Manufacturing method for a component with connecting hardware attached to a laminate formed by a metal 3D printer.

Abstract

This reduces the effort required when creating connecting structures in a layer formed by a metal 3D printer. [Solution] A method for manufacturing a member 7 having a connecting fitting 72 attached to a laminate 71 formed by a metal 3D printer 1 according to the present disclosure includes a laminate formation step of forming a laminate 71 by stacking metal materials with a metal 3D printer 1, and a joining step of joining the connecting fitting 72 to the laminate 71 on the metal 3D printer 1, wherein the laminate formation step includes a first step of forming a laminate 71 having a receiving portion 71B that receives the connecting fitting 72 during the joining step.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a member provided with a connecting fitting on a laminate formed by a metal 3D printer.

Background Art

[0002] Patent Document 1 discloses a shaping method in which a base plate is attached on a shaping table, and a shaped object is shaped on the base plate by a metal melting lamination method using arc welding in a metal 3D printer.

[0003] And in Patent Document 1, it is disclosed that the shaped object together with the base plate or the like is removed from the metal 3D printer, the shaped object is moved to the side of a cutting machine, and secondary processing such as cutting is performed.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, when the shaped object to be shaped is shaped as, for example, one member for constituting a complex structure, it is necessary to perform connection or the like when assembling the shaped objects shaped as each member into the structure.

[0006] And, for example, when bolt holes or the like for connection are required in the tip portion (the portion formed on the lamination end side) of the shaped object shaped as a member, it is necessary to perform hole opening processing or the like in a subsequent process, and the time and cost associated with the laboriousness increase.

[0007] The present disclosure has been made in view of such circumstances, and one object thereof is to reduce the labor when providing a connection structure to a laminate formed by a metal 3D printer. [Means for solving the problem]

[0008] The manufacturing method disclosed herein is a method for manufacturing a component in which a connecting metal fitting is provided on a laminate formed by a metal 3D printer, The aforementioned manufacturing method is The laminate formation step involves forming the laminate by stacking metal materials using the aforementioned metal 3D printer, The process includes a joining step of joining the connecting hardware to the laminate on the metal 3D printer, The laminate formation step includes a first step of forming a laminate having a receiving portion for receiving the connecting hardware during the joining step. [Effects of the Invention]

[0009] According to this disclosure, the effort required to provide a connecting structure to a laminate formed by a metal 3D printer can be reduced. [Brief explanation of the drawing]

[0010] [Figure 1] This is a side view of the metal 3D printer according to the first embodiment of the present disclosure. [Figure 2] Figure 1 is a side view of the metal 3D printer with the nozzle removed from the manipulator. [Figure 3] Figure 1 is a front view of the metal 3D printer with the nozzle removed from the manipulator. [Figure 4] This is a cross-sectional view of a member having connecting hardware attached to a laminate formed by a metal 3D printer according to the first embodiment of the present disclosure. [Figure 5] This is a top view of the connecting hardware of the first embodiment relating to this disclosure. [Figure 6] This figure illustrates the first step of the laminate formation step of the first embodiment of the present disclosure. [Figure 7] This is a cross-sectional view illustrating the joining step of the first embodiment relating to this disclosure. [Figure 8] This is a top view illustrating the joining step of the first embodiment relating to this disclosure. [Figure 9] It is a cross-sectional view showing a state where two members according to the first embodiment of the present disclosure are connected. [Figure 10] It is a cross-sectional view for explaining a method of manufacturing a member provided with a connecting fitting on a laminate formed by a metal 3D printer according to the second embodiment of the present disclosure. [Figure 11] It is a cross-sectional view for explaining a method of manufacturing a member provided with a connecting fitting on a laminate formed by a metal 3D printer according to the third embodiment of the present disclosure. [Figure 12] It is a cross-sectional view for explaining a method of manufacturing a member provided with a connecting fitting on a laminate formed by a metal 3D printer according to the fourth embodiment of the present disclosure.

Mode for Carrying Out the Invention

[0011] Hereinafter, embodiments for implementation (hereinafter referred to as "embodiments") will be described in detail with reference to the accompanying drawings. Throughout the description of the embodiments, the same elements are denoted by the same numbers or symbols.

[0012] <<First Embodiment>> A method for manufacturing a member 7 provided with a connecting fitting 72 on a metal 3D printer 1 according to the first embodiment of the present disclosure and a laminate 71 formed by the metal 3D printer 1 will be described while referring to FIGS. 1 to 9.

[0013] Note that expressions related to up and down such as the upper surface and the lower surface are expressions in the state at the time of manufacturing when the manufacturing method is being carried out, and do not specify the state when the member 7 is actually used.

[0014] FIG. 1 is a side view of a metal 3D printer 1 according to the first embodiment of the present disclosure. FIG. 2 is a side view of the metal 3D printer 1 of FIG. 1 with the nozzle 6 removed from the manipulator 2. FIG. 3 is a front view of the metal 3D printer 1 of FIG. 1 with the nozzle 6 removed from the manipulator 2.

[0015] <Metal 3D Printer 1> As shown in Figures 1 to 3, the metal 3D printer 1 comprises a manipulator 2, a base 3 for fixing the manipulator 2, a table 4 mounted on the base 3, a base material 5 provided on the table 4, and a nozzle 6 (see Figure 1) attached to the tip of the manipulator 2.

[0016] The metal 3D printer 1 includes a wire supply mechanism for supplying metal wire to the nozzle 6, a gas supply mechanism for supplying shielding gas to the tip of the metal wire (the part that melts due to the heat of the arc discharge), and a power supply for the arc discharge. Although not shown in the diagram, the wire supply mechanism, gas supply mechanism, and power supply can be general-purpose ones used in metal 3D printers.

[0017] [Manipulator 2] Manipulator 2 will be explained primarily with reference to Figures 2 and 3. The manipulator 2 comprises a manipulator base 21 fixed to the base 3, a swing head 22, a forearm 23, an upper arm 24, a wrist 25, and a swivel head 26.

[0018] (Manipulator Base 21) The manipulator base 21 is a fixing part for securing the manipulator 2 to prevent it from tipping over, and is positioned on the base part 3 and fixed to the base part 3 with bolts B1.

[0019] (Swinghead 22) As shown in Figure 2, the swing head 22 is rotatably connected to the manipulator base 21 around a first axis VA parallel to the vertical.

[0020] (Lower arm 23) As shown in Figure 2, the forearm portion 23 is connected to the swing head 22 so as to be rotatable (see arrow AR1) with its base end being on a second axis RC1 that is perpendicular to the vertical and parallel to the horizontal direction.

[0021] (Upper arm 24) As shown in Figure 2, the upper arm portion 24 is rotatably connected to the lower arm portion 23 (see arrow AR2) with its proximal end being the pivot point RC2, which is the third axis parallel to the second axis.

[0022] (Wrist part 25) The wrist portion 25 is connected to the tip of the upper arm portion 24 so that its base end can pivot (see arrow AR3 in Figure 3).

[0023] (Swivel section 26) As shown in Figure 2, the swivel section 26 is provided at the tip of the wrist section 25 so as to be able to swivel (see arrow AR4) in one direction perpendicular to the longitudinal direction of the wrist section 25.

[0024] The oscillating unit 26 has a rotation mechanism (not shown) that rotates the attachment (in this example, the nozzle 6) attached to the oscillating unit 26 relative to the oscillating unit 26 (see arrow AR3 in Figure 3).

[0025] [Base section 3] As shown in Figures 1 to 3, the base section 3 is a pedestal constructed by combining H-beams to securely hold the manipulator 2 and table 4. However, it is not limited to H-beams; any structure that can securely hold the manipulator 2 and table 4 in an appropriate positional relationship is acceptable.

[0026] Furthermore, the underside of the base section 3 is equipped with casters (wheels) for use during transport and adjusters to prevent movement during use.

[0027] [Table 4] Table 4 is mounted on the base 3 so as to be positioned at an appropriate distance from the manipulator 2, in order to properly perform the molding (hereinafter also referred to as layering) using molten metal from the nozzle 6 attached to the tip of the manipulator 2.

[0028] In this embodiment, the table 4 is fixed to the base portion 3 with bolts (not shown) while positioned on the base portion 3.

[0029] The suspension bolts visible in the diagram are provided for connecting shackles and other components that connect to the wires and other components of the lifting device used when moving table 4.

[0030] [Base material 5] The base material 5 is a substrate that serves as the target for the initial layering of metal material when using the metal 3D printer 1. After layering, it is fixed to the table 4 with bolts B2 so that it can be removed from the table 4 together with the component 7 (described later) which is equipped with connecting hardware 72 (described later) to the laminated body 71 (described later).

[0031] In the first embodiment, the base material 5 is placed on the table 4, but the table 4 itself may be used as the base material 5, and the laminated body 71 may be formed by laminating on the table 4.

[0032] However, the substrate (base material 5 in this example), which serves as the target for initially laminating the metal material, may be reused after the laminate 71 is removed by cleaning its surface (e.g., surface polishing), but it may also be discarded without being reused.

[0033] Therefore, the target substrate (base material 5 in this example) often serves as a disposable, supplementary component (also called a supplementary component) in the metal 3D printer 1.

[0034] Therefore, instead of using the table 4 as the target for initially laminating the metal material, it is preferable to place a base material 5, which can be used as a supplementary component, on the table 4, as in the first embodiment, and then perform lamination on the base material 5.

[0035] Furthermore, although the first embodiment shows the case where the base material 5 is in the shape of a plate, the base material 5 is not limited to being in the shape of a plate, and the shape can be selected as needed.

[0036] For example, when combining multiple molded objects M (not shown) to produce a single structure, the base material 5 may have a shape suitable for assembling the molded objects M (not shown) together (for example, a shape having a bonding structure for joining the molded objects M (not shown) in addition to the layered surface).

[0037] In this way, the base material 5 is not treated as disposable, but can be effectively utilized as one of the structural components in the fabrication of the structure.

[0038] [Nozzle 6] Nozzle 6 is a nozzle that melts the metal wire being fed out by the heat of an arc discharge while injecting a shielding gas (for example, carbon dioxide, argon, etc.) to surround the metal wire being fed out.

[0039] In other words, in the first embodiment, an arc welding type metal 3D printer is used as the type of metal 3D printer 1.

[0040] However, the nozzle 6 is not limited to a nozzle that melts metal powder using the heat of an arc discharge as described above; it may also be a nozzle that melts metal powder by spraying it in a way that collects the metal powder while irradiating it with a laser.

[0041] In other words, metal 3D printer 1 may be a directed energy deposition metal 3D printer.

[0042] Furthermore, the nozzle 6 may be a nozzle that binds metal particles together by spraying a mixture of metal powder and air at a speed of three times or more the speed of sound.

[0043] In other words, metal 3D printer 1 may be a metal 3D printer using the supersonic deposition method.

[0044] <Manufacturing method> Next, a method for manufacturing a member 7, which is formed by providing a connecting fitting 72 to a laminate 71 formed by a metal 3D printer 1 according to the first embodiment of this disclosure, will be described.

[0045] Figure 4 is a cross-sectional view of a member 7 formed by a metal 3D printer 1 according to the first embodiment of the present disclosure, in which a connecting fitting 72 is provided on a laminate 71, and the portion of the connecting fitting 72 is indicated by diagonal lines. Figure 5 is a top view of the connecting hardware 72 of the first embodiment according to this disclosure.

[0046] As shown in Figure 4, the member 7 manufactured by the manufacturing method of the first embodiment comprises a laminate 71 formed by a metal 3D printer 1 and a connecting fitting 72 provided so as to be partially embedded in the laminate 71.

[0047] Furthermore, in order to manufacture the component 7 shown in Figure 4, the manufacturing method of the first embodiment includes a laminate formation step of forming a laminate 71 by stacking metal materials in a metal 3D printer 1, and a joining step of joining a connecting metal fitting 72 to the laminate 71 on the metal 3D printer 1.

[0048] The laminated body 71 comprises a main body portion 71A, a receiving portion 71B for receiving the connecting fitting 72, a frame portion 71C along the outer circumference of the flange portion 72B of the connecting fitting 72, and a covering portion 71D that covers the flange portion 72B of the connecting fitting 72 so as to embed it inside the laminated body 71.

[0049] As will be explained later, the laminate formation step includes a first step and a second step. In the first step, the main body portion 71A, the receiving portion 71B, and the frame portion 71C of the laminate 71 are formed, and in the second step, the covering portion 71D of the laminate 71 is formed.

[0050] On the other hand, as shown in Figures 4 and 5, the connecting fitting 72 comprises a main body portion 72A, a flange portion 72B that protrudes outward from the main body portion 72A and is provided along the outer circumference of the main body portion 72A, and a pair of through holes 72C formed in the main body portion 72A for passing a bolt B3 (not shown), which will be described later.

[0051] The flange portion 72B is thinner than the main body portion 72A and is located on one side of the main body portion 72A in the thickness direction (the lower side in Figure 4). The flange portion 72B forms a stepped structure on the outer circumference of the connecting fitting 72.

[0052] In the first embodiment, the joining step is a welding step that forms a welded portion WL between the flange portion 72B and the frame portion 71C, as shown in Figure 4.

[0053] The manufacturing method of the first embodiment will be described below in accordance with the manufacturing procedure. Figure 6 is a diagram illustrating the first step of the laminate formation step of the first embodiment of the present disclosure, and corresponds to the cross-sectional view of Figure 4.

[0054] Figure 6(A) shows the formation of the main body portion 71A of the laminate 71 in the first step, Figure 6(B) shows the formation of the receiving portion 71B of the laminate 71 in the first step, and Figure 6(C) shows the formation of the frame portion 71C of the laminate 71 in the first step.

[0055] In Figure 6(C), the connecting hardware 72 is shown with a dotted line to illustrate its position during the connection step.

[0056] As shown in Figure 6(A), in the first step of the laminate formation process, the base material 5 is first used as the initial target for lamination, and the main body 71A of the laminate 71 is formed by lamination a required number of times.

[0057] Then, once the formation of the main body portion 71A is complete, the next step in the first step of the laminate formation process is to form a receiving portion 71B on the main body portion 71A to receive the connecting hardware 72.

[0058] This receiving portion 71B is the part that receives the connecting hardware 72 when performing the joining step described later, and the laminate formation step of the first embodiment includes a first step of forming a laminate 71 having a receiving portion 71B that receives the connecting hardware 72 when performing the joining step.

[0059] More specifically, as previously described, the connecting fitting 72 of the first embodiment is provided with a flange portion 72B on its outer circumference. In the first step of the laminate formation step of the first embodiment, the receiving portion 71B is formed to protrude inward from the laminate 71 (see Figure 4) by a layer with a wider width during lamination, so as to receive the entire flange portion 72B (the entire lower surface of the flange portion 72B during manufacturing).

[0060] For example, by slowing down the movement speed of the nozzle 6 of the metal 3D printer 1, the width of the layered material can be increased. Therefore, the receiving portion 71B can be formed by performing the layering with the movement speed of the nozzle 6 slower than the movement speed of the nozzle 6 when forming the main body portion 71A.

[0061] In the first embodiment, as shown in Figure 6(B), the receiving portion 71B is formed by laminating two layers that sequentially increase in width from the main body portion 71A. However, the number of layers to form the receiving portion 71B can be determined as needed.

[0062] Therefore, the receiving portion 71B may be formed by laminating a single layer, or conversely, by laminating three or more layers.

[0063] Furthermore, in the first embodiment, as described above, the receiving portion 71B is provided around the entire circumference of the end face on the other side (upper side in Figure 6) of the main body portion 71A so as to receive the entire flange portion 72B (the entire lower surface of the flange portion 72B during manufacturing), but it may also be provided only partially.

[0064] For example, in this case, the movement speed of the nozzle 6 when moving along the entire circumference of the other end face (upper side in Figure 6) of the main body 71A can be partially slowed down to form protruding receiving portions 41B at multiple locations in the circumferential direction, so as to extend inward into the laminate 71 (see Figure 4).

[0065] Furthermore, such protrusions can also be formed by slightly serpentine the nozzle 6 inward of the laminate 71 at the desired location, and when the receiving portion 41B is formed as multiple protrusions, it is preferable to provide three or more so that the connecting hardware 72 can be stably received.

[0066] Then, as described above, once the receiving portion 71B is formed, in the first step of the laminate formation step of the first embodiment, as shown in Figure 6(C), a layer is also formed on the receiving portion 71B, which will become the frame portion 71C along the outer circumference of the flange portion 72B when the flange portion 72B of the connecting hardware 72 is placed on the receiving portion 71B.

[0067] As shown in Figure 6(C), the frame portion 71C is formed to have approximately the same thickness as the flange portion 72B, and the other side (upper side in Figure 6) of the frame portion 71C and the flange portion 72B are almost flush.

[0068] Therefore, since there is no step at the boundary between the frame portion 71C and the flange portion 72B, the joining step described later is made easier to perform.

[0069] However, this is not limited to the frame portion 71C and the other side (upper side in Figure 6) of the flange portion 72B being flush with each other.

[0070] In the first embodiment, the frame portion 71C is shown as being formed by laminating a single layer, but the frame portion 71C may also be formed by laminating multiple layers, similar to the receiving portion 71B.

[0071] Then, once the formation of the frame portion 71C is complete, the first step of the laminate formation step of the first embodiment is completed, and next, a joining step is performed in which the connecting hardware 72 is joined to the laminate 71 on the metal 3D printer 1.

[0072] Figure 7 is a cross-sectional view illustrating the joining step of the first embodiment according to this disclosure, and corresponds to Figure 4. Figure 8 is a top view illustrating the joining step of the first embodiment according to this disclosure.

[0073] As shown in Figures 7 and 8, the connecting hardware 72 is positioned inside the frame portion 71C in order to perform the joining step.

[0074] Furthermore, the connecting hardware 72 positioned inside the frame portion 71C is supported by the receiving portion 71B at least on one side of the flange portion 72B (the lower side in Figure 7) (the entire lower surface of the flange portion 72B during manufacturing).

[0075] Furthermore, the connecting hardware 72, arranged as described above, is temporarily fixed by a temporary fixing jig, which is an L-shaped magnet MG in side view.

[0076] Specifically, as shown in Figure 7, the L-shaped magnet MG is attracted by magnetic force to the other side (upper side in Figure 7) of the main body portion 72A of the connecting hardware 72 (the upper surface during manufacturing), and is also attracted by magnetic force to the outer surfaces of the frame portion 71C and the receiving portion 71B, thereby temporarily fixing the connecting hardware 72 in place so that it does not move.

[0077] The temporary fixing jig only needs to be able to prevent the connecting hardware 72 from moving in order to facilitate the joining step, and may be, for example, a weight placed on the connecting hardware 72.

[0078] The joining step in the first embodiment, as shown in Figure 8, involves spot welding between the frame portion 71C and the flange portion 72B, thereby forming multiple welded joints WL.

[0079] As shown in Figure 8, in the first embodiment, the joining step involves spot welding the four corners of the flange portion 72B to the frame portion 71C. However, it may also be a step of welding the flange portion 72B and the frame portion 71C together with full-circumference welding. By forming a weld around the entire circumference, a higher joining strength can be obtained, so full-circumference welding is preferable when high joining strength is required.

[0080] Thus, when welding around the entire circumference, it is possible to use a temporary fixing jig with an L-shaped magnet MG in side view to perform temporary welding in a partial area, then remove the magnet MG and perform full-circumference welding. However, if the weight placed on the aforementioned connecting fitting 72 is used as the temporary fixing jig, it will not interfere with full-circumference welding, so it is preferable for the temporary fixing jig to be a weight when performing full-circumference welding.

[0081] Then, as described above, after the bonding step is performed, the second step of the laminate formation step of the first embodiment is carried out.

[0082] The second step, as shown in Figure 4, is to form a covering portion 71D that covers the flange portion 72B so as to embed it within the laminate 71. As can be seen in Figure 4, in the second step of the laminate formation process, layers are formed on the flange portion 72B and the frame portion 71C, and layers are formed along the flange portion 72B and the frame portion 71C.

[0083] Although the base material 5 is not shown in Figure 4, when the second process is being carried out, it has naturally not yet been removed from the base material 5, so the cover portion 71D is formed with the previously laminated portion still attached to the base material 5.

[0084] By providing such a covering portion 71D, the flange portion 72B becomes embedded in the laminate 71, and the covering portion 71D performs the function of fixing the connecting fitting 72 to the laminate 71, thereby increasing the fixing strength compared to when the connecting fitting 72 is fixed to the laminate 71 by the welded portion WL alone.

[0085] Furthermore, the covering portion 71D can also improve the appearance by positioning it at a height where the main body portion 72A of the connecting hardware 72 is not visible from the side of the member 7.

[0086] Furthermore, as shown in Figure 4, it is preferable that the height of the cover portion 71D is such that the other side surface of the cover portion 71D (upper side in Figure 4) (the upper surface during manufacturing) and the other side surface of the main body portion 72A of the connecting hardware 72 (upper side in Figure 4) (the upper surface during manufacturing) are approximately flush.

[0087] Then, as described above, the second step of the laminate formation step of the first embodiment is performed and the member 7 is formed, at which point the member 7 is removed from the base material 5 and the manufacturing process is completed.

[0088] For example, the removal of component 7 from the base material 5 can be done by cutting the main body portion 71A at the base material 5 side.

[0089] Figure 9 is a cross-sectional view showing the state in which the two members 7 of the first embodiment of the present disclosure are connected. Member 7 is provided with a connecting fitting 72 having a pair of through holes 72C through which a bolt B3 passes. By passing the bolt B3 through the through holes 72C and screwing a nut N1 onto the threaded portion (the threaded structure is not visible in Figure 9 as it is a cross-section) that protrudes from the through holes 72C, the two members 7 are connected by fastening the connecting fittings 72 together with the bolt B3 and nut N1.

[0090] According to the manufacturing method of the first embodiment described above, since the joining step of joining the connecting hardware 72 to the laminate 71 is performed on the metal 3D printer 1, there is no need to perform subsequent processes such as drilling holes, and the effort required to provide the connecting structure to the laminate 71 can be reduced.

[0091] In the first embodiment, the joining step was a welding step, but for example, the step may be to bond the surface (bottom surface) of one side of the flange portion 72B (lower side in Figure 4) and the surface (top surface) of the receiving portion 71B using an adhesive for joining metals.

[0092] Furthermore, in terms of improving the fixing strength of the connecting hardware 72 to the laminate 71 and for aesthetic reasons, it is preferable to perform the second step of the laminate formation step in the first embodiment. However, since the joining of the connecting hardware 72 is completed at the stage when the joining step is finished, the second step of the laminate formation step may be omitted if there are no problems with the member 7.

[0093] <<Second Embodiment>> Next, a method for manufacturing a member 7, which is formed by attaching a connecting fitting 72 to a laminate 71 formed by a metal 3D printer 1 according to the second embodiment of this disclosure, will be described with reference to Figure 10.

[0094] The manufacturing method of the second embodiment has the same basic configuration as the manufacturing method of the first embodiment. In the following, we will mainly explain the differences from the first embodiment, and may omit explanations of the similarities.

[0095] Figure 10 is a cross-sectional view illustrating a method for manufacturing a member 7 in which a connecting metal fitting 72 is provided on a laminate 71 formed by a metal 3D printer 1 according to a second embodiment of the present disclosure, and corresponds to Figure 4.

[0096] Although the base material 5 is not shown in Figure 10, the laminate 71 is actually placed on the base material 5 when the manufacturing method is being carried out.

[0097] As can be seen in Figure 10, the member 7 manufactured by the manufacturing method of the second embodiment differs from that of the first embodiment in that it does not have the frame portion 71C and the covering portion 71D shown in Figure 4.

[0098] Therefore, in the first embodiment, the frame portion 71C was formed in the first step of the laminate formation step, and then the joining step was performed. However, in the second embodiment, the receiving portion 71B is formed in the first step of the laminate formation step, and then the joining step is performed.

[0099] In addition, in the second embodiment, the first step of the laminate formation step is omitted, and the second step of the laminate formation step is omitted.

[0100] In the second embodiment, the joining step involves spot welding or full-circumferential welding between the receiving portion 71B and the flange portion 72B. More specifically, a welded portion WL is formed between the other side of the receiving portion 71B (upper side in Figure 10) (the upper surface during manufacturing), which is located outside the flange portion 72B, and the outer circumferential surface of the flange portion 72B.

[0101] In other words, the joining step in the second embodiment involves spot welding or full-circumference welding (so-called fillet welding).

[0102] In the manufacturing method of the second embodiment described above, as in the first embodiment, the joining step of joining the connecting hardware 72 to the laminate 71 is performed on the metal 3D printer 1. Therefore, there is no need to perform drilling or other subsequent processes, and the effort required to provide the connecting structure to the laminate 71 can be reduced.

[0103] <<Third Embodiment>> Next, a method for manufacturing a member 7, which is formed by providing a connecting fitting 72 to a laminate 71 formed by a metal 3D printer 1 according to the third embodiment of this disclosure, will be described with reference to Figure 11.

[0104] Furthermore, the manufacturing method of the third embodiment has the same basic configuration as the manufacturing method of the second embodiment. Below, we will mainly explain the differences from the second embodiment, and may omit explanations of the similarities.

[0105] Figure 11 is a cross-sectional view illustrating a method for manufacturing a member 7 in which a connecting metal fitting 72 is provided on a laminate 71 formed by a metal 3D printer 1 according to the third embodiment of the present disclosure, and corresponds to Figure 10.

[0106] Although Figure 11 omits the illustration of the base material 5, the laminate 71 is actually placed on the base material 5 when the manufacturing method is being carried out.

[0107] As can be seen in Figure 11, the connecting fitting 72 of the third embodiment does not have a flange portion 72B, and only has a pair of through holes 72C provided in the main body portion 72A.

[0108] Accordingly, the receiving portion 71B is formed to protrude inward from the laminated body 71 by a layer with a wider width during lamination, so as to receive the entire outer peripheral portion (hereinafter also referred to as the entire outer peripheral lower surface) of one side (lower side in Figure 11) of the connecting fitting 72.

[0109] Furthermore, in the third embodiment, the joining step involves spot welding or full-circumferential welding between the receiving portion 71B and the connecting fitting 72 (more specifically, the main body portion 72A). More specifically, a welded portion WL is formed between the other side (upper side in Figure 11) of the receiving portion 71B (the upper surface during manufacturing), which is located outside the connecting fitting 72 (more specifically, the main body portion 72A), and the outer circumferential surface of the connecting fitting 72 (more specifically, the main body portion 72A).

[0110] In other words, the joining step in the third embodiment involves spot welding or full-circumference welding (so-called fillet welding).

[0111] In the manufacturing method of the third embodiment described above, as in the first and second embodiments, the joining step of joining the connecting hardware 72 to the laminate 71 is performed on the metal 3D printer 1. Therefore, there is no need to perform subsequent processes such as drilling holes, and the effort required to provide the connecting structure to the laminate 71 can be reduced.

[0112] <<Fourth Embodiment>> Next, a method for manufacturing a member 7, which is formed by providing a connecting fitting 72 to a laminate 71 formed by a metal 3D printer 1 according to the fourth embodiment of this disclosure, will be described with reference to Figure 12.

[0113] Furthermore, the manufacturing method of the fourth embodiment has the same basic configuration as the manufacturing method of the third embodiment. Below, we will mainly explain the differences from the third embodiment, and may omit explanations of the similarities.

[0114] Figure 12 is a cross-sectional view illustrating a method for manufacturing a member 7 in which a connecting metal fitting 72 is provided on a laminate 71 formed by a metal 3D printer 1 according to the fourth embodiment of the present disclosure, and corresponds to Figure 11.

[0115] Although Figure 12 omits the illustration of the base material 5, the laminate 71 is actually placed on the base material 5 when the manufacturing method is being carried out.

[0116] As can be seen in Figure 12, the laminate 71 of the fourth embodiment is provided with a frame portion 71C along the outer circumference of the connecting fitting 72 (more specifically, the main body portion 72A). Therefore, in the first step of the laminate formation step of the fourth embodiment, a layer is also formed on the receiving portion 71B, which becomes the frame portion 71C along the outer circumference of the connecting fitting 72 (more specifically, the main body portion 72A) when the connecting fitting 72 (more specifically, the main body portion 72A) is placed on the receiving portion 71B.

[0117] In the fourth embodiment, the joining step involves spot welding or full-circumference welding between the frame portion 71C and the connecting fitting 72 (more specifically, the main body portion 72A).

[0118] Furthermore, if the joining step involves spot welding, multiple welded joints WL are formed between the frame portion 71C and the connecting hardware 72 (more specifically, the main body portion 72A).

[0119] In the manufacturing method of the fourth embodiment described above, as in the first, second, and third embodiments, the joining step of joining the connecting hardware 72 to the laminate 71 is performed on the metal 3D printer 1. Therefore, there is no need to perform drilling or other subsequent processes, and the effort required to provide the connecting structure to the laminate 71 can be reduced.

[0120] The above description has been based on specific embodiments of this disclosure, but this disclosure is not limited to the embodiments described above.

[0121] For example, not all necessary connection structures can be realized on the metal 3D printer 1, and depending on the form of the connection structure, post-processing may be required to create some of the connection structures.

[0122] However, if a certain degree of connection structure is formed on the metal 3D printer, the effort required to create the connection structure in subsequent processes can be significantly reduced.

[0123] However, the manufacturing method of this disclosure may also be a manufacturing method for manufacturing a specific member 7, that is, a manufacturing method for manufacturing a member 7 in which all necessary connection structures can be formed by joining the connecting hardware 72 to the laminate, thereby enabling all connection structures to be provided on the metal 3D printer 1.

[0124] Furthermore, although the above embodiment shows the case where the laminate 71 is a rectangular cylindrical body, the laminate 71 may also be a cylindrical body, in which case the connecting fitting 72 may also be circular.

[0125] Thus, this disclosure is not limited to the embodiments described above, and modifications and improvements to the embodiments are also included within the technical scope of the invention, which will be clear to those skilled in the art from the description of the claims. [Explanation of Symbols]

[0126] 1...Metal 3D printer, 2...Manipulator, 21...Manipulator base, 22...Swing head, 23...Forearm, 24...Upper arm, 25...Wrist, 26...Swivel head, 3...Base, 4...Table, 5...Base material, 6...Nozzle, 7...Component, 71...Laminate, 71A...Main body, 71B...Receiving part, 71C...Frame, 71D...Cover, 72...Connecting hardware, 72A...Main body, 72B...Flange, 72C...Through hole, B1, B2, B3...Bolt, N1...Nut, RC1, RC2...Rotation center, VA...First axis

Claims

1. A method for manufacturing a component having connecting hardware attached to a laminate formed by a metal 3D printer, The aforementioned manufacturing method is The laminate formation step involves forming the laminate by stacking metal materials using the aforementioned metal 3D printer, The process includes a joining step of joining the connecting hardware to the laminate on the metal 3D printer, A manufacturing method comprising a first step of forming a laminate having a receiving portion for receiving the connecting hardware during the joining step.

2. The aforementioned connecting fitting is provided with a flange on its outer circumference. The manufacturing method according to claim 1, wherein the receiving portion is formed to protrude inward from the laminate so as to receive the flange portion.

3. The manufacturing method according to claim 2, wherein the joining step is a step of welding the receiving portion and the flange portion together by spot welding or full-circumferential welding.

4. In the first step, a layer is also formed on the receiving portion, which forms a frame portion along the outer circumference of the flange portion when the flange portion is placed on the receiving portion. The manufacturing method according to claim 2, wherein the joining step is a step of welding the flange portion and the frame portion together by spot welding or full-circumferential welding.

5. The laminate formation step includes a second step of forming a covering portion that covers the flange portion so as to embed it within the laminate, The manufacturing method according to claim 4, wherein in the second step, a layer is formed on the flange portion and the frame portion, and a layer is formed along the flange portion and the frame portion.

6. The receiving portion is formed to protrude inward from the laminate so as to receive the lower outer surface portion of the connecting fitting. In the first step, a layer is also formed on the receiving portion, which forms a frame portion along the outer circumference of the connecting fitting when the connecting fitting is placed on the receiving portion. The manufacturing method according to claim 1, wherein the joining step is a step of welding the connecting fitting and the frame portion by spot welding or full-circumferential welding.

7. The manufacturing method according to claim 1, wherein the joining step is a step of welding the receiving portion and the connecting fitting by spot welding or full-circumferential welding.

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