11). If the control unit 50 determines that the formation of the object 38 has not been completed, the process returns to Step S6. As a result, the control unit 50 repeats the processes of Steps S6 to S10 for each layer from the third layer onwards. If the control unit 50 determines that the formation of the object 38 has been completed, the process ends at that point. By the above-described three-dimensional additive manufacturing process, the desired object 38 is obtained.

[0042] <Configuration of 3D additive manufacturing system> FIG. 4 is a diagram showing an example of the configuration of a three-dimensional additive manufacturing system according to an embodiment of the present invention. As shown in FIG. 4, the three-dimensional additive manufacturing system 100 includes a three-dimensional additive manufacturing device 10 and a modeling data creation device 30. The configuration and operation of the three-dimensional additive manufacturing device 10 are as described above. The modeling data creation device 30 creates modeling data using three-dimensional shape data of an object generated by a three-dimensional CAD or the like. The modeling data created by the modeling data creation device 30 is recorded, for example, in a portable recording medium, and the modeling data is provided to the three-dimensional additive manufacturing device 10 using this recording medium. The provided modeling data is read into a control unit 50 of the three-dimensional additive manufacturing device 10. The control unit 50 controls the operation of the three-dimensional additive manufacturing device 10 based on the modeling data read from the recording medium. As a result, the three-dimensional additive manufacturing device 10 models an object according to the modeling data created by the modeling data creation device 30.

[0043] The method of providing the modeling data from the modeling data creation device 30 to the three-dimensional additive manufacturing device 10 is not limited to the method using the portable recording medium described above. For example, the modeling data created by the modeling data creation device 30 may be provided to the three-dimensional additive manufacturing device 10 via a cable or a network. In addition, the three-dimensional additive manufacturing device 10 may be configured to have each of the functions of the modeling data creation device 30 (see FIG. 5).

[0044] The modeling data created by the modeling data creation device 30 includes modeling data for controlling the operation of the beam irradiation device 14, modeling data for controlling the powder coating device 16, and modeling data for controlling the plate moving device 26. However, in this specification, the creation of modeling data for controlling the operation of the beam irradiation device 14 will be described, and a description of the creation of other modeling data will be omitted.

[0045] <Configuration of modeling data creation device> FIG. 5 is a block diagram showing an example of the configuration of a modeling data creating apparatus according to an embodiment of the present invention. 5, the modeling data creation device 30 includes a cutout unit 301, an area division unit 302, a condition application unit 303, a condition setting unit 304, and an output unit 305. Although not shown, the modeling data creation device 30 is configured by a computer including a processor such as a CPU, and a storage unit such as a ROM, a RAM, a HDD, and an SSD. Each function of the modeling data creation device 30 is realized by the processor reading a program written in advance in the ROM into the RAM and executing the program.

[0046] The cut-out unit 301 cuts out the cross-sectional shape of each layer from the three-dimensional shape data input to the modeling data creating device 30. This cross-sectional shape is a two-dimensional cross-sectional shape that represents the shape of a region to be melted by irradiation of a beam (electron beam 15 in this embodiment) in each powder layer 32a, i.e., a melting target region. The cross-sectional shape cut out by the cut-out unit 301 is a shape represented by a set of one or more outer contour lines and zero or more inner contour lines inside the outer contour lines.

[0047] The region dividing unit 302 performs a process for dividing the cross-sectional shape cut out by the cutting out unit 301 into a fine region and a coarse region (hereinafter, also referred to as "region dividing process"). When the cutting out unit 301 cuts out one cross-sectional shape corresponding to one powder layer 32a, the region dividing unit 302 performs a process for dividing the one cross-sectional shape into a fine region and a coarse region. When the cutting out unit 301 cuts out a plurality of cross-sectional shapes corresponding to one powder layer 32a, the region dividing unit 302 performs a process for dividing each of the plurality of cross-sectional shapes into a fine region and a coarse region. That is, the region dividing process by the region dividing unit 302 is performed for each cross-sectional shape. The details of the region dividing process will be described later.

[0048] The condition application unit 303 generates shaping data by applying different shaping conditions to the fine region and the coarse region divided by the region division unit 302. This shaping data corresponds to shaping data (operation sequence program) for the control unit 50 to control the operation of the beam irradiation device 14 in the main sintering steps S5 and S10 (FIG. 3).

[0049] The molding conditions include beam scanning conditions and beam irradiation conditions. The beam scanning conditions are conditions that are applied when the surface of the powder layer 32a is scanned with the electron beam 15. The beam irradiation conditions are conditions that are applied when the surface of the powder layer 32a is irradiated with the electron beam 15. There are various beam scanning conditions, and there are also various beam irradiation conditions. Specific examples of the beam scanning conditions and the beam irradiation conditions are described below.

[0050] The beam scanning conditions include the beam scanning method, the distance between adjacent scanning lines (scanning line interval), scanning speed, etc. The beam scanning methods include raster scanning, tree-ring-shaped vector scanning, random scanning, etc. Raster scanning is a method of generating parallel scanning lines and scanning the beam along the generated scanning lines. Raster scanning includes one-way raster scanning and alternating direction raster scanning. Tree-ring-shaped vector scanning is a method of generating scanning lines a certain distance inward from the contour line that forms the cross-sectional shape and scanning the beam along the generated scanning lines. There are other scanning methods for vector scanning besides tree-ring-shaped vector scanning. Random scanning is a method of randomly scanning the area of ​​the cross-sectional shape with the beam. When the surface of the powder layer 32a is scanned with the electron beam 15, the center of the spot of the electron beam 15 moves on the scanning line.

[0051] On the other hand, the beam irradiation conditions include the amount of current of the charged particle beam, the beam size on the printing surface, etc. The amount of current of the charged particle beam corresponds to the amount of beam current. In this embodiment, an electron beam 15 is used as the charged particle beam. Therefore, the amount of current of the electron beam 15 corresponds to the amount of current of the charged particle beam. Also, the size (spot size) of the electron beam 15 on the printing surface 32b corresponds to the beam size on the printing surface. When the beam irradiated to the surface of the powder layer 32a is a laser beam, the beam irradiation conditions include the laser intensity, the beam size on the printing surface, etc. The laser intensity corresponds to the intensity of the laser beam, i.e., the beam intensity.

[0052] The condition application unit 303 refers to the condition setting unit 304 when applying different modeling conditions to the fine region and the coarse region divided by the region division unit 302. The condition setting unit 304 has modeling conditions to be applied to the fine region and modeling conditions to be applied to the coarse region set in advance. This will be described in detail below.

[0053] The condition setting unit 304 is a unit that sets the first modeling condition to be applied to the fine region, the second modeling condition to be applied to the coarse region, and the third modeling condition to be applied to other parts, etc., in advance according to the user's designation. For example, prior to additive manufacturing using the three-dimensional additive manufacturing device 10, the user inputs information required for setting the modeling conditions into the condition setting unit 304, for example, by key operation, mouse operation, etc. while looking at a screen for setting modeling conditions. As a result, the condition setting unit 304 sets the first modeling condition (beam scanning condition and beam irradiation condition) to be applied to the fine region and the second modeling condition (beam scanning condition and beam irradiation condition) to be applied to the coarse region, respectively, according to the information input (designated) by the user. In addition, the user sets the third modeling condition (beam scanning condition and beam irradiation condition) to be applied to other parts as necessary.

[0054] FIG. 6 is a diagram showing an example of setting beam scanning conditions. As shown in Fig. 6, different beam scanning conditions are set for the fine region and the coarse region. Specifically, for the fine region, the beam scanning method is set to "annular vector scanning", the distance between adjacent scanning lines is set to "short", and the scanning speed is set to "slow". For the coarse region, the beam scanning method is set to "raster scanning", the distance between adjacent scanning lines is set to "long", and the scanning speed is set to "fast". In other words, for the fine region, beam scanning conditions that prioritize shape reproducibility of the modeling are set, and for the coarse region, beam scanning conditions that prioritize high speed (throughput) of the modeling are set.

[0055] In Fig. 6, for convenience of explanation, the distance between adjacent scanning lines is shown in two stages, "short" and "long", but the user may select a desired distance from three or more stages and set the distance, or may set the distance by inputting a numerical value. This also applies to the scanning speed.

[0056] FIG. 7 is a diagram showing an example of setting beam irradiation conditions in the case of a charged particle beam. As shown in Fig. 7, different beam irradiation conditions are set for the fine region and the coarse region. Specifically, for the fine region, the amount of current of the charged particle beam (electron beam 15) is set to "low," and the beam size on the printing surface is set to "small." For the coarse region, the amount of current of the charged particle beam is set to "high," and the beam size on the printing surface is set to "large." In other words, for the fine region, beam irradiation conditions that prioritize shape reproducibility of the printing are set, and for the coarse region, beam irradiation conditions that prioritize high speed printing are set.

[0057] In Fig. 7, for convenience of explanation, the amount of current of the charged particle beam is shown in two stages, "low" and "high", but the amount of current may be set by the user by selecting a desired beam current amount from three or more stages, or by the user inputting a numerical value. This also applies to the beam size on the modeling surface.

[0058] FIG. 8 is a diagram showing an example of setting beam irradiation conditions in the case of a laser beam. As shown in Fig. 8, different beam irradiation conditions are set for the fine region and the coarse region. Specifically, for the fine region, the intensity of the laser beam (beam intensity) is set to "low" and the beam size on the printing surface is set to "small." For the coarse region, the intensity of the laser beam is set to "high" and the beam size on the printing surface is set to "large." In other words, for the fine region, beam irradiation conditions that prioritize shape reproducibility of the modeling are set, and for the coarse region, beam irradiation conditions that prioritize high-speed modeling are set.

[0059] In Fig. 8, for convenience of explanation, the laser beam intensity is shown in two stages, "low" and "high", but the user may select a desired laser beam intensity from three or more stages and set the laser intensity, or may set the laser intensity by inputting a numerical value. This also applies to the beam size on the modeling surface.

[0060] The output unit 305 outputs the modeling data generated by the condition application unit 303 to an electronic file. The modeling data output to the electronic file is provided to the three-dimensional additive manufacturing apparatus 10 by the above-mentioned method (for example, a method using a portable recording medium). When an article to be modeled is to be modeled by dividing it into, for example, 100 layers, modeling data for 100 layers is provided to the three-dimensional additive manufacturing apparatus 10. The control unit 50 of the three-dimensional additive manufacturing apparatus 10 sequentially controls the operation of the entire three-dimensional additive manufacturing apparatus 10 in accordance with the modeling data provided from the modeling data creation device 30.

[0061] <Processing procedure of modeling data creation device> FIG. 9 is a flowchart illustrating an example of a processing procedure (modeling data creating method) of the modeling data creating device. First, the modeling data creating device 30 imports three-dimensional shape data (step S31). The import of the three-dimensional shape data may be performed by the cutout unit 301, or by an import unit (not shown) provided in front of the cutout unit 301. Next, the cutout unit 301 cuts out the cross-sectional shape of one layer from the three-dimensional shape data (step S32). One layer includes one or more cross-sectional shapes.

[0062] Next, the region dividing unit 302 divides the cross-sectional shape cut out by the cutting unit 301 into a fine region and a coarse region (step S33). Next, the condition application unit 303 applies different modeling conditions to the fine region and the coarse region divided by the region division unit 302, and generates modeling data (step S34). At that time, the condition application unit 303 determines which modeling condition to apply to each region (fine region, coarse region) of the cross-sectional shape by referring to the condition setting unit 304.

[0063] Next, the output unit 305 outputs the shaping data generated by the condition application unit 303 in step S34 to an electronic file (step S35). Next, the modeling data creation device 30 determines whether or not there is a next layer (step S36). This determination is made, for example, by the cut-out unit 301. If there is a next layer (Yes in step S36), the process returns to step S32, and if there is no next layer (No in step S36), the process ends.

[0064] <Area division processing> Next, the region division process performed by the region division section 302 will be described in detail. The region division process includes a process for identifying a fine region (hereinafter referred to as "fine region identification process") and a process for identifying a coarse region (hereinafter referred to as "coarse region identification process"). The region division unit 302 divides the cross-sectional shape of each layer cut out by the cut-out unit 301 into a fine region and a coarse region by morphological graphic processing. When the cross-sectional shape of each layer is divided into one or more fine regions and one or more coarse regions, each fine region is a region that is mainly surrounded by the original contour line of a region where the translated contour lines intersect with each other and the region disappears when the entire contour line of the cross-sectional shape of the same layer is moved inward in parallel to the same region by a certain distance, and each coarse region is a region that is mainly surrounded by the original contour line of a region where the translated contour lines do not intersect with each other and the region does not disappear when the entire contour line of the cross-sectional shape of the same layer is moved inward in parallel to the same region by a certain distance.

[0065] In this embodiment, the cross-sectional shape cut out by the cut-out unit 301 is represented by, for example, figure A shown in FIG. 10. Figure A is a figure representing a two-dimensional cross-sectional shape. Figure A has sawtooth (comb-like) shaped parts 41a, 41b, 41c, 41d, 41e, and 41f, and a shape part 42 other than that. Figure A corresponds to a specific example of a cross-sectional shape in which shape elements having conflicting suitable modeling conditions are mixed. The two-dimensional cross-sectional shape formed by figure A is a shape represented by polygonal vector data. However, the cross-sectional shape to be the subject of region division may be a shape represented by a curve or a shape represented by bitmap data. In other words, the representation format of the cross-sectional shape does not matter.

[0066] When dividing the cross-sectional shape of figure A into regions, the region dividing unit 302 uses a threshold value t for determining (identifying) a fine region and an arbitrary value ε that satisfies a predetermined condition described later. The threshold value t is a value determined in advance by the user, and is expressed in mm. In FIG. 10, the size (dimension) of the threshold value t is shown diagrammatically as the length of a straight line. This also applies to other figures. The threshold value t is preferably 1.0 mm or more, more preferably 2.0 mm or more, and even more preferably 2.5 mm or more. Moreover, the threshold value t is preferably 5.0 mm or less, more preferably 4.0 mm or less, and even more preferably 3.5 mm or less. Furthermore, in order to prioritize shape reproducibility of the object, the threshold value t is preferably at least 5 times the beam size when the device sets the beam size to its smallest, more preferably at least 10 times, and even more preferably at least 15 times. Furthermore, in order to prioritize high modeling speed (throughput), the threshold value t is preferably less than three times the beam size when the apparatus has the largest beam size, more preferably less than two times, and even more preferably less than one time. For example, when the beam size is 0.2 mm when the apparatus reduces the beam size to its smallest, the threshold value t is preferably 1.0 mm or more, more preferably 2.0 mm or more, and further preferably 3.0 mm or more. For example, when the beam size is 2.0 mm when the apparatus maximizes the beam size, the threshold value t is preferably 6.0 mm or less, more preferably 4.0 mm or less, and further preferably 2.0 mm or less.

[0067] The arbitrary value ε is a value that is larger than a calculation rounding error that is expected to occur in a computer and is smaller than the modeling dimension reproduction accuracy of the 3D additive manufacturing apparatus 10. The value ε is a value determined on a CAM software program, and is expressed in units of μm.

[0068] (Fine area specific processing) First, the region dividing unit 302 performs a process of identifying a minute region from the figure A in the following procedure. As shown in FIG. 11, the region division unit 302 generates a figure B (figure shown by a broken line in FIG. 11) by reducing the figure A by a dimension of t / 2. At this time, the maximum values ​​of the widths Wa, Wb, and Wc between the contours of the shape parts 41a, 41b, and 41c of the figure A shown in FIG. 10 are all less than the threshold value t. Therefore, the shape parts 41a, 41b, and 41c disappear when reduced by a dimension of t / 2. In contrast, the maximum values ​​of the widths Wd, We, and Wf between the contours of the shape parts 41d, 41e, and 41f are all equal to or greater than the threshold value t. Therefore, the shape parts 41d, 41e, and 41f do not disappear even when reduced by a dimension of t / 2, and are reflected in part of the figure B. Moreover, the width between the contours of the shape part 42 is sufficiently larger than the threshold value t, so it is reflected in the figure B in a form that is slightly smaller by a dimension of t / 2.

[0069] Next, as shown in FIG. 12, the region dividing unit 302 enlarges the above-mentioned figure B by a dimension of (t / 2+ε) to generate a figure C (a figure shown by a dashed line in FIG. 12). At this time, when the acute angle part of the figure B is enlarged by a dimension of (t / 2+ε), the apex of the acute angle part moves to the left in FIG. 12, generating a spike shape. In order to prevent the generation of this spike shape, the region dividing unit 302 limits the apex movement distance of the acute angle part. As a specific example, the region dividing unit 302 sets an upper limit value for the apex movement distance in advance, and performs a process of cutting out the acute angle part whose apex movement distance exceeds the upper limit value due to the above-mentioned enlargement process. In this way, the region dividing unit 302 can generate a figure C without a spike shape from the figure B including the acute angle part. The above-mentioned upper limit value may be determined in advance on the CAM software program.

[0070] Next, as shown in Fig. 13, the region dividing unit 302 generates a figure D (indicated by a dashed line in Fig. 13) by removing a figure portion included within the range of the figure C from the figure A. The figure D corresponds to a part of the sawtooth shaped portions 41a, 41b, 41c, 41d, 41e, and 41f (see Fig. 10) described above.

[0071] Next, the area dividing unit 302 enlarges the above-mentioned figure D by the dimension ε, as shown in Fig. 14, to generate a figure E (a figure indicated by a dashed line in Fig. 14). The figure E is a figure slightly larger than the figure D.

[0072] Next, as shown in Fig. 15, the region dividing unit 302 generates a figure F (a figure indicated by a two-dot chain line in Fig. 15) by extracting a figure portion included within the range of the figure E from the figure A. Then, the region dividing unit 302 specifies the region of this figure F as a minute region.

[0073] In the above-mentioned fine region specifying process, the figure A corresponds to the first figure, the figure B corresponds to the second figure, the figure C corresponds to the third figure, the figure D corresponds to the fourth figure, the figure E corresponds to the fifth figure, and the figure F corresponds to the sixth figure.

[0074] (Crowded area identification process) Next, the region dividing unit 302 performs a process of identifying a coarse region from the figure A in the following procedure. First, the area dividing unit 302 generates a figure G (indicated by a broken line in FIG. 16) by enlarging the figure F by a dimension ε, as shown in FIG. 16. The figure G is a size larger than the figure F.

[0075] Next, as shown in FIG. 17, the area dividing section 302 generates a graphic H (indicated by a broken line in FIG. 17) by removing a graphic portion included within the range of the graphic G from the graphic A.

[0076] Next, as shown in FIG. 18, the area dividing unit 302 enlarges the above-mentioned figure H by a dimension ε to generate a figure I (a figure indicated by a dashed line in FIG. 18).

[0077] Next, as shown in Fig. 19, the region dividing unit 302 generates a figure J (a figure indicated by a two-dot chain line in Fig. 19) by extracting a figure portion included within the range of the figure I from the figure A. Then, the region dividing unit 302 specifies the region of this figure J as a coarse region.

[0078] The region division unit 302 divides one cross-sectional shape 51 into a fine region 52 (the region shown by the dotted line in Figure 20) and a coarse region 53 (the region shown by the dotted line in Figure 20) by a region division process including the fine region identification process and the coarse region identification process described above, as shown in Figure 20.

[0079] On the other hand, of the fine region 52 and the coarse region 53 divided by the region dividing unit 302, the condition applying unit 303 applies the first modeling condition to the fine region 52 and applies the second modeling condition to the coarse region 53. As a result, for example, in the case of the setting examples shown in Fig. 6 and Fig. 7, the condition applying unit 303 applies "tree-ring-shaped vector scanning" to the fine region 52 and applies "raster scanning" to the coarse region 53. This also applies to modeling conditions other than the beam scanning method.

[0080] Furthermore, when generating shaping data by applying different shaping conditions to the fine region 52 and the coarse region 53, the condition application unit 303 performs a process (hereinafter also referred to as a "combining process") of combining scanning lines generated for scanning each region (52, 53) with the electron beam 15 into one. In other words, the combining process is a process of combining a scanning line for beam scanning the fine region 52 with a scanning line for beam scanning the coarse region 53. As the combining process performed by the condition application unit 303, for example, two combining processes (a first combining process and a second combining process) can be considered.

[0081] (First synthesis process) FIG. 21 is a diagram showing an example of scanning lines generated by the first synthesis process. First, the condition application unit 303 generates scanning lines by applying different modeling conditions to the fine region 52 and the coarse region 53 divided by the region division unit 302. In other words, the condition application unit 303 regards the fine region 52 and the coarse region 53 as cross-sectional shapes of independent articles, and generates scanning lines for each region. As a result, in the fine region 52, scanning lines for tree-ring-shaped vector scanning are generated, and in the coarse region 53, scanning lines for raster scanning are generated.

[0082] 21, the condition application unit 303 combines the scanning line for tree-ring-shaped vector scanning generated in the fine region 52 and the scanning line 56 for raster scanning generated in the coarse region 53 into one scanning line for scanning one cross-sectional shape 51 with the electron beam 15. In other words, the condition application unit 303 combines the scanning lines 55 and 56 having different beam scanning methods as a scanning line for beam scanning one cross-sectional shape 51. By performing the first synthesis process described above, even if one cross-sectional shape 51 is divided into a fine region 52 and a coarse region 53, the condition application unit 303 can generate one piece of modeling data for each cross-sectional shape 51.

[0083] (Second synthesis process) FIG. 22 is a diagram showing an example of scanning lines generated by the second synthesis process. First, the condition application unit 303 generates scanning lines for the original cross-sectional shape that is the subject of region division under a first modeling condition to be applied to the fine region 52, and generates scanning lines under a second modeling condition to be applied to the coarse region 53. As a result, scanning lines are generated by applying tree-ring-shaped vector scanning to the cross-sectional shape consisting of figure A (see FIG. 10), and scanning lines are generated by applying raster scanning to the cross-sectional shape consisting of figure A.

[0084] Next, the condition application unit 303 extracts scanning lines from each of the fine region 52 and the coarse region 53 obtained by dividing the cross-sectional shape of the figure A as described above. At this time, the scanning lines extracted from the fine region 52 are scanning lines to which the tree-ring-shaped vector scanning, which is one of the first modeling conditions, is applied, and the scanning lines extracted from the coarse region 53 are scanning lines to which the raster scanning, which is one of the second modeling conditions, is applied.

[0085] 22, the condition application unit 303 combines the scanning line 57 extracted from the fine region 52 and the scanning line 58 extracted from the coarse region 53 into one scanning line for scanning one cross-sectional shape 51 with the electron beam 15. In other words, the condition application unit 303 combines the scanning lines 57 and 58, which have different beam scanning methods, into one scanning line for beam scanning one cross-sectional shape 51. By performing the second synthesis process described above, even if one cross-sectional shape 51 is divided into a fine region 52 and a coarse region 53, the condition application unit 303 can generate one piece of modeling data for each cross-sectional shape 51.

[0086] The condition application unit 303 may generate a scanning line for beam scanning the vicinity of the contour of the cross-sectional shape 51 by applying a modeling condition dedicated to the contour. The modeling condition dedicated to the contour is different from the first modeling condition applied to the fine region and the second modeling condition applied to the coarse region. For example, the modeling condition dedicated to the contour is different from the first modeling condition and the second modeling condition in at least one of the scanning speed, the current amount of the electron beam 15, and the beam size on the modeling surface. The condition application unit 303 generates a scanning line to which the modeling condition dedicated to the contour is applied along the contour of the cross-sectional shape 51. As a result, the portion of the contour of the cross-sectional shape 51 is scanned by the electron beam 15 in a so-called one-stroke manner based on the modeling condition dedicated to the contour.

[0087] FIG. 23 is a diagram showing a first example of generating scanning lines in the vicinity of the contour line of a cross-sectional shape. 23, one scanning line 59 is generated along the contour line near the contour line of the cross-sectional shape 51. In addition, scanning line 55 for tree-ring-shaped vector scanning and scanning line 56 for raster scanning are generated inside scanning line 59. Scanning line 55 and scanning line 56 are scanning lines generated by the first synthesis process described above.

[0088] FIG. 24 is a diagram showing a first example of generating scanning lines in the vicinity of the contour line of a cross-sectional shape. 24, one scanning line 60 is generated along the contour line near the contour line of the cross-sectional shape 51. In addition, scanning line 57 for tree-ring-shaped vector scanning and scanning line 58 for raster scanning are generated inside scanning line 60. Scanning line 57 and scanning line 58 are scanning lines generated by the second synthesis process described above.

[0089] In this way, by generating the scanning line 59 or the scanning line 60 for beam scanning the vicinity of the contour line of the cross-sectional shape 51 under molding conditions dedicated to the contour line, it is possible to reduce or eliminate steps that occur at the contour line of the cross-sectional shape 51 when the actual cross-sectional shape 51 portion is melted by irradiation with the electron beam 15. This makes it possible to smoothly finish the surface of the article obtained by molding.

[0090] As described above, in the embodiment of the present invention, a cross-sectional shape extracted from three-dimensional shape data of an article is divided into a fine region and a coarse region, and the article is formed by applying different modeling conditions to the fine region and the coarse region, respectively. This makes it possible to form the entire cross-sectional shape under appropriate modeling conditions even when shape elements for which appropriate modeling conditions are contradictory are mixed in one cross-sectional shape. As a result, it becomes possible to form an article while achieving both shape reproducibility and high speed.

[0091] In the above embodiment, the region division unit 302 identifies the fine region 52 using one threshold value t for determining the fine region, but the present invention is not limited to this, and multiple threshold values ​​for determining the fine region may be used to identify multiple fine regions with different degrees of fineness.

[0092] For example, when performing region division processing using two threshold values t1 and t2 (where 0 < t1 < t2), the region division unit 302 first identifies the first fine region by performing the same fine region identification processing as described above using the threshold value t1. Next, the region division unit 302 identifies the second fine region by performing the same fine region identification processing as described above using the threshold value t2 on the portion other than the figure identified as the first fine region. As a result, as shown in FIG. 25, one cross-sectional shape 51 can be divided into a first fine region 52-1, a second fine region 52-2, and a coarse region 53. Also, the condition application unit 303 can generate modeling data by applying different modeling conditions to the first fine region 52-1 and the second fine region 52-2, respectively. Therefore, the fine regions 52-1 and 52-2 with different degrees of fineness can be modeled under more appropriate modeling conditions.

[0093] In the above embodiment, an example in which the region division unit 302 performs region division processing on the two-dimensional cross-sectional shape cut out by the cut-out unit 301 from the three-dimensional shape data of the article has been described. However, the present invention is not limited to this, and the region division processing by the region division unit 302 may be performed on a three-dimensional figure representing the three-dimensional shape of the article. That is, the order of the processing performed by the cut-out unit 301 and the processing performed by the region division unit 302 may be swapped. In that case, the region division unit 302 performs processing (region division processing) for dividing the three-dimensional shape of the article into fine regions and a coarse region using the three-dimensional shape data before being cut out by the cut-out unit 301. Also, the cut-out unit 301 cuts out the cross-sectional shape of each layer from the three-dimensional shape data subjected to the region division processing by the region division unit 302. Therefore, at the time when it is cut out from the three-dimensional shape data, the cross-sectional shape is in a state of being divided into fine regions and a coarse region. Even in this case, the same effects as in the above embodiment can be obtained.

[0094] In addition, when an article is modeled by the three-dimensional additive manufacturing apparatus 10, the article that becomes the model 38 has an upward portion, a downward portion, an intermediate surface portion, and a contour portion. The upward portion of the article is the portion that is arranged upward in FIG. 1, and is also called the upskin. The downward portion of the article is the portion that is arranged downward in FIG. 1, and is also called the downskin. For example, if the article has a three-dimensional shape like a cup, the mouth of the cup and the bottom portion of the cup that receives the liquid are the upward portions, and the bottommost portion of the cup is the downward portion. The intermediate surface portion and the contour portion are portions that do not belong to either the upward portion or the downward portion. The upward portion and the downward portion of the article are given priority in finishing so that they look beautiful (smooth), and the intermediate surface portion of the article is given priority in finishing quickly.

[0095] Therefore, when forming an article, the condition application unit 303 may change the forming conditions applied to the fine region for each of the upward, downward, intermediate, and outline parts of the article. Similarly, the condition application unit 303 may change the forming conditions applied to the coarse region for each of the upward, downward, intermediate, and outline parts of the article. For example, taking the forming conditions applied to the fine region as an example, the condition setting unit 304 sets four forming conditions to be applied to the fine region corresponding to each of the upward, downward, intermediate, and outline parts of the article. Then, the condition application unit 303 changes the forming conditions to be applied to the fine region depending on whether the fine region divided by the region division unit 302 corresponds to the upward, downward, intermediate, or outline part of the article. This is also true for the forming conditions applied to the coarse region. This allows the article to be formed under more appropriate conditions.

[0096] <Modifications, etc.> The technical scope of the present invention is not limited to the above-described embodiments, but also includes forms in which various modifications and improvements are made within the scope that can derive specific effects obtained by the constituent elements of the invention and their combinations.

[0097] For example, in the above embodiment, the modeling conditions include beam scanning conditions and beam irradiation conditions, but the present invention is not limited to this, and the modeling conditions may include at least one of beam scanning conditions and beam irradiation conditions.

[0098] In addition, in the above embodiment, the beam scanning conditions include the beam scanning method, the distance between adjacent scanning lines, and the scanning speed, but the present invention is not limited to this, and the beam scanning conditions may include at least one of the beam scanning method, the distance between adjacent scanning lines, and the scanning speed.

[0099] In addition, in the above embodiment, the beam irradiation conditions include the beam current amount, the beam intensity, and the beam size on the printing surface, but the present invention is not limited to this, and the beam irradiation conditions may include at least one of the beam current amount, the beam intensity, and the beam size on the printing surface.

[0100] In addition, the first modeling conditions applied to the fine region 52 and the second modeling conditions applied to the coarse region 53 may differ in at least one of the requirements of the beam scanning conditions and the requirements of the beam irradiation conditions described above. For example, the first modeling conditions applied to the fine region 52 and the second modeling conditions applied to the coarse region 53 may differ only in the beam scanning method or the amount of beam current.

[0101] In addition, in the above embodiment, the area division unit 302 identified coarse areas by the graphic processing shown in Figures 16 to 19, but the present invention is not limited to this, and after identifying fine areas by the graphic processing shown in Figures 11 to 15, areas other than the identified fine areas may be identified as coarse areas.

[0102] In the above embodiment, the cross-sectional shape is divided into a fine region and a coarse region using a threshold value t for determining a fine region and a value ε that satisfies a predetermined condition, but the present invention is not limited to this. For example, among the contour lines forming the cross-sectional shape, a graphic portion in which the distance (width) between adjacent contour lines is less than the threshold value t may be specified as a fine region, and a graphic portion in which the distance (width) exceeds the threshold value t may be specified as a coarse region. In other words, the region dividing unit 302 may perform region division using only the threshold value t. Furthermore, the region dividing process performed by the region dividing unit 302 is not limited to a specific process, and various processes can be adopted.

[0103] The region dividing unit 302 may divide the cross-sectional shape into a fine region and a coarse region based on a manual operation by a user. However, in order to reduce the burden on a user for preparing modeling data, it is preferable that the region dividing unit 302 automatically divides the cross-sectional shape into regions as in the above embodiment. [Explanation of symbols]

[0104] 10...3D additive manufacturing device 15...Electron beam (charged particle beam) 30...Modeling data creation device 38...Sculpted object (article) 51…Cross-sectional shape 52...Minute area 53…coarse area 55,56,57,58,59,60...scan lines 100...3D additive manufacturing system 302…Area division part 303…Condition application section

Claims

1. A modeling data creation device that creates modeling data for controlling a three-dimensional additive manufacturing device that melts a cross-sectional shape of each layer by irradiating the layer with a beam to create an article, comprising: a region dividing unit that performs processing for dividing the cross-sectional shape cut out from the three-dimensional shape data of the article into a fine region and a coarse region; a condition application unit that applies different modeling conditions to the fine region and the coarse region divided by the region dividing unit to generate modeling data; A modeling data creation device comprising:

2. The modeling conditions include at least one of a beam scanning condition and a beam irradiation condition. The modeling data creating apparatus according to claim 1 .

3. The beam scanning conditions include at least one of a beam scanning method, a distance between adjacent scanning lines, and a scanning speed. The modeling data creating apparatus according to claim 2 .

4. The beam irradiation conditions include at least one of a beam current amount, a beam intensity, and a beam size on a modeling surface. The modeling data creating apparatus according to claim 2 .

5. The region dividing unit uses a threshold value t for determining the fine region and a value ε that satisfies a predetermined condition, a process of reducing a first figure representing the cross-sectional shape by a dimension of t / 2 to generate a second figure; enlarging the second figure by a dimension of (t / 2+ε) to generate a third figure; a process of generating a fourth graphic by removing a graphic portion included within the range of the third graphic from the first graphic; a process of enlarging the fourth figure by a dimension ε to generate a fifth figure; a process of extracting a part of the first graphic included in the range of the fifth graphic to generate a sixth graphic; A region of the sixth figure is identified as the fine region. The modeling data creating apparatus according to claim 1 .

6. The region dividing unit limits a vertex movement distance of an acute angle portion of the second figure when enlarging the second figure by a dimension of (t / 2+ε). The modeling data creating apparatus according to claim 5 .

7. The condition application unit applies different modeling conditions to the fine region and the coarse region divided by the region division unit to generate scanning lines, and then combines the scanning lines of the fine region and the scanning lines of the coarse region to generate the modeling data. The modeling data creating apparatus according to claim 1 .

8. The condition application unit generates scanning lines for the cross-sectional shape under modeling conditions to be applied to the fine region and under modeling conditions to be applied to the coarse region, extracts from the fine region the scanning lines generated under the modeling conditions to be applied to the fine region, extracts from the coarse region the scanning lines generated under the modeling conditions to be applied to the coarse region, and combines the scanning lines extracted from the fine region and the scanning lines extracted from the coarse region into one to generate the modeling data. The modeling data creating apparatus according to claim 1 .

9. The condition application unit generates a scanning line for beam scanning in the vicinity of a contour line of the cross-sectional shape by applying a modeling condition different from a modeling condition applied to the fine region and a modeling condition applied to the coarse region. The modeling data creating apparatus according to claim 1 .

10. a three-dimensional additive manufacturing device that melts the cross-sectional shape of each layer by irradiating the layer with a beam to form an article; A three-dimensional additive manufacturing system comprising: a modeling data creation device that creates modeling data for controlling the three-dimensional additive manufacturing device, The modeling data creation device includes: a region dividing unit that performs processing for dividing the cross-sectional shape cut out from the three-dimensional shape data of the article into a fine region and a coarse region; a condition application unit that applies different modeling conditions to the fine region and the coarse region divided by the region dividing unit to generate modeling data, The three-dimensional additive manufacturing apparatus includes: Modeling the article according to the modeling data. 3D additive manufacturing system.

11. A three-dimensional additive manufacturing method for forming an article by melting a cross-sectional shape of each layer by irradiating the layer with a beam, comprising the steps of: The cross-sectional shape cut out from the three-dimensional shape data of the article is divided into a fine region and a coarse region, and the article is modeled by applying different modeling conditions to the fine region and the coarse region, respectively. Three-dimensional additive manufacturing method.

Images