Molding system, information acquisition device, light receiving device, and molding method

Abstract

This invention provides a technology that contributes to suppressing the occurrence of manufacturing defects in a three-dimensional object manufacturing device. [Solution] A computing device used in a fabrication apparatus that fabricates a three-dimensional object from a solidified layer formed by heating a powder material by irradiation with energy rays, comprising: a detection unit that determines the state of at least a part of a predetermined region including a molten area where the powder material is melted by heating by irradiation with energy rays; and an output unit that outputs state information based on the state determined by the detection unit in order to change the fabrication conditions of the fabrication apparatus.

Description

Technical Field

[0001] The present invention relates to a shaping system, an information acquisition device, a light receiving device, and a shaping method.

Background Art

[0002] Conventionally, a manufacturing apparatus for a three-dimensional object that manufactures a three-dimensional object by laminating layers in which a powdery substance is solidified by the action of light or the like is known (for example, Patent Document 1). However, there is a risk that defects may occur in the manufactured object.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

[0004] According to a first aspect, there is provided a shaping system for shaping a three-dimensional shaped object by solidifying a powder material melted by irradiation with an energy beam,

[0005] [Figure 1] [Figure 2]

Brief Description of the Drawings

[0005] [Figure 1] It is a block diagram schematically showing the configuration of a shaping apparatus according to a first embodiment. [Figure 2] This diagram schematically shows an example of the specific configuration and arrangement of the optical unit of a 3D printer. [Figure 3] This diagram schematically shows an example of the specific configuration and arrangement of the optical unit for 3D printing in a modified example. [Figure 4] This diagram schematically shows the state of the molten pool on a material layer and its vicinity, which are created when laser light is irradiated onto the material. [Figure 5] This figure schematically shows an example of a temperature image corresponding to the generated temperature image data. [Figure 6] This diagram illustrates the process of determining sputtering from the generated temperature image data. [Figure 7] This diagram illustrates the process of determining Humes from generated temperature image data. [Figure 8] This diagram illustrates the relationship between the molding conditions, the basic conditions of power density, energy density, and temperature distribution, and the parameters related to those basic conditions. [Figure 9] This diagram illustrates the relationship between the molding conditions, the basic conditions of power density, energy density, and temperature distribution, and the parameters related to those basic conditions. [Figure 10] This is a flowchart explaining the process for handling real-time changes. [Figure 11] This is a flowchart explaining the process for handling real-time changes. [Figure 12] This is a flowchart explaining the process for handling real-time changes. [Figure 13] This flowchart explains the process for making changes during the subsequent layer printing process. [Figure 14] This flowchart explains the process for making changes during the subsequent layer printing process. [Figure 15] This flowchart explains the process for making changes during the subsequent layer printing process. [Figure 16] This flowchart explains the process for making changes during the subsequent layer printing process. [Figure 17] This is a schematic block diagram showing the main components of the molding apparatus in a modified example (2) of the first embodiment. [Figure 18] This is a schematic block diagram showing the main components of the molding apparatus and detection system in a modified example (3) of the first embodiment. [Figure 19] This is a schematic block diagram showing the configuration of the molding apparatus according to the second embodiment. [Figure 20] This figure schematically shows an example of the specific configuration and arrangement of the shaping optical unit in the shaping apparatus of the second embodiment. [Figure 21] This is a flowchart illustrating the process performed by the molding apparatus in the second embodiment. [Figure 22] This is a flowchart illustrating the process performed by the molding apparatus in the second embodiment. [Figure 23] This is a follow chart illustrating the process performed by the molding apparatus in the second embodiment. [Figure 24] This diagram schematically shows the cross-sectional shape in the ZX plane of a predetermined amount of powder material that is the target of pre-detection. [Figure 25] This is a flowchart illustrating the process performed by the molding apparatus in the second embodiment. [Figure 26] This is a schematic block diagram showing the main components of the molding apparatus in a modified example of the second embodiment. [Figure 27] This is a schematic block diagram showing the main components of the molding apparatus and detection system in a modified example of the second embodiment. [Figure 28] This is a schematic block diagram showing the configuration of the molding apparatus according to the third embodiment. [Figure 29] This figure schematically shows an example of the specific configuration and arrangement of the optical unit of the third embodiment of the 3D printing apparatus. [Figure 30] This is a flowchart illustrating the process performed by the molding apparatus in the third embodiment. [Figure 31] This is a schematic block diagram showing the main components of the molding apparatus in a modified example of the third embodiment. [Figure 32] This is a schematic block diagram showing the main components of the molding apparatus and detection system in a modified example of the third embodiment. [Modes for carrying out the invention]

[0006] -First Embodiment- The molding apparatus according to the first embodiment will be described with reference to the drawings. So, using the known powder bed fusion (PBF) method, we can fabricate three-dimensional objects (three-dimensional fabricated objects). We will explain using a 3D printing device as an example. Note that powder bed fusion (PBF) is a method that uses powder It is also called Sintering Laser Sintering (SLS). The manufacturing equipment uses powder bed fusion (PB). Not limited to F), directed energy stacking (DED), material jetting method, electron beam melting Equipment that creates three-dimensional objects using other methods such as EBM (Evidence-Based Manufacturing) and Fused Deposition Modeling (FDM). It's also fine to just place it down. First, the configuration of the molding apparatus 1 will be explained with reference to Figures 1 and 2. Figure 1 shows the configuration of the molding apparatus 1. This is a block diagram schematically showing the structure, and Figure 2 shows the specific details of the 35 optics unit 35 of the 3D printer 1. This diagram schematically illustrates an example of a typical configuration and arrangement. It is intended to facilitate understanding. Then, as shown in Figures 1 and 2, using a Cartesian coordinate system consisting of the X, Y, and Z axes, the following Give an explanation.

[0007] The molding apparatus 1 comprises a housing 10, a material layer forming unit 20, a molding unit 30, and a computing unit 50. The material layer forming section 20 includes a material supply tank 21 and a recoater 22. 0 comprises a molding tank 31 and a molding optical unit 35. For the sake of explanation, the material layer forming unit 2 Although the 0 and the molding section 30 are shown separately as different components, the material layer forming section 20 and the molding section 30 are It can also be collectively referred to as the "shaping section."

[0008] The material supply tank 21 contains powder material P, which is the material used to create three-dimensional objects. It is a container for holding the material. The bottom surface 211 of the material supply tank 21 is made up of, for example, a piston. The drive mechanism 212 moves along the vertical direction (Z direction). Bottom surface of the material supply tank 21 As 211 moves toward the Z-direction + side (upward), material supply is adjusted according to the amount the bottom surface 211 rises. The powder material P inside tank 21 is pushed out to the outside, and this pushed-out powder material P will be described later. The material is transferred to the molding tank 31, which will be described later, by the recoater 22.

[0009] The material supply tank 21 has a heater 213 for heating the powder material P contained inside. A heater 213 is provided. The heater 213 is controlled by the computing device 50, which will be described later, so that the powder material P Heat to the desired temperature. Heater 213 uses an existing heating method heater. This can be done. Furthermore, a temperature control element such as a Peltier element may be used for the heater 213. The heater 213 heats the powder material P in the material supply tank 21, thereby creating Before the powder material P is transferred to the molded tank 31 and heated by laser light irradiation (described later), the powder The temperature of the raw material P is increased. This increases the temperature of the powder material P that is heated by the irradiation of the laser light. The amount of heat required to raise the temperature to the desired temperature (e.g., the melting point) decreases. Also, The heater 213 heats the powder material P, which has high moisture absorption and low fluidity, thereby heating the powder material The moisture absorption of material P is reduced and its fluidity is increased. As a result, the powder material P is transferred to the molding tank 31. This makes it easier, and the flatness, thickness, and density of the material layers formed in the way described in detail below are uniform. As a result, as will be explained in detail later, when laser light is irradiated onto the material layer, The temperature rise within the material layer due to irradiation with light becomes uniform. Furthermore, the material supply tank 21 is driven outwards by a drive mechanism 212 from the lower part in the Z direction. It is not limited to what is dispensed. The powder material P contained in the material supply tank 21 It is supplied to a dispenser located below (Z-direction side), and the dispenser is supplied The powder material P is discharged from the bottom (Z-direction side) of the dispenser to the molding tank 31. The powder material P falls onto the plate 311, and the fallen material P is handled by the recoater 22 described later. The material may be spread to a uniform thickness by moving the blade 221.

[0010] As the powder material P, for example, metal powder, resin powder, or metal particles mixed with a resin binder... Powders such as those made from iron are used. Metal powders are powders mainly composed of iron-based powder, or iron-based powders. Among nickel powder, nickel-based synthetic powder, copper powder, copper-based alloy powder, and graphite-based powder, etc. The powder may further contain at least one of the following: for example, iron with an average particle size of about 20 μm. The blending amount of the system powder is 60-90% by weight, and both nickel powder and nickel-based alloy powder are also The proportion of one of the ingredients is 5-35% by weight, and the proportion of both or one of the copper powder and copper-based alloy powder is... Examples include powders containing 5-15% by weight of [the substance] and 0.2-0.8% by weight of graphite powder. For example, polyamide with an average particle size of about 30 μm to 100 μm can be used as the resin powder. Powders such as polypropylene and ABS can be used. A resin binder is applied to metal particles. As a polished powder, for example, the surface of metal particles is coated with additives such as phenolic resin or nylon. A coated version may be used. Furthermore, ceramic powder may be used as the powder material P. It is acceptable to include them. Ceramic powders include oxides such as alumina and zirconia, and nitrides. Nitrides such as ion may also be used as powder. Note that the powder material P may be other materials than those mentioned above. The powder material P may be, for example, an existing metal powder, an existing resin powder, or an existing ceramic powder. Alternatively, you could combine at least two materials, such as existing metals, existing resins, and existing ceramics. A mixture of powdered ingredients may also be used. The following explanation will use the case where metal powder is used as the powder material P as an example.

[0011] The recoater 22 includes a blade 221 as a material layer forming member and a drive mechanism (not shown) It has a blade mounting section (not shown). The blade 221 extends, for example, along the Y direction. It is a plate-shaped component. The blade 221 can be exchanged between multiple types with different materials and shapes. It can be attached to the blade mounting section. The drive mechanism is, for example, a motor or along the X direction. It has a drive mechanism such as an extendable guide rail, which moves the blade mounting section along the X direction. This allows the blade 221 to move along the X direction to position A in Figure 1 (X direction side of the material supply tank 21). Move between the end (edge) and position B (X direction + side end of the molding tank 31). By moving the do 221, the powder material P contained in the material supply tank 21 (more details The amount of rise of the bottom surface 211 of the material supply tank 21 in the Z direction + side (upwards) corresponds to the material supply tank 2 The powder material P) extruded from the outside of 1 is transferred to the molding tank 31 of the molding unit 30, which will be described later. At this time, the blade 221 applies pressure to press the powder material P downwards (towards the Z direction). It moves while adding the powder material P. A powder bed laid out to a constant thickness Δd, with the surface (the side on the Z-direction + side) shaped to be flat. A layer of powdered material called a powder bed (hereinafter referred to as the material layer) is formed. The blade 221 functions as a material layer forming member. A pressing mechanism (not shown) consisting of a dare and the like can apply pressure to the powder material P. ru.

[0012] The blade 221 transfers the powder material P to the top of the solidified layer formed as described later. In this case, the solidified layer is formed by irradiating the previously formed material layer with laser light. After a predetermined time has elapsed, the blade 221 moves again from position A along the X direction. Then, the powder material P is transferred to the top of the solidification layer. In this specification, this predetermined time is used with blades. This is called the waiting time for 221. Note that the constant thickness Δd mentioned above refers to the base plate 3, which will be described later. When the powder material P is transferred onto 11, the surface of the base plate 311 is moved to the surface of the material layer. This is the thickness up to the (Z-direction + side) and the upper part of the solidified layer (Z-direction) which is formed as described later. When the powder material P is transported in the direction of the positive (+) side, from the upper surface of the solidified layer (the surface on the positive (+) side in the Z direction) This is the thickness from the top of the solidified layer to the surface (the Z-direction + side) of the material layer formed on top of it. The moving speed of the blade 221 and the pressure applied to the powder material by the blade 221 are as described above. The waiting time of the blade 221 is controlled by the computing unit 50. The formation of the layers will be described in detail later. In this embodiment, a plate-shaped blade 221 is given as an example of a material layer forming member. As explained, the material layer forming member can be used to form rollers and other material layers. Any member is acceptable. For example, if a roller is used as a material layer forming member, the roller is The rotation axis is mounted so as to be aligned with the Y-axis direction, and moves along the X-direction by the drive mechanism. When moving, it rotates. This allows the roller to apply pressure to the powder material P. Then, the powder material P is spread into the molding tank 31 to a constant thickness Δd.

[0013] The molding tank 31 of the molding unit 30 is used for forming a material layer and solidifying the formed material layer. By repeatedly shaping and stacking multiple solidified layers along the Z-direction, a three-dimensional shape is created. This is a container for shaping objects. The solidification layer in this embodiment will be described later. As described above, the powder material P that forms the material layer is heated by irradiation with laser light, and the powder material This is a layer formed by the melting and solidification of material P. The base plate 3 is the bottom surface of the molding tank 31. 11 is a support member that supports the formed material layer and the solidified layer from the Z-direction side. The plate 311 is driven by a drive mechanism 312, such as a motor, included in the molding tank 31. It moves along the downward direction (Z direction). As will be described in detail later, on the base plate 311 The material layer formed from the supplied powder material P is heated by laser irradiation to solidify the layer. Once formed, the base plate 311 moves downward (towards the Z-direction), and then the solidified layer A new material layer is formed on the upper surface (Z-direction + side). This new material layer solidifies. A new solidified layer is formed. The base plate 311 consists of multiple plates with different materials and thicknesses in the Z direction. It is attached to the molding tank 31 in a way that allows interchangeability between different types of plates. In other words, The molding tank 311 is interchangeable between multiple types of plates with different rigidities. It could also be said that it is attached to it.

[0014] The base plate 311 has a heater 313 for heating the base plate 311. It is provided. The heater 313 is controlled by the calculation unit 50, which will be described later, and the base plate The material layer and solidified layer supported by the 311 are heated (preheated) to the desired temperature. The heater 313 uses an existing heating method. A temperature control element such as a Peltier element may be used. This heater 313 is located inside the molding tank 31. The material layer and solidification layer are heated (preheated). The heater 313 heats the powder material P that makes up the material layer. Before being heated by laser irradiation, the powder material P is preheated to raise its temperature. As a result, the temperature of the powder material P heated by the laser beam reaches a desired temperature (e.g., melt). The amount of heat required to rise to the point is reduced. Also, the heater 313 is molded The solidified layer is heated. This suppresses the generation of residual stress during the cooling of the solidified layer. This relieves residual stress that has accumulated in the solidified layer.

[0015] The molding optical unit 35 of the molding unit 30 includes an acquisition unit 310, an illumination unit 32, a scanning unit 33, and It has a casing lens 323. The acquisition unit 310 is divided into two parts with the imaging device 41, which will be described in detail later. The branch optical system 42, the chromatic aberration correction optical system 43, the half mirror 301, and the field aperture 302 The acquisition unit 310 includes a predetermined region (powder material P) that contains the molten portion where the powder material P is melted. The molten part, the unmelted powder material P (material layer), and the solidified part after melting. At least some information from the solidified area (details will be described later) will be obtained. The radar 301 is connected to the acquisition unit 310 in accordance with the arrangement of each component of the molding optical unit 35, which will be described in detail later. It does not need to be included.

[0016] Here, the acquisition unit 310 is integrally configured with the irradiation unit 32 and the scanning unit 33, For the sake of clarity, it will be described as part of the 35th molding optics unit (i.e., part of the 30th molding unit). Meanwhile, the acquisition unit 310 is a component of the molding unit 30 other than the acquisition unit 310 (i.e., the molding tank). 31, illumination unit 32, focus lens 323, and scanning unit 33) have different functions (described later) To obtain information on at least a portion of a predetermined region including the molten area where the powder material P is melted. Since it has a configuration that includes the function of, it can also be represented as a separate configuration from the molding unit 30. In this case, the molding unit 30 has an illumination unit 32, a scanning unit 33, and a focus lens 323. The configuration includes a molding optical unit 35 and a molding tank 31. In this case, half-million Since the 301 is also part of the 35-form optics unit, it is not part of the acquisition unit 310, but rather part of the 35-form optics unit. It can also be represented as a composition of 35.

[0017] The irradiation unit 32, as an example, uses laser light as irradiation light for heating the material layer. A laser oscillator 321 that emits light, and the laser light emitted from the laser oscillator 321 is converted into parallel light. Includes a collimator lens 322 for collimation (see Figure 2). Laser oscillator 321 For example, carbon dioxide lasers, Nd:YAG lasers, and fiber lasers can be used. be. The laser oscillator 321 consists of, for example, a resonator mirror and is filled with an increasing amount of laser energy. It has a beam chamber and an excitation light source. The laser medium is excited by the light from the excitation light source and emits light. The light, after repeated reflections within the amplifier, oscillates and is converted into laser light from the laser oscillator. The laser oscillator 321 uses excitation light as the oscillation mode (oscillation form) of the laser light. Continuous wave (CW) oscillation, which continuously lights the power source, and pulsed illumination of the excitation light source, The output waveform of the laser beam is controlled by electrically controlling the illumination time and current value. Q-switches emit pulsed laser light with a narrow pulse width and high peak output over a short period of time. This includes pulse oscillation, etc. The laser oscillator 321 is, for example, a laser with a wavelength of 1070 nm. It emits light. Note that the laser oscillator 321 emits light of other wavelengths, for example, 800 nm or higher. Large infrared light, visible light in the range of 400nm to 800nm, and ultraviolet light shorter than 400nm It may emit light. The specific configuration of the irradiation unit 32 will be explained later. The irradiation unit 32 is controlled by the computing device 50, and uses a known shape-variable mirror or the like to emit rays. The intensity distribution of the laser light from the oscillator 321 is compared between a Gaussian distribution and a top-hat distribution, etc. Switch and fire. Furthermore, the irradiation unit 32 can use existing light-emitting diodes (LEDs), electron beams, or ray beams instead of laser light. The powder material P may be heated by irradiating the material layer with existing particle beams such as sub-beams or neutron beams. In this embodiment, the irradiation unit 32 is an existing laser beam, an existing light-emitting diode, or an existing This applies to devices capable of emitting energy rays, including particle beams, etc.

[0018] The scanning unit 33 is composed of a galvanometer mirror and measures the laser light emitted from the irradiation unit 32. The scanning unit 33 scans along at least one of the X and Y directions on the material layer. The specific configuration will be explained later.

[0019] The imaging device 41 captures the molten portion of the material layer that has been irradiated and melted by the laser light from the irradiation unit 32. A predetermined area in the vicinity is imaged to capture an image of the predetermined area including the molten part of the material layer and its vicinity. Image data is generated. The generated image data includes a predetermined area of ​​the material layer, including the molten portion and its vicinity. The signal intensity of each pixel obtained by photoelectric conversion of light from the region by the image sensor 411 described later is Yes. The generated image data is output to the processing unit 50, which will be described later. The specific structure of item 1 will be explained later. As mentioned above, the molding optics unit 35 has a configuration that irradiates the material layer with laser light, and the material layer Since it shares some components with the configuration for capturing the image, it can also be called an imaging optical system.

[0020] The housing 10 includes a material supply tank 21, a recoater 22, and a molding tank 31 in which the solidified layer is contained. It houses inside. Furthermore, one of the drive mechanisms 212 that moves the bottom surface 211 of the material supply tank 21 The housing 10 It does not have to be housed inside the housing. The housing 10 is formed with an air intake port 11 and an exhaust port 12. The intake port 11 is filled with a tank 13 containing an inert gas such as argon or nitrogen. It is connected via an intake device 131 such as a valve. The exhaust port 12 is connected to, for example, a vacuum pump. An exhaust system 14 equipped with the following is connected. The exhaust system 14 and intake system are controlled by the computing unit 50. 131 refers to exhausting the inside of the housing 10 so that the set pressure inside the housing 10 is achieved. Furthermore, the intake device 131 introduces the inert gas filled in the tank 13 into the interior of the housing 10. This lowers the oxygen concentration inside the enclosure 10. As the oxygen concentration inside the enclosure 10 decreases, the powder The oxidation of the raw material P is prevented. Flow rate and flow rate of the inert gas introduced into the housing 10 This is controlled by the opening degree of the valve of the intake device 131 and the exhaust volume of the exhaust device 14. 10 is provided with a heater 15 that heats the inside, and is controlled by a computing device 50 which will be described later. The inside of the enclosure 10 is heated to the desired temperature. The heater 15 is an existing heating A heater of this type is used. Furthermore, the heater 15 is a temperature control element such as a Peltier element. This may be used. This heater 15 heats the inside of the housing 10, thereby heating the molding tank 3 Heats the material layer and solidified layer inside. Heater 15 heats the powder material P that makes up the material layer. The temperature of the powder material P is raised beforehand before it is heated by irradiation with light. This is necessary because the temperature of the powder material P irradiated with light rises to the desired temperature (e.g., melting point). The amount of heat is reduced.

[0021] As described above, the oxygen concentration inside the housing 10, the flow rate and velocity of the inert gas, and the inert gas The atmosphere inside the housing 10, including the type, pressure inside the housing 10, and temperature inside the housing 10, is controlled. Furthermore, in order to allow the laser light from the irradiation unit 32 to pass through, the upper surface (Z direction + side) of the housing 10 At least a portion of this area is formed of a light-transmitting material such as glass. Some areas are, for example, areas that intersect with the optical path of the laser beam traveling from the scanning unit 33 onto the material layer. It is a region.

[0022] Here, we will explain an example of the specific configuration and arrangement of the 35 molding optics unit with reference to Figure 2. do. As shown in Figure 2, the laser emitted from the laser oscillator 321 of the irradiation unit 32 was directed toward the Z-direction. The laser light is reflected towards the X-direction + side by the half mirror 301 and then into the focus lens 323. The laser beam passes through and enters the scanning unit 33. The direction of emission of the laser beam from the irradiation unit 32 is the Z direction. The direction in which the half-mirror 301 reflects the laser light is not limited to the - side, but is limited to the X direction + side. It is not possible. The position where the irradiation unit 32 is located, the position of the material layer and / or the molding optical unit 35 Based on the relationship with the positions where other components are placed, the laser beam emission direction and the half mirror 30 The reflection direction of 1 is determined to be in a direction that is as favorable as possible.

[0023] The focusing lens 323 has a concave lens 323a and a convex lens 323b. (Details will be provided later.) The galvanometer mirrors 331 and 332 adjust the focal position (focal length) of the laser beam reflected by them. Therefore, the concave lens 323a is controlled by the computing unit 50 and driven by a drive mechanism (not shown) in the X direction. It is configured to be movable along the X direction. Therefore, the position of this concave lens 323a in the X direction The beam diameter (spot size) of the laser beam on the material layer can be adjusted accordingly. In this case, The drive of the galvanometer mirrors 331 and 332 described above (i.e., galvanometer mirrors 331 and 332 Due to the change in angle, the distance the laser beam travels to reach the surface of the material layer varies. The focus lens 323 concentrates the laser light reflected by the galvanometer mirrors 331 and 332. In accordance with the movement of the galvanometer mirrors 331 and 332, the light spot and the surface of the material layer are aligned. The focal point of the laser beam can be adjusted.

[0024] Furthermore, the focusing point of the laser beam and the material are not necessarily determined by the driving of the galvanometer mirrors 331 and 332. The focal position of the laser beam does not need to be adjusted to align with the surface of the layer. For example, a material layer The laser beam diameter (spot size) is changed for each laser beam irradiation position shown above. In addition, the drive of galvanometer mirrors 331 and 332 (change in angle of galvanometer mirrors 331 and 332) ) In accordance with this, the position of the concave lens 323a is determined by a drive mechanism (not shown) controlled by the computing device 50. The convex lens 323a does not necessarily have to be configured to be movable. The lens 323b may be configured to be movable in the X direction by a drive mechanism not shown, Both the concave lens 323a and the convex lens 323b are driven in the X direction by a drive mechanism not shown. It may be configured to be movable. Also, the focus lens 323 is a concave lens 323a It does not have to be a so-called Galilean type, including the convex lens 323b; other existing optical systems can be used. It is also possible to do so. Furthermore, the concave lens 323a and convex lens 323b of the focus lens 323 move in the X direction. Not limited to those that can be configured. The position in which the focus lens 323 is positioned and the construction Based on the relationship with the positions in which the other components of the optical unit 35 are arranged, the concave lens 323a and the convex lens The direction of movement of lens 323b is determined to be in a direction that is as desirable as possible.

[0025] The scanning unit 33 has galvanometer mirrors 331 and 332. The galvanometer mirror 331 is It is positioned at a predetermined angle of inclination with respect to the Z-axis. The tilt angle is changed by control from the calculation unit 50. The galvanometer mirror 331 is - The laser beam traveling from the cass lens 323 towards the X direction (+) is directed more towards the Z direction than the galvanometer mirror 331. The light is reflected towards the galvanometer mirror 332 located on the positive side.

[0026] The galvanometer mirror 332 is positioned at a predetermined angle of inclination with respect to the XY plane. The tilt angle of the vanomirror 332 with respect to the XY plane is changed by control from the computing unit 50. The laser light reflected by the galvanometer mirror 331 is then reflected by the galvanometer mirror 332. , guided to the surface of the material layer. The tilt angle of the galvanometer mirror 331 with respect to the Z axis, and the galvanometer By changing the tilt angle of mirror 332 with respect to the XY plane, the laser light is irradiated. The position on the material layer moves along at least one of the X and Y axes. This causes, The position on the material layer irradiated by the laser light can be moved, or scanned, on the XY plane. can. Furthermore, the arrangement of galvanometer mirrors 331 and 332, and the laser beam emitted by galvanometer mirror 331. The reflection direction is not limited to the arrangement and reflection direction described above. The position in which the scanning unit 33 is positioned and Based on the relationship with the positions in which the other components of the shaping optics unit 35 are arranged, the galvanometer mirror 331 The arrangement of 332 and the direction of reflection of the laser light by the galvanometer mirror 331 are appropriately preferred. It is determined so that it is the direction of reflection.

[0027] As the scanning angle amount set by the galvanometer mirrors 331 and 332 above increases, the laser light The scanning distance increases. The scanning distance is the position on the material layer irradiated by the laser light (irradiation position). This is the distance the irradiation position moves when the object moves on the XY plane. Also, galvanometer mirror 331 As the rate at which the tilt angle of 332 is changed increases, the scanning speed of the laser beam increases. Velocity refers to the speed at which the irradiation position on the material layer moves along the XY plane. The arithmetic unit 50 controls the scanning angle and change speed of the galvanometer mirrors 331 and 332. This controls the scanning distance and scanning speed of the laser beam. The angle of tilt of the galvanometer mirrors 331 and 332 determines the irradiation position of the laser beam on the surface of the material layer. The position is determined. When imaging is performed by the imaging device 41 described later, the generated image data The irradiation position information and time information are associated and stored in the storage unit 58. The report contains information indicating the irradiation position of the laser beam. As mentioned above, the irradiation position of the laser beam is Gal Since it moves according to the tilt angle of the vanomirrors 331 and 332, it is detected by an encoder or the like. Based on the tilt angles of the galvanometer mirrors 331 and 332, the irradiation position of the laser beam on the material layer is determined. The following is calculated. In addition, the irradiation position information associated with the image data is the galvanometer mirror 33 1. The tilt angle may be 332. Time information is based on the start of laser light irradiation. This is time information indicating the timing at which imaging was performed by the imaging device 41.

[0028] Furthermore, the scanning unit 33 is composed of the galvanometer mirrors 331 and 332 described above. It is not limited to this. For example, the scanning unit 33 moves the base plate 311 of the molding tank 31 in the X direction. This may be configured by a drive mechanism that moves along at least one of the Y and Y directions. In this case, the drive mechanism includes a motor and guide rails extending in the X direction and guide rails extending in the Y direction. It is composed of a rod, etc., and moves the base plate 311 on the XY plane. This allows, The relative positional relationship between the laser beam irradiation position and the material layer on the XY plane is changed, and the laser beam The laser is scanned on the material layer. In this case, the laser is provided by the galvanometer mirrors 331 and 332 described above. The movement of the irradiation position in the XY plane of light and the movement of the base plate 311 cause the X of the material layer The laser beam may be scanned by movement in the Y-plane. The tilt angles of the galvanometer mirrors 331 and 332 are fixed, and the movement of the base plate 311 The laser beam may be scanned by moving only the material layer in the XY plane. The relative position of the laser beam and the base plate 311 (i.e., the material layer) on the XY plane. The configurations that change the spatial relationships are not limited to the above-mentioned configurations; other existing configurations can also be applied. ru.

[0029] A predetermined region on the material layer that includes the molten portion where the powder material P is melted (where the powder material P is melted) The molten part, the unmelted powder material P (material layer), and the solidified part after melting. Light from at least a portion of a region (hereinafter referred to as thermal radiation for convenience of explanation) The laser light travels in the opposite direction along a coaxial optical path. That is, the thermal radiation travels from the surface of the material layer in the Z direction. It moves toward the positive side and is reflected toward the galvanometer mirror 331 by the galvanometer mirror 332. Then, it is reflected in the X-direction-side by the galvanometer mirror 331. From a predetermined region that proceeds in the X-direction-side The light enters the focusing lens 323 and passes through the convex lens 323b and the concave lens 323a. Then, it becomes a parallel beam of light. The thermal radiation that has passed through the focusing lens 323 is directed towards the half mirror 3 The laser light passes through 01, travels toward the X-direction, and enters the chromatic aberration correction optical system 43. The optical element that reflects and transmits thermal radiation does not have to be a half-mirror. For example, a dike Existing optical components such as lock mirrors may also be used.

[0030] The chromatic aberration correction optical system 43 is activated by the thermal radiation generated when the light passes through the focusing lens 323. It corrects axial chromatic aberration, lateral chromatic aberration, etc. The chromatic aberration correction optical system 43 is the first lens 431 This includes a second lens 432 and a third lens 433, arranged in this order from the X-direction + side. The first lens 431 and the second lens 432 are composed of a convex lens and a concave lens, respectively. It is a cemented lens made by combining two lenses. The first lens 431 has a positive refractive index, and the second lens 432 The first lens has a negative refractive index, and the third lens has a positive refractive index. The first lens 431 and the second lens 432 refers to the thermal radiation light that passes through the half-mirror 301 and is incident on the X direction in the state of a parallel beam. - The light beam is directed into the third lens 433 on the - side, and the third lens 433 focuses this parallel light beam to form a primary image. A plane is formed. To prevent axial chromatic aberration and lateral chromatic aberration from occurring on this primary image plane, the first lens 4 The dispersion between 31, the second lens 432, and the third lens 433 is determined. In this case, the first lens The chromatic aberration contained in the thermal radiation light transmitted through lens 431 and the second lens 432 is reflected in the third lens 4 The dispersion of each lens is determined such that it is canceled out by the chromatic aberration caused by the 33 light-gathering elements. Yes, they are. Furthermore, the first lens 431, second lens 432, and third lens 43 of the chromatic aberration correction optical system 43 The arrangement of 3 is not limited to those arranged along the X direction. Based on the position and the relationship between the position and the position where the other components of the shaping optical unit 35 are arranged, the first lens 4 31. The direction in which the second lens 432 and the third lens 433 are positioned will be a suitably preferred direction. It can be decided that way.

[0031] A field diaphragm 302 is positioned on the primary image plane. Thermal radiation is directed through an opening provided in the field diaphragm 302. By passing through the opening with the X-direction facing the X-side, the light beam incident on the imaging device 41, which will be described later, is formed The field of view of the image (image data) generated is limited. In this embodiment, the field of view aperture The aperture 302 generates an image (image data) of a predetermined region including the laser beam irradiation position. The size of the aperture is determined in this way. As a result, images outside a predetermined area on the material layer are not captured. It is suppressed from being included in the image (image data). The thermal radiation that passes through the field aperture 302 The light then enters the bifurcated optical system 42, which is located on the X-direction side of the field aperture 302.

[0032] The bifurcated optical system 42 includes an objective lens 421, a light beam splitting section 422, and a light beam deflection section 423. 424, light beam combining unit 425, imaging lens 426, first filter 427, second filter It has a 428. The objective lens 421 is a collimating lens, and the field aperture 302 The arriving thermal radiation is collimated into parallel light. The light beam splitting section 422 is, for example, dichroic. It consists of components such as a back mirror and a beam splitter, which transmit a beam of light of a specific wavelength from the thermal radiation. It passes through and reflects light beams other than specific wavelengths. In this embodiment, the light beam splitting section 422 is incident Of the thermal radiation, light with wavelength λ1 is transmitted to the first filter 42 located on the X-side. It guides the light to 7, reflecting the light with wavelength λ2 and directing it to the light beam deflection section 423 located on the Z-direction + side. The beam deflection section 423 is composed of, for example, a dichroic mirror, and the wavelength is λ2. The light is reflected and guided to the second filter 428 located on the X-direction side. Let's say wavelength λ1 is, for example, 1250 [nm], and wavelength λ2 is, for example, 1600 [nm]. The explanation will be given assuming that [m] is the case, but the wavelengths λ1 and λ2 are not limited to the above values. stomach.

[0033] The first filter 427 is a bandpass filter that transmits light with a wavelength of λ1. Light with wavelength λ1 that has passed through the split section 422 passes through the first filter 427 and is on the X-side The light beam is incident on the positioned light beam deflection unit 424. The second filter 428 transmits light with a wavelength of λ2. This is a bandpass filter that causes the following: Light with wavelength λ2 reflected by the beam deflection section 423 is second The light passes through the filter 428 and enters the light beam combining unit 425. The light beam deflection unit 424 is, for example, It is composed of dichroic mirrors, etc., and the reflective surface of the light beam is at a predetermined inclination angle with respect to the XY plane. They are arranged so that they are in a specific direction.

[0034] The light beam combining section 425 is composed of, for example, a dichroic mirror, and the reflective surface of the light beam It is positioned so as to be at a predetermined inclination angle with respect to the XY plane. The light beam is reflected by the light beam deflection unit 424. Light with a wavelength of λ1 travels toward the Z-direction (+ side), passes through the light beam combining unit 425, and forms an image lens. The light is focused by the 426 and incident on the imaging device 41. The wavelength incident on the light beam combining unit 425 is The light from λ2 is reflected by the light beam combining unit 425 and then travels toward the Z-direction + side, forming the image lens. The light is focused by 426 and incident on the imaging device 41. Here, the reflective surface of the light beam deflection unit 424 The tilt angle and the tilt angle of the reflective surface of the light beam combining unit 425 are arranged to be at different angles from each other. Therefore, the wavelength of light from the beam deflection unit 424 is λ1, and the wavelength of light from the beam combining unit 425 is also used. Light with a wavelength of λ2 is incident on the imaging lens 426 at a different angle, as will be explained later. The imaging device 41 focuses light at different positions on the imaging surface of the image sensor 411.

[0035] In this embodiment, the reflective surfaces of the light beam deflection unit 424 and the light beam combining unit 425 are in the XY plane and The angle between them can be changed. That is, the angle between the light beam deflection unit 424 and the light beam combining unit 425 A drive mechanism (not shown) for driving the firing plane is provided, and the drive mechanism is controlled from the computing unit 50. Therefore, the reflective surfaces of the light beam deflection unit 424 and the light beam combining unit 425 are driven so that the reflective surfaces are in the XY plane. The angle between them is changed. This changes the angle between the light of wavelength λ1 and the light of wavelength λ2 on the image sensor 411. The incident position is changed in real time.

[0036] Furthermore, the reflective surface of the light beam splitting section 422 and the reflective surface of the light beam deflection section 423 are in the XY plane. The angle between them may be configured to be changeable. That is, the reflective surface of the light beam splitting section 422 and the light A drive mechanism (not shown) is provided to drive the reflective surface of the beam deflection unit 423, and the drive mechanism is a calculation unit According to the control from position 50, the reflective surface of the light beam splitting section 422 and the reflective surface of the light beam deflection section 423 are The angle at which the reflective surface makes contact with the XY plane may be changed by driving the mechanism. Also, the reflection of the light beam splitting section 422 The example is not limited to cases where the surface and the reflective surface of the luminous beam deflection section 423 are driven by a drive mechanism, but rather the luminous beam component Even if the reflective surface of the split section 422 and the reflective surface of the light beam deflection section 423 are manually adjusted by the user, Good. This manual adjustment is, for example, when setting up the device after delivering the molding device 1, This is performed during maintenance of molding device 1. Furthermore, the arrangement of each component of the bifurcated optical system 42 and the reflection direction of the thermal radiation are determined by the arrangement and reflection described above. It is not limited to the direction of emission. The position in which the bifurcated optical system 42 is arranged and the other configuration of the molding optical unit 35 Based on the relationship with the position where the components are arranged, the arrangement of each component of the bifurcated optical system 42 and the thermal radiation The reflection direction is determined to achieve a suitable arrangement and reflection direction as appropriate.

[0037] The imaging device 41 includes an image sensor 411, which is composed of, for example, a CMOS, CCD, etc., and A readout circuit that reads out the image signal converted by photoelectric conversion in the image sensor 411, and a drive circuit for the image sensor 411. It has a control circuit and the like that controls the imaging device 41. The thermal radiation incident on the imaging device 41 is directed to the imaging lens 426 This concentrates the light onto the imaging surface of the image sensor 411. The imaging device 41 converts the incident light beam into photoelectric form. Then, image data is generated and output to the arithmetic unit 50. As described above, the tilt angle of the reflective surface of the light beam deflection section 424 and the reflective surface of the light beam combining section 425 The inclination angles are arranged to be different from each other. Therefore, the predetermined area of ​​the material layer Of the thermal radiation from the region, the light of wavelength λ1 reflected by the beam deflection unit 424 and the beam synthesis unit 4 The light of wavelength λ2 reflected at 25 is incident on the imaging lens 426 at a different angle. As a result, the light is focused at different positions on the imaging surface of the image sensor 411. That is, a predetermined position of the material layer Images of two different wavelengths of thermal radiation from a region are projected onto the same image. They appear in different positions (on the same image data).

[0038] Furthermore, as mentioned above, the angle that the reflective surfaces of the light beam deflection sections 422 and 423 make with the XY plane, The angle between the reflective surfaces of the light beam deflection unit 424 and the light beam combining unit 425 and the XY plane can be changed. Therefore, the computing unit 50 determines that the reflective surfaces of the light beam deflection unit 424 and the light beam combining unit 425 are in the XY plane. By controlling the angle between the two, the light with wavelength λ1 of the thermal radiation is directed onto the image sensor 411. The relative position between the light-collecting position and the position where light of wavelength λ2 is collected on the image sensor 411. This allows for adjustment of the relationship. As mentioned above, the reflective surface of the luminous beam splitting section 422 and the luminous beam splitting section If the angle with respect to the reflective surface of the forward section 423 can be changed, the reflective surface of the luminous beam splitting section 422 and the luminous beam By changing the angle between the deflection section 423 and the reflective surface, the light of wavelength λ1 and wavelength λ2 can also be changed. This allows for adjustment of the position at which the light is collected on the image sensor 411.

[0039] Having the above-described configuration shown in Figure 2, the optical system for irradiating laser light and The optical system for imaging with the imaging device 41 is arranged coaxially. This simplifies the design and prevents the device from becoming larger. Furthermore, the provision of the bifurcated optical system 42 allows light of two different wavelengths, λ1 and λ2, to be transmitted. The light is focused at different positions on the image sensor 411. That is, the molten liquid in the powder material P A predetermined region including the molten part (the molten part where the powder material P is melted, and the unmelted powder that has not yet melted) Two rays of thermal radiation with different wavelengths from the base material P (material layer, region solidified after melting, etc.) Each resulting image appears at a different position on the same image (on the same image data). (See below for further details.) The detection unit 54 of the calculation device 50 uses a known two-color method, described later, to find this identical image (identical image) The ratio of the brightness information of images at different positions on the image data is obtained by melting the powder material P. A predetermined region including the molten portion (the molten portion where the powder material P is melted, and the unmelted portion where it is not yet melted) Convert the temperature of the molten powder material P (material layer, region solidified after melting, etc.) to this. Here, brightness The information refers to brightness values ​​and values ​​related to brightness. In the material layer irradiated with laser light, the details are later As described above, the region in which the powder material P has melted and the region in which the powder material P has not melted are Because there are regions that solidify after melting, the phase states are different. Therefore, a predetermined region of the material layer Within the system, the emissivity of light differs depending on the phase state. Furthermore, the emissivity of light also varies depending on the type of powder material P. They are different.

[0040] Furthermore, as will be explained in detail later, the powder material P melts when irradiated with laser light. Fumes are generated from the area where they are located. Fumes are heated by laser irradiation and turn into powder material. P turns into vapor, and that vapor cools in the air, becoming a solid and floating in the air as numerous fine particles. Therefore, thermal radiation containing two wavelengths is attenuated by scattering by Hume. However, two-color In the law, the luminance information of image data generated based on light of wavelength λ1 and light of wavelength λ2 Based on the ratio of the luminance information of the image data generated based on (for example, the ratio of luminance values), Since it is converted to temperature, a predetermined region of the powder material P that includes the molten part (powder material P The molten part, the unmelted powder material P (material layer), and the solidified part after melting. The emissivity of solid regions, etc., and thermal radiation containing two wavelengths are affected by scattering by Humes. No. Therefore, based on the image data generated by the imaging device 41, the laser light is irradiated. The state of the powder material P, and information regarding the temperature of the material layer without being affected by fumes, etc. The report is obtained.

[0041] Note that the configuration and arrangement of the 35 shaping optics unit are not limited to the example shown in Figure 2 above. For example, the acquisition unit 310 has two imaging devices 41, and one of the imaging devices captures thermal radiation. The first imaging device captures light of wavelength λ1, and the second imaging device captures light of wavelength λ2 from the thermal radiation. Good. The imaging plane of the image sensor in one imaging device is parallel to the YZ plane, and the other imaging device The two imaging devices are arranged so that the imaging planes of the image sensors are parallel to the XY plane. The bifurcated optical system 42, as shown in Figure 2, includes a light beam splitting section 422, a first filter 427, and a second It has a filter 428. Also, the field aperture 302 shown in Figure 2 is not provided. Chromatic aberration correction The third lens 433 of the normal optical system 43 is positioned in front of each of the two imaging devices 41. That is, between the second lens 432 and the third lens 433 of the chromatic aberration correction optical system 43, The first filter 427, the second filter 428, and the light beam splitting unit 422 of the branched optical system 42 are arranged It is placed. It passes through the first lens 431 and the second lens 432 of the chromatic aberration correction optical system 43. The luminous beam is transmitted by the luminous beam splitter 422, and the light with wavelength λ1 is transmitted through the first filter 427. It moves toward the X-direction and is focused onto the image sensor of one of the imaging devices by one of the third lenses 433. The light of wavelength λ2 reflected by the beam splitter 422 travels towards the Z-direction + side, and is then filtered by the second filter 4 The light passes through 28 and is focused onto the image sensor of the other imaging device by the other third lens 433. This allows each imaging device to generate image data for different wavelengths. ru.

[0042] Furthermore, the acquisition unit 310, for example, instead of the bifurcated optical system 42 shown in Figure 2, acquires the transmitted light A filter with switchable wavelengths may be used. This filter is part of the chromatic aberration correction optical system 43. A region positioned between the second lens 432 and the third lens 433 that transmits light of wavelength λ1 ( The filter has a first region and a second region that transmits light of wavelength λ2. The first region and the second region are alternately inserted into the optical path of the thermal radiation at predetermined time intervals. For example, a disc-shaped component (turret) is equipped with multiple filters with different wavelength transmittances. The turret's surface is positioned parallel to the YZ plane, and the turret's center is moved by a drive mechanism (not shown). It is configured to be rotatable as the center of rotation. For example, a turret can have multiple elements with different wavelength transmittances. Assuming that a first filter and a second filter are provided as filters, the drive mechanism As the turret rotates, the first and second filters are activated at time intervals corresponding to the rotation speed. The first filter is inserted alternately into the optical path of the thermal radiation. While it is being used, the light with wavelength λ1 of the thermal radiation is transmitted through the third lens 433 to the imaging device. The light is focused onto the 41 image sensor 411, and while the second filter is inserted in the optical path, the wavelength λ2 The light passes through and is focused onto the image sensor 411 by the third lens 433. As a result, the turret At time intervals corresponding to the rotation speed of the net, the imaging device 41 generates an image based on light of wavelength λ1. This process involves generating data and generating image data based on light of wavelength λ2. In this case, The field diaphragm 302 shown in Figure 2 is not provided. As a result, the imaging device 41 does not have to capture images at different wavelengths. Image data can be generated at time intervals corresponding to the rotation speed of the turret. Alternatively, on the image sensor 411 of the imaging device 41, the arrangement of pixels constituting the image sensor 411 Accordingly, even if filters are placed to select wavelengths λ1 and λ2, Good. In this case, the bifurcated optical system 42 and field diaphragm 302 shown in Figure 2 are not provided. This makes it possible to generate image data at wavelengths λ1 and λ2.

[0043] Alternatively, as shown in Figure 3(a), the focal position of the laser beam on the material layer can be adjusted. The focal position of the synchrotron radiation from the material layer on the image sensor 411 is adjusted using a focus lens 324. It may also have a second focusing lens 325 for adjusting the first focusing lens 324 and The second focusing lens 325 is a concave lens of the focusing lens 323 shown in Figure 2. Convex lens 324a, 325a, and convex lens 324b are similar to lens 323a and lens 323b. It has 325b. In the example shown in Figure 3(a), the laser beam from the laser oscillator 321 travels towards the Z+ direction, The light passes through the focus lens 324 and the half mirror 301 before entering the scanning unit 33. The thermal radiation is incident on the half mirror 301 via the scanning unit 33, and the half mirror 301 It is reflected and propagates towards the Z-direction + side. The thermal radiation passes through the second focus lens 325, as shown in Figure 2. The chromatic aberration correction optical system 43, which has a configuration similar to that shown, is passed through to the bifurcated optical system 42. It is incident. The bifurcated optical system 42 also has the same configuration as shown in Figure 2, so the thermal radiation is 2 The light is split into two wavelengths, and each wavelength of light is on a different image sensor 411 of the imaging device 41. It focuses the light at the desired position.

[0044] Furthermore, the laser oscillator 321 and the first focus lens 324 are arranged along the Z direction. The second focusing lens 325, the chromatic aberration correction optical system 43, and the bifurcated optical system 42 are in the X direction They may be arranged along the lines. In other words, in the example shown in Figure 3(a), the acquisition unit 310 is divided into two parts with the imaging device 41. The cross optical system 42, the chromatic aberration correction optical system 43, the second focusing lens 325, and the half mirror -301 has. As a result, the acquisition unit 310 has molten powder material P A predetermined region including the part (the molten part where the powder material P is melted, and the unmelted powder that has not yet melted) Information about material P (material layer, region solidified after melting, etc.) is obtained. Furthermore, the acquisition unit 310 has a different function from the configuration of the molding unit 30 other than the acquisition unit 310 (powder (A function that acquires information on at least a portion of a predetermined area including the molten part where the end material P is melted.) Since it has a configuration that includes this, it is represented as a separate configuration from the molding unit 30 (molding optics unit 35). It is also possible to do so. In this case, the half-mirror 301 is also part of the shaping optics unit 35. Therefore, it can also be represented as the configuration of the molding optics unit 35, rather than the acquisition unit 310.

[0045] Alternatively, as shown in Figure 3(b), the fθ lens 326 can be used instead of the focus lens 323. A scanning unit 33 may be provided between the scanning unit 33 and the material layer. The fθ lens 326 If the focal length is f, then this lens focuses light at an incident angle θ to a position with an image height of f × θ. Therefore, when the laser beam is scanned by the scanning unit 33, the galvanometer mirrors 331 and 332 The focal point of the laser beam, whose incident angle changes depending on the tilt angle, is on the same plane (i.e., on the material layer). Set it to a different position in ). In this case, the laser light emitted from the irradiation unit 32 travels towards the X-direction + side, and the half mirror 301 The thermal radiation light passes through and is irradiated onto the material layer via the scanning unit 33 and the fθ lens 326. The half mirror 301 is reached via the fθ lens 326 and scanning unit 33. At -301, it is reflected to the + side in the Z direction, and through the first lens 431 and the bifurcated optical system 42. The light enters the imaging device 41. This creates images for each different wavelength, similar to the case shown in Figure 2. This makes it possible to generate data.

[0046] Furthermore, the laser oscillator 321 is arranged along the Z direction, and the first lens 431 and bifurcated optics are connected. System 42 may be arranged along the X direction. In other words, the acquisition unit 310 consists of the imaging device 41 shown in Figure 3(b) and the bifurcated optical system 42. It has a chromatic aberration correction optical system 43 and a half mirror 301. This allows the acquisition unit 310 This refers to a predetermined region of the powder material P that includes the molten portion (where the powder material P is molten). (Melted area, unmelted powder material P (material layer), region solidified after melting, etc.) Retrieve information. Furthermore, the acquisition unit 310 has a different function from the configuration of the molding unit 30 other than the acquisition unit 310 (powder (A function that acquires information on at least a portion of a predetermined area including the molten part where the end material P is melted.) Since it has a configuration that includes this, it is represented as a separate configuration from the molding unit 30 (molding optics unit 35). It is also possible to do so. In this case, the half-mirror 301 is also part of the shaping optics unit 35. Therefore, it can also be represented as the configuration of the molding optics unit 35, rather than the acquisition unit 310.

[0047] Note that the detection unit 54 does not necessarily have to use the two-color method. For example, when the powder material P is molten The thermal radiation from at least a portion of a predetermined area including the molten part is due to light of any one wavelength. Temperature image data may be generated based on the image data. In this case, two of the acquisition unit 310 The branched optical system 42 has an objective lens 421 and a filter for selecting any one wavelength. Alternatively, the configuration may be replaced with one that includes an imaging lens 426. In this case, the color of the acquisition unit 310 may also be replaced. The aberration correction optical system 43 is not required. Furthermore, the detection unit 54 detects only light of any one wavelength. Instead, temperature image data is generated based on image data from three or more different wavelengths of light. It may be done. Even in this case, the optical path in the bifurcated optical system 42 of the acquisition unit 310 The structure should be designed to increase the number of branches.

[0048] The arithmetic unit 50 in Figure 1 has a microprocessor and its peripheral circuits, and is non-volatile. The storage unit 58, which is composed of a storage medium (for example, flash memory, etc.), is pre-stored. By loading and executing the control program, the various parts of the molding apparatus 1 are controlled. It is a reducer. The arithmetic unit 50 consists of a setting unit 59, a detection unit 54, an output unit 55, and a calculation unit. It comprises a unit 56 and a determination unit 57. The arithmetic unit 50 is a CPU, an ASIC, or a programmer. It may be configured using a Gramable MPU, etc.

[0049] The setting unit 59, based on the status information output from the output unit 55 (described later), determines that the molding device 1 This sets various conditions (forming conditions) for creating a three-dimensional object. Further explanation will follow. The setting unit 59 consists of a material control unit 51, a molding control unit 52, and a housing control unit. It comprises part 53. The material control unit 51 controls the material according to the material layer formation conditions, which are the conditions for forming a material layer. The operation of the layer forming unit 20 is controlled. The material layer forming conditions include the movement speed of the blade 221 and the blade The pressure applied by blade 221 to the powder material P, the waiting time of blade 221, and blade 21 It includes material 1 and . In addition, the material control unit 51 controls according to the conditions related to the powder material P. This controls the operation of the material layer forming unit 20. Details regarding the conditions related to the powder material P will be described later. This includes the particle size distribution of the powder material P, the moisture absorption of the powder material P, and the type of powder material P. In this case, the material control unit 51 drives the bottom surface 211 of the material supply tank 21. The operation of 212 and the heater 213 that heats the powder material contained in the material supply tank 21 The heating temperature is controlled. When change information is generated by the calculation unit 56 described later, the material control unit 5 1 is based on the content of the change information and the conditions related to the material layer formation conditions and powder material P, The operation of the material layer forming unit 20 is changed.

[0050] The molding control unit 52 controls the operation of the molding unit 30. The molding control unit 52 adds powder material P. The irradiation unit 32 is controlled based on the conditions of the laser light emitted to the powder material P for heating. The conditions for the laser light are, in detail later, the output of the laser light, the wavelength of the laser light, and This includes the intensity distribution of the laser light and the size of the laser beam (spot size). (Format control) Based on scanning conditions for scanning the laser beam to heat the powder material P, The scanning unit 33 is controlled. The scanning conditions include the scanning speed of the laser beam, which will be described in detail later, and This includes the spacing of the laser light irradiation positions and the scanning path of the laser light. The molding control unit 52 controls the powder Based on the support conditions related to the material P and the base plate 311 that supports the solidified layer, Controls the operation of the base plate 311. The support conditions are as follows (details will be described later): The temperature of rate 311 is included, and the molding control unit 52 controls the base based on this support condition. The heating temperature of the heater 313 that heats the rate 311 is controlled. Also, the molding control unit 5 2 controls the operation of the drive mechanism 312 that drives the base plate 311 of the molding tank 31. The molding control unit 52 modifies the solidification layer and the design data of the three-dimensional object according to the content of the change information. This will be done. As design data, the slice model data and the shape data of the support parts will be described in detail later. The data is included. When the change information is generated by the calculation unit 56, which will be described later, the molding control unit 52 The operation of the molding unit 30 and the design data are modified according to the contents of the change information.

[0051] The housing control unit 53 controls the intake device 131 according to conditions related to the atmosphere inside the housing 10. And it controls the operation of the exhaust device 14 and the heater 15. The atmosphere inside the enclosure 10 The conditions related to this include the flow rate of the inert gas introduced into the housing 10, which will be described in detail later. This includes the speed and the internal temperature of the enclosure 10. Change information is generated by the calculation unit 56, which will be described later. When this happens, the enclosure control unit 53 will adjust the internal atmosphere of the enclosure 10 based on the content of the change information. The operation of the intake device 131, exhaust device 14, and heater 15 is modified according to the conditions. In addition to the control program described above, the memory unit 58 also processes the melting portion as detected by the detection unit 54, which will be described later. Detection of the state of at least a part of the predetermined area, generation of change information by the calculation unit 56, and judgment Various types of information used during the determination process by the determination unit 57 are stored here.

[0052] The detection unit 54, based on the image data generated by the imaging device 41 described above, determines the material layer The state of at least a part of a predetermined region is determined. Here, the predetermined region is as described later. In this area, the powder material P is melted by laser irradiation, and there is a molten portion where it has not yet melted. A molten powder material P (material layer), a region that solidified after melting, and a region where sputtering occurred. This includes the region where fumes are generated. In the following explanation, this predetermined region will be referred to as the detection target region. .

[0053] The output unit 55 is used to set the molding conditions of the molding device 1, based on the information obtained by the detection unit 54. The state information based on the state of at least a part of the detection target area is set by the setting unit 59 (that is, The output is then sent to at least one of the material control unit 51, the molding control unit 52, and the housing control unit 53. The state information, which is based on the state of at least a part of the detected area, is as described later. Modification to change the printing conditions for creating the three-dimensional object generated by the calculation unit 56. Information and information about the state of at least a part of the detection target area detected by the detection unit 54 Includes. For the sake of explanation below, the expression "at least a part of the detection target area" will be used instead of simply "detection target". It is called a domain.

[0054] The calculation unit 56 determines the molding conditions based on the state of the detection target area determined by the detection unit 54. It generates change information for making changes. In addition, the calculation unit 56 is determined by the determination unit 57, which will be described later. If it is determined that the formed solidified layer requires repair, then the necessary repairs will be carried out on the solidified layer. Generate correction information. The determination unit 57 determines the molding conditions based on the state of the detection target area determined by the detection unit 54. The determination unit 57 determines whether or not a change is necessary. In addition, the determination unit 57 determines the detection target area obtained by the detection unit 54. Based on the condition of the area, the necessity of repairs to the formed solidified layer is determined. Details of the processes performed by the detection unit 54, calculation unit 56, and determination unit 57 will be explained later. To do so.

[0055] Next, the operation of the molding apparatus 1 having the above configuration will be described. First, the housing control unit 53 controls the intake system so that the inside of the housing 10 has a set atmosphere. It controls the 131, exhaust system 14, and heater 15. The housing control unit 53 controls the intake device 131 so that the set pressure inside the housing 10 is obtained. The valve opening and the exhaust volume of the exhaust device 14 are controlled. The housing control unit 53 also controls the intake device By controlling the opening of valve 131, an inert gas is introduced into the housing 10, The oxygen concentration in body 10 is reduced. As the oxygen concentration decreases, the powder material P is exposed to the laser light. When injected and melted, the powder material P is oxidized, forming an oxide film on the particle surface of the powder material P. This process is suppressed. When an oxide film is formed on the particle surface of the powder material P, the oxide film Because the specific heat changes depending on the thickness, when laser light is irradiated, as will be described later, The irradiation of light may affect the heat absorption and heat conduction of the powder material P. In addition, the powder material P may not melt completely, or the solidified layer formed may have shape defects or insufficient strength. This can lead to melting defects such as failure to obtain a solidified layer with the desired metallic structure. A decrease in oxygen concentration can cause the powder material P to malfunction, resulting in melting failures and other problems as described above. The transformation is suppressed. The housing control unit 53 adjusts the temperature so that it reaches the internal temperature of the housing 10 set as the molding condition. The heating output of the heater 15 is controlled to heat the inside of the housing 10.

[0056] An inert gas is introduced into the enclosure 10, and the oxygen concentration becomes lower than a predetermined concentration. Furthermore, when the inside of the housing 10 is heated to the temperature set by the heater 15, material control The part 51 controls the drive mechanism 212 to move the bottom surface 211 of the material supply tank 21 in the +Z direction (ascend). The shaping control unit 52 controls the drive mechanism 312 to move the base plate 311 of the shaping tank 31 in the -Z direction (descend) by the thickness Δd of the material layer to be formed next . The material control unit 51 controls the drive mechanism of the recoater 22 to move the blade 221 along the X direction from the position A to the position B. The blade 22 1 that starts moving from the position A transfers the powder material P extruded from the material supply tank 21 due to the ascent of the bottom surface 211 onto the base plate 311 of the shaping tank 31 in the +X direction . The powder material P transferred onto the base plate 311 is pressed downward (-Z direction) by the lower end (-Z direction) of the blade 221 moving in the +X direction, so that it is spread on the base plate 311 in a state where the height (thickness in the Z direction) from the surface of the base plate 311 is uniform. Thus, a material layer with a constant thickness (lamination thickness) from the surface of the base plate 311 is formed . At this time, by controlling the moving speed of the blade 221 and the pressure applied by the blade 221 to the powder material P by the material control unit 51, the lamination thickness of the material layer desired by the user, the flatness of the surface of the material layer, the density, etc. can be obtained. Note that the density is the thickness of the material layer with respect to the amount of the powder material P in the formed material layer, and the lower the density, the higher the proportion of gaps existing in the material layer .

[0057] The irradiation unit 32 irradiates the formed material layer with laser light. The scanning unit 33 scans the laser light from the irradiation unit 32 on the surface of the material layer. The path (scanning path) for scanning the laser light is based on the design data of the three-dimensional shaped object to be shaped by the shaping apparatus 1, for example, CAD data or CAD data Shape data related to the three-dimensional shape of a three-dimensional object such as the converted STL data is sliced along the Z direction at a predetermined interval (for example, the interval of the stacking thickness of the material layer), and is set based on the slice model data that is a collection of the sliced shape data. This slice model data is the shape data of the solidified layer that determines the shape of the solidified layer in each layer. The control unit 52 of the arithmetic device 50 determines a scanning path for scanning the laser beam by the scanning unit 33 so that the powder material P on the surface of the material layer is irradiated according to the shape determined by the slice model data of the three-dimensional object corresponding to the position of the base plate 311 in the Z direction. In addition, in order to prevent deformation and damage of the three-dimensional object and the solidified layer during the shaping process, the shaping is performed while forming a support portion that supports the solidified layer and the three-dimensional object during shaping. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. The shaping posture data of the three-dimensional object is data indicating the shaping posture of the three-dimensional object (the shape data of the three-dimensional object) for setting the slice model data. The shaping posture is, for example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. It is the posture of shaping the three-dimensional object.

[0058] When generating the slice model data, the design data is not used as it is. The control unit 52 of the arithmetic device 50 determines a scanning path for scanning the laser beam by the scanning unit 33 so that the powder material P on the surface of the material layer is irradiated according to the shape determined by the slice model data of the three-dimensional object corresponding to the position of the base plate 311 in the Z direction. In addition, in order to prevent deformation and damage of the three-dimensional object and the solidified layer during the shaping process, the shaping is performed while forming a support portion that supports the solidified layer and the three-dimensional object during shaping. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. In addition, in order to prevent deformation and damage of the three-dimensional object and the solidified layer during the shaping process, the shaping is performed while forming a support portion that supports the solidified layer and the three-dimensional object during shaping. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. In addition, in order to prevent deformation and damage of the three-dimensional object and the solidified layer during the shaping process, the shaping is performed while forming a support portion that supports the solidified layer and the three-dimensional object during shaping. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. That is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data. The support portion shape data representing information such as the shape and thickness of the support portion is the shape data of the support portion in the three-dimensional object shape data (that is, the shape data of the support portion in the CAD data and STL data), and the slice model data created based on the three-dimensional object shape data.

[0059] The shaping posture data of the three-dimensional object is data indicating the shaping posture of the three-dimensional object (the shape data of the three-dimensional object) for setting the slice model data. The shaping posture is, for example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. It is the posture of shaping the three-dimensional object. The shaping posture data of the three-dimensional object is data indicating the shaping posture of the three-dimensional object (the shape data of the three-dimensional object) for setting the slice model data. The shaping posture is, for example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. It is the posture of shaping the three-dimensional object. For example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. For example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. For example, when shaping a three-dimensional object in the shape of a prism, whether the solidified layer is stacked along the axial direction of the prism, or the shaping of the solidified layer starts from the side surface of the prism and the solidified layer is stacked along a direction intersecting the axial direction of the prism. It is the posture of shaping the three-dimensional object. When generating the slice model data, the design data is not used as it is. Furthermore, it is preferable to generate slice model data while also considering shape changes due to thermal expansion. In particular, at the time the solidified layer is formed, the laser irradiation causes the solidified layer to be higher than at room temperature. It is heated. However, the temperature in the environment in which the three-dimensional object is used and the shape of the solidified layer If there is a significant difference between the temperature at which the process is carried out and the temperature at which it is carried out, the coefficient of linear expansion due to that temperature difference should be taken into consideration. Then, from the data with the above changes made to the design data (shape data of the 3D model), slide It is preferable to generate model data.

[0060] Furthermore, for each slice model data, the allowable capacity calculated based on the CAD data is It is also preferable to set difference information. This tolerance information can be found, for example, in Japanese Patent Publication No. 2006- Set tolerance information for each slice model data in accordance with the procedure described in Publication No. 59014. It is possible. The design data for the shape of the three-dimensional object includes the shape data of the solidified layer, the printing orientation data, and solid Shape data of the support structure that supports the layer or 3D printed object, or the shape of the 3D printed object. Includes data. The molding control unit 52 uses laser light from the irradiation unit 32 according to this design data. The material layer is scanned. The molding control unit 52 modifies the design data of the three-dimensional object. When the slice model data based on the design data is changed, the changed slice model According to the data, the molding control unit 52 scans the surface of the material layer with laser light from the irradiation unit 32. Let it.

[0061] The laser light irradiated onto the powder material P is affected by conditions such as the output and wavelength of the emitted laser light, and the powder The absorption rate is determined by the type of material P, the shape of the powder material P particles, the surface shape of the material layer, etc. The laser light is absorbed by the material P. The powder material irradiated with the laser light absorbs the laser light. The material P is rapidly heated, causing its temperature to rise and heat to be conducted to the surrounding powder material P. When the temperature reaches the melting point of the powder material P, the powder material P on the surface of the material layer melts and vaporizes. In both cases, the increase in vapor pressure causes the evaporated material to be ejected, forming molten depressions on the surface of the material layer. The laser light irradiated into this recess is further absorbed by the molten portion, causing the molten, vaporized, and evaporated material to disintegrate. The ejection is repeated. As a result, the recess becomes a hole with increased depth below the material layer (Z-direction side) As a result, the laser light undergoes multiple reflections from the walls of the hole, significantly increasing the absorption rate of the laser light. This creates a deeper hole (keyhole) that extends further downwards. The laser beam undergoes multiple reflections from the wall of the hole, resulting in a cross-sectional shape of the keyhole in the XY plane. It approaches a circular shape. A keyhole is formed at the location where the laser beam is irradiated, causing the material layer to... The inside of the keyhole will be directly heated by the irradiation of the powder material. The greater the energy transferred to material P, the deeper the opening becomes, and the higher the temperature of the powder material P, the larger the opening. It is known to become larger. In a keyhole, as described above, multiple reflections of rays from the wall surface occur. As the absorption rate of light increases, evaporated material is generated and becomes fumes at the keyhole opening (top surface) It is ejected from the opening. Along with the ejection of fumes, a portion of the molten area around the keyhole (molten) A portion of the molten powder material P is scattered as particulate sputter.

[0062] When the laser beam is scanned by the scanning unit 33 with the keyhole formed, the inside of the keyhole The keyhole is maintained by the balance of forces such as the vapor pressure of the molten part, the surface tension of the molten part, and the gravity of the molten part. In the applied state, when the laser beam scans in the direction in which it travels (when scanning toward the + side in the X direction), the powder material P located on the + side in the X direction melts. When the powder material P melts, the melt generated mixes with the melt generated from the powder material P around the keyhole, and forms a melt pool (melt pool) which is a liquid phase around the keyhole.

[0063] Fig. 4 schematically shows the state of the melt pool generated by irradiating the material layer with a laser beam and its vicinity. Fig. 4(a) is a plan view schematically showing the state of the melt pool on the material layer in the XY plane and its vicinity, and Fig. 4(b) is a cross-sectional view in the ZX plane thereof. In Fig. 4, the keyhole KH formed as described above, the melt pool MP, the powder material P that has not yet started to melt, the fume FU, the spatter SP, and the solidification region BE formed by solidification of the melt pool MP as will be described later are shown. In Fig. 4, the case where the laser beam is scanned from the + side to the - side in the X direction is shown. Also, in Fig. 4(a), the isotherms in the melt pool MP are shown by broken lines. Inside the melt pool MP, due to the difference in surface tension caused by the temperature difference between the surface and the inside of the melt pool MP, convection as shown by the arrow C in Fig. 4(b) occurs as an example. When the convection C increases due to the heat generated by the irradiation of the laser beam, the amount of fume FU generated increases, and a part of the melted powder material P around the keyhole KH is blown off from the melt pool MP and scattered around the keyhole KH and the melt pool MP as spatter SP. In addition, in Fig. 4(a), the isotherms in the melt pool MP are shown by broken lines. Inside the melt pool MP, due to the difference in surface tension caused by the temperature difference between the surface and the inside of the melt pool MP, convection as shown by the arrow C in Fig. 4(b) occurs as an example. When the convection C increases due to the heat generated by the irradiation of the laser beam, the amount of fume FU generated increases, and a part of the melted powder material P around the keyhole KH is blown off from the melt pool MP and scattered around the keyhole KH and the melt pool MP as spatter SP. Inside the melt pool MP, due to the difference in surface tension caused by the temperature difference between the surface and the inside of the melt pool MP, convection as shown by the arrow C in Fig. 4(b) occurs as an example. When the convection C increases due to the heat generated by the irradiation of the laser beam, the amount of fume FU generated increases, and a part of the melted powder material P around the keyhole KH is blown off from the melt pool MP and scattered around the keyhole KH and the melt pool MP as spatter SP. and a part of the melted powder material P around the keyhole KH is blown off from the melt pool MP and scattered around the keyhole KH and the melt pool MP as spatter SP.

[0064] When the heat generated by the irradiation of the laser beam becomes excessive, the convection C in the melt pool MP increases or the convection C becomes turbulent. When the convection C increases, the melt pool MP is more agitated, so the spatter When the convection C increases, the melt pool MP is more agitated, so the spatter The amount of sputtered SP increases, and the scattering velocity of sputtered SP increases. Also, convection C When the particles become disordered and irregular within the molten pool MP, the scattering direction of the sputter SP is visible from the keyhole KH. The laser beam is not fixed in a specific direction (for example, backward relative to the scanning direction of the laser beam), It also scatters forward and to the sides in the scanning direction. Furthermore, the more heat generated by the laser beam irradiation, the greater the... As the amount of fumes (FU) generated increases, the concentration of fumes (FU) becomes higher, or fumes (F) increase. The range over which U originates from the keyhole KH and diffuses becomes wider.

[0065] As the laser beam scans, the keyhole KH moves, and the direction of the keyhole KH's movement ( A new molten pool MP is formed around the X-direction (side in Figure 4), and the already formed ( The molten pool MP (which has not yet solidified) is relatively behind the keyhole KH (on the +X side in Figure 4). Because it is located in this position, the overall shape of the melting pool MP is an ellipse on the XY plane, as shown in Figure 4(a). It becomes circular. As the laser beam is scanned and moves away from the irradiation position, the energy of the laser beam is lost. The absorption is weakened, or the area is cooled due to the flow rate and velocity of the inert gas inside the housing 10. The area solidifies and forms a solidified region BE. As the laser beam is scanned, the keyhole KH moves. By continuing the process, the powder material P solidifies in the region of the material layer that has been irradiated with laser light. Solidification occurs, forming a continuous solidification region BE. The solidification region BE that is about to be formed and the already The formed solidification region BE and (in Figure 4(a), two solidification regions BE extending in the X direction) The solidified region is formed by irradiating it with laser light so that the gaps between them are in contact. The BEs weld together. Note that between the two different solidified regions BEs that extend in the same direction as described above The interval is determined by the scanning interval (scanning pitch) when scanning the laser beam. The scanning pitch is the direction that intersects the scanning direction of the laser beam (the X direction in Figure 4(a)). This is the distance between the irradiation positions of two adjacent laser beams in the Y direction (in Figure 4(a)). When multiple solidified regions BE are welded together, a layer having a predetermined thickness is formed along the Z direction. A solidified layer is formed.

[0066] During the formation of the solidified layer, the imaging device 41 captures images of the surface of the material layer and generates image data. As shown in 2, the thermal radiation incident on the imaging device 41 is a laser emitted from the irradiation unit 32. Since it travels in the opposite direction along the same axis as light, it reaches the center of the imaging field of view of the imaging device 41 (i.e., imaging device 4 The center of the image captured by (1) approximately coincides with the irradiation position of the laser beam on the material layer. When the material layer is irradiated with laser light by the irradiation unit 32, the imaging device 41 This refers to the irradiation position of the laser beam on the surface of the material layer (if keyhole KH is present, the keyhole The detection target region, including the molten pool MP, is imaged in the XY plane, centered on the position of the molten pool KH. This generates image data. In other words, the detection target area contains the material layer just before melting begins. Powder material P (unmelted powder material P), molten pool MP, and solidification region BE (in other words, solid It includes (part of the chemical layer). Also, sputter SP and fume FU are emitted from the keyhole KH. If present, sputtered SP and fume FU are also included in the detection area. Scanning unit 3 As the laser beam is scanned by 3, the detection target area imaged by the imaging device 41 is the material It moves along the surface of the layer. Imaging by the imaging device 41 is performed, for example, at predetermined time intervals, or when the laser beam reaches the scanning unit 33. This is performed each time the XY plane is scanned by a predetermined distance.

[0067] Once the solidified layer is formed, the molding control unit 52 controls the drive mechanism 312 to move the molding tank 31. Move the base plate 311 toward the Z-direction by the amount of the layer thickness Δd of the material layer to be formed. The material control unit 51 controls the drive mechanism 212 to lower the bottom surface 2 of the material supply tank 21. Move 11 to the Z-direction + side and control the drive mechanism of the recoater 22 to move the blade 221 Move along the X direction from position A to position B. This will move the upper part of the solidified layer (Z direction). On the positive side, the powder material P is arranged in a state where the height (thickness in the Z direction from the top of the solidified layer) is uniform. It is laid out. This creates a layer on top of the solidified layer with a consistent thickness from the top of the solidified layer. A new material layer with Δd is formed.

[0068] For the new material layer, the laser light from the irradiation unit 32 is scanned by the scanning unit 33 onto the XY plane. It is scanned. By irradiation with laser light, a molten pool MP is formed in which the powder material P is melted, and the above In this manner, it welds to adjacent solidification regions BE in the X and Y directions, and also to the molten pool MP It flows to the lower layer (Z-direction side) and welds to the already formed lower (Z-direction side) solidified layer. As a result, a new solidified layer is formed on top of the already formed solidified layer. The molding apparatus 1 repeatedly forms material layers and solidified layers, and multiple solidified layers are formed along the Z direction. This creates a three-dimensional object by layering materials.

[0069] As described above, when creating a three-dimensional object, defects, shape abnormalities, or surface defects may occur in the solidified layer. If molding defects such as surface roughness or abnormalities in the metallic structure occur after the 3D printed object has been created, Therefore, repairing defects in three-dimensional printed objects is difficult, especially the internal structure of three-dimensional printed objects. Repairing shape defects is difficult. Furthermore, setting the conditions for creating three-dimensional objects is also difficult. Because there are many parameters, conditions for creating three-dimensional objects to prevent molding defects Setting the details before creating the model is difficult and time-consuming. In the molding apparatus 1 of this embodiment, the detection unit 54, calculation unit 56 and determination unit of the calculation unit 50 57 is based on the state of the detection target area obtained at the start of or during the creation of the three-dimensional object. By changing various conditions for creating three-dimensional objects (hereinafter referred to as "creation conditions"), or by changing the solidification layer Information for repair is generated. Based on this information, the material control unit 51 and the molding control unit 52, The housing control unit 53 controls the operation of each component of the molding apparatus 1 to prevent molding defects from occurring in the solidified layer during molding. This prevents defects from occurring and allows for repairs to be made if molding defects occur. This is used to repair defects in the molding process.

[0070] The following describes the processes performed by the detection unit 54, the calculation unit 56, and the determination unit 57. First, the detection unit 54, calculation unit 56, and determination unit 57 are designed to perform the processing described later. I will explain about that. In this embodiment, the powder material P of the material layer is irradiated with laser light from the irradiation unit 32 to fabricate This suppresses the occurrence of molding defects in the solidified layer that is formed, resulting in a three-dimensional object with suppressed molding defects. To create the object, the following basic conditions are controlled to be kept within a certain range. As a matter of matter, the amount of heat that flows into the powder material P per unit area of ​​the material layer due to laser irradiation is A certain power density PD [J / mm²] 2 ] and, by irradiation with laser light, per unit volume of the material layer Energy density ED [J / mm²] is the amount of heat flowing into the powder material P.2 ] and laser beam irradiation The temperature distribution T(r)[°C] of the molten molten pool MP and the surrounding region of the powder material P. Let's take the following as an example. Power density PD, energy density ED, and temperature distribution T(r) are as follows: These are expressed by equations (1) to (3) below. PD = {η × (P L +P0)} / (d×v) …(1) ED = ρ × {η × (P L (+P0)} / (v×Δy×Δz) …(2) T(r) = {η × P} L / (2π×k×r)}×exp{(-v)×(x+r) / 2α}+ T0…(3)

[0071] In equations (1) to (3), the parameters are as follows: P L is laser This is the light output (hereinafter referred to as laser output) [W]. P0 is the external heat source, i.e., the base plate. 311 etc. are added to the powder material P, or an external heater etc. of the molding device 1 is added to the powder material P Represents energy [W]. η is the energy absorption rate of the powder material P, for example, powder material The value varies depending on the type of material P. v is the scanning speed of the laser beam [mm / s]. d is Δy is the luminous beam size (spot size) [mm] of the laser beam at the surface of the material layer. This refers to the spacing between scanning paths (scanning pitch) [mm], i.e., the direction in which the laser beam is scanned. This is the distance between the laser beam irradiation positions in the direction of the beam. Δz is the layer thickness, i.e., the distance between the formed layers. This is the thickness [mm] of the material layer in the Z direction. ρ is the density of the material layer. k is the heat of the powder material P. Conductivity [W / mm / K], r is defined as the distance from the center of a sphere, centered on the laser beam irradiation position. Distance [mm], x is the distance on the XY plane along the scanning direction from the laser beam irradiation position [mm] , α is the thermal diffusivity [mm 2 / s] of the powder material P, and T0 is the initial temperature [°C] of the powder material P. It is.

[0072] The larger the value of the power density PD shown in the above formula (1), that is, the larger the amount of heat flowing into the powder material P, the easier it is for the powder material P to melt. Formula (1) shows that in order to increase the power density PD and make it easier for the powder material P to melt, at least one of the parameters should be controlled based on the following policy. Regarding the parameter η, for example, it is advisable to use a powder material P with a high absorption rate of laser light. Regarding the parameters P and P0, for example, it is advisable to increase the laser output or increase the amount of heat applied to the powder material P from the outside. Regarding the parameter d, for example, by reducing the spot size of the laser beam and L increasing the amount of heat per unit area on the material layer by laser beam irradiation, the heat input efficiency of the heat flowing into the powder material P should increase. Regarding the parameter v, for example, by reducing the scanning speed and increasing the time during which the powder material P contained per unit area of the material layer is irradiated with the laser beam, the amount of heat flowing into the powder material P should increase. Moreover, the smaller the value of the power density PD shown in formula (1), the more difficult it is for the powder material P to melt. When the powder material P is overmelted, at least one of the above parameters should be controlled in the opposite direction to the above policy so that the value of the power density PD in formula (1) decreases. The opposite policy means that at least one of the policies exemplified below is carried out

[0073] . Regarding the parameter η, for example, it is to use a powder material P with a low absorption rate. Regarding the parameter P When the powder material P is overmelted, at least one of the above parameters should be controlled in the opposite direction to the above policy so that the value of the power density PD in formula (1) decreases. Regarding the parameter η, for example, it is to use a powder material P with a low absorption rate. Regarding the parameter P decreases. Regarding the parameter P and P0, for example, it is to reduce the laser output or reduce the amount of heat applied to the powder material P from the outside. Regarding the parameter d, for example, it is to increase the spot size of the laser beam and reduce the heat input efficiency of the heat flowing into the powder material P. Regarding the parameter v, for example, it is to increase the scanning speed and reduce the time during which the powder material P contained per unit area of the material layer is irradiated with the laser beam. Regarding the parameter η, for example, it is that a powder material P with a low absorption rate is used. Regarding the parameter P LRegarding P0, for example, by lowering the laser output or from an external source... The goal is to reduce the amount of heat added to the powder material P. Regarding parameter d, for example, This involves increasing the pot size. Regarding reduction, the parameter v can be changed, for example, the scan speed. It's about increasing the degree.

[0074] (2) The larger the value of the energy density ED shown in equation (2), the easier the powder material P is to melt. (2) Equation (2) increases the value of the energy density ED and makes the powder material P easier to melt. This indicates that at least one parameter should be controlled based on the following policy. Yes. Regarding the parameter η, as in the case of equation (1) above, for example, the absorption of laser light. The key is the use of a powder material P with a high yield. Parameter P L Regarding P0, for example Alternatively, increase the laser output or increase the amount of heat applied to the powder material P from an external heating device. The goal is to increase the density of the material layer. Regarding the parameter ρ, for example, by increasing the density of the material layer The goal is to reduce the gaps. This allows the heat generated by the laser beam irradiation to be transferred to the powder material. Material P becomes easier to conduct. Regarding parameter v, for example, by reducing the scanning speed, the material layer This is achieved by increasing the time that the powder material P contained per unit area is irradiated with laser light. This increases the amount of heat flowing into the powder material P. Regarding the parameter Δy, for example... For example, by narrowing the scanning pitch. This allows heat from adjacent solidification regions BE to The impact becomes greater. Regarding the parameter Δz, for example, this can be achieved by reducing the layer thickness. As a result, the thermal influence of the solidified layer already formed in the lower layer (Z-direction side) becomes greater. The initial temperature of the powder material P becomes high. Therefore, the powder material P irradiated with laser light reaches the desired temperature. The amount of heat required to raise the temperature (for example, to the melting point) decreases.

[0075] Furthermore, the smaller the value of the energy density ED shown in equation (2), the more difficult the powder material P is to melt. i. In cases where the powder material P is excessively melted, the value of the energy density ED in equation (2) To reduce the above, at least one of the above parameters is set to the opposite of the above policy. It would be good if it were controlled in this way. The opposite policy is that at least one of the following policies is implemented. This is the case. Regarding the parameter η, for example, a powder material P with low absorption rate is used. Parameter P L Regarding P0, for example, by lowering the laser output or by using powdered material from an external source... The goal is to reduce the amount of heat added to the substance P. Regarding the parameter ρ, for example, by reducing the density... The goal is to reduce it. Regarding parameter v, for example, this could involve lowering the scanning speed. Regarding the parameter Δy, for example, it can be used to widen the scanning pitch. The parameter Δz... Regarding this, for example, it involves increasing the thickness of the laminate layer.

[0076] As power density PD and energy density ED increase, powder material P becomes easier to melt, If the power density PD or energy density ED is increased too much, the convection within the molten region MP as described above will be affected. C is affected, and the generation of sputtered SP and fume FU increases. Sputtered SP scattered from the molten pool MP landed on material layers that had not yet been irradiated with laser light or already When it falls onto the solidification area BE formed by the material and solidifies, granular material forms on the surface of the material layer and on the upper surface of the solidified layer. It solidifies and remains as an adhering substance. Because Sputter SP is spherical, a new layer forms on top of the solidified layer. When a material layer is formed, the sputtered SP that solidified on the solidification region BE and the solidified layer below it The powder material P may not be able to penetrate between the surface and the material, potentially creating voids. The resulting voids are cavities that form within the solidified layer when the next solidified layer is formed. This may cause melting failures, etc. Also, sputtering S occurs when forming other solidification regions BE. If P is remelted, the desired metallic structure (crystal) will be formed in the area where the sputtered SP has been remelted. The structure may not be obtained, potentially resulting in a defective print. Furthermore, fumes (FU) generated by laser irradiation are located on the material layer at the laser irradiation position. When it lingers in the vicinity of the material, the energy of the laser beam directed towards the material layer is attenuated by the Hume FU. Therefore, the effect of heating the powder material P by laser irradiation is reduced, and the expected melting occurs. The desired conditions may not be achieved. This could result in the adhesion of sputtered particles (SP) and the generation of fumes (FU). Defects, shape defects, and other issues arising from poor melting in three-dimensional objects. Failure to obtain the desired metal structure (crystal structure) can result in molding defects such as insufficient strength. That's true. As mentioned above, sputtering (SP) and fume (FU) can cause defects in the three-dimensional printed objects. To suppress the generation of sputter SP and fume FU, the power density PD is used. It is necessary to control the energy density ED so that it does not increase too much.

[0077] Furthermore, if the power density PD or energy density ED decreases too much, the powder material P will be irradiated. The powder material P could no longer receive sufficient energy from the laser beam and did not melt. Failures such as incomplete melting (unmelted) or inability to obtain a molten pool MP of the desired size may occur, resulting in three dimensions This can cause defects in the printed object. Therefore, power density PD and energy density ED are It is necessary to control it so that it does not fall too low. Thus, power density PD and energy density ED can become too large or too small. It needs to be kept within a certain range without becoming excessive. This certain range is determined by the three-dimensional object. The optimal product is calculated based on the results of various tests and simulations conducted by users. Furthermore, the power density (PD) and energy density (ED) must be within a certain range for the 3D printed object to be considered a good product. The enclosure is referred to as the desired range.

[0078] (3) The temperature distribution T(r) shown in equation (3) is determined by the irradiation of laser light under the currently set molding conditions. When irradiated onto a material layer, the irradiation position of the laser beam on the material layer is the center. It is thought that this can be obtained at a position (x, y, z) at any distance r on or within the material layer. This indicates the set temperature. That is, equation (3) is the laser light under the currently set molding conditions. When irradiated, the state of heat conduction due to laser light irradiation within the material layer is estimated. This is the equation. Therefore, from equation (3), the surface (X direction and Y direction) and depth direction of the material layer The state of melting or solidification after melting of the powder material P in the (Z direction) is estimated. (3) According to equation (3), the powder material P is expressed in proportion to the distance from the position where the laser beam was irradiated. The state in which the temperature changes can be estimated. Therefore, the molten pool M is a region with a temperature higher than the predetermined temperature. Understanding the estimated range of P (for example, an elliptical range on the XY plane) is important. This becomes possible. The temperature distribution in the area estimated to be the molten pool MP can be determined from the laser beam irradiation position. It becomes possible to understand the temperature distribution in three dimensions depending on the distance. Therefore, the temperature distribution T(r) is constant. By setting the molding conditions so that the temperature remains within a certain range, the temperature changes within the molten pool MP. The state is controlled. This allows the crystalline structure within the solidified layer after solidification to be maintained in the desired structure. This allows for controlling the convection C of the melting pool MP.

[0079] Furthermore, the convection C in the molten pool MP due to laser irradiation affects the shape of the molten pool MP (i.e., solidification). This affects the shape of the subsequent solidification region BE and the depth of melting in the Z-direction. Therefore, by keeping the temperature distribution T(r) within a certain range, the molten pool MP is maintained. The state of convection C in the molten pool MP, which is the behavior of heat due to irradiation with light, is controlled. This suppresses the occurrence of poor penetration and reduces molding defects such as insufficient strength of the solidified layer and reduced durability. This is suppressed. Also, as mentioned above, convection C is suppressed in the generation of sputter SP and fume FU. Because it has an effect, the temperature distribution T(r) is kept within a certain range, so sputter SP This suppresses the generation of sputter SP and fume FU, and prevents molding defects caused by sputter SP and fume FU. The process is suppressed. Within this range, the user's individual actions are taken to ensure that the three-dimensional object is a good product. It is calculated from the results of various tests and simulations. Furthermore, the three-dimensional modeling will be considered a good product. A certain range of the temperature distribution T(r) is referred to as the desired range. Furthermore, if at least one of the basic conditions (1) to (3) satisfies the desired range Just be there.

[0080] Next, in order to change the molding conditions based on equations (1) to (3) described above, the detection unit 54 Next, we will explain the processes performed by the calculation unit 56 and the determination unit 57. The detection unit 54, based on the image data from the imaging device 41, determines the state of the detection target area described above. Determine the state. The state of the detection target area is the powder material before it is heated by laser irradiation. The state of P, the melting state in the detection target area, the state of sputtering SP, and the laser beam illumination At least one state of the fume FU generated by being injected and heated Includes. The detection unit 54, as an example of the melting state in the detection target area, for example, a melt pool. The difference between the MP and its vicinity (the semi-solid region where the solution is about to become a solid phase after melting, or the solidified region BE) At the very least, some temperature information is requested. The detection unit 54 determines the state of the sputtered SP as follows: For example, determine at least one of the following: the scattering direction of sputtered sputtering particles (SP), the amount of particles scattered, and the scattering velocity. The detection unit 54 determines the state of the fume FU, for example, the concentration and range of the fume FU. We will find at least one. Note that determining the state of the detection target area is the same as determining the target. The state of the area to be detected (specifically, the state of the powder material P, the melting state, and the sputtered SP as described above) Considering the state of the area to be detected (including the state of the fumes), Calculating the state of the detection target area, evaluating the state of the detection target area, or detecting This can also be described as detecting the state of the elephant domain.

[0081] In this embodiment, the state of the detection target area determined by the detection unit 54 is used to create The shape conditions can be changed in real time, changed during the next layer's creation, or changed during the creation of the next object. Yes. In real-time changes, the material layer used to determine the state of the detected area is changed. When creating the solidified layer by laser irradiation, or during the creation process, the creation conditions may change. Therefore, in real-time changes, the unmelted powder material in the material layer during the formation of the solidified layer The molding conditions are changed for material P. When changing during the next layer molding, the material for the next layer is changed after the solidified layer has been molded. When forming a material layer or when starting the formation of a solidified layer from the next material layer, the molding conditions are changed. Therefore, when changing during the next layer fabrication process, the new powder material supplied onto the fabricated solidified layer will be used. The molding conditions are changed for material P or new powder material P supplied onto the solidified layer. During the modification process, the solidification layer is stacked to complete the creation of the 3D object, and the next 3D object is created. The printing conditions are changed when the printing process begins.

[0082] The following describes the process by which the detection unit 54 determines the state of the target area, and the calculation unit 56 determines the molding conditions. The explanation will be divided into two parts: the process of generating change information to modify the system, and the process of generating change information to modify the system.

[0083] (1) Process to determine the state of the area to be detected The detection unit 54 uses the image data generated by the imaging device 41 to detect the detection target on the material layer. Determine the state of the image region. As described above, the image data output from the imaging device 41 includes, The detection unit contains information about the thermal radiation from the target area, specifically the light with different wavelengths λ1 and λ2. 54 contains the brightness information of wavelength λ1 included in the image data captured from this detection target area, and the image Based on the ratio of the luminance information of wavelength λ2 included in the data, the smallest distance between the melting pool MP and its vicinity. At least some temperature information is obtained. In this case, the detection unit 54 is, for example, a known two-color Using this method, the brightness information of wavelengths λ1 and λ2 in the image data is converted to temperature. (Hereafter referred to as temperature image data) is generated. Temperature image data consists of each image corresponding to the temperature. This is the signal intensity for each element. The detection unit 54 detects the brightness information of light with wavelength λ1 included in the image data. This is calculated as the ratio of the luminance information of light with wavelength λ2 (for example, the ratio of luminance values), and is used to determine gray and black colors. By comparing the relationship data between the ratio of reference brightness values ​​obtained based on the body, etc., and temperature, the image data The ratio of the luminance values ​​at wavelengths λ1 and λ2 at any position on the data is converted to temperature. Temperature image data is generated that represents the temperature at any location within the detection target area on the image data. The detection unit 54 uses this temperature image data to determine the temperature distribution of the area to be detected, as well as the maximum and minimum temperatures. Temperature, average temperature, etc. can be determined. The detection unit 54 is generated by the imaging device 41. Temperature image data is generated for each image data. The detection unit 54 generates temperature image data. Each time, the data is stored in the memory unit 58.

[0084] Figure 5 shows the detection unit 54 based on image data captured from the detection target area shown in Figure 4(a). This is a schematic diagram showing an example of a temperature image corresponding to the temperature image data generated by [the system]. This shows the case where the light is scanned on the material layer from the + side to the - side in the X direction. In section 5, for illustrative purposes, the temperature differences in the melting pool MP in the temperature image are shown with dashed lines. The graph uses isotherms, and areas affected by Hume FU are indicated with diagonal lines.

[0085] As described above, when the material layer is irradiated with laser light, the imaging device 41 Therefore, the detection target region within the material layer, including the molten pool MP, is imaged. The temperature image data (temperature image) has the keyhole KH at the center of the image, and the molten pool MP and the condensate. The solidification region BE, where solidification has been completed, and the powder material P are included. The laser beam is directed towards the X-side. Because it is being scanned, in the temperature image the molten pool MP is on the X-side relative to the keyhole KH. It also has a large elliptical region on the X-direction + side. Furthermore, granular particles are formed by irradiation with laser light. If sputtering SP is scattered, the sputtering SP also generates heat, so temperature image data will be available. (Included in the temperature image). In addition, fumes (FU), which are evaporated products, are generated by irradiation with laser light. If this is the case, fumes (FU) also possess heat and therefore should not be included in the temperature image data (temperature image). Born.

[0086] The detection unit 54 uses a temperature image, as illustrated in Figure 5, to determine the state of the target region, and then uses a radar The state of the powder material P before heating by irradiation with light, the state of melting in the detection target area, and Determine the state of the patter SP and the state of the fumes FU. The following describes the state of the detection target area: Detection of the state of powder material P before heating by laser irradiation, and detection of melting in the target area. The explanation will be divided into state detection, sputtering SP state detection, and fume FU state detection. To do so.

[0087] <Detection of the state of powder material P before heating by irradiation with laser light> The detection unit 54 detects the state of the powder material P before heating by laser irradiation from the temperature image data. For example, we seek information about the temperature of regions other than the molten pool MP and the solidification region BE. In this case, the detection unit 54 determines the region where the temperature is lower than the first predetermined temperature. The first predetermined temperature is For example, it is set based on the melting point of the powder material P. Note that the first predetermined temperature is not limited to the melting point. It may be either the solidus temperature or the liquidus temperature, or any temperature within the range from the solidus temperature to the liquidus temperature. Any temperature is fine. Here, the detection unit 54 determines the temperature of the powder material P in the material layer before heating by laser irradiation. In this case, the temperature of the powder material P should be determined in the scanning direction region relative to the laser beam irradiation position. It can be estimated as a region on the material layer. The detection unit 54 detects the first predetermined temperature within this estimated region. The temperature of the powder material P before heating by laser irradiation is determined to be in the range below a certain degree.

[0088] The detection unit 54 detects the detection target area captured by an imaging device different from the imaging device 41. From the image data, the molten pool MP and solidification region BE were determined, and the molten pool determined from the image data Based on MP and solidification region BE, the molten pool MP and solidification region BE in the temperature image data are used to determine the relationship between the molten pool MP and the solidification region BE. After removing it, the powder material P before heating by laser irradiation can be determined from the temperature image data. In this case, the imaging device 41 and an imaging device different from the imaging device 41 capture the area to be detected. The timing of the imaging needs to be controlled to ensure it is synchronized.

[0089] Using temperature image data, the detection unit 54 detects the temperature of the powder material P before heating by laser irradiation. Temperature information includes the temperature distribution of the powder material P before heating, the maximum temperature, the minimum temperature, and the average temperature. The degree, etc., is determined. As a result, the detection unit 54 determines the initial temperature, which is a parameter of equation (3) above. T0 can be calculated. Furthermore, the detection unit 54 utilizes known image processing methods from the image data captured by the imaging device 41. Using this method, the state of the powder material P before heating is determined by removing foreign matter and spatter SP contained in the powder material P. You may ask for it.

[0090] Furthermore, the detection unit 54 uses two-color method temperature image data to determine the temperature before heating by laser irradiation. It is not necessary to determine the state of the powder material P. For example, regarding the acquisition unit 310, the imaging device 41 In place of the bifurcated optical system 42, the chromatic aberration correction optical system 43, and the field aperture 302, the existing radiation thermometer Using this method, temperature data based on infrared radiation from the powder material P before heating by laser irradiation is obtained. It may be beneficial. In this case, the detection unit 54 is acquired by the acquisition unit 310 (radiation thermometer not shown). Based on the temperature data obtained, the state of the powder material P before heating by laser irradiation can be determined. good.

[0091] Furthermore, the acquisition unit 310 does not have to be a radiation thermometer; it can be an existing contact type thermometer such as a thermocouple. A thermometer may be used. In this case, the acquisition unit 310 may be the molding tank 31 of the molding unit 30 or the material layer. Multiple thermocouples are installed at arbitrary positions in the forming section 20, and each of these multiple thermocouples is used at each position Temperature data is acquired. Then, the detection unit 54 uses the temperature data acquired by the thermocouple and a laser Using data on the correlation with the temperature data of powder material P before heating by light irradiation Alternatively, the state of the powder material P before heating by laser irradiation may be determined. This can be obtained using a thermocouple. Correlation between the measured temperature data and the temperature data of the powder material P before heating by laser irradiation. The data related to this is stored in the memory unit 58 beforehand.

[0092] <Detection of the molten state> The detection unit 54, based on the temperature image data, determines the melting state as the molten pool MP and its vicinity (detection). Information regarding the temperature of the solidification region BE) within the target region is obtained. In this case, the detection unit 54 determines the temperature Among the temperature image data, the high-temperature region above the first predetermined temperature is defined as the keyhole KH and the molten pool MP. The region is determined as the included area. In addition, the detection unit 54 determines the temperature of the solidification region BE after irradiation with laser light. In this case, the region opposite to the scanning direction relative to the laser beam irradiation position is the solidification region BE. This can be estimated as the region where the temperature should be determined. The detection unit 54 detects the first location within this estimated region. The region below the constant temperature is determined as the temperature of the solidification region BE after heating by laser irradiation. . Furthermore, the detection unit 54 detects the molten pool of the liquid phase in the region of the temperature image data that is above a first predetermined temperature. The region where MP begins to solidify and becomes a solid phase (semi-solid region) is divided into the keyhole KH and the molten pool MP. Alternatively, you can separate and estimate the temperature of this region to determine its temperature.

[0093] The detection unit 54 obtains information related to the temperature of at least a portion of the molten pool MP and its vicinity, and Therefore, the temperature distribution of the melting pool MP, maximum temperature, minimum temperature, average temperature, and the location of the keyhole KH are as follows: , the opening diameter of the keyhole KH at the top surface (surface of the material layer) (e.g., the length of the minor axis), molten pool MP size, thermal conductivity, temperature gradient on the surface of the molten pool MP, molten pool MP on the surface This includes the change in temperature at the boundary, such as the coagulation rate and temperature history. Similarly, detection unit 5 4. Information related to temperature includes the temperature distribution of the solidification region BE and semi-solidification region, the maximum temperature, and the highest temperature. The low temperature, average temperature, size, thermal conductivity, temperature gradient, solidification rate, temperature history, etc., are determined.

[0094] The detection unit 54, for example, detects multiple regions estimated to be melt pool MPs from the temperature image data. The temperature at the location is determined, and isotherms are set for predetermined temperature intervals, thereby determining the temperature of the molten pool MP. The cloth is sought. The detection unit 54 searches the region estimated to be the molten pool MP among the temperature image data. The highest temperature is determined as the maximum temperature, and the lowest temperature is determined as the minimum temperature. 54 is the region estimated as the melt pool MP in the temperature image data, with multiple locations. The temperature at each location is determined, and the average of the determined temperatures is calculated to determine the average temperature of the molten pool MP. The temperature is determined. The detection unit 54 determines the position of the keyhole KH by finding the center of the temperature image data. The detection unit 54 detects a range that can be considered to have approximately the same temperature as the temperature at the center of the temperature image data. The opening of the keyhole KH at the top surface is determined, and the length of the minor axis of the determined opening is calculated as the opening diameter. Mel.

[0095] The detection unit 54 determines the size of the molten pool MP from the area of ​​the region on the temperature image that is above a first predetermined temperature. The detection unit 54 determines the thermal conductivity from the size of the molten pool MP. The protrusion 54 is the distance from the keyhole KH in the temperature image data to the position of the first predetermined temperature. Convert this to the distance r on the material layer, and add the value of the first predetermined temperature, the distance r, and the current Enter the values ​​of each parameter determined by the currently set molding conditions, and then use equation (3) for the parameters The thermal conductivity is calculated by solving for k. The detection unit 54 determines the degree of density of isotherms on the temperature image (temperature image data) based on , the temperature gradient on the surface of the molten pool MP, and the temperature change at the boundary of the molten pool MP on the surface Determine a certain coagulation rate. Multiple temperature image data generated by taking images at predetermined intervals are used The detection unit 54 determines the temperature history in the molten pool MP and its vicinity. The temperature history is determined by the material This data represents temperature changes in a specific area of ​​a layer. An example of temperature history detection is explained below. do.

[0096] As described above, the image data generated by the imaging device 41 and the irradiation position of the laser light (sun The irradiation position information, which indicates the position of the keyhole (KH), and the time information are associated and stored in memory. The detection unit 54, based on the irradiation position information associated with the image data, determines the temperature history. We request the detection process of temperature history by the detection unit 54, which involves a certain temperature image (first temperature image). In this case, the distance from position Q2, where the keyhole KH (i.e., the center of the image) is located, is in the X direction + direction. Let's take the case of determining the temperature history at a position Q1 located a distance m away as an example. The detection unit 54 Then, the temperature at position Q1 is determined from the first temperature image data. After a predetermined time, (laser light After the irradiation position has changed by a predetermined distance, the detection unit 54 detects a second temperature different from the first temperature image. Determine the position of Q1 on the image.

[0097] Specifically, the detection unit 54 determines the irradiation position of the laser beam when the first image data is generated and Based on the laser beam irradiation position when the second image data was generated, the first temperature image is converted to The position of the keyhole KH1, which is the center, on the material layer, and the center in the second temperature image. Determine the position of a keyhole KH2 on the material layer. The laser beam is directed towards the X-side. Assuming scanning is occurring, the difference n in the positions of keyholes KH1 and KH2 on the material layer is measured by temperature. The position obtained by shifting the center of the second temperature image towards the +X direction by the value converted to distance on the temperature image is, This corresponds to the position Q2 (the keyhole KH in the first temperature image) on the second temperature image. The detection unit 54 detects a position m further to the +X direction from position Q2 on the second temperature image. The location is determined as position Q1, and the temperature at this location is determined from the second temperature image data. The detection unit 54 then similarly determines the temperature at position Q1 from multiple temperature image data. This allows us to determine the temperature history at position Q1.

[0098] The detection unit 54, from the temperature image data, determines the state of the vicinity of the molten pool MP as the solidification region BE. Information regarding temperature is sought. In this case, the detection unit 54 obtains information about the temperature distribution and average temperature of the solidification region BE. The degree, etc., is determined. The detection unit 54 determines the state of the powder material P before heating. Information regarding the temperature of material P may be obtained as a state near the melting pool MP.

[0099] Furthermore, the detection unit 54 uses two-color method temperature image data to detect the molten pool MP and its vicinity (detection). Even without obtaining information about the temperature of the solidification region (BE) within the target region (i.e., the state of melting), Good. For example, regarding the acquisition unit 310, the imaging device 41, the bifurcated optical system 42, and the chromatic aberration correction light Instead of the 43 and 302 field diaphragms, an existing radiation thermometer was used, and measurements were taken from the melting pool MP and its vicinity. Temperature data based on infrared radiation may be acquired. In this case, the detection unit 54 is acquired by the acquisition unit 310. The state of moltenness may be determined based on temperature data obtained from a radiation thermometer (not shown).

[0100] Furthermore, the acquisition unit 310 does not have to be a radiation thermometer; it can be an existing contact type thermometer such as a thermocouple. A thermometer may be used. In this case, the acquisition unit 310 may be the molding tank 31 of the molding unit 30 or the material layer. Multiple thermocouples are installed at arbitrary positions in the forming section 20, and each of these multiple thermocouples is used at each position Temperature data is acquired. The detection unit 54 then compares the temperature data acquired by the thermocouple with the molten pool data. Data regarding the correlation between MP and temperature data of the nearby area (solidification region BE within the detection target area) The melting state may also be determined using the thermocouple data. Regarding the correlation between temperature data of the molten pool MP and its vicinity (solidification region BE within the detection target area) The data is stored in the memory unit 58 beforehand.

[0101] <Detection of the state of sputtered sputtering sputtering> The detection unit 54 determines the state of the sputtering SP by determining the amount of sputtering SP scattered, the direction of scattering, and Determine at least one of the following: the dispersion rate. As mentioned above, the state of sputtering SP is the molten pool M Since it is related to the convection C in P, the detection unit 54 determines the state of sputtered SP by This allows us to indirectly determine the state of convection C inside the melting pool MP.

[0102] Figure 6 shows temperature image data used to determine the state of the sputtered SP, for illustrative purposes. As a corresponding temperature image, the temperature image obtained by excluding the fume FU and solidification region BE from Figure 5 is shown. The detection unit 54 uses a temperature image data to determine the state of the sputtered SP in the region of interest. Set it within the terminal.

[0103] In this case, the detection unit 54 detects the keyhole KH and melted in the temperature image shown in Figure 6(a). The region excluding the area occupied by the pond MP is set as the region of interest. The detection unit 54, even Then, from equation (3) which represents the temperature distribution T(r) described above, the keyhole KH and the molten pool MP are included. The region (the region to be excluded) can be estimated. Equation (3), which represents the temperature distribution T(r), is above As described above, any distance r from the laser beam irradiation position (i.e., the position of the keyhole KH) This represents the temperature of the powder material P in the fabrication process, and the output of the laser light, etc., for fabricating three-dimensional objects. Shape conditions are used as parameters.

[0104] The detection unit 54 uses equation (3), which represents this temperature distribution T(r), and the set molding conditions to determine the temperature distribution T(r). Based on this, a first predetermined temperature or higher including the location of the keyhole KH (i.e., the center of the temperature image) The high-temperature region is determined, and this high-temperature region is designated as the region to be excluded. As described above, molten pool M Since P is elliptical in the XY plane, the region consists of the keyhole KH and the molten pool MP. The region is elliptical in shape. The detection unit 54 adds the value of the first predetermined temperature to the temperature distribution T(r) in equation (3). Then, input the values ​​of each parameter determined by the currently set molding conditions, and calculate the parameter r. By doing so, an elliptical region with a temperature above the first predetermined temperature is calculated. Detection unit 54 This involves using a high-temperature image data (thermal image) to define the region included in the calculated elliptical area. The high-temperature region is detected and designated as the region to be excluded. Furthermore, the area to be excluded is an elliptical area that includes the keyhole KH and molten pool MP. Not limited to cases where it is released, the solidification region BE is included in addition to the elliptical high-temperature region described above. The region may be detected as a region to be excluded.

[0105] Figure 6(b) shows the exclusion region determined by the detection unit 54 for the temperature image shown in Figure 6(a). Based on R1 (shown with diagonal lines in Figure 6(b)) and the determined exclusion region R1 This diagram schematically shows the defined region of interest R2. The region of interest R2 is the area where melting of the powder material P due to laser irradiation does not occur. Therefore, if a high-temperature region exists in the region of interest R2, the detection unit 54 will scan that high-temperature region. The temperature SP is determined. The detection unit 54 counts the number of high-temperature regions included in the region of interest R2. The amount of sputtered spatter scattered can be determined by this method.

[0106] The detection unit 54 detects the region of interest R2 from the center of the temperature image, i.e., the irradiation position of the laser light. By determining the direction to each high-temperature region, on the XY plane of the sputtered SP, The direction of dispersion can be determined. The detection unit 54 uses multiple temperature image data to determine the scattering velocity of the sputtered SP. The output unit 54, for example, in the case of determining the temperature history, obtains two temperatures with different time information. From the image data, sputtered sputtered particles (SP) that have fallen onto the material layer and solidified area (BE) are solidified. The sputtered particles SP that remain in the same location on the material layer or solidification region BE are extracted, and the scattering velocity is determined. It is excluded from the detection target. The detection unit 54 then detects the remaining sputtered SP (i.e., As time progresses, one of the sputtered sputtered sputters (SP) that has been displaced is analyzed using temperature image data (temperature image). The size and temperature in one location and the size and temperature in the other temperature image data (thermal image) Spattered sputtering particles that can be considered identical are determined as sputtered sputtering particles (identical sputtering). The detection unit 54 detects one of the temperature images of the sputter SP obtained as the same sputter. The position (first position) in the upper space of the material layer is determined from the data (temperature image), and the other temperature image data The position (second position) in the upper space of the material layer is determined from the data (temperature image). The detection unit 54, From the first position, the second position, and the time information difference between the two temperature image data, sputter SP( The scattering velocity of the same spatter particles is calculated (detected).

[0107] Furthermore, the detection unit 54 does not set a region of interest R2 in the temperature image data (temperature image). The state of the sputtered SP may be determined. In this case, the detection unit 54 outputs the result of the imaging device 41. Multiple temperature image data generated from the image data are added together and averaged to obtain the average temperature image. Image data is generated. Note that multiple temperature image data are associated with different time information. Temperature image data generated from image data is also acceptable. Furthermore, multiple temperature image data can be used. , temperature image data at different times and locations that have been generated in advance and stored in the memory unit 58 It may also be a data. The detection unit 54 generates average temperature image data each time it generates temperature image data. You may generate a temperature image file, or you may generate an average temperature image file each time you generate a predetermined number of temperature image files. It may also be generated. Sputter SP generation state (number of sputter SPs on the temperature image data) The location, size, etc., differ for each temperature image data. Therefore, on multiple temperature images... Even if sputtered SPs are detected in one temperature image at the same location, in other numerous locations... In these temperature images, sputtered SPs are not always detected. In average temperature image data (average temperature image) generated based on a certain temperature image data ( The location where sputtered SPs were detected in the temperature image is found in a large number of other temperature image data (temperature image) By adding and averaging the locations where sputter SP was not detected in ) the sputter SP SP is removed. The average temperature image data (average temperature image) from which sputtered SP has been removed is This includes keyhole KH and molten pool MP.

[0108] Figure 6(c) shows the average temperature image data corresponding to the average temperature image data generated by the above process. An example of the image is schematically shown. As shown in Figure 6(c), the average temperature image shows keyhole KH And there are no high-temperature regions other than the molten pool MP. The detection unit 54 is the spa shown in Figure 6(a) Temperature image data (image data to be detected) corresponding to the temperature image used for detecting the tatta SP. From this, we take the difference between this and the average temperature image data corresponding to the average temperature image shown in Figure 6(c). As shown in Figure 6(d), the keyhole KH and molten pool MP can be detected from the target image. An image with the sputtered areas removed is generated. The high-temperature region on this image is the sputtered area (SP), so it can be detected. Section 54, as described above, is based on the high-temperature region, similar to the case explained using Figure 6(b). Then, determine at least one of the following: the amount of sputtered SP scattered, the scattering direction, and the scattering velocity. In particular, the detection unit 54 is located on the X-direction + side (relative to the scanning direction of the laser beam) relative to the center of the temperature image. The sputtered particles scattered to the rear and their scattering direction can also be determined.

[0109] Furthermore, the detection unit 54 does not need to determine the sputtering state from the temperature image data obtained by the two-color method. This is also fine. For example, regarding the acquisition unit 310, the imaging device 41, the bifurcated optical system 42, and chromatic aberration correction Instead of the optical system 43 and field aperture 302, an imaging device (not shown) is used to obtain an image of the detection target area. You may obtain a data entry. Also, the imaging device not shown has the same configuration as the imaging device 41 in Figure 1. Alternatively, other existing configurations may be used. In this case, the detection unit 54 is the acquisition unit 3 Using the image data acquired by 10 (imaging device not shown), existing image processing is performed, and the image A circular image of a predetermined size is detected as the sputtering image. Then, the detection unit 54 From the time change in the position and number of detected sputter images, the amount and direction of sputter SP scattering can be determined. Determine at least one of the following: dispersion rate.

[0110] Furthermore, the state of the spatter SP (amount of spatter SP scattering, scattering direction, and scattering speed) and the molten pool M The correlation between P and convection C, and the relationship between convection C in the molten pool MP and the melting state of the molten pool MP (related to temperature). Correlation with (information) Correlation between the state of sputtered SP and the melting state of molten pool MP This can be determined. Therefore, the detection unit 54, based on the determined state of sputtered SP, (indirectly) The melting state of the molten pool MP may also be determined. In this case, the state of sputter SP and the molten pool MP Data relating to the molten state is stored in the storage unit 58 in advance.

[0111] <Detection of Hume FU status> The detection unit 54 determines the state of the fume FU from the temperature image data, and the concentration of the fume FU and Determine at least one of the ranges. As mentioned above, the state of the fume FU is the melting pool MP Because it is related to the internal convection C, the detection unit 54 determines the state of the fume FU, The state of convection C inside the melting pool MP can be determined indirectly.

[0112] Figure 7 shows the temperature corresponding to the temperature image data used to determine the state of fumes (FU). An example image is shown. Note that in Figure 7, the coagulation region BE is omitted for illustrative purposes. As mentioned above, fumes (FU) are generated from the molten pool (MP) created by irradiation with laser light. Therefore, the light from the detection target area of ​​the material layer is affected by fumes (FU), resulting in a decrease in brightness. In Figure 7, the shaded areas are illuminated due to the influence of Hume FU. This indicates a region where the frequency value is decreasing. Figure 7(a) is the same temperature image as the one shown in Figure 5. The original image data of the temperature image data, that is, light of wavelength λ1 and light of wavelength λ2, is captured by the image sensor 411 Figure 1 shows the corresponding image data generated by incident light at different positions. This is schematically shown in 7(b). In the original image of Figure 7(b), light of wavelength λ1 is visible on the left side of the paper. Image D1 is shown, and image D2, produced by light of wavelength λ2, is shown on the right side of the page.

[0113] As mentioned above, synchrotron radiation from the detection target region of the material layer is affected by Hume FU and shines brightly. Since the degree value has decreased, the brightness values ​​of both image D1 and image D2 have decreased. For example, image D1 Assume that image D2 is brighter (higher brightness). However, Hume FU Due to the scattering of light caused by the influence of Hume FU, the effect of Hume FU is not present in both bright image D1 and dark image D2. Brightness decreases in the affected regions R3 and R4. At this time, the bright image D1 and the dark image D2 The respective brightness reduction rates are substantially equal. The detection unit 54 detects the molten pool MP and the keyhole K The distinction between H and sputtered SP and fume FU is made by luminance values ​​between image D1 and image D2. This is done based on whether the ratio changes or not. Fume FU blocks light from the molten pool MP. The luminance values ​​for both the light of wavelength λ1 and the light of wavelength λ2 decrease, but between image D1 and image D2 The ratio of brightness values ​​does not change. In contrast, the molten pool MP, keyhole KH, and sputter S At P, the ratio of luminance values ​​changes. Since the luminance information of each pixel in image D1 and image D2 is known, The detection unit 54 determines the molten pool MP, keyhole KH and based on whether or not there is a change in the ratio of brightness values. The sputtered SP and the fume FU can be separated. The detection unit 54 is as follows: The Hume FU (region R3 of image D1 and region R4 of image D2) that was separated is Hume F We will determine the range of U.

[0114] The detection unit 54 uses either image D1 or image D2 to determine the degree of decrease in brightness value. The concentration of fume FU is determined by the above. The detection unit 54 is determined as described above. Brightness values ​​in the Hume FU range (region R3 of image D1, or region R4 of image D2), and other regions Brightness in the region where the brightness value has not decreased because it is not affected by Hume FU. The difference between the value and the actual value is calculated, and the concentration of fume (FU) is calculated based on this difference. Data relating the difference and the concentration of fumes is pre-stored in the storage unit 58, and the detection unit 5 Step 4 calculates the fume (FU) concentration from the difference calculated by referring to this data. Outlet 54 is different from when image data corresponding to the original image shown in Figure 7(b) was acquired. The brightness values ​​of image D1 or image D2 in the acquired image data and the original image in Figure 7(b) The difference may be calculated by comparing it with the luminance value of image D1 or image D2 in the image data of the image. Furthermore, the brightness values ​​in both image D1 and image D2 are reduced due to the influence of Hume FU. Therefore, it is generated based on the ratio of the luminance information of light with wavelength λ1 to the luminance information of light with wavelength λ2. The resulting temperature image is unaffected by the obstruction of thermal radiation by Hume FU.

[0115] The detection unit 54 may also determine the state of the fume (FU) using average temperature image data. The average temperature image data was generated using the method described in the process for determining the state of the sputtered SP. It is generated in a similar manner. Fume FU generation state (on the temperature image data of fume FU) The density and range differ for each temperature image data. Therefore, the same position on multiple temperature images is different. In this case, even if fumes (FU) are detected in one temperature image, they may not be detected in many other temperature images. This does not necessarily mean that fumes (FU) are detected. Averaging these multiple temperature image data results In the average temperature image data obtained, the degree to which Hume FU was affected in a given temperature image data is shown. The location is added to the location unaffected by Hume FU in a large number of other temperature image data. By averaging, the effects of fumes (FU) are removed. The uniform temperature image data includes keyhole KH and molten pool MP. In this case, the detection unit 54 generates average temperature image data corresponding to the average temperature image shown in Figure 6(c). To accomplish.

[0116] The detection unit 54 corresponds to the temperature image for detecting fume FU shown in Figure 7(a). The difference between the temperature image data (image data to be detected) and the average temperature image data is calculated. As shown in Figure 7(c), the keyhole KH and molten pool MP are removed from the detection target image. A decomposed image is generated. The high-temperature regions on this image (image data) are fumes (FU) and spalls. This is sputtered SP. Sputtered SP appears as small grains in the image (data image), so it can be detected. The output section 54 determines the range of fume FU by excluding these granular high-temperature regions from the image data. This allows the detection unit 54 to determine the diffusion state of the fume FU, that is, the range of the fume FU. The detection unit 54 determines the range. Since fumes FU also have heat, the detected fumes The temperature within the FU range is determined from the image data corresponding to the image shown in Figure 7(c). The more fumes (FU) are generated, the higher the concentration of fumes (FU). This is possible. Therefore, the detection unit 54 is based on the temperature within the determined range of fume FU. Next, we determine the concentration of fumes (FU). In this case, the temperature and concentration of fumes are related. The deleted data is stored in the storage unit 58 beforehand, and the detection unit 54 refers to this data. The concentration of fumes (FU) can be determined from the temperature obtained from the image shown in Figure 7(c).

[0117] Furthermore, in the process of determining the state of the sputtered SP described above, the fume FU was omitted. As explained using Figure 6, in reality, fumes (FU) are generated, and the temperature image shows fumes (F). The image of U may be included. Therefore, the detection unit 54 determines the state of Hume FU. Using the method described in the melting process, the molten pool MP, keyhole KH, and sputter S Separate P from fume FU and remove fume FU from temperature image data (temperature image). The detection unit 54 uses the temperature image data (temperature image) from which the fume FU has been removed to determine the figure. The state of the sputtered SP can be determined using the method described with 6. Also, the detection unit 5 4 is the image data corresponding to the image shown in Figure 7(c), which was generated based on the average temperature image data. By separating the fume FU and sputter SP based on the difference in area, Alternatively, the state of the sputtered sputtering sputter can be determined. In this case, the size of the sputtered sputtering sputter can be assumed in advance. The area that can be treated is set as a threshold, and the detection unit 54 detects an area larger than this threshold as a fume. The FU (Filler Unit) is determined, and the area smaller than the threshold is determined as the sputtered SP (Sputter Sputter).

[0118] Furthermore, the detection unit 54 determines the state of the fume FU from the two-color temperature image data. It is not necessary. For example, regarding the acquisition unit 310, the imaging device 41 and the bifurcated optical system 42 and chromatic aberration Instead of the corrective optical system 43 and field aperture 302, an illumination device and an imaging device (not shown) may be used. In this case, as an example, in the space between the base plate 311 and the printing optical system 35 In Figure 1, the illumination device is located on the X-positive side relative to the center of the base plate 311, and the imaging device is located on the X-negative side. The devices are then positioned accordingly. Note that the illumination device and the imaging device are connected by the illumination light from the illumination device. They are positioned opposite each other so that the light is received by the imaging device. As an example, the illumination device (not shown) is existing The LED is a surface-emitting type, and the imaging device (not shown) has the same configuration as the imaging device 41 in Figure 1. .

[0119] Here, the space between the base plate 311 and the molding optical system 35 is created by the irradiation of laser light. When fumes (FU) are generated, the illumination light from the lighting device is scattered by the fumes. The light is received by the imaging device. In other words, it is received through a region where no fumes (FU) are generated. The intensity of light received through the region where Hume FU is generated is lower compared to the intensity of light itself. Therefore, the detection unit 54 detects the signal strength of each pixel in the image data generated by the imaging device. By comparing the degree with a predetermined threshold, the range in which fumes are being generated can be determined. Furthermore, the higher the concentration of fumes (FU), the greater the effect of scattering by fumes (FU). Therefore, the intensity of the illumination light from the lighting device is greatly attenuated. Consequently, the detection unit 54 is in the imaging device The Hume FU concentration (concentration) is determined based on the signal intensity of each pixel in the generated image data. The distribution can be determined.

[0120] Furthermore, the acquisition unit 310 consists of a set of illumination and imaging devices (not shown) arranged in different directions ( For example, with respect to the center of the base plate 311, the X-direction + side and the Y-direction + side (An illumination device is placed on the X-side and Y-side respectively, and detection is performed.) The unit 54 is based on the signal intensity of each pixel in the image data generated by each imaging device. Then, determine the spatial range and spatial concentration (concentration distribution) of fumes (FU) being generated. That's good too.

[0121] Note that lighting devices not shown do not necessarily have to be surface-emitting LEDs, and do not generate fumes (FU). Other existing configurations may be used as long as they allow for surface illumination across a possible space. Surface emission is not required; existing point-emitting type lighting devices may be used. Furthermore, the phase relationship between the state of the fume FU (range and concentration of sputtered SP) and the convection C of the molten pool MP. Relationship and correlation between convection C in the molten pool MP and the melting state (temperature information) of the molten pool MP. From this relationship, we can see the correlation between the state of the fume FU and the melting state of the melting pool MP. Based on the determined state of the fume FU, the detection unit 54 (indirectly) determines the melting of the molten pool MP. The state may also be determined. In this case, the phase between the state of the fume FU and the melting state of the melting pool MP Data related to the relationships is stored in the storage unit 58 in advance.

[0122] (2) Process to change the molding conditions The calculation unit 56 determines the state of the detection target area obtained by the detection unit 54 as described above. Based on this, if it is necessary to change the molding conditions, the power expressed by equations (1) to (3) above will be used. At least one of the values ​​of density PD, energy density ED, and temperature distribution T(r) is within the desired range. Set the values ​​of the parameters mentioned above included in each formula so that they are maintained. (Modification conditions change) If necessary, when printing is performed under the currently set printing conditions, the three-dimensional object will melt. In cases where there is a possibility of manufacturing defects such as shortages, abnormal shapes, or failure to obtain the desired metal crystals. The determination unit 57 determines whether or not the molding conditions need to be changed. The determination unit 57 is a detection unit If the state of the detection target area determined by 54 satisfies the reference range described later, the molding strip It has been determined that the item needs to be changed.

[0123] The calculation unit 56 uses information to change the molding conditions so that they match the set parameter values. To generate some change information. In this embodiment, the following are the molding conditions to be changed: Examples are given in 2-1) to (2-7). (2-1) Conditions of the laser light emitted toward the powder material P of the material layer, i.e., the irradiation unit 32 Related conditions (2-2) Scanning conditions for scanning the material layer with laser light, i.e., related to the scanning unit 33 Conditions for doing so (2-3) Conditions related to the atmosphere inside the enclosure 10 (2-4) Conditions for forming a material layer (2-5) Support conditions related to the base plate 311 of the molding tank 31 (2-6) Design information (design data) regarding the shape of the solidified layer or three-dimensional object. (2-7) Conditions related to powder material P

[0124] Specific examples of the molding conditions (2-1) to (2-7) above are shown below. As an example, Figures 8 and 9 show the main molding conditions and the basic conditions of power density PD and energy The relationship between energy density ED and temperature distribution T(r) and the parameters shown in equations (1) to (3) Figures 8 and 9 show the basic conditions that can be controlled by each molding condition, indicated by circles. Basic conditions that are absent or have little effect when controlled are indicated by blank spaces. Also, Figures 8 and 9 show each shaping strip. The relevant parameters in equations (1) to (3) are shown below. Note that Figures 8 and 9 are... Each printing condition can be changed in real time, during the printing of the next layer, and during the printing of the next object, as described above. This indicates when changes can be made.

[0125] (2-1) Conditions related to the irradiation unit 32 As a specific example of the fabrication conditions related to the conditions of the laser light emitted from the irradiation unit 32, see Figure 8. As shown, the output of the laser light [W] (laser power), the wavelength of the laser light [nm], and the laser The intensity distribution (profile) of the laser beam and the size of the laser beam [mm] (spot size). There is at least one condition that is met.

[0126] The laser output is determined by the laser beam emitted from the laser oscillator 321, which irradiates the powder material. The amount of heat transferred to P is affected; the higher the laser power, the greater the amount of heat absorbed by the powder material P. The laser output is determined by the parameter P mentioned above. L Modeling conditions for which change information is generated in relation to As mentioned above, when the laser output is increased, the power density PD and energy density increase. The ED and temperature distribution T(r) values ​​increase. The change information for changing the laser output is provided for irradiation. The new output value of the laser beam emitted from section 32, and the currently set output value of the laser beam. This is the correction value.

[0127] The wavelength of the laser light is related to the absorption rate of the powder material P, which absorbs the laser light. Generally, It is known that the shorter the wavelength of laser light, the higher the absorption rate of the powder material P. The wavelength of the laser light is a fabrication condition in which change information is generated in relation to parameter η. As the wavelength of light increases, the value of parameter η decreases. Therefore, the wavelength of laser light is important for power. - Affects the values ​​of density PD and energy density ED. For changing the wavelength of laser light. Change information includes, for example, which wavelengths of laser light can be emitted as laser light. This information indicates whether or not to fire.

[0128] As for the intensity distribution (profile) of the laser light, in this embodiment, as described above, Gau It is possible to switch between a cyan-distributed laser beam and a top-hat-distributed laser beam. The intensity distribution of a cyan-distributed laser beam is strongest near the central axis of the laser beam and increases towards the periphery. It gradually weakens. The intensity distribution of a top-hat laser beam is different from that of a Gaussian laser beam. Compared to the light beam, the laser beam is more uniform even in the peripheral areas away from the central axis. Therefore, in the case of a laser beam with a top-hat distribution, compared to a laser beam with a Gaussian distribution... Then, a laser beam with the necessary intensity for melting the powder material P is irradiated over a wide area of ​​the material layer. Therefore, the intensity distribution of the laser beam affects the spot size of the laser beam on the upper surface of the material layer. It gives; that is, the intensity distribution of the laser light changes in relation to parameter d, and information is generated. These are the fabrication conditions. Switching the laser beam intensity distribution to a top-hat distribution changes the spot size. As the amount increases, the amount of powder material P per unit area on the material layer flows in due to the irradiation of laser light. The amount of heat decreases. Therefore, when the intensity distribution is set to a top-hat distribution, the value of parameter d increases. As a result, the values ​​of power density PD and energy density ED decrease.

[0129] In a Gaussian-distributed laser beam, the intensity distribution is strongest near the central axis of the laser beam. Therefore, compared to a laser beam with a top-hat distribution, it has the intensity necessary for melting the powder material P. The laser beam is directed onto a narrow area on the material layer. This results in a smaller spot size. Therefore, the amount of heat flowing into the powder material P per unit area on the material layer increases due to the irradiation of laser light. Therefore, when the intensity distribution is a Gaussian distribution, the value of parameter d decreases, and power - The values ​​of density PD and energy density ED increase. Modification information for changing the intensity distribution of laser light includes, for example, a Gaussian distribution and a top-level distribution. This information indicates which intensity distribution of the chromatic distribution will be used to emit the laser beam. The intensity distribution of the laser light is determined by the laser quality [M 2 It is affected by ]. 2 If it is 1, The intensity distribution of the laser light is a single-mode Gaussian distribution, M 2 The more it changes from 1 Do (M 2 (where is a value of 1 or greater), the intensity distribution of the laser light changes from a single-mode Gaussian distribution. Therefore, the value of parameter d changes depending on the laser quality.

[0130] The spot size of the laser beam is the range on the XY plane of the material layer irradiated by the laser beam. This affects the material layer. The smaller the spot size of the laser beam irradiating the upper surface of the material layer, the more it affects the material layer. The amount of heat per unit area increases, and the amount of powder material per unit area on the material layer increases due to laser irradiation. The amount of heat flowing into P increases. As a result, the melting of the powder material P irradiated with laser light is accelerated. This affects the convection C within the molten pool MP. Therefore, the spot size of the laser beam is para This is a molding condition in which change information is generated in relation to meter d. The spot size increases. As a result, the parameter d becomes larger, and the laser beam irradiation causes the powder per unit area on the material layer to... As the amount of heat flowing into material P decreases, the values ​​of power density PD and energy density ED decrease. The spot size affects the value of the temperature distribution T(r). Change information for changing the lens is, for example, the concave lens 323a of the focus lens 323. This is the position in the X direction, or the amount of movement from the current position of the concave lens 323a. The wavelength of the laser light can be changed when creating the next object. Other printing conditions are as follows: Whether the change is made in real time, during the creation of the next layer, or during the creation of the next object, It can be changed.

[0131] (2-2) Conditions related to the scanning unit 33 As a specific example of the fabrication conditions for scanning material layers using laser light, , the scanning speed of the laser beam [mm / s] and adjacent in the direction intersecting the scanning direction of the laser beam The distance between the irradiation positions of the two laser beams (scanning pitch) [mm] and the distance between them and the scanning path of the laser beams. There is at least one condition. The scanning speed of the laser beam is the time it takes for the laser beam to irradiate a unit area of ​​the surface of the material layer. Related to this is the amount of heat that flows into the powder material P per unit area of ​​the material layer due to laser irradiation. Also, the temperature change (temperature gradient) in the molten pool MP due to the movement of the position where the laser beam is irradiated. There is an effect. When the scanning speed of the laser beam is high, the surface of the material layer is affected by the irradiation of the laser beam. The amount of heat flowing into the powder material P per unit area decreases. Laser beam scanning speed When the value is low, the amount of powder material contained per unit area of ​​the surface of the material layer is reduced by irradiation with laser light. The amount of heat flowing into material P increases. The scanning speed of the laser light is related to the above parameter v. These are the molding conditions under which change information is generated. As the scanning speed increases, the parameter v also increases, The values ​​of watt density PD, energy density ED, and temperature distribution T(r) decrease. The scanning speed is changed. Change information for this purpose includes, for example, new changes to the tilt angle of galvanometer mirrors 331 and 332. This is a correction value for speed and the rate at which the currently set tilt angle changes.

[0132] When the scanning pitch is small, adjacent coagulation regions already formed by laser irradiation may be affected. The heat from BE has a significant effect. Therefore, the initial state of powder material P that is not irradiated with laser light As the temperature rises, the amount of heat required to reach the desired temperature (e.g., the melting point) decreases. In other words, the smaller the scanning pitch, the greater the heat absorption rate of the powder material P. The larger the scanning pitch, the lower the heat absorption rate of the powder material P. Also, if the scanning pitch is small, the molten pool M At point P, heat from a direction different from the scanning direction of the laser beam affects convection C.

[0133] When the scanning pitch is large, adjacent coagulation regions already formed by laser irradiation Because the thermal influence from BE is small, the initial temperature of the powder material P that is not irradiated by the laser light is The amount of heat required to reach the desired temperature (e.g., the melting point) increases. The scanning pitch is a molding condition in which change information is generated in relation to the parameters η and Δy. When the scanning pitch is large, the value of parameter η is small and the value of parameter Δy is large. As a result, the energy density ED value becomes smaller. Scanning pitch is related to power density PD and temperature distribution. This affects the value of T(r). Change information for changing the scanning pitch is, for example, galvanic. A new setting angle to change from the current setting angle of Nomirror 331, 332, or the current This is a correction value used to change the angle from one set to a new set angle.

[0134] The scanning path of the laser beam is a method for setting the path for irradiating the surface of the material layer with laser light. These are the molding conditions. For example, the scanning path is based on the shape of the slice model data. After irradiating the outline of the (modeled object) with laser light, laser light is then irradiated into the inside of the outline. After irradiating the inside of the contour of the shape (modeling model) based on the slice model data with laser light Then, laser light is irradiated along the contour of the shape (modeling model) based on the slice model data. These include... Also, the scanning path of the laser beam is determined by the initial temperature of the material layer before the laser beam is irradiated. Based on T0, for example, residual stress is less likely to occur in the solidified layer fabricated by laser light. The path is determined to be such that...

[0135] As the scanning path of the laser beam, for example, as illustrated above, the slice model data After irradiating the base shape (model) with laser light along its contour, the laser light is then directed into the interior of the contour. When irradiation is performed, the light is directed onto the contour of the shape (modeling model) that is already based on the slice model data. The initial temperature of the powder material P inside the contour rises due to the diffusion of heat caused by the laser light. Therefore, the scanning path of the laser beam is related to the parameter P0 depending on the scanning path being changed. These are the molding conditions for which change information is generated in succession, including power density PD, energy density ED, and temperature. This affects the value of the degree distribution T(r). Change information for modifying the scan path is, for example, The new tilt angle values ​​for Rubano mirrors 331 and 332 and the timing for setting those tilt angle values. This is information about the ng. Each of the above printing conditions can be changed in real time, during the printing of the next layer, and during the printing of the next object. It can be changed at any time.

[0136] (2-3) Conditions related to the atmosphere inside the enclosure 10 As a concrete example of using the internal atmosphere of the enclosure 10 as a molding condition, the following is introduced into the enclosure 10. Flow rate of inert gas [mm 3 [mm / s] and the flow rate of the inert gas introduced into the housing 10 There is at least one condition, which is the temperature inside the enclosure 10 [°C]. In this embodiment, the flow rate and velocity of the inert gas are the initial values ​​of the material layer before irradiation with laser light. Temperature and laser irradiation affect the fumes FU generated from the powder material P. For example, if the flow rate or velocity of the inert gas is high, the inert gas will affect the surface of the material layer. As it cools, the temperature of the powder material P irradiated with laser light reaches the desired temperature (even if The amount of heat required to rise to the melting point increases. Therefore, the flow rate and velocity of the inert gas This affects the initial temperature of the powder material P before it is irradiated with laser light, so the parameter These are the molding conditions related to P0.

[0137] Furthermore, for example, if the flow rate or flow velocity of the inert gas is low, the laser light irradiation will be Therefore, the generated fumes (FU) remain near the laser beam irradiation position, and the laser beam moves towards the material layer. The light path of the laser is blocked. Therefore, the amount of heat flowing into the powder material P due to laser irradiation This can lead to a decrease in the expected melting state, resulting in a melting state different from the anticipated one. Therefore, The flow rate and velocity of the inert gas are determined by the absorption of heat when the powder material P absorbs heat caused by laser irradiation. Since it affects the rate, it is a molding condition related to the parameter η. The flow rate of the inert gas and the flow rate. Speed ​​refers to the shaping conditions in which change information is generated in relation to parameters P0 and η, for example. As the flow rate of the inert gas increases and the flow velocity increases, the value of parameter P0 decreases, The value of meter η increases, and the value of the temperature distribution T(r) decreases. The flow rate of the inert gas and the flow Speed ​​affects the values ​​of power density PD and energy density ED. The inert gas flow rate and Change information for changing the flow rate is, for example, a new valve in the intake device 131. Valve opening angle, new displacement of exhaust device 14, or currently set valve opening angle and displacement This is the correction value.

[0138] The temperature inside the housing 10 affects the initial temperature of the material layer before laser light is irradiated, and parameters These are the molding conditions under which change information is generated in relation to P0 of the data. The higher the temperature inside the housing 10, the better. The powder material P is also heated and its initial temperature is high, so the temperature of the powder material P is increased by the irradiation of the laser light. The amount of heat required for the temperature to rise to the desired temperature (e.g., the melting point) decreases. The temperature inside the housing 10 affects the initial temperature of the powder material P before it is irradiated with laser light. Therefore, it is a molding condition related to parameter P0, for example, when the temperature inside the enclosure 10 rises. Then, the value of parameter P0 increases, and power density PD, energy density ED, temperature The value of the cloth T(r) increases. Change information for changing the temperature inside the enclosure 10 is, for example, The new heating output value of heater 15, and the correction of the currently set heating output of heater 15. It is a value.

[0139] The temperature inside the enclosure 10 should be changed when the next layer is being fabricated or when the next object is being fabricated. This is possible. The flow rate and flow velocity of the inert gas introduced into the enclosure 10 can be changed in real time. Changes can be made at any time, whether during layer printing or during the printing of the next object. .

[0140] (2-4) Conditions for forming a material layer As a specific example of the molding conditions for forming the material layer, the travel speed of the blade 221 [mm / [s], the pressure [Pa] applied by the blade 221 to the powder material P, and the solidified layer after the formation of the solidified layer The time [s] the blade 221 waits before starting to form a new material layer on top of the blade, and The shape of the blade 221, the material of the blade 221, and the layer of material on the base plate 311 There is at least one condition related to the layer thickness [mm].

[0141] The moving speed of the blade 221 and the pressure that the blade 221 applies to the powder material P are formed This affects the flatness of the surface of the material layer, as well as the thickness and density of the material layer. For example, blade 2 When the movement speed of 21 is fast, compared to when the movement speed of blade 221 is slow, the material The flatness of the layer surface decreases, the layer thickness increases, and the density decreases. Also, the blade 221 is powder material When the pressure applied to material P is high, the flatness of the surface of the material layer is higher compared to when the pressure is low. The layer thickness increases, the density increases, and so does the travel speed of blade 221. These are the molding conditions that affect Δz, ρ, k, and α, for example, the movement of the blade 221. When the velocity is changed, the values ​​of energy density ED and temperature distribution T(r) are affected. The pressure applied by code 221 to the powder material P changes in relation to the parameters Δz, ρ, k, and α. These are the shaping conditions under which the report is generated. For example, as the pressure increases, the values ​​of the parameters ρ, k, and α As it increases, the value of the parameter Δz decreases, and the energy density ED and temperature distribution T(r) The value of increases. Change information for changing the movement speed of Blade 221 is for Blade 2 New values ​​for the motor output that constitutes the drive mechanism that moves 21, and the currently set motor This is a correction value for the output. It is a change to modify the pressure that blade 221 applies to the powder material P. The information includes, for example, the new drive amount value for the pressing mechanism and the currently set drive of the pressing mechanism. A correction value for the quantity is also acceptable.

[0142] The waiting time of blade 221 is, as mentioned above, due to the lasers applied to the material layer for the formation of the solidified layer. After the irradiation of the light is finished, the blade 221 feeds the powder material P from the material supply tank 21 to the molding tank. This is the time until the transfer to 31 begins. The waiting time for blade 221 is when new solidification layer is created on top of the solidified layer. It also affects the initial temperature of the material layer being formed. In other words, the longer the waiting time, the more the laser As the temperature of the solidified layer, which had risen due to light irradiation, decreases, new formation occurs on top of the solidified layer. The initial temperature of the material layer being treated becomes less likely to rise. In this case, the powder material irradiated with laser light The amount of heat required to raise the temperature of P to the desired temperature (e.g., the melting point) increases. Therefore, the waiting time of blade 221 is related to the generation of change information in relation to parameter P0. These are the molding conditions. For example, if the waiting time is long, the value of parameter P0 will decrease. Power density PD, energy density ED, and temperature distribution T(r) values ​​decrease. Blade 22 Change information for changing the waiting time of 1 is, for example, the drive mechanism that moves blade 221. A value indicating the timing of the start of drive for the motors that make up the structure, and the currently set motor drive This is a correction value for the timing of the start of movement.

[0143] If, for example, there is a defect in the blade 221, the thickness of the material layer will be adjusted according to the shape of the defect. The thickness may not be consistent, resulting in a decrease in flatness, or the laminate thickness may differ from the desired thickness, or within the material layer... The density may become uneven, and the surface roughness may increase. Also, blade 22 Even if there are no defects in 1, if the shape of the blade 221 changes, the powder material P Because the contact area of ​​the blade 221 changes, the density and flatness of the material layer change according to its shape. The layer thickness changes. Depending on the properties of the material of blade 221 and the material (type) of powder material P, Due to factors such as friction, the movement of the blade 221 is hindered, causing the base plate 311 and the fixed If the powder material P is not uniformly transferred onto the layer, the flatness of the formed material layer decreases, or the lamination becomes difficult. The thickness may differ from the desired thickness, the uniformity of density within the material layer may decrease, or the surface roughness may be large. There is a possibility that it may become damaged. Therefore, the shape and material of blade 221 are parametric. These are the molding conditions that affect Δz, ρ, k, and α, as well as the shape and material of the blade 221. When this is changed, the values ​​of energy density ED and temperature distribution T(r) are affected.

[0144] Note that changing the shape and material of blade 221 will result in changing the type of blade 221. This can be done by changing the shape and material of the blade 221. The change information is, for example, information indicating the replacement of blade 221. In this case, the molding apparatus 1 For example, the 3D printer will issue a notification prompting the replacement of blade 221. The notification method will be as follows: 1 monitors a message (not shown) indicating that the type of inert gas needs to be changed. It would be good to display the information or emit sound from a speaker (not shown). Also, between multiple types If the blade 211 has a configuration that allows for automatic replacement, control from the material control unit 51 Therefore, the type of blade 211 is automatically replaced. Also, the blade 221 mentioned above If the structure has a variable shape, the blade will be controlled according to the control from the material control unit 51. The shape of 221 can be changed. In this case, the change information generated is, for example, blade 221 This is information that instructs a change in shape.

[0145] When the thickness of the material layer is high, the amount of heat generated by the irradiation of the laser beam is in the Z direction of the material layer. - This can result in insufficient melting reaching the side surface (bottom surface), potentially causing molding defects such as insufficient melting. It is possible. Layer thickness is a fabrication condition in which change information is generated in relation to the parameter Δz. For example, as the layer thickness increases, the value of the parameter Δz increases, and the value of the energy density ED changes. The value decreases. Change information for changing the layer thickness is, for example, the recoater 22 as described above. This could be a new pressure value applied by blade 221 to the powder material P, or a correction value for the current pressure. New drive values ​​for the pressing mechanism of blade 221 and the currently set drive values ​​for the pressing mechanism Correction values ​​are also acceptable. The shape and material of blade 221 can be changed during the next printing process. The movement speed of the Raid 221, the pressure applied to the powder material P, the waiting time, and the thickness of the material layer are as follows: This can be changed when modifying the next layer or when modifying the next object.

[0146] (2-5) Support conditions related to the base plate 311 of the molding tank 31 As a molding condition related to the base plate 311 of the build tank 31, base plate 311 There is a temperature [°C] and The temperature of the base plate 311 affects the initial temperature of the material layer formed on top, The higher the temperature of the base plate 311, the more the powder material P is heated. Therefore, the base plate The higher the temperature of 311, the higher the initial temperature of the powder material P. In this case, the laser light is irradiated. The amount of heat required to raise the temperature of the powdered material P to a desired temperature (e.g., melting point) It decreases. Therefore, the temperature of the base plate 311 is related to the parameter P0. These are the molding conditions under which change information is generated. When the temperature of the base plate 311 is high, the parameters As the value of P0 increases, the values ​​of power density PD, energy density ED, and temperature distribution T(r) increase. It increases. Change information for changing the temperature of the base plate 311 is, for example, the heater. The new heating output value for 313, and the correction value for the currently set heating output of heater 313. That is the case.

[0147] Furthermore, if the temperature of the base plate 311 is high, the solidified layer that rises due to laser irradiation will When the temperature of the molten pool MP decreases, the amount of temperature decrease becomes smaller, so when the molten pool MP solidifies... The effect of residual stress is reduced. Also, as mentioned above, the temperature of the base plate 311 If it is high, it is necessary for the temperature of the powder material P irradiated with laser light to rise to the desired temperature. Because it requires less heat, it is possible to increase the scanning speed without changing the laser beam output. Yes. The temperature of the base plate 311 is changed when the next layer is fabricated or when the next object is fabricated. It can be changed.

[0148] (2-6) Design data related to the shape of the solidified layer or three-dimensional object Specific examples of using design data related to the shape of the solidified layer or three-dimensional object as the fabrication condition. As such, slice model data is the shape data of the solidified layer that is fabricated, and solidified layer and three dimensions There is at least one data set of shape data for the support part that supports the printed object.

[0149] Slice model data includes the shape of the solidified layer to be fabricated on the XY plane and the thickness of the solidified layer (S This is shape data used to determine parameters such as rice pitch. This is a molding condition in which change information is generated in relation to Δz. That is, the thickness of the solidified layer is large. As it gets worse, the value of the parameter Δz increases. The slice model data, which is the shape data, When changed, various shaping conditions for the laser beam from the irradiation unit 32 and scanning by the scanning unit 33 are affected. Because various molding conditions may change, the slice model data is power-dense. This affects the values ​​of degree PD, energy density ED, and temperature distribution T(r). Change information for modifying the data includes, for example, a new shape of the solidified layer in the XY plane or solidification Correction values ​​for the new thickness of the layer, or the shape of the solidified layer in the XY plane, or the thickness of the solidified layer. That is the case.

[0150] As mentioned above, the shape data of the support section is used to prevent deformation and damage between solidified layers and to the three-dimensional fabricated object. To prevent damage, the shape of the support structure, such as its thickness and length, is shown. The shape of the part is determined by the supporting solidified layer, the shape and size of the three-dimensional object, etc. The larger the volume of the support section, the more the support section of the solidified layer is formed by laser irradiation. The heat from the affected area has a significant impact on the material layer (powder material P) formed on top of that solidified layer. Furthermore, the powder material P is heated by the base plate 311, and the higher the initial temperature, Through the support structure formed within the solidified layer, the material is transferred from the base plate 311. The amount of heat transferred to the layer (powder material P) increases. Therefore, the shape data of the support part is The volume of the port section and the temperature of the base plate 311 can affect parameter P0. These are the build conditions and affect the values ​​of energy density ED and temperature distribution T(r). Support Change information for modifying the shape data of a part includes, for example, the new shape of the support part (length or These are values ​​such as thickness, and correction values ​​for the current shape of the support section (length, thickness, etc.). Slice model data and support member shape data will be updated when the next object is fabricated. It can be corrected.

[0151] (2-7) Conditions related to powder material P As a specific example of molding conditions related to powder material P, the particle size and particle size distribution of powder material P, and powder There is at least one condition related to the moisture absorption of material P and the type of powder material P. The variation in particle size and particle size distribution of the powder material P within the material layer is due to the material layer irradiated with laser light. It may affect thermal diffusivity and thermal conductivity, potentially causing melting failures. Also, particle size... When powder material P, which has a variability in particle size distribution, is transferred to the molding tank 31 by the blade 221, In the material layer, variations in thickness and density may occur, resulting in the solidified material being formed. The layer may contain defects such as voids. The particle size and particle size distribution are determined by the parameters Δz and ρ. These are molding conditions in which change information is generated in relation to k and α. For example, particle size / grain size distribution As it gets larger (the variability increases), the value of the parameter Δz increases, and the parameter As the values ​​of ρ, k, and α decrease, the values ​​of energy density ED and temperature distribution T(r) increase. The modification information for changing the particle size / particle size distribution of the powder material P is, for example, the formed material layer. This information instructs the removal of the old material and the formation of a new material layer.

[0152] The highly hygroscopic powder material P has low fluidity and can be smoothly transferred to the molding tank 31 by the blade 221. It is difficult to transport. Therefore, the flatness and thickness of the formed material layer are not uniform, and Surface roughness tends to increase. In other words, the hygroscopicity of the powder material P affects the parameter Δz. These are the molding conditions that give the following. Also, if the moisture absorption of the powder material P is high, the flatness of the material layer and the layer thickness will be affected. Because the density is not uniform, the temperature rise due to laser irradiation is not uniform, resulting in incomplete melting. Poor quality may result in defects such as voids in the solidified layer formed during molding. Furthermore, moisture absorption High-quality powder material P has low thermal conductivity and thermal diffusivity, so due to poor melting, the solidified layer formed during fabrication... Defects such as voids may occur. Therefore, the moisture absorption of the powder material P is a parameter. These are the molding conditions for which modification information is generated in relation to k and α. For example, the moisture absorption of powder material P. When the temperature is high, the values ​​of parameters k and α decrease, and the value of the temperature distribution T(r) decreases. The moisture absorption of the powder material P affects the values ​​of power density PD and energy density ED. Information for changing humidity, for example, requires heating the powder material P with heater 213. This includes information indicating the need for the heater and the value of the heating output of heater 213.

[0153] There are different types of powder materials P, each with different powder materials and additives. Different types of the raw material P result in differences in powder particle size, thermal conductivity, thermal diffusivity, etc. For example, when forming a material layer, the blade 221 can be used to cut powder material P of different particle sizes into the same material. Even when pressure is applied, if a large particle size powder material P is used, the small particle size powder material Because the gaps between particles within the material layer become larger than when material P is used, the material layers are stacked. The thickness increases, and the density decreases. Therefore, the type of powder material P depends on the parameters Δz and ρ. These are the fabrication conditions that affect k and α, and they also affect the energy density ED and temperature distribution T(r). The change information for changing the type of powder material P is, for example, different types of powder material This is information indicating the use of material P. In this case, the molding device 1, for example, provides the user with powder The molding device 1 will issue a notification prompting the replacement of material P. A message indicating that changes need to be made will be displayed on the monitor (not shown), or an audio message will be played. It is preferable to emit from a peaker (not shown). Also, different types for each of the multiple material supply tanks 21. When the powder material P is contained and the system has a configuration in which multiple material supply tanks 21 can be automatically replaced, According to the control from the material control unit 51, the material supply tank 21 is replaced, thereby supplying the powder material P The type will be automatically changed.

[0154] The particle size, particle size distribution, and type of the powder material P can be changed when creating the next molded object. The moisture absorption of the powder material P should be corrected when changing it during the next layer's fabrication or when changing it during the next fabrication of the object. It is possible. Furthermore, in the explanation using Figures 8 and 9 mentioned above, the following are included in (2-1) to (2-7) above. The parameters that are particularly relevant to each printing condition and that change significantly in response to changes in the printing conditions are as follows: The relevant parameters are shown as examples. However, if each molding condition is changed, equation (1) ~ ( 3) Among the parameters included in equation 3), parameters other than those exemplified above also have an effect. Therefore, taking into account that parameters other than those exemplified above may change, At least one of the power density PD, energy density ED, and temperature distribution T(r) is Modification information may be generated to change the molding conditions to achieve the desired range.

[0155] In this embodiment, the molding conditions are as shown in (2-1) to (2-8) above. In addition to the shape conditions, other existing molding conditions in the molding apparatus 1 may also be included. Other molding conditions This includes the oscillation mode of the laser light from the irradiation unit 32, the polarization state of the laser light, and the inert gas The type of oxygen, the oxygen concentration inside the housing 10, the pressure [Pa] inside the housing 10, and the base plate 3 11 types, build orientation data, 3D object shape data, and oxygen concentration of powder material P. It includes.

[0156] As mentioned above, the laser light oscillation mode in this embodiment is CW (continuous wave) oscillation. It is possible to switch between oscillation and pulse oscillation. In the case of pulse oscillation, compared to CW oscillation, Because the time it takes to become irradiated is short, the amount of heat absorbed by the powder material P at the location where the laser light is irradiated is However, it is smaller compared to the case of CW oscillation. Therefore, depending on the oscillation mode, the flow into the powder material P The difference in the amount of heat input affects the melting of the powder material P, particularly the depth of the keyhole KH. It is known that this affects the coagulation region BH width. In other words, the oscillation mode is power It affects the values ​​of density PD, energy density ED, and temperature distribution T(r). Laser light oscillation The change information for changing the mode is, for example, whether to use CW (continuous) oscillation or pulse oscillation. This information indicates whether the laser beam is emitted in real time. The laser beam oscillation mode is real time Changes can be made in any case, whether it is a change in the base, a change during the next layer of printing, or a change during the next layer of printing. It is possible.

[0157] Laser light can be polarized in various ways, such as circularly polarized or linearly polarized. The powder material P is a metal material. In the case of materials, the absorption of laser light is affected by the polarization state of the laser light. The polarization state affects the amount of heat flowing into the powder material P when irradiated with laser light. The polarization state of laser light is determined by the values ​​of power density PD, energy density ED, and temperature distribution T(r). It is a fabrication condition that affects at least one of the following: changing the polarization state of the laser light. The change information is, for example, the settable polarization state of the laser light emitted from the irradiation unit 32 (for example This information indicates which polarization state (such as circular polarization or linear polarization) to set. The polarization state of the light can be changed when modifying the next object during the printing process.

[0158] The type of inert gas can be selected from options such as nitrogen or argon. The type of inert gas is a molding condition selected according to the type of powder material P. For example, If the powder material P is titanium, and nitrogen is used as the inert gas, the powder material P will react with the nitrogen. Because it reacts, it is best to use argon as an inert gas. In this way, powder materials If an appropriate inert gas is not selected for the type of P, the powder material P and the inert gas will be used. The reaction causes the power density PD, energy density ED, and temperature distribution T(r) to change. This affects the value. The change information for changing the type of inert gas is different types of inert gas. This is information indicating the use of gas. In this case, the molding device 1 is, for example, deactivated by the user. The molding device 1 will provide a notification prompting the exchange of the inert gas. The notification method will be as follows: A message indicating that changes need to be made will be displayed on the monitor (not shown), or an audio message will be played. It is best to emit it from a beaker (not shown). Note that the type of inert gas will be changed when replacing tank 13. This can be done by using different types of inert gas in each of the multiple tanks 13. If the housing is equipped with a configuration that allows for the automatic replacement of multiple tanks 13, the housing control unit 53 According to the control system, the type of inert gas is automatically changed when tank 13 is replaced. The type of inert gas can be changed when the next object is fabricated.

[0159] The oxygen concentration inside the enclosure 10 is set to a concentration that does not oxidize the material layer during molten and solidified processes. These are the molding conditions. As mentioned above, an oxide film is formed on the surface of the powder material P as it oxidizes. The specific heat changes depending on the thickness of the oxide film, which affects the heat absorption and conduction of the powder material P. This will have an effect. Therefore, the oxygen concentration inside the enclosure 10 will affect the energy density ED and temperature distribution T( These are the molding conditions that affect the value of r). Changes to change the oxygen concentration inside the enclosure 10. The report may include, for example, new valve openings for the intake valve 131 or new exhaust valve 14. This is the displacement, or the correction value for the currently set valve opening or displacement. Inside the housing 10 The oxygen concentration can be changed when creating the next layer or when creating the next object. .

[0160] The three-dimensional object is created while the inside of the enclosure 10 is maintained at a predetermined pressure, so the enclosure 1 The pressure inside 0 is controlled as a molding condition. The pressure inside the housing 10 is controlled by the surface tension of the molten pool MP. It has an effect. As mentioned above, convection C in the molten pool MP affects the interaction between the surface and interior of the molten pool MP. Since this occurs due to differences in surface force, the pressure inside the housing 10 affects the convection C of the molten pool MP. These are the molding conditions that give the following. Convection C affects the temperature distribution in the molten pool MP, so the housing 1 The pressure inside 0 is a molding condition that affects the temperature distribution T(r). The pressure inside the enclosure 10 is changed. The change information for this purpose may include, for example, a new displacement for the exhaust system 14, or currently set This is a correction value for the exhaust volume. The pressure inside the housing 10 is changed during the next layer molding or during the molding of the next object. You can change it when you make a change.

[0161] As mentioned above, the build orientation data is data that indicates the build orientation of the solidified layer and the three-dimensional object. It is used when setting up slice model data. When the printing orientation is changed, the irradiation area Various shaping conditions for the laser beam from 32, and various shaping conditions for scanning by the scanning unit 33. This may change. Therefore, the build orientation data will be power density PD, energy It affects the values ​​of density ED and temperature distribution T(r). The changes generated relative to the build orientation data Further information includes, for example, information indicating the slicing direction when a new molding orientation is set. The build orientation data can be changed when creating the next object.

[0162] The shape data of a 3D model is in the form of design data (i.e., CAD data or STL data). Therefore, when the shape data of the three-dimensional object is changed, the laser from the irradiation unit 32... Various shaping conditions for light and various shaping conditions for scanning by the scanning unit 33 can be changed. These are the conditions for creating a three-dimensional object. For this reason, the shape data of the three-dimensional object is determined by the power density PD, e Energy density ED and temperature distribution T(r) are affected. The shape data of the 3D printed object The change information used for modification includes, for example, values ​​indicating the new shape of the 3D object, and the current 3D object. This is a correction value for the shape of the printed object. The shape data of the 3D printed object will be changed when the next object is printed. It can be corrected to this.

[0163] As described above, in this embodiment, the base plate 311 has different thickness and material It is configured to allow installation by selecting from several types of base plates 311. This prevents the solidified layer from deforming due to residual stress generated when the molten pool MP solidifies, and solidifies A base plate 311 having the necessary rigidity (thickness and material) to maintain the shape of the layer is selected. These are the shaping conditions for the material. Residual stress is caused by the temperature change until the molten powder material P solidifies. Since it occurs accordingly, the type of base plate 311 to suppress the generation of residual stress is warm This is a molding condition related to the degree distribution T(r). The base plate 311 is used when the next object is fabricated. It is possible to change this. Change information for changing the type of base plate 311 is, for example, This information indicates that different types of base plates 311 are used. In this case, the molding process Device 1, for example, notifies the user to replace the base plate 311. Method of notification For example, the molding device 1 communicates that it is necessary to change the type of base plate 311. When a message is displayed on a monitor (not shown) or sound is emitted from a speaker (not shown), Good. Also, if the base plate 311 has a configuration that allows for automatic exchange between multiple types... In that case, the type of base plate 311 is automatically selected according to the control from the molding control unit 52. It will be replaced with this.

[0164] When the powder material P is oxidized, an oxide film is formed on the surface of the powder material P as described above, The specific heat changes depending on the thickness of the oxide film. The oxide film of the powder material P is the heat transfer of the powder material P. This can affect conductivity and potentially cause melting failures. Therefore, the oxygen in the powder material P Concentration is a molding condition and affects the energy density ED. Oxygen concentration of powder material P. The change information generated for this purpose is, for example, that the powder material P needs to be heated by the heater 213. This includes information indicating the presence of the acid in the powder material P, and the value of the heating output of heater 213. The elemental density can be changed when modifying the next object during printing.

[0165] Next, we will explain specific examples of change information generated by the arithmetic unit 56. In the following explanation, At least one of the power density PD, energy density ED, and temperature distribution T(r) is within the desired range. To maintain the constraints, let's consider an example where the arithmetic unit 56 generates change information.

[0166] Based on the state of the detection target area determined by the detection unit 54, parameter P L It has been changed. Let's explain the case where this occurs. Parameter P L When increasing the power density PD, When increasing the value of the energy density ED or the temperature distribution T(r), the calculation unit 56, for example, For example, change information is generated to increase the laser output of the laser beam from the irradiation unit 32. Meter P L When reducing power density PD, energy density ED, or temperature When the value of the distribution T(r) is reduced, the calculation unit 56 calculates the laser beam from the irradiation unit 32. The system generates modification information to reduce the output. In this case, the generated modification information is for the irradiation unit 32 This is the output value of the laser light emitted from it. The output unit 55 outputs the generated change information as status information. The setting unit 59 outputs this to the molding control unit 52. The molding control unit 52, for example, is configured The output value of the laser beam is changed to the output value indicated in the change information, and the irradiation part is changed to the output value. A laser beam is emitted from 32. Parameter P L The data relating the value to the laser output is pre-stored in the storage unit 58. The calculation unit 56 then calculates the parameter P from this data. L The desired value corresponds to the ray The output value is read, and the newly read laser output value is generated as change information.

[0167] Based on the state of the detection target area determined by the detection unit 54, parameter P0 is changed. Let's explain the case where the parameter P0 is increased, i.e., the power density PD. When increasing the value of the energy density ED or the temperature distribution T(r), the calculation unit 56 then This generates change information so that at least one of the following changes to the molding conditions is made. In this case, as a change in the molding conditions, for example, a decrease in the flow rate and flow velocity of the inert gas, and the housing The temperature inside body 10 increases, the waiting time of blade 221 is reduced, and the temperature of base plate 311 is reduced. This includes an increase in degree. When the parameter P0 is reduced, i.e., power density PD, energy When reducing the energy density ED or the temperature distribution T(r), the calculation unit 56 performs the following calculations. The change information is generated so that at least one of the shape condition changes is made. In this case, As a change in the molding conditions, for example, increasing the flow rate and flow velocity of the inert gas, and the housing 10 Internal temperature decrease, extended standby time for blade 221, and temperature decrease of base plate 311. It includes.

[0168] If change information is generated to change the flow rate and velocity of the inert gas, output unit 5 5 outputs the generated change information as status information to the housing control unit 53 of the setting unit 59. The housing control unit 53, for example, sets the valve opening of the intake device 131 and the exhaust device 1 Change the displacement of 4 to the valve opening and displacement shown in the change information, and the changed valve opening and The intake system 131 and exhaust system 14 are operated based on the exhaust volume. If change information is generated to change the temperature inside the enclosure 10, the output unit 55 will generate The modified information is output to the enclosure control unit 53 as status information. Then, change the heating output of the set heater 15 to the heating output indicated in the change information. The heater 15 is operated using the updated heating output.

[0169] If change information is generated to change the waiting time of blade 221, output unit 55 The output unit 55 then sends the generated change information as status information to the material control unit 51 of the setting unit 59. Output. The material control unit 51, for example, waits for the set waiting time indicated by the change information. The time is changed to machine time, and blade 221 is moved during the changed waiting time. If change information is generated to change the temperature of the base plate 311, output unit 5 5 outputs the generated change information as status information to the molding control unit 52 of the setting unit 59. The molding control unit 52, for example, indicates the change in the set heating output of the heater 313 using change information. The heating output is changed, and the heater 313 is operated at the changed heating output.

[0170] The value of parameter P0, the flow rate and velocity of the inert gas, the temperature inside the housing 10, and the blade The data, which associates the waiting time of 221 with the temperature of the base plate 311, is stored in the memory unit. The data is stored in 58 beforehand. The calculation unit 56 selects the desired value from this data as the parameter value. The values ​​for each molding condition corresponding to the conditions are read, and the read new values ​​are generated as change information. . The parameter P0 is related to the scanning path of the laser beam, the volume of the support section, and the base plate. Depending on the temperature of 311, the shape of the support part (thickness, length, etc.) can also have an effect. The calculation unit 56 generates change information regarding the scanning path of the laser beam and the shape data of the support part. You may do so.

[0171] Based on the state of the target area determined by the detection unit 54, the parameter η is changed. Let's explain the case where the parameter η is increased, that is, the temperature distribution T(r) When the value is decreased or the value of the energy density ED is increased, the calculation unit 56, for example, The system generates change information so that at least one of the following changes to the molding conditions is made. In this case, the changes to the molding conditions include changing the wavelength of the laser light to a shorter wavelength and reducing the scanning pitch. This includes increasing the flow rate of the inert gas and increasing the flow velocity of the inert gas. On the other hand, when the parameter η is decreased, that is, when the value of the temperature distribution T(r) is increased... When reducing the total or energy density ED values, the calculation unit 56 considers, for example, the following molding conditions The change information is generated so that at least one of the changes is made. The changes include changing the wavelength of the laser light to a longer wavelength, increasing the scanning pitch, and using an inert gas. This includes a decrease in flow rate and a decrease in flow velocity.

[0172] Information regarding the change in the wavelength of the laser light is output to the molding control unit 52 by the output unit 55. For example, Unit 52 changes the set wavelength of the laser light to the wavelength indicated in the change information. Then, laser light is emitted from the irradiation unit 32 at the modified wavelength. If change information is generated to change the wavelength of the laser light, the output unit 55 will output the generated information. The modified information is output as status information to the molding control unit 52 of the setting unit 59. For example, the set wavelength of the laser light is changed to the wavelength indicated in the change information, and after the change... Laser light is emitted from the irradiation unit 32 at the specified wavelength. If change information for changing the scanning pitch is generated, the output unit 55 will output the generated The change information is output as status information to the molding control unit 52 of the setting unit 59. The molding control unit 52 then For example, the current setting angle of galvanometer mirrors 331 and 332 is changed to a new setting indicated in the change information. The angle is changed to a fixed angle, and the scanning unit 33 is operated at the changed set angle. If change information is generated to change the flow rate and velocity of the inert gas, As described above, the output unit 55 outputs status information to the housing control unit 53 of the setting unit 59. The housing control unit 53, for example, with the valve opening and exhaust volume changed based on the change information, The intake system 131 and exhaust system 14 are activated. The value of parameter η, the scanning pitch, and the flow rate and velocity of the inert gas are correlated. The data is pre-stored in the memory unit 58. The arithmetic unit 56 takes this data as parameters. The values ​​of each molding condition corresponding to the desired value are read, and the read new values ​​are used as change information. It generates.

[0173] Based on the state of the target area determined by the detection unit 54, parameter d is changed. Let's explain the case where the parameter d is increased, that is, the power density PD and e When the value of the energy density ED is reduced, the calculation unit 56 changes, for example, the following molding conditions Generate change information so that at least one of the modifications is performed. In this case, the molding conditions The changes include changing the laser beam intensity distribution to a top-hat distribution, and the laser beam spot size This includes an increase in the size. When the parameter d is decreased, i.e., power density PD and e When the value of the energy density ED is increased, the calculation unit 56 changes, for example, the following molding conditions Generate change information so that at least one of the modifications is performed. In this case, the molding conditions The changes include changing the laser beam intensity distribution to a Gaussian distribution and the laser beam spot size. This includes a decrease in [something].

[0174] If modification information is generated to change the intensity distribution of the laser light, the output unit 55 will The modified information is output as status information to the molding control unit 52 of the setting unit 59. 52, for example, changes the set laser light intensity distribution to the intensity distribution indicated in the change information. The laser beam is emitted from the irradiation unit 32 with the modified intensity distribution. If change information for changing the spot size is generated, the output unit 55 will output the generated information. The modified information is output as status information to the molding control unit 52 of the setting unit 59. For example, it controls a drive mechanism (not shown) to move a concave lens to the position in the X direction indicated by the change information. Move 323a. The data relating parameter d to the intensity distribution and spot size of the laser light The data is pre-stored in the memory unit 58. The arithmetic unit 56 then selects the desired parameters from this data. Read the values ​​of each molding condition corresponding to the value, and generate the read new value as change information. do. Furthermore, when changing parameter d, the calculation unit 56 affects the intensity distribution of the laser light. Change information may be generated regarding the divergence angle of the laser beam.

[0175] Based on the state of the target area determined by the detection unit 54, the parameter v is changed. Let's explain the case where the parameter v is increased, that is, the power density PD and e When the values ​​of energy density ED and temperature distribution T(r) are reduced, the calculation unit 56, for example, - Generates change information to increase the scanning speed of the light. When parameter v is decreased, In other words, when increasing the values ​​of power density PD, energy density ED, and temperature distribution T(r) The calculation unit 56 generates change information, for example, to reduce the scanning speed of the laser beam.

[0176] If change information is generated to change the scanning speed of the laser beam, the output unit 55 will The modified information is output as status information to the molding control unit 52 of the setting unit 59. Molding control Part 52 controls, for example, the speed at which the tilt angle of the set galvanometer mirrors 331 and 332 is changed. The value is changed to the rate of change of the tilt angle indicated in the change information, and the rate of change of the tilt angle after the change is set to Then the scanning unit 33 is operated. Data relating parameter v to the scanning speed of the laser beam is pre-recorded in the storage unit 58. The calculation unit 56 calculates the value corresponding to the desired parameter v value from this data. The scan speed value is read, and a new laser beam scan speed is generated as change information.

[0177] Based on the state of the target area determined by the detection unit 54, the parameter Δy is changed. Let's explain the case where the parameter Δy is increased, i.e., the energy density When the value of ED is decreased, the calculation unit 56 generates change information so that the scanning pitch increases. To do this, decrease the parameter Δy, i.e., increase the value of the energy density ED. In this case, the calculation unit 56 generates change information so that the scanning pitch decreases. As described above, the information is sent as status information by the output unit 55 to the molding control unit 52 of the setting unit 59. The output is sent to the following location. The molding control unit 52, for example, changes the setting angle indicated in the change information. Then, the scanning unit 33 is operated at the changed set angle. The data relating the parameter Δy to the scanning pitch is pre-stored in the storage unit 58. The calculation unit 56 scans the data to determine the desired value for the parameter Δy. The pitch value is read, and a new scan pitch is generated as change information.

[0178] Based on the state of the target region determined by the detection unit 54, the parameter Δz is changed. Let's explain the case where the parameter Δz is increased, i.e., the energy density When the value of ED or the temperature distribution T(r) is reduced, the calculation unit 56 performs, for example, the following Generate change information so that at least one of the condition changes is made. As a change in shape conditions, the pressure applied by the blade 221 to the powder material P is reduced, and the layer thickness is increased. The process involves adding material, increasing the particle size and particle size distribution to increase particle size variation, and solidifying This includes increasing the thickness of the slice model data, which is the shape data of the layer. This makes it more difficult for heat from laser irradiation to be transferred to the powder material P. Parameter Δz If you decrease it, that is, increase the value of the energy density ED or the temperature distribution T(r) If so, the calculation unit 56 determines that at least one of the following changes to the molding conditions is performed. The system generates change information accordingly. In this case, as a change in the molding conditions, the blade 221 is powder By increasing the pressure applied to material P, the layer thickness is reduced, and the particle size and particle size distribution are reduced. This reduces the variation in particle size and the thickness of the slice model data. This includes the fact that the heat from the laser beam irradiation is more easily transferred to the powder material P.

[0179] If change information is generated to change the pressure that blade 221 applies to the powder material P, The output unit 55 uses the generated change information as status information for the material control unit 51 of the setting unit 59. Output is sent to the material control unit 51, for example, by controlling the pressing mechanism of the blade 221, The D221 applies pressure to the powder material P based on the change information. If change information is generated to change the particle size / particle size distribution, the output unit 55 will output the generated information. The modified information is output as status information to the material control unit 51 and the molding control unit 52 of the setting unit 59. The material control unit 51 and the molding control unit 52, for example, the recoater 22 and the drive mechanism 212 and drive The moving mechanism 312 controls the removal of the formed material layer and the formation of a new material layer. To perform an action.

[0180] Change information is generated to modify the slice model data, which is the shape data of the solidified layer. If this occurs, the output unit 55 uses the generated change information as status information to control the molding process of the setting unit 59. Output to unit 52. The molding control unit 52 determines that the solidified layer has a new thickness based on the change information. The values ​​of the fabrication conditions for the irradiation unit 32 to emit laser light so that fabrication is possible, and the scanning unit The values ​​of the molding conditions for scanning the laser beam by 33, and the amount of movement of the drive mechanism 312 are changed. In this case, the thickness of the solidified layer to be fabricated and the fabrication conditions for the irradiation unit 32 to emit laser light. The data is stored in which the values ​​and the fabrication conditions for scanning the laser beam by the scanning unit 33 are associated. It is stored in unit 58. The molding control unit 52 refers to this data and sets the new solidification layer thickness. The irradiation unit 32 and the scanning unit 33 are operated under suitable molding conditions.

[0181] The parameters Δz, the pressure applied to the powder material P, the particle size / particle size distribution, and the slice model Data associated with the thickness of the data is pre-stored in the storage unit 58. The calculation unit 56 performs the following: From this data, read out the values ​​of each molding condition that correspond to the desired value of the parameter Δz. Then, the newly read value is generated as change information. Note that the parameter Δz is related to the movement speed of the blade 221 and the type (shape) of the blade 221. The calculation is affected by the shape and material, the moisture absorption of the powder material P, and the type of powder material P. Section 56 may generate change information for each of the above. Furthermore, Δz can also be changed by changing the amount of movement of the base plate 311 in the Z direction. Therefore, the calculation unit 56 is a drive mechanism for moving the base plate 311. Change information may be generated based on the drive amount of 312.

[0182] Based on the state of the detection target region determined by the detection unit 54, the parameters ρ, k and Let's explain what happens when α is changed. When the parameters ρ, k, and α are increased, In other words, when increasing the values ​​of energy density ED and temperature distribution T(r), the calculation unit 56 For example, change information is generated so that at least one of the following changes to the molding conditions is made. To achieve this, in this case, as a change in the molding conditions, the pressure that the blade 221 applies to the powder material P is This includes increasing the particle size and reducing the particle size distribution, thereby minimizing particle size variation. This increases the density of the powder material P, and consequently, the thermal conductivity and thermal diffusivity of the powder material P. This increases. As a result, heat from laser irradiation is more easily conducted through the material layer. When ρ, k and α are reduced, i.e., the energy density ED and temperature distribution T( When the value of r) is reduced, the calculation unit 56 considers, for example, at least one of the following changes to the molding conditions. The system generates change information so that at least one change is performed. In this case, the change in the molding conditions is as follows: The Rade 221 reduces the pressure applied to the powder material P and increases the particle size and particle size distribution. This involves increasing the variation in particle size. As a result, the density of the powder material P is low. As a result, the thermal conductivity and thermal diffusivity of the powder material P decrease. The heat becomes less likely to be conducted through the material layer.

[0183] The parameters ρ, k, and α are related to the pressure applied to the powder material P and the particle size / size distribution. The deleted data is stored in the memory unit 58 beforehand. The arithmetic unit 56 uses this data to calculate each parameter The values ​​of each molding condition corresponding to the desired value are read as the meter value, and the new value read is Generate this as change information. The parameters ρ, k, and α are the movement speed of the blade 221 and the movement of the blade 221. Since it is also affected by the type (shape and material) and the type of powder material P, the calculation unit 56 is as described above. Change information may be generated for each of these. Furthermore, parameters k and α are also affected by the moisture absorption of the powder material P. When increasing k and α, that is, when increasing the value of the temperature distribution T(r), The calculation unit 56 reduces the amount of absorbed moisture.

[0184] As described above, when the calculation unit 56 generates change information, the output unit 55 outputs the generated change The material control unit 5 of the setting unit 59 uses the information as state information and adjusts it according to the content of the changes to the molding conditions. It outputs to 1, the molding control unit 52, and the housing control unit 53. The material control unit 51 outputs, for example, material The operation of the layer forming section 20, that is, the drive mechanism 212 that drives the bottom surface 211 of the material supply tank 21. Operation, and the movement of blade 221 (movement speed of blade 221, blade 221 and powder material) The pressure applied to P, the waiting time of the blade 221, and the powder material contained in the material supply tank 21. The heating temperature of the heater 213 that heats the material is controlled. Also, for example, the molding control unit 52 In accordance with the contents of the change information, the operation of the irradiation unit 32, scanning unit 33, and base plate 311 and The operation of the drive mechanism 312 that drives the motor 313 is controlled, and the design data is modified. For example, the housing control unit 53 controls the heater 15, the intake device 131, and the exhaust according to the change information. The operation of device 14 is controlled to control the atmosphere inside the housing 10. The calculation unit 56 calculates the difference between the newly generated values ​​of each molding condition and the current values ​​of the molding conditions. The correction value, which is a value, may also be used as change information. In this case, the output unit 55 is generated by the calculation unit 56. The modified information is output to the setting unit 59 as status information. Material control unit 51, molding control unit 52, The housing control unit 53 uses the input state information as a correction value to correct the molding conditions, and adjusts each part Operation control.

[0185] Next, we will discuss one specific example of the processing performed by the detection unit 54 and the calculation unit 56 in real time. This section explains the cases of changes to the model and changes made during subsequent layer printing. First, we will explain one specific example of how to handle real-time changes. In the following description, the detection unit 54 determines the state of the target area as the powder material P before heating. Let's look at two examples: one where the state is determined, and another where the molten state is determined. First, as a process for real-time changes, the detection unit 54 determines the state of the detection target area as follows: Powder material P (i.e., molten pool) that has not yet begun to melt before being heated by laser irradiation. The calculation unit 56 obtains information about the temperature (near MP) and calculates the energy density ED value as desired. Let's take the example of generating change information to keep it within the range. Note that the calculation unit 56 is energy - Not limited to generating change information to keep the density ED value within a desired range, power At least one of the following: density PD value, energy density ED value, and temperature distribution T(r) value You may generate change information to keep one of them within the desired range.

[0186] Each process in the flowchart shown in Figure 10 is stored in the storage unit 58 of the arithmetic unit 50 and calculated It is read by device 50 and executed. In step S31, the material control unit 51 processes the material layer forming unit 20 according to the set molding conditions. The process proceeds to step S32 after forming a material layer. In step S32, the molding control unit 52 sets The molding unit 30 is made to create a solidified layer under predetermined molding conditions. The calculation unit 50 controls the irradiation unit 3 When laser light irradiation by 2 is started, the imaging device 41 detects the target area on the surface of the material layer. The system is made to take an image. The detection unit 54 uses the image data generated by the imaging device 41 to perform the following actions. Then, temperature image data is generated, and from the temperature image data, the powder material P in the material layer before melting is obtained. The temperature is determined. The detection unit 54 also determines the temperature of the solidification region BE adjacent to the path through which the laser light is scanned. You may also calculate the temperature.

[0187] In step S33, the determination unit 57 determines the powder material P of the material layer determined by the detection unit 54. It is determined whether the temperature meets a predetermined first reference range. The first reference range is The temperature of the material layer (powder material P) is such that the energy density ED is kept within the desired range described above. This is a range of degrees. This first reference range (temperature range of powder material P) is, for example, for the user The temperature and energy of the powder material P, determined through various tests and simulations. - It is set based on its correlation with density ED. This first reference range is reserved in the memory unit 58. The data is stored, and the determination unit 57 reads out this first reference range and proceeds to step S33 or the following steps. This is used for the determination process in step S34.

[0188] The first reference temperature range is, for example, when the powder material P is aluminum, room temperature In this case, the temperature should be within the range of 20°C ± 5°C, and when preheating, it should be within the range of 200°C ± 10°C. Yes, if the determination unit 57 determines that the temperature of the material layer does not meet the first reference range. Then the process proceeds to step S34, and if the temperature of the material layer meets the first reference range, the determination unit 5 If the determination is made according to 7, the process proceeds to step S37 described later. In other words, determination In step S33, unit 57 determines whether or not it is necessary to generate change information. Furthermore, the first reference range mentioned above is not limited to energy density ED, but also includes power density PD and temperature The degree distribution T(r) may be set to be kept within a desired range.

[0189] In step S34, the determination unit 57 determines whether the temperature of the material layer is higher than the first reference range, or the second Determine if it is lower than the first reference range. Determine if the temperature of the material layer is higher than the first reference range. If determined by section 57, the process proceeds to step S35, and the temperature of the material layer is first If the determination unit 57 determines that the value is lower than the reference range, the process proceeds to step S36. nothing. Furthermore, if the detection unit 54 determines the temperature of the adjacent solidification region BE, the determination unit 57 will determine the temperature of the adjacent When affected by the heat of the solidification region BE in contact with it, the energy density ED and power density PD and the range of temperatures of the material layer such that at least one of the temperature distributions T(r) is kept within a desired range. A comparison is made with the first reference range, which is set as the boundary.

[0190] In step S35, the calculation unit 56 calculates to include the energy density ED within the desired range. This generates change information to modify the build conditions in order to lower the energy density (ED) value. The reason for lowering the energy density ED is that the temperature of the material layer is higher than the first reference range. Because the heat is also high, when laser light is irradiated onto the powder material P, even with a small amount of heat, the powder material P The temperature rises to the desired temperature (e.g., the melting point). Therefore, the energy absorbed by the powder material P This is because it is predicted that the energy density ED of the energy will be excessive. To lower the energy density ED and reduce the energy absorbed by the powder material P, By reducing the output of the laser light from the irradiation unit 32, the energy absorbed by the powder material P is reduced. It is possible to reduce the -. Also, increase the flow rate of the inert gas and the flow velocity of the inert gas By increasing the temperature and cooling the surface of the material layer, the temperature of the powder material P is lowered, allowing the laser light to... It is also conceivable to reduce the effect of heating the powder material P by irradiation. By increasing the scanning speed of the laser beam, the laser beam can irradiate the same position on the material layer. It is also possible to shorten the time and reduce the energy absorbed by the powder material P.

[0191] Based on the above reasoning, the calculation unit 56, in order to reduce the value of the energy density ED, for example, Parameter P L At least one of the following is done: lowering P0 and raising parameter v. Change information is generated so as to. In this case, the calculation unit 56 generates change information so as to change the molding conditions shown below. Generate change information so that at least one of the following occurs. Parameter P L Related construction The change in shape conditions is to lower the laser power. The shape conditions related to parameter P0 The changes involve increasing the flow rate and velocity of the inert gas. The shape is related to parameter v. The change in conditions is to increase the scanning speed.

[0192] In this case, the calculation unit 56 determines the temperature of the material layer and the first reference range determined by the detection unit 54. The value of the energy density ED is reduced based on the difference from any value within it (e.g., maximum or median). Calculate the amount to be reduced (decrease). In this case, the decrease in energy density ED and the material The difference between the temperature of the layer and any value within the first reference range (e.g., maximum or median) is correlated. The generated data is pre-stored in the storage unit 58, and the calculation unit 56 uses this data to generate energy. The calculation unit 56 calculates the decrease in the value of the energy density ED. Next, from equation (2), each parameter P L The calculation unit 56 calculates new values ​​for P0 and v. The values ​​of each parameter and the values ​​of each molding condition, which have been stored in the memory unit 58 in advance, are associated with each other. By referring to the data, calculate the values ​​of each molding condition corresponding to the newly calculated parameter values. The values ​​of the molding conditions are generated as change information. As mentioned above, the calculation unit 56 generates new A correction value, which is the difference between the value of the existing molding condition and the current value of the molding condition, is generated as change information. The output unit 55 may output this correction value as status information to the setting unit 59.

[0193] The output unit 55 uses the change information generated by the calculation unit 56 as state information, and the setting unit 59 (shaping control Output is sent to at least one of the control unit 52 and the housing control unit 53. The molding control unit 52 is changed. When a report is input, the molding control unit 52 will turn on at least one of the irradiation unit 32 and the scanning unit 33. , and cause at least one of the following actions to be performed. In this case, the operation of the irradiation unit 32 is changed The laser beam is emitted at a new laser output based on the report. The operation of the scanning unit 33 is as follows: The galvanometer mirrors 331 and 332 are driven at a new tilt angle change rate based on the change information. This is what happens. When the housing control unit 53 inputs change information, the housing control unit 53 will... The device 131 and the exhaust device 14 are operated with new valve openings and exhaust volumes based on the change information. The process then returns to step S32.

[0194] In step S36, the calculation unit 56 adjusts the molding conditions to increase the value of the energy density ED. Generate change information to modify it. The reason for increasing the energy density ED value is as follows: Because the temperature of the material layer is lower than the first reference range, the laser light is irradiated onto the powder material P. In that case, a large amount of heat is required for the temperature of the powder material P to rise to the desired temperature (e.g., melting point). Therefore, the energy density ED of the energy absorbed by the powder material P is insufficient. Because it is predicted that this will happen.

[0195] In this case, the calculation unit 56 operates using the opposite approach to the one described in step S35 above. The molding conditions are changed to increase the energy density ED. In this case, the calculation unit 56, Parameter P L At least one of the following will happen: increase P0 and decrease parameter v. Change information is generated. In this case, the calculation unit 56 generates change information for the following changes in the molding conditions. Generate change information so that at least one action is taken. Parameter P L Related design elements The change in question is to increase the laser output. This involves changing the build conditions related to parameter P0. This is due to a decrease in the flow rate and velocity of the inert gas. The molding conditions related to parameter v. The change involves reducing the scanning speed. The calculation unit 56 calculates the material obtained by the detection unit 54. Based on the difference between the temperature of the layer and an arbitrary value in the first reference range (e.g., minimum or median), E Calculate the amount (increase) that increases the value of the energy density ED. In this case as well, the increase, and The difference between the temperature of the material layer and an arbitrary value in the first reference range (e.g., minimum or median) is associated with the temperature of the material layer. The deleted data is stored in the storage unit 58 beforehand, and the calculation unit 56 refers to this data to determine the energy The calculation unit 56 calculates the increase in the value of the energy density ED. Based on this, each parameter P L The calculation unit 56 calculates new values ​​for P0 and v. The data stored in section 58, which associates the values ​​of each parameter with the values ​​of each molding condition, is referenced. By referring to the newly calculated parameter values, the values ​​of each molding condition corresponding to those values ​​are calculated, and the molding condition Generate the value in question as change information.

[0196] The output unit 55 sets the change information as status information to the setting unit 59 (formation control unit 52 and housing control). Output to at least one of section 53. If the molding control unit 52 inputs change information, The molding control unit 52 controls at least one of the following operations: At least one operation is performed. In this case, the operation of the irradiation unit 32 is based on the change information and new radar The output is to emit laser light. The operation of the scanning unit 33 is based on the change information. The galvanometer mirrors 331 and 332 are driven at a speed that changes the tilt angle. (Enclosure control) If unit 53 inputs change information, the housing control unit 53 will control the intake device 131 and exhaust device 1 4 is operated with new valve openings and displacements based on the change information. After that, the process is st Return to step S32. In this case as well, the calculation unit 56 calculates the new molding condition values ​​and the current molding conditions. The output unit 55 generates a correction value, which is the difference from the value of the shape condition, as change information, and the output unit 55 uses this correction value as state The information may also be output to the setting unit 59.

[0197] In step S37, which proceeds when the temperature of the material layer meets the first reference range, the computing unit 5 A value of 0 indicates whether the fabrication of the first solidified layer has been completed. If none exists, the arithmetic unit 50 determines that step S37 is invalid, and the process returns to step S32. When the formation of one solidified layer is completed, the calculation unit 50 makes a positive determination in step S37. Then the process proceeds to step S38. In step S38, the computing unit 50 processes all solidified layers. Determine whether the molding process is complete or not. If the processing of all solidified layers is not complete, The calculation device 50 determines that step S38 is negative, and the process proceeds to step S31. All solidification When the processing of the layer is completed, the arithmetic unit 50 confirms step S38 and processes all End of discussion.

[0198] In the above explanation, the detection unit 54 detects the powder material before it is heated by laser irradiation. The example given was determining the temperature of material P, but the example is not limited to this case. For example, the powder of the material layer. Foreign matter and spatter SP mixed in the material P may also be detected. In this case, the detection unit 54 uses a two-color method. Without obtaining temperature information using the imaging device 41, Foreign matter and sputtered SP may be detected using an image processing method. In this case, detection unit 5 4, for example, uses pre-acquired training images to analyze the particles, foreign matter, and sputter of the powder material P. Based on the differences in size and shape of SP, the image data captured by the imaging device 41 is used to determine the powder material Alternatively, P, foreign matter, and sputtered SP can be separated and determined separately. Also, for example, an imaging device... Foreign objects and sputtered SPs can be detected on a color image generated by an imaging device different from the one in position 41. You can do that. By performing the above process, one of the basic conditions for the melting and solidification of the powder material P is achieved. Maintain the energy density ED within the desired range, and prevent energy deficiencies or excesses in the powder material P. This can suppress the occurrence of molding defects in the solidified layer due to excessive pressure.

[0199] Next, as one example of a specific case of processing when making real-time changes, the detection unit 54 The calculation unit 56 obtains information regarding the temperature of the molten pool MP and its vicinity as the state of melting, and then... Let's take the example of generating change information to keep the energy density ED value within a desired range. The calculation unit 56 generates modification information to maintain the energy density ED value within a desired range. This is not limited to the following: the power density PD value, the energy density ED value, and the temperature distribution T. Change information may be generated to keep at least one of the values ​​of (r) within a desired range.

[0200] Each process in the flowchart shown in Figure 11 is stored in the storage unit 58 of the arithmetic unit 50 and calculated It is read by device 50 and executed. The processes in steps S41 and S42 are shown in step S31 in the flowchart of Figure 10. The process is the same as in S32. However, in step S42, the detection unit 54 is the imaging unit Using the temperature image data generated from the image data obtained by imaging with device 41, the melting pool As information regarding the temperature of MP and its vicinity, the temperature distribution of the melting pool MP is determined. This is shown in Figure 11. In this specific example, the detection unit 54 uses temperature image data to determine any temperature among the melting pool MPs. Let's take the case of determining the diameter of a degree isotherm as an example.

[0201] In step S43, the determination unit 57 determines the temperature of the molten pool MP obtained by the detection unit 54. The diameter of the isotherm at any temperature of the cloth, i.e., the molten pool MP, is within a predetermined first reference range. Determine whether the condition is met. The first reference range is when the temperature distribution T(r) is kept within the desired range. This is the range of diameters of isotherms for which... The temperature distribution of the molten pool MP (at any temperature) is determined by tests and simulations. This is set based on the correlation between the diameter of the heating element and the temperature distribution T(r). The range is pre-stored in the memory unit 58, and the determination unit 57 reads out this first reference range and... Used for the determination process in step S43 and step S44 described later. Diameter of the isotherm of the molten pool MP. If the determination unit 57 determines that the first standard range is not met, the process proceeds to step S. Proceed to 44, and if the determination unit 57 determines that the diameter of the isotherm meets the first reference range, The process then proceeds to step S47, which will be described later. In other words, the determination unit 57 proceeds to step S43 In this process, it is determined whether or not it is necessary to generate change information. Furthermore, the first reference range mentioned above is not limited to the temperature distribution T(r), but also includes power density PD and energy The energy density ED may be set to be kept within a desired range. Also, the first reference range The range of the diameter of the resulting isotherm is the temperature between the melting point and the liquidus temperature of the powder material P used. Alternatively, it may be the range of isotherm diameters corresponding to the temperature range between the melting point and the solidus temperature.

[0202] In step S44, the determination unit 57 determines whether the diameter of the isotherm is higher than the first reference range, or the first Determine if it is lower than the reference range. If the diameter of the isotherm is higher than the first reference range, determination unit 5 If determined by step 7, the process proceeds to step S45, and the diameter of the isotherm falls within the first reference range. If the determination unit 57 determines that the value is lower than the enclosure, the process proceeds to step S46.

[0203] In step S45, the calculation unit 56 includes the value of the energy density ED within the desired range. Therefore, change information is generated to modify the build conditions in order to lower the energy density (ED) value. The reason for lowering the energy density ED is the diameter of the isotherms of the molten pool MP. If it is greater than the first reference range, then the molten pool MP is the currently set molding condition This means that the resulting molten pool MP is larger than expected. It is estimated that the energy density ED of the energy absorbed by the internal powder material P is excessive. This is for the purpose of cutting.

[0204] In this case, the calculation unit 56 performs the same procedure as in step S35 of Figure 10, To lower the value of degree ED, parameter PL Lowering P0 and increasing parameter v Change information is generated so that at least one of the following occurs. That is, the arithmetic unit 56 By lowering the laser power, increasing the flow rate and velocity of the inert gas, and increasing the scanning speed The arithmetic unit 56 generates change information so that at least one of the following is performed: reduce. The specific processing performed to generate the additional information is as follows: Similarly, this is done while referring to the data stored in the memory unit 58. The output unit 55 performs The change information generated by the calculation unit 56 is used as status information by the setting unit 59 (shaping control unit 52 and housing). Output to at least one of the control units 53. When the molding control unit 52 receives change information. The molding control unit 52 controls at least one of the following operations of the irradiation unit 32 and the scanning unit 33. Perform at least one action. In this case, the operation of the irradiation unit 32 is based on the change information. The laser emits laser light at the laser output. The operation of the scanning unit 33 is based on the change information. The galvanometer mirrors 331 and 332 are driven at a new rate of change in tilt angle. If the control unit 53 receives change information, the housing control unit 53 will control the intake device 131 and exhaust device The device 14 is operated with new valve openings and exhaust volumes based on the change information. The process then proceeds as follows: Return to step S42.

[0205] In step S46, the calculation unit 56 includes the value of the energy density ED within the desired range. Therefore, change information is generated to modify the build conditions in order to increase the energy density (ED) value. The reason for increasing the energy density ED is that the diameter of the isotherms in the melting pool MP is Being smaller than the first reference range means that the molten pool MP is at the currently set molding conditions. This means that the resulting molten pool MP is smaller than expected. It is estimated that the energy density ED of the energy absorbed by the powder material P in the section is insufficient. This is for the purpose of cutting.

[0206] In this case, the calculation unit 56 performs the same procedure as in step S36 of Figure 10, To increase the degree of ED, parameter P L Increasing P0 and decreasing parameter v Change information is generated so that at least one of the following is performed. That is, the arithmetic unit 56 performs By increasing the fan power, reducing the flow rate and velocity of the inert gas, and lowering the scanning speed... The arithmetic unit 56 generates change information so that at least one of the following is performed. The specific process performed to generate the product is the same as in step S36 as explained in Figure 10. This is done while referring to the data stored in the memory unit 58. The output unit 55 is the arithmetic unit 56 The change information generated by the setting unit 59 (formation control unit 52 and housing control unit 53) is set as status information. Output to at least one of the following. If the molding control unit 52 receives change information, the molding control unit The unit 52 performs at least one of the following operations: the irradiation unit 32 and the scanning unit 33 One operation is performed. In this case, the operation of the irradiation unit 32 is a new laser output based on the change information. The laser beam is emitted. The operation of the scanning unit 33 is based on the new tilt information. The galvanometer mirrors 331 and 332 are driven by the angle change speed. (Housing control unit 53) If change information is entered, the housing control unit 53 will control the intake device 131 and exhaust device 14. The system operates with new valve openings and displacements based on the changed information. The process then proceeds to step S. Return to 42. In steps S45 and S46, the calculation unit 56 calculates the new molding condition values ​​and the current molding conditions. The output unit 55 generates a correction value, which is the difference from the value of the shape condition, as change information, and the output unit 55 uses this correction value as state The information may also be output to the setting unit 59.

[0207] If the diameter of the isotherm satisfies the first reference range, the process in steps S47 and S48 proceeds as follows: This is similar to the process in steps S37 and S38 of Figure 10. By performing the above process, the basic conditions for the melting and solidification of the powder material P are brought to a desired range. This maintains the structure and suppresses the occurrence of molding defects in the solidified layer due to insufficient or excessive melting. In step S42, the detection unit 54 detects the temperature of the molten pool MP and its vicinity. The information includes the ratio of the major axis to the minor axis of the melting pool MP on the XY plane, and the melting pool on the XY plane. The temperature gradient of the molten pool MP may also be determined. In this case as well, the energy density ED and power density P For at least one of D and the temperature distribution T(r) to be kept within the desired range, the molten pool MP The ratio of the major axis to the minor axis on the XY plane, and the temperature gradient of the molten pool MP on the XY plane, are defined as follows: It may be used as the reference range. In this case as well, the first reference range is, as described above, for the user. It is set based on the results of various tests and simulations.

[0208] If the ratio of the long axis to the short axis of the molten pool MP is greater than the first reference range, the powder material P is absorbed. The energy density ED of the energy being used becomes excessive, and the melting pool MP is currently set to It can be estimated that the molten pool MP is larger than what would be expected from the shape conditions. Therefore, The calculation unit 56, in the same manner as in step S45, reduces the value of the energy density ED. The change information should be generated. The ratio of the long axis to the short axis of the melting pool MP is smaller than the first reference range. In the opposite case, the calculation unit 56 generates change information in the same manner as in step S46. That's all you need to do. Furthermore, if the temperature gradient of the molten pool MP is greater than the first reference range, the powder material P will absorb it. The energy density ED of the energy being used becomes excessive, causing rapid temperature changes within the melting pool MP. It can be inferred that this is the case. Therefore, the calculation unit 56 determines that the value of the energy density ED is decreasing. The change information can be generated in the same manner as in step S45. The temperature of the melting pool MP. If the gradient is smaller than the first reference range, the calculation unit 56 proceeds to step S4 by the reverse logic. You can generate the change information in the same way as in step 6.

[0209] Next, as one example of a specific case of processing when making real-time changes, the detection unit 54 The state of sputtering SP is determined, and the calculation unit 56 maintains the energy density ED within a desired range. Let's take the case where change information is generated as an example. Note that the calculation unit 56 calculates the energy density ED Not limited to generating change information to keep the value within a desired range, the power density PD value At least one of the values ​​of the energy density ED and the temperature distribution T(r) is desired. You may generate change information to keep it within the specified range.

[0210] Each process in the flowchart shown in Figure 12 is stored in the storage unit 58 of the arithmetic unit 50 and calculated It is read by device 50 and executed. The processes in steps S51 and S52 are shown in step S31 in the flowchart of Figure 10. The process is the same as in S32. However, in step S52, the detection unit 54 is the imaging unit Using the temperature image data generated from the image data obtained by imaging with device 41, Figure 6 was created. The state of the sputtered sputtering plate (SP) is determined from the temperature image data using the method described above. (Figure 12) In the specific example shown in the flowchart, the detection unit 54 determines the state of sputtering SP as sputtering SP Let's take the case of determining the amount of dispersion as an example.

[0211] In step S53, the determination unit 57 determines the state of the sputtered SP as determined by the detection unit 54. In other words, it is determined whether the amount of sputtered SP scatter meets the first standard range. The sub-range is the range of sputtering spatter spatter for which the energy density ED is kept within the desired range. This is the range. The range of the amount of sputtering SP is, for example, various tests and by the user. The relationship between the amount of sputtered sputtering SP and the energy density ED, determined by simulations, etc. It is set based on the relationship. The range of the amount of sputter SP scattering (first reference range) is, The memory unit 58 stores the first reference range in advance, and the determination unit 57 reads this first reference range and steps Used in the determination process of S53 and step S54 described later. The amount of sputtered SP is the first basis If the determination unit 57 determines that the condition does not meet the specified range, the process proceeds to step S54. If the determination unit 57 determines that the amount of sputter SP scattering meets the first standard range, The process then proceeds to step S57, which will be described later. In other words, the determination unit 57 proceeds to step S53. Then, determine whether or not it is necessary to generate change information. Furthermore, the first reference range mentioned above is not limited to energy density ED, but also includes power density PD and temperature The degree distribution T(r) may be set to be kept within a desired range.

[0212] In step S54, the determination unit 57 determines that the amount of sputter SP is greater than the first reference range. It is determined whether the amount of sputtered SP is less than the first reference range. If the determination unit 57 determines that the amount is greater, the process proceeds to step S55, and then... If the determination unit 57 determines that the amount of scattering of the SP is less than the first reference range, The process proceeds to step S56.

[0213] In step S55, the calculation unit 56 includes the value of the energy density ED within the desired range. Therefore, change information is generated to modify the build conditions in order to lower the energy density (ED) value. The reason for lowering the energy density ED is as follows: namely, sputtering SP If the amount of dispersion is greater than the first standard range, it means that the amount of heat applied to the powder material P is excessive. This means that the convection C in the molten pool MP is large. In other words, the energy absorbed by the powder material P This is because it can be estimated that the energy density ED of the energy is in excess.

[0214] In this case, the calculation unit 56 is the same as in step S35 in Figure 10 and step S45 in Figure 11. Similarly, in order to lower the value of the energy density ED, the parameter P L , lowering P0 Generate change information so that at least one of the following occurs: increasing parameter v. That is, the calculation unit 56 reduces the laser output and increases the flow rate of the inert gas and Change the information so that at least one of the following is performed: increase the flow velocity and increase the scanning speed. The specific process that the arithmetic unit 56 performs to generate the change information is explained in Figure 10. This is done in the same manner as before, by referring to the data stored in the memory unit 58. Output unit 5 5 uses the change information generated by the calculation unit 56 as state information, and the setting unit 59 (modeling control unit 52) The output is sent to at least one of the enclosure control units 53. The molding control unit 52 receives the change information. In that case, the molding control unit 52 will output a new laser power to the irradiation unit 32 based on the change information. By emitting laser light, the scanning unit 33 changes the tilt angle based on the change information. The housing performs at least one of the following: driving the galvanometer mirrors 331 and 332 at a certain speed. If the control unit 53 receives change information, the housing control unit 53 will control the intake device 131 and exhaust device The device 14 is operated with new valve openings and exhaust volumes based on the change information. The process then proceeds as follows: Return to step S52.

[0215] In step S56, the calculation unit calculates to include the value of the energy density ED within the desired range. This generates change information to modify the build conditions in order to increase the energy density (ED) value. The reason for increasing the energy density ED is as follows: namely, the scattering of sputtered particles SP. If the quantity is less than the first reference range, it means that the amount of heat applied to the powder material P is insufficient, and melting will not occur. This means that the convection C in the pond MP is small. In other words, the energy absorbed by the powder material P is small. This is because it can be estimated that the energy density ED is insufficient.

[0216] In this case, the calculation unit 56 is the same as in step S36 in Figure 10 and step S46 in Figure 11. Similarly, in order to increase the value of the energy density ED, the parameter P L , to increase P0 Generate change information so that at least one of the following occurs: lowering parameter v. That is, the calculation unit 56 increases the laser output and decreases the flow rate of the inert gas and Change the information so that at least one of the following is performed: reduce the flow rate and reduce the scanning speed. The specific process that the arithmetic unit 56 performs to generate the change information is explained in Figure 10. This is done in the same way as before, by referring to the data stored in the memory unit 58.

[0217] The output unit 55 uses the change information generated by the calculation unit 56 as state information and sends it to the molding control unit 52 and Output to at least one of the housing control units 53. When the molding control unit 52 receives change information. The molding control unit 52 controls at least one of the following operations of the irradiation unit 32 and the scanning unit 33. To perform at least one of the following. In this case, the operation of the irradiation unit 32 is to perform a new operation based on the change information. The laser emits laser light at a certain laser output. The operation of the scanning unit 33 is based on change information. The new method involves driving the galvanometer mirrors 331 and 332 at a new rate of change in tilt angle. When the body control unit 53 inputs change information, the housing control unit 53 controls the intake device 131 and exhaust The device 14 is operated with new valve openings and exhaust volumes based on the change information. Then, processing Return to step S52. In steps S55 and S56, the calculation unit 56 calculates the new molding condition values ​​and the current molding conditions. The output unit 55 generates a correction value, which is the difference from the value of the shape condition, as change information, and the output unit 55 uses this correction value as shape condition The status information may also be output to the setting unit 59.

[0218] If the amount of sputtering meets the first standard range, the process proceeds to steps S57 and S58. The principle is the same as the processes in steps S37 and S38 of Figure 10. By performing the above process, the state inside the melting pool MP is controlled, so melting The occurrence of internal defects in the solidified layer formed by the solidification of the pond MP is reduced.

[0219] In step S52, the detection unit 54 uses Figure 6 to determine the state of the sputtered SP. The scattering direction and scattering velocity of sputtered sputter particles can be determined using the method described. When the detection unit 54 determines the scattering direction of the sputter SP, the first reference range is the power density P At least one of D, energy density ED, and temperature distribution T(r) is kept within a desired range. This is the range of the scattering direction of the sputtered SP. The reference range of 1 is, for example, similar to step S53 above, various tests performed by the user. It is set based on the results of simulations and so on. The determination unit 57 determines the keyhole KH The scattering direction of the sputtered SP is in a constant direction (for example, behind the scanning direction of the laser beam). If the values ​​are not fixed in a particular way and are irregularly scattered, it is determined that the first standard range is not met. As mentioned above, the fact that the scattering direction of sputtered SP is not fixed in a certain direction means that This is a state where the powder material P receives excess energy. In this state, the keyhole KH is deep. This means that the convection C in the melting pool MP is intense, so the calculation unit 56 calculates the energy density Generate change information to reduce the value of ED.

[0220] When the detection unit 54 determines the scattering velocity of sputter SP, the first reference range is the power density P At least one of D, energy density ED, and temperature distribution T(r) is kept within a desired range. This is the range of scattering velocities of sputtered SPs for this purpose. This range of scattering velocities of sputtered SPs (the The reference range of 1 is, for example, similar to step S53 above, various tests performed by the user. The setting is determined based on the results of simulations and so on. The determination unit 57 determines if the scattering velocity is large. In all cases, it is determined that the first standard range is not met. As mentioned above, the scattering speed of sputter SP A large value means that the convection C in the melting pool MP is intense, so the calculation unit 56 is Generate change information to reduce the value of energy density ED.

[0221] Furthermore, the detection unit 54 may determine the state of the fume FU as the state of the area to be detected. . The detection unit 54, using the method described with reference to Figure 7, determines the state of the fume FU as fume Let's explain how to determine the concentration of FU. In this case, the first reference range is the power density PD, e Since at least one of the energy density ED and the temperature distribution T(r) is kept within the desired range, This is the range of fume FU concentration. This range of fume FU concentration (first reference range) For example, as with steps S33, S43, and S53 described above, It is set based on the results of various tests and simulations conducted by the company. The determination unit 57 is The higher the concentration, the less likely it is to meet the first standard range. As mentioned above, fumes (FU) The higher the concentration, the more fumes (FU) are generated, and the more energy the powder material P absorbs. This means that the temperature in the molten pool MP is too high due to excess energy. Therefore, the calculation unit 56 generates modification information to reduce the value of the energy density ED.

[0222] The detection unit 54, using the method described with reference to Figure 7, determines the state of the fume FU as fume Let's explain how to determine the range of FU. In this case, the first reference range is the power density PD, e Since at least one of the energy density ED and the temperature distribution T(r) is kept within the desired range, This is the range of Hume FU. This range of Hume FU (first reference range) is, for example, Similar to step S53 described above, the results of various tests and simulations performed by the user. It is set based on the range of Hume FU, i.e., the surface on the temperature image. If the product is wide, it is determined that the first criterion range is not met. As mentioned above, Hume FU A wide range means that a large amount of fumes (FU) are generated, and the energy absorbed by the powder material P is large. There is an excess of ghee, which means the temperature in the molten pool MP is too high. Therefore, calculation unit 5 6 generates modification information to reduce the value of the energy density ED.

[0223] Note that steps S35 and S3 of the flowchart shown in Figures 10, 11, and 12 above. In steps 6, S45, S46, S55, and S56, the calculation unit 56 calculates the parameter P L , P Regarding which of the 0 and v parameters to change or not change, It depends on the user's requirements for creating the three-dimensional object. For example, if the user is... If you want to avoid a prolonged interval, the scanning speed of the laser beam will not decrease. In steps S36, S46, and S56 described above, the calculation unit 56 calculates the parameter P L It is possible to change the value of parameter v while keeping the value of parameter v unchanged. If the energy density ED is lower than the desired range, the calculation unit 56 calculates the parameter v Without changing the value, the calculation unit 56 calculates the parameter P L Generate change information to increase the value. In this case, the molding time is maintained, but the powder material P melted by the laser irradiation... Because the temperature change during the solidification process is large, the residual stress in the solidified layer increases, and the molding process becomes difficult. The quality of the three-dimensional objects produced may decrease.

[0224] On the other hand, if the user wants to avoid a decrease in the quality of the three-dimensional object being printed, In order to prevent the laser beam output from increasing, in steps S36, S46, and S56 above... Then, the calculation unit 56 changes the value of parameter v, and parameter P L Do not change the value. This can be done, for example, when the energy density ED is lower than the desired range. Then, the calculation unit 56 processes the parameter P L Without increasing the value of , decrease the value of parameter v. The system generates change information to achieve this. In this case, the residual stress in the solidified layer due to temperature changes does not increase. The quality of the resulting three-dimensional object will be maintained, but the printing time may increase.

[0225] As described above, the parameters can be changed to maintain the energy density ED within the desired range. Since there are multiple types of data, the parameters that the calculation unit 56 changes based on the user's instructions are It may be determined. In this case, the arithmetic unit 56 determines the parameter to be changed. The system will inform the user of the information necessary to accept the user's specified designation (hereinafter referred to as "designation target information"). For example, the calculation unit 56 changes in order to maintain the energy density ED within a desired range. Possible parameters (for example, parameter v and parameter P) L ) as the target information and displayed on a display device (not shown), such as a liquid crystal display, which is configured to communicate with the calculation unit 56. It is also possible to do so. The user then uses a specified device (not shown) such as a mouse to display the information on the display device. Specify the indicated parameter (for example, specify parameter v). The calculation unit 56 then... To maintain the energy density ED within the desired range, the parameters specified by the user are used. This generates change information to modify the value of parameter v (for example).

[0226] For the sake of explanation, the parameter v is based on the flowcharts shown in Figures 10 to 12. and parameter P L These two types of parameters are used as target information and are displayed on a display device (not shown). As an example, the parameters to be displayed on the display device as specified target information are parameters Data v and parameter P L It is not limited to these two types of parameters. For example, the arithmetic unit 56 is a Lameter v and parameter P L Other parameters P0, η, d, Δy, Δz, which are different from those mentioned above. Maintain the basic and detailed conditions (described later) among ρ, k, r, x, α, and T0 within the desired range. Multiple parameters that can be changed may be displayed on the display device as target information. If at least one of the multiple parameters shown is specified by the user, the calculation will proceed. Section 56 allows the user to maintain the basic conditions and detailed conditions (described later) within the desired range. It generates change information that modifies the value of the specified parameter.

[0227] Furthermore, the specified target information that the calculation unit 56 displays on a display device (not shown) is not limited to parameters. For example, the calculation unit 56 will determine the basic conditions and detailed conditions (described later) from among the above-mentioned molding conditions. Multiple modifiable molding conditions are displayed on the display device as target information to maintain them within a specified range. You may do so. Furthermore, the parameters and printing conditions that are changed will affect the printing time and quality of the 3D printed object. As this occurs, the user specifies the parameters and molding conditions to be changed as described above. It is not limited to this, but also emphasizes (maintains) the time required to create 3D objects and the quality of 3D objects. The user may choose to prioritize (maintain) certain aspects. In this case, one example is performance The calculation unit 56 uses items related to time emphasis and quality emphasis as designated target information, (not shown). The display is shown on the display device. The user uses a specified device (not shown), such as a mouse, to display the information on the display device. Specify one of the displayed items related to time emphasis and quality emphasis. The calculation unit 56 The user specifies that the basic and detailed conditions (described later) should be kept within the desired range. It generates change information that modifies the values ​​of parameters and molding conditions according to the selected items. For example, If the energy density ED is lower than the desired range, the time-related items will be specified by the user. If determined, the calculation unit 56 will not change the value of parameter v, and parameter P L Change the value The system generates change information so that it can be used. On the other hand, items related to quality are specified by the user. Then, the calculation unit 56 determines the parameter P L The value of parameter v will not be changed, but the value of parameter v will be changed. Generate change information.

[0228] In addition to prioritizing time and quality, there is also a "balance-oriented" approach that emphasizes a balance between molding time and quality. The items related to this, along with at least one item from the time-focused and quality-focused categories, are specified as the target information. This may be displayed on a display device not shown. For example, if the energy density ED is within the desired range If it is lower than that, and if the user specifies an item related to prioritizing balance, the calculation unit 56 , parameter v and parameter P L Generate change information to modify both values. . Furthermore, regarding the display devices for each item related to time emphasis, quality emphasis, and balance emphasis... The display format can be any existing format, such as text examples or icons, as long as the user can recognize it. good. Note that the display device not shown does not have to be a liquid crystal display; it may be an organic EL display. Existing display devices such as head-mounted displays may also be used. The specified device does not have to be a mouse; it can be an existing device such as a touch panel. stomach. Furthermore, the method of informing the user of the specified target information is not limited to display on a display device. For example, Using a speaker and microphone (not shown), the arithmetic unit 56 receives ...

Claims

1. A fabrication system that creates three-dimensional objects by solidifying powder material that has been molten by irradiation with energy rays, The system includes a molding unit that fabricates the three-dimensional object under molding conditions set based on the state of at least a portion of the molten area formed in the powder material by irradiation with energy rays, and the state of at least one of the fumes and / or sputter generated by the melting of the powder material by irradiation with energy rays. The aforementioned molding conditions are: The intensity distribution of the aforementioned energy rays, The scanning pitch of the energy line, The flow rate of the inert gas and A molding system comprising the flow rate of the inert gas and at least one of the following.

2. A fabrication system that creates three-dimensional objects by solidifying powder material melted by irradiation with energy rays, A molding system comprising a molding unit that molds the three-dimensional object under molding conditions set based on user-specified results, either prioritizing the molding quality of the three-dimensional object or prioritizing the molding time of the three-dimensional object.

3. An information acquisition device used for setting the fabrication conditions of a three-dimensional object, comprising a layered unmelted material layer made of unmelted powder material, and a solidified layer formed by irradiation with energy rays in which at least a portion of the unmelted material layer has solidified, A light-receiving unit that receives light from the unmelted material layer, The system includes an output unit that outputs the light reception result from the light receiving unit, The three-dimensional object is fabricated under fabrication conditions set based on the state of the shape of the unmelted material layer, which is determined based on the light reception result at the light receiving unit. The aforementioned molding conditions include the energy ray conditions, and the information acquisition device is also provided.

4. A fabrication system used for setting fabrication conditions for a three-dimensional object, comprising a layered unmelted material layer made of unmelted powder material, and a solidified layer formed by irradiation with energy rays in which at least a portion of the unmelted material layer has solidified, The device comprises a molding section that fabricates the three-dimensional object using molding conditions that include material layer formation conditions for forming an unmelted material layer, The material layer formation conditions include at least one of the moving speed of the material layer forming member that forms the unmelted material layer, the pressure applied to the powder material by the material layer forming member, and the waiting time until the formation of the material layer on top of the solidified layer begins.

5. An information acquisition device used for setting the fabrication conditions of a three-dimensional object, comprising a layered unmelted material layer made of unmelted powder material, and a solidified layer formed by irradiation with energy rays in which at least a portion of the unmelted material layer has solidified, A light-receiving unit that receives light from the unmelted material layer, The system includes an output unit that outputs the light reception result from the light receiving unit, An information acquisition device that fabricates a three-dimensional object under fabrication conditions set based on the density of the unmelted material layer, which is determined based on the light reception result output from the output unit.

6. A light receiving device used in a fabrication apparatus that creates three-dimensional objects by solidifying a powder material melted by irradiation with energy rays, The system includes a building optics unit that irradiates an unmelted powder material with energy rays, and an acquisition unit that receives light of a first wavelength and light of a second wavelength different from the first wavelength from the unmelted powder material irradiated with energy rays, via at least a part of the building optics unit. The acquisition unit is, An optical system in which light of a first wavelength and light of a second wavelength are incident through at least a part of the molding optical system, comprising a chromatic aberration correction optical system that corrects chromatic aberration occurring in at least one of the light of the first wavelength and light of the second wavelength as it progresses through at least a part of the molding optical system, A light-receiving device including an image sensor that receives light of a first wavelength and light of a second wavelength from the chromatic aberration correction optical system.

7. A fabrication method used in a fabrication apparatus that fabricates a three-dimensional object consisting of a layered unmelted material layer made of unmelted powder material, and a solidified layer formed by irradiation with energy rays in which at least a portion of the unmelted material layer has solidified, Projecting projection light onto the unmelted material layer via a scanning unit of the molding apparatus that scans the unmelted material layer with energy rays for solidifying at least a portion of the unmelted material layer, A molding method comprising receiving light from the unmelted material layer onto which the projected light from the scanning unit is projected.

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