Powder laminate molding device

Abstract

To be able to suppress a change in the supply amount of a powder material.SOLUTION: A powder laminate moulding device 1 comprises a moulding unit 2 that forms a moulded article 91 by irradiating a spread powder material 90 with an energy beam and a powder material supply unit 3 that supplies powder material 90 to the moulding unit 2. The powder material supply unit 3 has a powder feed tank 31 that forms a region for containing powder material 90, and a powder agitation mechanism 34, including a powder agitation rod 342, arranged to be immersed in the powder material 90 contained within the powder feed tank 31.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a powder rapid prototyping apparatus. [Background technology]

[0002] When an energy beam is irradiated onto a spread powder material, the exposed area partially melts and then solidifies. By repeating this process of spreading powder material and irradiating it with an energy beam, additive manufacturing technology is being investigated, which can produce three-dimensional objects. In additive manufacturing technology, the amount of powder material spread evenly is important.

[0003] For example, Patent Document 1 points out the importance of the bulk density of the powder material to be irradiated with an energy beam and discloses a technique for vibrating the powder material to increase the bulk density. Patent Document 2 discloses a technique for preventing the amount of powder material spread evenly from exceeding a predetermined amount. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-78214 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-87595 Summary of the Invention [Problem to be solved by the invention]

[0005] It is desirable that the thinly spread and evenly distributed powder material have a constant thickness before being irradiated with the energy beam. To achieve a constant thickness, it is necessary to supply a constant amount of powder material to the area to be irradiated with the energy beam. If the amount of powder material supplied is small, defects will occur in the molded object. If the amount of powder material supplied is large, some of the powder material will be wasted. Therefore, it is desirable that the amount of powder material supplied to the area to be irradiated with the energy beam be kept constant even if the spreading and evenly distribution is repeated.

[0006] The present invention provides a powder rapid prototyping apparatus that can suppress changes in the supply amount of powder material. [Means for solving the problem]

[0007] A powder additive manufacturing device according to one embodiment of the present invention comprises a manufacturing unit that forms a molded object by irradiating an energy beam onto a spread powder material, and a powder material supply unit that supplies powder material to the manufacturing unit. The powder material supply unit has a powder material storage unit that forms an area for storing powder material, and a powder vibration unit that applies vibrations to the powder material stored in the powder material storage unit.

[0008] This powder rapid prototyping device includes a powder vibration unit that applies vibrations to the powder material contained in the powder material supply unit. Vibrating the powder material with this powder vibration unit reduces unevenness in the bulk density of the powder material. As a result, even when repeating a coating operation that spreads the powder material evenly on the modeling unit and a modeling operation that targets the spread powder material, the unevenness in bulk density is reduced, making it possible to suppress changes in the amount of powder material supplied from the powder supply unit to the modeling unit.

[0009] The powder vibrating unit of the powder rapid prototyping apparatus may be disposed so as to be embedded in the powder material contained in the powder material containing unit. With this configuration, vibrations can be applied evenly to the powder material.

[0010] The powder material container of the powder rapid prototyping device may have a wall surface with which the powder material comes into contact, and the powder vibrator may be spaced from the wall surface. With this configuration, the powder material contained in the powder material container can be evenly vibrated.

[0011] The powder rapid prototyping apparatus may further include a control unit that controls the operations of the modeling unit and the powder material supply unit, the modeling unit having an energy beam source that emits an energy beam, and the control unit controls the operations of the energy beam source and the powder vibrating unit. With this configuration, the operation of eliminating the bias in the bulk density of the powder material and the operation of emitting the energy beam can be performed in a desired order.

[0012] The powder material container of the powder rapid prototyping device may have a wall portion surrounding the powder material and a powder material support portion that forms the bottom surface of the area surrounded by the wall portion and supports the powder material surrounded by the wall portion and pushes up the powder material, and the powder vibrator may have a plurality of vibrating rods that extend in the direction in which the powder material support portion pushes up the powder material and are arranged two-dimensionally in a plan view. This configuration also makes it possible to evenly vibrate the powder material contained in the powder material container.

[0013] The powder vibrating unit of the powder rapid prototyping device may have a plurality of frame parts arranged two-dimensionally in a plan view. This configuration also allows the powder material contained in the powder material container to be evenly vibrated. [Effects of the Invention]

[0014] According to the present invention, there is provided a powder rapid prototyping apparatus that can suppress changes in the supply amount of powder material. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a cross-sectional perspective view showing a powder rapid prototyping apparatus according to a first embodiment. [Figure 2] FIG. 2 is a functional block diagram of the powder rapid prototyping apparatus of FIG. [Figure 3]Fig. 3(a) is a cross-sectional view for explaining the supplying operation, and Fig. 3(b) is a cross-sectional view for explaining the applying operation. [Figure 4] Fig. 4(a) is a cross-sectional view for explaining the irradiation operation, and Fig. 4(b) is a cross-sectional view for explaining the feeding operation. [Figure 5] Fig. 5(a) is a diagram showing a state in which the bulk density of the powder material is uneven before vibration is applied, and Fig. 5(b) is a diagram showing a state in which the bulk density of the powder material is uneven after vibration is applied, and [Figure 6] FIG. 6 is a plan view of the supply tank of FIG. [Figure 7] Fig. 7(a) is a flowchart showing a first operation example of the powder rapid prototyping apparatus of Fig. 1. Fig. 7(b) is a flowchart showing a modified example of the first operation example of the powder rapid prototyping apparatus of Fig. 1. [Figure 8] Fig. 8(a) is a flowchart showing a second operation example of the powder rapid prototyping apparatus of Fig. 1. Fig. 8(b) is a flowchart showing a third operation example of the powder rapid prototyping apparatus of Fig. 1. [Figure 9] FIG. 9 is a perspective view showing a powder rapid prototyping apparatus according to the second embodiment. [Figure 10] 10 is a cross-sectional view of a powder material supplying unit included in the powder rapid prototyping apparatus of FIG. [Figure 11] FIG. 11 is a plan view of a powder material supplying unit included in the powder rapid prototyping apparatus of FIG. [Figure 12] FIG. 12 is a schematic diagram showing a rotary powder rapid prototyping apparatus which is a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same elements are designated by the same reference numerals, and duplicated explanations will be omitted.

[0017] [First embodiment] The three-dimensional powder additive manufacturing apparatus (hereinafter referred to as "powder additive manufacturing apparatus 1") shown in FIGS. 1 and 2 is a so-called 3D printer that manufactures a molded object 91 from a powder material 90. The powder material 90 is a metal powder, such as titanium-based metal powder, Inconel powder, or aluminum powder. The powder material 90 is not limited to a metal powder, but may be a powder containing carbon fiber and resin, such as CFRP (Carbon Fiber Reinforced Plastics). The powder material 90 may also be other powders that have electrical conductivity. The powder material in the present disclosure is not limited to those that have electrical conductivity. For example, when a laser is used as the energy beam, the powder material does not have to have electrical conductivity.

[0018] The powder rapid prototyping apparatus 1 applies energy to the powder material 90. Examples of the energy include an electron beam and a laser. In other words, the powder rapid prototyping apparatus 1 increases the temperature of the powder material 90. As a result, the powder material 90 melts or sinters. When the powder rapid prototyping apparatus 1 stops applying energy, the temperature of the powder material 90 drops, causing it to solidify. In other words, the powder rapid prototyping apparatus 1 repeats the application and cessation of energy application multiple times to manufacture a molded object 91. The molded object 91 is, for example, a mechanical part. Note that the molded object 91 may also be other structures.

[0019] The powder rapid prototyping apparatus 1 has a modeling unit 2 (modeling section), a powder material supply unit 3 (powder material supply section), a housing 4, and a controller 5 (control section). The modeling unit 2 irradiates powder material 90 with an energy beam to obtain a three-dimensional modeled object 91. The powder material supply unit 3 supplies powder material 90 to the modeling unit 2. The housing 4 forms a modeling space that houses the modeling unit 2 and the powder material supply unit 3. The modeling space is an airtight space that can be depressurized. The controller 5 provides a control signal φ to the components of the modeling unit 2 and the powder material supply unit 3. The components of the modeling unit 2 and the powder material supply unit 3 perform operations in accordance with the control signal φ to obtain the modeled object 91.

[0020] The modeling unit 2 includes an energy beam source 20, a modeling tank 21, a modeling table 22, and an excess powder recovery tank 23.

[0021] The energy beam source 20 generates laser light, which is an example of an energy beam, and irradiates the powder material 90 with the laser light. The energy beam source 20 that irradiates the laser light has, for example, a laser light source. The energy beam source 20 that irradiates the laser light may include optical components such as lenses and / or mirrors as necessary. The energy beam source 20 may generate an electron beam, which is another example of an energy beam, and irradiate the powder material 90 with the electron beam. The energy beam source 20 that irradiates the electron beam has, for example, an electron gun. The energy beam source 20 that has an electron gun uses a coil to control the direction of travel of electrons emitted from the electron gun.

[0022] The modeling tank 21 forms an area for holding the powder material. The modeling object 91 is also accommodated in this area. The modeling tank 21 may have a rectangular shape in a plan view. The modeling tank 21 includes an upper opening 21a and a lower opening 21b. In other words, the shape of the modeling tank 21 is rectangular.

[0023] The modeling table 22 is disposed on the side of the lower opening 21b of the modeling tank 21. In other words, strictly speaking, the area for holding the powder material is defined by the modeling tank 21 and the modeling table 22. A base plate 26 is disposed on the modeling table 22. The modeling table 22 is capable of moving vertically downward in accordance with the progress of the modeling operation S20. Therefore, the modeling table 22 is provided with a modeling table drive mechanism 25 for moving the modeling table 22 back and forth in the vertical direction.

[0024] When the powder material 90 is supplied from the powder material supply unit 3 to the modeling unit 2, a surplus of the powder material 90 may occur. The surplus powder recovery tank 23 recovers the surplus powder material 90. The surplus powder recovery tank 23 is disposed on the opposite side of the modeling tank 21 from the powder material supply unit 3.

[0025] The powder material supply unit 3 is disposed adjacent to the modeling unit 2. The powder material supply unit 3 includes a powder supply tank 31 (powder material storage section), a powder supply table 32 (powder material support section), a powder application mechanism 33, and a powder vibration mechanism 34.

[0026] The powder supply tank 31 forms an area for holding the powder material 90 to be fed to the modeling unit 2. The shape of the powder supply tank 31 may be rectangular in plan view. The powder supply tank 31 includes an upper opening 31a and a lower opening 31b. In other words, like the modeling tank 21, the shape of the powder supply tank 31 is also rectangular.

[0027] The powder feeding table 32 is disposed on the side of the lower opening 31b of the powder feeding tank 31. In other words, strictly speaking, the area for holding the powder material 90 is defined by the powder feeding tank 31 and the powder feeding table 32. The powder feeding table 32 can move toward the upper opening 31a. For this movement, a feeding table drive mechanism 35 is also provided on the powder feeding table 32 for reciprocating the powder feeding table 32 in the vertical direction. As the powder feeding table 32 moves toward the upper opening 31a, the powder material 90 slightly overflows from the upper opening 31a. The powder material 90 overflowing from the upper opening 31a is transported to the modeling unit 2 by the powder application mechanism 33.

[0028] The powder application mechanism 33 includes a recoater 331 and a recoater driver 332. The recoater 331 can move back and forth from the end of the powder supply tank 31 to the end of the modeling tank 21. This movement is performed by the recoater driver 332. As the recoater 331 moves from the end of the powder supply tank 31 to the end of the modeling tank 21, the powder material 90 that slightly protrudes from the upper opening 31a is transported to the modeling unit 2.

[0029] The controller 5 supplies a control signal φ to each of the energy beam source 20, the modeling table driving mechanism 25 of the modeling tank 21, the supply table driving mechanism 35 of the powder supply tank 31, and the recoater driving unit 332 of the powder coating mechanism 33. Below, a brief description will be given of the modeling operation S20 in accordance with the control signal φ.

[0030] First, the controller 5 sends a control signal φ to the supply table driving mechanism 35 of the powder supply tank 31. As a result, the supply table driving mechanism 35 of the powder supply tank 31 moves the powder supply table 32 slightly upward (supply operation S21: see FIG. 3(a)). The amount of supply of the powder material 90 may be controlled by the amount of this movement. Next, the controller 5 sends a control signal φ to the recoater driving unit 332 of the powder application mechanism 33. As a result, the recoater 331 moves from the end of the powder supply tank 31 to the end of the modeling tank 21 (application operation S22: see FIG. 3(b)). This movement causes the powder material 90 that has spilled out of the powder supply tank 31 to be spread evenly over the modeling surface 90S of the powder material 90 contained in the modeling tank 21. Next, the controller 5 sends a control signal φ to the energy beam source 20. The control signal φ sent to the energy beam source 20 includes information about the cross-sectional shape of the model 91. The information on the cross-sectional shape of the model 91 indicates the area to be irradiated with the energy beam. As a result, the energy beam source 20 irradiates the area defined by the control signal φ with the energy beam (irradiation operation S23: see FIG. 4(a)). Then, the controller 5 provides the control signal φ to the modeling table driving mechanism 25 of the modeling tank 21. As a result, the modeling table driving mechanism 25 moves the modeling table 22 slightly downward (feed operation S24: see FIG. 4(b)).

[0031] By repeating the supplying operation S21, the applying operation S22, the irradiating operation S23, and the feeding operation S24 described above, the shaped object 91 can be obtained.

[0032] As explained above, the amount of powder material 90 supplied to the modeling tank 21 may be controlled by the movement amount of the powder feeding table 32. Assume that the powder material 90 is transported from the powder feeding tank 31 to the modeling tank 21 without leakage during transportation from the powder feeding tank 31 to the modeling tank 21. In this case, the amount of powder material 90 supplied is calculated by multiplying the volume, which is the product of the area of ​​the powder feeding tank 31 in a plan view (the area of ​​the powder feeding table 32) and the movement amount of the powder feeding table 32, by the bulk density of the powder material 90.

[0033] Of the several parameters that define the supply amount of powder material 90, the area of ​​powder supply tank 31 in a plan view is determined by the dimensions of powder supply tank 31 and powder supply table 32, and therefore does not vary for each supply operation S21. It is assumed that powder supply table 32 also moves a correct amount in accordance with the control signal φ received from controller 5. On the other hand, like the area of ​​powder supply tank 31 in a plan view and the movement amount of powder supply table 32, there may be cases where the bulk density of powder material 90 cannot be considered to be always constant.

[0034] The powder material 90 is an aggregate of fine powder particles. Therefore, depending on the state of contact between the powder particles, the powder may be sparse with many gaps, or dense with few gaps. Generally, the bulk density tends to be higher closer to the powder supply table 32 (see region 90D1 in FIG. 5(a)). In other words, the bulk density tends to be lower closer to the upper opening 31a (see region 90D2 in FIG. 5(a)). This density difference is thought to be due to the weight of the powder material 90.

[0035] With such a distribution of bulk density present, the supplying operation S21 is repeated while maintaining a constant movement amount of the powder supplying table 32. As the number of supplying operations S21 increases, the bulk density of the supplied powder material 90 gradually increases, and the supply amount of the powder material 90 gradually increases.

[0036] To address this issue, one possible approach is to change the amount of movement of the powder supply table 32 depending on the number of supply operations S21. Another possible approach is to keep the amount of movement of the powder supply table 32 constant while measuring the amount of powder material 90 actually spread evenly on the build surface 90S to adjust the excess or shortage. However, these approaches require more complex controls and mechanisms.

[0037] Therefore, the powder rapid prototyping apparatus 1 of the present disclosure uses a simpler device to suppress changes in the supply amount of powder material 90. Therefore, the powder rapid prototyping apparatus 1 of the present disclosure is provided with a powder vibrating mechanism 34 (powder vibrating unit).

[0038] The powder vibration mechanism 34 is one of the components of the powder material supply unit 3. The powder vibration mechanism 34 applies vibrations to the powder material 90 contained in the powder supply tank 31. When the powder material 90 is subjected to vibrations, unevenness in the gaps therebetween gradually disappears, and the overall bulk density imbalance is eliminated. As a result of the vibrations, the bulk density variations along the vertical direction are eliminated, so that the bulk density of the powder material 90 along the vertical direction becomes constant (see region 90D3 in FIG. 5(b)).

[0039] More specifically, referring again to FIG. 1, the powder vibration mechanism 34 has a vibration substrate 341 , a plurality of powder vibration rods 342 , and a vibration insulating member 343 .

[0040] The vibrating substrate 341 generates vibrations that are applied to the powder material 90. The vibrating substrate 341 is fixed so as not to move relative to the powder supply tank 31. The size of the rectangular vibrating substrate 341 in a plan view may be smaller than the size of the powder supply table 32 in a plan view. The vibrating substrate 341 is disposed, for example, between the powder supply table 32 and the supply table drive mechanism 35. A substrate through-hole 341h through which the drive shaft 351 is inserted is provided in the center of the vibrating substrate 341. The drive shaft 351 is movable up and down relative to the fixed vibrating substrate 341. In other words, the powder supply table 32 attached to the drive shaft 351 is also movable up and down relative to the vibrating substrate 341.

[0041] The vibration substrate 341 may have a function of generating vibrations by itself. If the vibration substrate 341 has a function of generating vibrations, the vibration substrate 341 may start and stop vibrations in response to a control signal φ received from the controller 5. Parameters indicating the state of vibrations, such as the frequency and amplitude of vibrations, may also be in accordance with the control signal φ given from the controller 5. Note that the vibration substrate 341 may receive vibrations from another vibration generating source. The direction of vibration of the vibration substrate 341 may be, for example, vertical.

[0042] A plurality of powder vibration bar 342 are fixed to the main surface 341a of the vibration plate 341. The powder vibration bar 342 is shaped like a long, thin cylinder. The longitudinal direction of the powder vibration bar 342 is aligned with the depth direction of the powder supply tank 31. As shown in FIG. 6, the plurality of powder vibration bar 342 are arranged two-dimensionally at predetermined intervals on the main surface 341a of the vibration plate 341 in a plan view. The lower ends of the powder vibration bar 342 are fixed to the vibration plate 341. Therefore, the powder vibration bar 342 also vibrates in response to the vibration of the vibration plate 341.

[0043] The powder material 90 present around the powder vibration rods 342 is affected by the vibrations of the powder vibration rods 342. However, there is a limit to the range of influence of the vibrations caused by one powder vibration rod 342. Suppose that the range of influence caused by the vibrations caused by one powder vibration rod 342A is set as influence range K34A. The influence range K34A of a certain powder vibration rod 342A may overlap with the influence range K34B of the adjacent powder vibration rod 342B. In other words, the spacing between the powder vibration rods 342 may be determined based on the range of influence caused by the vibrations. With this setting, the vibrations can be evenly applied to the powder material 90 present in the powder supply tank 31.

[0044] The position of the tip 342e of the powder vibration bar 342 is below the upper opening 31a of the powder supply tank 31 (see FIG. 4(a) etc.). With this arrangement, the recoater 331 does not come into contact with the tip 342e of the powder vibration bar 342. There is a small area between the tip 342e of the powder vibration bar 342 and the surface 90d of the powder material 90 where the powder vibration bar 342 is not present. However, if the surface 90d of the powder material 90 is included in the range of influence of the powder vibration bar 342, the powder material 90 present in this area can also be affected by the vibrations.

[0045] Since the vibration board 341 is disposed below the powder feeding table 32, the powder vibration rod 342 penetrates the powder feeding table 32. The powder feeding table 32 is provided with a plurality of feeding table through-holes 32h for allowing the powder vibration rod 342 to penetrate therethrough.

[0046] The vibrating substrate 341 and powder vibrating rod 342 have an insulating structure to prevent vibrations from being transmitted to the powder supply tank 31 and powder supply table 32. For example, the vibrating substrate 341 is fixed to the powder supply tank 31, but a vibration insulating member 343 for insulating vibrations is provided between the vibrating substrate 341 and the powder supply tank 31. Similarly, a vibration insulating member 343 is provided between the vibrating substrate 341 and the drive shaft 351. A vibration insulating member 343 is also provided between the powder vibrating rod 342 and the powder supply table 32.

[0047] [Example of operation including vibration] We have already explained the basic modeling operations S20 of the powder rapid prototyping apparatus 1, including the supplying operation S21, the applying operation S22, the irradiating operation S23, and the feeding operation S24. Below, we will provide some examples of the relationship between these operations and the vibration operation S10 by the powder vibration mechanism 34.

[0048] [First operation example] First, the controller 5 lowers the powder supply table 32 to its lowest position. This operation maximizes the powder material 90 storage area formed by the powder supply tank 31 and the powder supply table 32. Next, as shown in FIG. 7(a), the powder material 90 is poured into the powder material 90 storage area (S1). The powder material 90 may be poured mechanically or manually by an operator. When pouring the powder material 90, the controller 5 stops the application of vibration by the powder vibration mechanism 34. After a predetermined amount of powder material 90 has been poured, the controller 5 starts a vibration operation S10 by the powder vibration mechanism 34 (S11). As a result, the bulk density of the powder material 90 gradually approaches uniformity. After a predetermined time has elapsed, the controller 5 stops the vibration operation S10 by the powder vibration mechanism 34 (S12). This change in bulk density may cause the surface 90d of the powder material 90 to drop. In this case, the powder material 90 may be charged again (S1). That is, the charging of the powder material 90 (S1) and the vibration operation S10 may be repeated until the surface 90d of the powder material 90 reaches the upper opening 31a of the powder supply tank 31. By such an operation, a state in which the bulk density distribution of the powder material 90 is uniform can be obtained.

[0049] Next, the controller 5 stops the vibration operation S10 by the powder vibration mechanism 34 (S12). Then, the controller 5 repeats the supply operation S21, the application operation S22, the irradiation operation S23, and the feeding operation S24. As a result, a shaped object 91 can be obtained.

[0050] In the above example, when the powder material 90 is added (S1), the controller 5 explicitly stops the vibration operation S10 by the powder vibration mechanism 34. For example, when the powder material 90 is added (S1), the controller 5 may perform the vibration operation S10 by the powder vibration mechanism 34. In other words, the addition of the powder material 90 (S1) and the vibration operation S10 may be performed in parallel. For example, as shown in FIG. 7(b), the controller 5 first starts the vibration operation S10 (S11). Next, the powder material 90 is added (S1). Then, the controller 5 stops the vibration operation S10 (S12).

[0051] According to the first operation example, a vibration operation S10 for uniforming the bulk density of the powder material 90 is performed before the supply operation S21, the application operation S22, the irradiation operation S23, and the feeding operation S24 for obtaining the model 91. According to the first operation example, the vibration operation S10 for uniforming the bulk density of the powder material 90 is not performed in the modeling operation S20 in which the supply operation S21, the application operation S22, the irradiation operation S23, and the feeding operation S24 are repeated.

[0052] [Second example of operation] In contrast, as shown in FIG. 8(a), in the second operation example, the vibration operation S10 is included in the modeling operation S20 in which the supplying operation S21, the coating operation S22, the irradiating operation S23, and the feeding operation S24 are repeated. For example, the controller 5 may perform the vibration operation S10 before the supplying operation S21. The controller 5 causes the powder vibration mechanism 34 to apply vibration for a certain period of time. Next, the controller 5 explicitly stops the application of vibration by the powder vibration mechanism 34. Next, the controller 5 performs the supplying operation S21, the coating operation S22, the irradiating operation S23, and the feeding operation S24 in this order. Then, the controller 5 causes the powder vibration mechanism 34 to again perform the vibration operation S10 for a certain period of time.

[0053] [Third example of operation] As shown in FIG. 8(a), in the second operation example, the vibration operation S10 was not performed in parallel with the supply operation S21, the application operation S22, the irradiation operation S23, and the feeding operation S24. As shown in FIG. 8(b), in the third operation example, the vibration operation S10 may be performed in parallel with at least one of these operations. For example, the controller 5 may perform the vibration operation S10 in parallel with the irradiation operation S23 and / or the feeding operation S24. According to such an operation example, the time required for a series of steps including the vibration operation S10 can be shortened.

[0054] [Action and effect] The powder rapid prototyping apparatus 1 includes a modeling unit 2 that forms a model 91 by irradiating a spread powder material 90 with an energy beam, and a powder material supplying unit 3 that supplies the powder material 90 to the modeling unit 2. The powder material supplying unit 3 includes a powder supply tank 31 that forms an area for storing the powder material 90, and a powder vibrating mechanism 34 that includes a powder vibrating rod 342 that is arranged so as to be embedded in the powder material 90 stored in the powder supply tank 31.

[0055] This powder rapid prototyping apparatus 1 is equipped with a powder vibration rod 342 of a powder vibration mechanism 34 that is arranged so as to be embedded in the powder material 90 contained in a powder supply tank 31. Vibrating the powder material 90 with this powder vibration rod 342 can reduce unevenness in the bulk density of the powder material 90. As a result, even when the application operation S22 of spreading the powder material 90 evenly on the modeling unit 2 and the irradiation operation S23 of irradiating the spread powder material 90 with an energy beam are repeated, the unevenness in bulk density is reduced, so that it is possible to suppress changes in the amount of powder material 90 supplied from the powder material supply unit 3 to the modeling unit 2.

[0056] Powder supply tank 31 has a wall surface 311 with which powder material 90 comes into contact. Powder vibrating rod 342 of powder vibrating mechanism 34 is spaced apart from wall surface 311. With this configuration, powder material 90 contained in powder supply tank 31 can be vibrated evenly.

[0057] The powder rapid prototyping apparatus 1 further includes a controller 5 that controls the operations of the modeling unit 2 and the powder material supply unit 3. The modeling unit 2 has an energy beam source 20 that emits an energy beam. The controller 5 controls the operations of the energy beam source 20 and the powder vibrating mechanism 34. With this configuration, the vibration operation S10 that eliminates bias in the bulk density of the powder material 90 and the irradiation operation S23 can be performed in a desired order.

[0058] Powder supply tank 31 has a wall surface 311 that surrounds powder material 90, and a powder supply table 32 that forms the bottom of the area surrounded by wall surface 311, supports powder material 90 surrounded by wall surface 311, and pushes up powder material 90. Powder vibrating mechanism 34 extends in the upward direction in which powder supply table 32 pushes up powder material 90, and has multiple powder vibrating rods 342 that are arranged two-dimensionally when viewed from above in the upward direction. This configuration also makes it possible to evenly vibrate powder material 90 contained in powder supply tank 31.

[0059] [Second embodiment] In the first embodiment, a configuration is exemplified in which powder material 90 contained in powder supply tank 31 is pushed up by powder supply table 32. In the second embodiment, a configuration is exemplified in which powder material 90 contained in powder supply tank 61 is dropped, as shown in Fig. 9. Even with this supply configuration, it is possible to prevent changes in the supply amount of powder material 90 due to the action of powder vibrating mechanism 64.

[0060] 9 is a schematic diagram of a powder rapid prototyping apparatus 1A of the second embodiment. The powder rapid prototyping apparatus 1A of the second embodiment has a modeling unit 2, a powder material supplying unit 6, a housing 4, and a controller 5. Here, the modeling unit 2, the housing 4, and the controller 5 are the same as those of the first embodiment, so detailed description thereof will be omitted. Below, the powder material supplying unit 6 will be described.

[0061] The powder material supply unit 6 has a powder supply tank 61 , a powder receiving shelf 62 , a powder application mechanism 63 , and a powder vibration mechanism 64 .

[0062] The powder receiving shelf 62 is disposed adjacent to the modeling tank 21. The powder receiving shelf 62 receives the powder material 90 that has fallen from the powder supply tank 61. A shelf main surface 62a of the powder receiving shelf 62 is disposed at approximately the same height as the upper opening 21a of the modeling tank 21.

[0063] As shown in FIG. 10, powder supply tank 61 is disposed above powder receiving shelf 62. Powder supply tank 61 includes a storage section 611 and a hopper section 612. Hopper section 612 is formed below storage section 611. Powder material 90 stored in storage section 611 drops from a hopper opening 61t of hopper section 612 into powder receiving shelf 62. Hopper section 612 may be provided with a mechanism for switching between an operation of dropping powder material 90 and an operation of not dropping powder material 90.

[0064] The powder material 90 contained in the powder supply tank 61 is subjected to vibration in the boundary region between the container section 611 and the hopper section 612 .

[0065] More specifically, powder vibrating mechanism 64 has a vibration source 641 and a powder vibrating net 642. Vibration source 641 is disposed outside powder supply tank 61. Vibration source 641 is connected to powder vibrating net 642 via a connecting member 643. Connecting member 643 leads to the inside of powder supply tank 61 via a tank through-hole 61h provided in wall portion 611a of container portion 611. For example, tank through-hole 61h may be provided near ridge 61e, which can be considered the boundary between container portion 611 and hopper portion 612. Powder vibrating net 642 is attached to the end of connecting member 643.

[0066] As shown in FIG. 11 , the shape of the powder vibrating net 642 is substantially the same as the internal shape of the container 611 in plan view. The powder vibrating net 642 is composed of multiple frame portions 642a arranged two-dimensionally in plan view. That is, the powder vibrating net 642 includes multiple mesh through-holes 642h. The powder material 90 passes through these mesh through-holes 642h to reach the hopper 612. Furthermore, the powder material 90 is subjected to vibrations from the powder vibrating net 642 immediately before passing through the mesh through-holes 642h, while passing through them, and immediately after passing through them. The direction of the vibrations may be along the depth direction of the powder supply tank 61 or may be intersecting the depth direction.

[0067] [Example of operation] For example, the controller 5 may synchronize the operation of dropping the powder material 90 from the hopper 612 with the vibration operation of applying vibrations by the powder vibrating net 642. In other words, the powder vibrating net 642 may be vibrating while the powder material 90 is being dropped from the hopper 612. Alternatively, the controller 5 may continuously vibrate the powder vibrating net 642 regardless of whether the powder material 90 is being dropped from the hopper 612. In this case, the vibration operation of applying vibration is performed in parallel with the operation of dropping the powder material 90, and the vibration operation is performed even when the powder material 90 is not being dropped.

[0068] <Action and effect> In a configuration in which the powder material 90 is supplied by dropping the powder material 90 from the hopper section 612, the bulk density of the powder material 90 dropping from the hopper section 612 tends to be high, while the bulk density of the powder material 90 contained in the container section 611 tends to be lower. If this is the case, and the operation of dropping the powder material 90 from the hopper section 612 is controlled, for example, by the time taken to drop the powder material 90, the amount of powder material 90 dropping onto the powder receiving shelf 62 gradually decreases. This also reduces the amount of powder material 90 supplied to the modeling unit 2, which may result in defective modeling.

[0069] To address this problem, the powder vibrating mechanism 64 of the powder material supply unit 6 of the second embodiment is provided with a powder vibrating network 642 including a plurality of frame portions 642a arranged two-dimensionally when viewed from above in the upward direction. This configuration also makes it possible to evenly vibrate the powder material 90 contained in the powder supply tank 61.

[0070] Furthermore, according to the powder material supplying unit 6 of the second embodiment, accumulation of the powder material 90 on the inclined surface 61k of the hopper portion 612 can also be suppressed.

[0071] [Variations] The present invention can be implemented in various forms, including the above-described embodiment, with various modifications and improvements based on the knowledge of those skilled in the art. Furthermore, it is also possible to configure modified examples by utilizing the technical matters described in the above-described embodiment. The configurations of the embodiments and the like may be used in appropriate combination.

[0072] The mechanism of the present disclosure can also be applied to a so-called rotary type powder rapid prototyping apparatus 1B shown in FIG. 12. As shown in FIG. 12, the powder rapid prototyping apparatus 1B has a rotary table drive source 71, a controller 72, a processing unit 73, and a housing 74. The rotary table drive source 71 performs various operations required for modeling. The processing unit 73 processes powder material 90 to obtain a model 91. Specifically, the processing of the powder material 90 includes a supply process of the powder material 90, a preheating process of the powder material 90, and a modeling process of the powder material 90. The housing 74 is supported by a plurality of columns 741. The housing 74 forms a modeling space S. The modeling space S is a decompressible airtight space that contains the powder material 90 and is used for processing the powder material 90 by the processing unit 73.

[0073] A turntable 75 and a modeling tank 76 are arranged in the modeling space S. The turntable 75 is a processing stage on which modeling processing is performed. The turntable 75 has, for example, a disk shape, and a powder material 90, which is the raw material of the model 91, is arranged on the turntable 75. The turntable 75 may be arranged so that its central axis overlaps with the central axis of the housing 74. A turntable driving source 71 is connected to the turntable 75. Therefore, the turntable 75 rotates and moves linearly along the rotation axis by the turntable driving source 71.

[0074] The rotary table driving source 71 rotates and elevates the rotary table 75. The rotary table driving source 71 has a rotation unit 711 and an elevation unit 712. The rotation unit 711 rotates the rotary table 75. The upper end of the rotation unit 711 is connected to the rotary table 75, and a drive source (e.g., a motor) is attached to the lower end of the rotation unit 711. The elevation unit 712 elevates and lowers the rotary table 75 relative to the modeling tank 76. This elevation is along the rotation axis of the rotation unit 711. Note that the rotary table driving source 71 may be any mechanism that can rotate and elevate the rotary table 75, and the rotary table driving source 71 is not limited to the mechanism described above.

[0075] The processing section 73 includes a powder material supply unit 731, a heater 732, and an energy beam source 733. The powder material supply unit 731 supplies the powder material 90. The heater 732 preheats the powder material 90. The energy beam source 733 shapes the powder material 90. The feeder 41, the heater 732, and the energy beam source 733 are arranged in this order along the rotation direction (counterclockwise direction) of the turntable 75.

[0076] The heater 732 uses radiant heat to increase the temperature of the powder material 90. As the heater 732, for example, an infrared heater or a gas heater may be used.

[0077] The energy beam source 733 generates a laser beam, which is an example of an energy beam, and irradiates the powder material 90 with the laser beam.

[0078] The powder material supply unit 731 supplies powder material 90 to the rotary table 75. The powder material supply unit 731 includes, for example, the same powder supply tank 61 and powder vibration mechanism 64 as those included in the powder material supply unit 6 of the second embodiment. As a result, it is possible to obtain the same effects as those of the powder rapid prototyping apparatus 1 of the second embodiment.

[0079] In the first and second embodiments, the powder vibrating rod 342 that vibrates the powder material 90 is embedded in the powder material 90. The configuration for vibrating the powder material 90 is not limited to embedding a vibration-imparting component in the powder material 90. For example, the wall surface 311 of the powder supply tank 31 may be vibrated, or the powder supply table 32 may be vibrated. [Explanation of symbols]

[0080] 1,1A,1B Powder additive manufacturing equipment 2. Modeling unit (modeling section) 3 Powder material supply unit (powder material supply section) 5 Controller (control unit) 20,733 Energy Beam Source 31 Powder supply tank (powder material storage section) 32 Powder supply table (powder material support part) 90 Powder materials 91 Sculptures 311 Wall section 642a Frame

Claims

1. a modeling unit that forms a model by irradiating the spread powder material with an energy beam; a powder material supply unit that supplies the powder material to the modeling unit, The powder material supply unit includes: a powder material containing portion that forms an area for containing the powder material; a powder vibration unit that applies vibration to the powder material contained in the powder material containing unit.

2. The powder rapid prototyping apparatus according to claim 1 , wherein the powder vibrator is disposed so as to be embedded in the powder material contained in the powder material containing section.

3. the powder material container has a wall surface with which the powder material comes into contact, The powder rapid prototyping apparatus according to claim 1 , wherein the powder vibrating unit is spaced apart from the wall surface unit.

4. a control unit that controls operations of the modeling unit and the powder material supply unit, the modeling unit has an energy beam source that emits the energy beam, The powder rapid prototyping apparatus according to claim 1 , wherein the control unit controls operations of the energy beam source and the powder vibrator.

5. The powder material containing portion is a wall portion surrounding the powder material; a powder material support portion that forms a bottom surface of an area surrounded by the wall portion, supports the powder material surrounded by the wall portion, and pushes up the powder material, 5. The powder rapid prototyping device according to claim 1, wherein the powder vibration unit has a plurality of vibration rods that extend in a direction in which the powder material support unit pushes up the powder material and are arranged two-dimensionally in a plan view.

6. 5. The powder rapid prototyping apparatus according to claim 1, wherein the powder vibrating unit has a plurality of frame parts arranged two-dimensionally in a plan view.

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