3D modeling apparatus and method for manufacturing 3D model

Abstract

To ensure the accuracy of a shape of a molding object.SOLUTION: A three-dimensional molding device laminates and molds a material layer containing a molding material that is flown onto the surface of a molding object. The three-dimensional molding device includes a plurality of carriers that carries and conveys the molding material and flying means for making the molding material carried by the carriers fly onto the surface of the molding object. The flying means makes the molding material carried by the stopped carriers among the plurality of carriers fly.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a three-dimensional modeling apparatus. and a method for manufacturing a three-dimensional object Regarding. [Background technology]

[0002] Generally, additive manufacturing methods using technologies such as fused deposition modeling (MEX; Materials Extrusion), laser photopolymerization (VPP; Vapor Photo Polymerization), powder bed fusion (PBF; Powder Bed Fusion), material jetting (MJT; Material Jetting), binder jetting (BJT; Binder Jetting), sheet lamination (SHL; Sheet Lamination), and directed energy deposition (DED; Directed Energy Deposition) are known as devices for creating three-dimensional objects (3D objects).

[0003] Furthermore, in an apparatus for stacking modeling material by sandwiching the modeling material carried on a carrier between the stacking surface of a stage or a model on the stacking surface and a pressing member, a configuration has been disclosed in which the carrier is pressed against the model by adjusting the parallelism of the carrier and the model (see, for example, Patent Document 1). Summary of the Invention [Problem to be solved by the invention]

[0004] However, the configuration of Patent Document 1 leaves room for improvement in terms of shape accuracy of the model.

[0005] An object of the present invention is to ensure the shape precision of a molded object. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, a three-dimensional modeling apparatus that stacks material layers containing a modeling material that has been flown onto a surface of a modeled object includes a plurality of carriers that carry and transport the modeling material, a flying means that causes the modeling material carried by the carriers to fly onto the surface of the modeled object, and a rotating means that rotates the modeled object around a rotation axis that is parallel to the lamination direction of the material layers, wherein the rotating means rotates every time one material layer is laminated, and the flying means causes the modeling material carried by a carrier that is stationary among the plurality of carriers to fly, and stacks the material layers of the same layer by leaving a gap. Among the plurality of supports, a first support supports a first modeling material, a second support supports a second modeling material different in type from the first modeling material, the first modeling material is resin-coated sand, and the second modeling material is an amorphous resin. . Effect of the Invention

[0007] According to the present invention, the shape precision of the shaped object can be ensured. [Brief description of the drawings]

[0008] [Figure 1] 1A and 1B are diagrams showing an example of the overall configuration of a three-dimensional object forming apparatus according to a first embodiment, in which (a) is a side view and (b) is a cross-sectional view taken along the line AA' in (a). [Diagram 2] 2 is a block diagram showing an example of a hardware configuration of a control unit according to the embodiment; FIG. [Diagram 3] 4 is a block diagram showing an example of a functional configuration of a control unit according to the embodiment; FIG. [Figure 4] 3A to 3C are diagrams illustrating an example of the configuration of a shaping guide according to the first embodiment. [Diagram 5] 3A to 3C are diagrams illustrating an example of the configuration of the periphery of a shaping guide according to the first embodiment. [Figure 6] 4A to 4C are diagrams illustrating an example of a configuration around a plurality of shaping guides according to the first embodiment. [Figure 7] 13 is a diagram illustrating another example of the configuration around the multiple shaping guides according to the first embodiment. FIG. [Figure 8] 13A and 13B are diagrams illustrating an example of irradiation with a flight pulse laser beam. [Figure 9] 1A and 1B are diagrams showing an example of a method for laminating material layers according to an embodiment, where (a) is a diagram of a comparative example, and (b) is a diagram of an example of the embodiment. [Figure 10] FIG. 13 is a diagram illustrating an example of the configuration of a three-dimensional object forming apparatus according to a second embodiment. [Figure 11] 10A to 10D are diagrams illustrating an example of a stacking method using a 3D modeling apparatus according to a second embodiment, in which (a) to (d) are diagrams illustrating modeling steps. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] In a three-dimensional modeling device that ejects the modeling material carried by a carrier and stacks a material layer containing the ejected modeling material onto the surface of the model, when the modeling material is ejected from the carrier that is transporting the modeling material, the position at which it arrives on the surface of the model is likely to shift, which can reduce the shape accuracy of the model.

[0010] In an embodiment, the modeling material carried by a stationary carrier among multiple carriers carrying and transporting the modeling material is caused to fly, thereby suppressing a decrease in the shape accuracy of the modeled object caused by the modeling material flying from the carrier being transported.

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the following description, parts having the same reference numerals in multiple drawings indicate the same or equivalent parts or members.

[0012] Furthermore, the embodiments shown below are examples of a three-dimensional modeling apparatus for embodying the technical ideas of the present invention, and the present invention is not limited to the embodiments shown below. The dimensions, materials, shapes, relative positions, etc. of the components described below are intended to be illustrative, and not to limit the scope of the present invention, unless otherwise specified. Furthermore, the sizes and positional relationships of the components shown in the drawings may be exaggerated to clarify the explanation.

[0013] In addition, in the figures shown below, directions may be indicated by the X-axis, Y-axis, and Z-axis, but the X-direction along the X-axis indicates the direction in which the carrier provided in the three-dimensional printing apparatus of the embodiment transports the printing material in a plane parallel to the material layer containing the printing material, the Y-direction along the Y-axis indicates the direction perpendicular to the X-axis in a plane parallel to the material layer, and the Z-direction along the Z-axis indicates the stacking direction of the material layers.

[0014] Additionally, the X direction in which the arrow points is denoted as the +X direction, and the opposite direction of the +X direction is denoted as the -X direction, the Y direction in which the arrow points is denoted as the +Y direction, and the opposite direction of the +Y direction is denoted as the -Y direction, and the Z direction in which the arrow points is denoted as the +Z direction, and the opposite direction of the +Z direction is denoted as the -Z direction. However, these directions do not limit the orientation of the 3D modeling device when in use, and the orientation of the 3D modeling device is arbitrary.

[0015] [First embodiment] <Overall configuration example of 3D modeling apparatus 500> First, an apparatus for forming a three-dimensional object according to an embodiment (hereinafter referred to as a three-dimensional object forming apparatus 500) will be described with reference to Fig. 1. Fig. 1 is a diagram illustrating an example of the overall configuration of the three-dimensional object forming apparatus 500. Fig. 1(a) is a side view, and Fig. 1(b) is a cross-sectional view taken along the line A-A' in Fig. 1(a).

[0016] 1, the three-dimensional object forming apparatus 500 includes a modeling unit 100 and a control unit 400. The modeling unit 100 includes a build plate 101, a Y-axis stage 102, a Z-axis stage 103, a chamber 104, carriers 111a to 111e, a supply unit 112, a laser light source 115, a verify scanner 117, and modeling guides 155a to 155e.

[0017] Under the control of the control unit 400, the modeling unit 100 stacks material layers containing the modeling material scattered by the irradiation of the laser light from the laser light source 115 in the Z direction based on slice data of the three-dimensional object input to the three-dimensional modeling device 500 to form the three-dimensional object 200. The slice data refers to data obtained by thinly slicing the three-dimensional object to be modeled into each material layer. The three-dimensional object can be formed by stacking the material layers represented by the slice data.

[0018] The build plate 101 is a member that supports the model 200. The Y-axis stage 102 is an example of a moving means that moves the build plate 101 back and forth in the Y-axis direction. The Z-axis stage 103 raises and lowers the build plate 101 in the Z-axis direction at intervals of, for example, 0.05 mm in the model thickness.

[0019] The multiple support members 111a to 111e are each composed of an endless belt-like member that moves in a circular motion, and are arranged at approximately equal intervals along the Y axis. In the following, when the support members 111a to 111e are not particularly distinguished from one another, they will be collectively referred to as support member 111.

[0020] The support 111 includes, for example, a PET film (Lumirror manufactured by Toray Industries, Inc.). However, it may also include a polyimide film (Kapton H manufactured by Toray Industries, Inc.). The support 111 is disposed on the +Z direction side of the build plate 101, and is wound around rollers 151, 152, 153, and 154 and modeling guides 155a to 155e.

[0021] The support 111 supports the particulate modeling material 201 and transports the modeling material 201 along a transport direction 210 to directly above (the +Z direction side) the modeled object 200 placed on the build plate 101. However, the support 111 is not limited to an endless belt-like member, and may be configured as a rotating drum made of a cylindrical glass member or the like that supports the modeling material 201 and rotates in the transport direction 210.

[0022] The shaping guides 155a to 155e are an example of a plurality of guide members that respectively support the plurality of carriers 111. Each of the shaping guides 155a to 155e is a rectangular plate-like member that extends in a direction along the conveying direction 210 and includes a slit portion that passes the laser light emitted by the laser light source 115, and has a longitudinal direction along the conveying direction 210.

[0023] The shaping guide 155a supports the support 111a, the shaping guide 155b supports the support 111b, the shaping guide 155c supports the support 111c, the shaping guide 155d supports the support 111d, and the shaping guide 155e supports the support 111e. In the following, when the shaping guides 155a to 155e are not particularly distinguished from one another, they are collectively referred to as shaping guides 155.

[0024] The molding material 201 should be appropriately selected depending on the desired molded object 200, and in the case of resin, examples include PA12 (polyamide 12), PBT (polybutylene terephthalate), PSU (polysulfone), PA66 (polyamide 66), PET (polyethylene terephthalate), LCP (liquid crystal polymer), PEEK (polyether ether ketone), POM (polyacetal), PSF (polysulfone), PA6 (polyamide 6), PPS (polyphenylene sulfide), etc. In addition, the molding material 201 is not limited to crystalline resins, and may be amorphous resins such as PC (polycarbonate), ABS (acrylonitrile butadiene styrene), PEI (polyetherimide), or a mixed resin of crystalline and amorphous resins.

[0025] In addition to resin, various materials such as metal, ceramic, liquid, etc. can be used as the modeling material 201. In addition, the modeling material 201 may be a material having a viscosity of 1 Pa·s or more.

[0026] In this embodiment, the modeling material 201 is supported by the peripheral surface of the support 111 by van der Waals forces. In addition, when the modeling material 201 has a high resistance value, it can be supported by electrostatic adhesion alone.

[0027] A supply unit 112 that supplies a modeling material 201 to the peripheral surface (surface) of the support 111 is disposed around the support 111 .

[0028] The supply unit 112 includes supply units 112a to 112e. Each of the supply units 112a to 112e includes a knurled roller, a blade, and the like, and supplies the modeling material 201 to the support 111 via the knurled roller so as to form a thin layer of the modeling material 201 on the peripheral surface of the support 111 by rubbing the modeling material 201 with the blade to break up the agglomeration.

[0029] More specifically, supply unit 112a supplies modeling material 201 to support 111a, supply unit 112b supplies modeling material 201 to support 111b, supply unit 112c supplies modeling material 201 to support 111c, supply unit 112d supplies modeling material 201 to support 111d, and supply unit 112e supplies modeling material 201 to support 111e.

[0030] In this embodiment, the supply units 112a to 112e are configured to supply different modeling materials 201 to the carriers 111a to 111e. The carriers 111a to 111e also support and transport the different modeling materials 201 supplied from the supply units 112a to 112e.

[0031] All of the supplies 112a-112e may supply different build materials 201, or only some of the supplies 112a-112e may supply different build materials 201.

[0032] For example, the carriers 111a and 111b carry and transport the first modeling material supplied from the supply units 112a and 112b, and the carriers 111c to 111e carry and transport the second modeling material supplied from the supply units 112c to 112e. The first modeling material and the second modeling material can be different types. For example, the first modeling material is resin-coated sand, and the second modeling material is amorphous resin.

[0033] Here, resin-coated sand refers to a material in which the surface of sand is coated with phenolic resin, and is used to manufacture casting products, etc. If resin-coated sand, as the first modeling material, is modeled in parallel around amorphous resin, as the second modeling material, it becomes possible to model amorphous resin, which is difficult to control the temperature.

[0034] The supply by the supply unit 112 is not limited to a knurled roller, and a configuration using a mesh roller, contact supply by a rotating body, non-contact supply, non-contact scattering from a mesh, fluidized immersion by powder air current agitation, etc. are also possible.

[0035] The laser light source 115 arranged inside the support 111 is an example of a flying means for flying the modeling material 201 carried by the support 111 from the peripheral surface of the support 111 onto the surface of the model 200 .

[0036] Here, "flying" means that the modeling material 201 moves from the support 111 to the build plate 101 side without contact. Unlike transfer, the modeling material 201 can move without contact, which reduces loss of the modeling material 201 and improves modeling accuracy.

[0037] The laser light source 115 irradiates the modeling material 201 with a pulsed laser beam 115a for flight from inside the support 111. The irradiation position corresponds to the modeling position. The laser light source 115 is also configured to irradiate the support 111 with the pulsed laser beam 115a for flight through a slit portion of a modeling guide 155 that supports the support 111.

[0038] When the modeling material 201 is subjected to the flying pulsed laser light 115a, the powder's adhesive force is released by a force called radiation pressure, and the modeling material 201 falls downward by gravity. Laser transfer LIFT (Laser Induced Forward Transfer) described in US006025110A and the like is a method of non-contact transfer of a foil-like or liquid material adhered to a carrier by laser irradiation, in which the material is locally heated and vaporized, so that it flies from the peripheral surface of the carrier 111 in the direction of the flying pulsed laser light 115a.

[0039] In this embodiment, it cannot be said that the contribution of the latter mechanism is zero, but the reasons why the former mechanism is considered to be the main mechanism are as follows.

[0040] 1. The launch energy is the same for black powder and transparent powder, which have high laser light absorption rates.

[0041] 2. Even if the carrier is a transparent resin film, the transparent powder will fly.

[0042] 3. The transparent resin film of the carrier does not deteriorate even when irradiated with multiple pulse lasers up to 1000 times.

[0043] The gap distance between the support 111 and the model 200 is preferably maintained at approximately 3 to 4 times the average particle size of the modeling material 201. This makes it possible to prevent contact between the upper and lower modeling materials before and after flight, and to prevent scattering due to flight.

[0044] There are no particular limitations on the laser light source 115, and it is preferable that it is capable of pulse oscillation of picoseconds to nanoseconds. Examples of solid-state lasers include YAG lasers and titanium sapphire lasers. Examples of gas lasers include argon lasers, helium neon lasers, and carbon dioxide gas lasers. Semiconductor lasers are also preferable because they are small in size. Fiber lasers are the most suitable light source for commercializing the present invention in terms of their high peak energy and ability to be miniaturized.

[0045] The wavelength of the pulsed laser light can be appropriately selected, but is preferably 300 nm or more and 11 μm or less. In particular, when the modeling material 201 is a resin, the vicinity of 2460 nm is a composite absorption band of CH and CC bonds, and the absorption rate is 80% or more for various resins, including those containing carbon.

[0046] Furthermore, the flight pulse laser light 115a having a wavelength of 2300 nm to 2500 nm has an absorptance of 65% or more, and stable flight energy can be imparted even in this range.

[0047] This wavelength range has a high transmittance for ordinary glass, so it can be easily combined with the base material. The laser pulse frequency can be selected appropriately in combination with the laser scanning speed. If there is a lot of overlap in the beam diameter, which is determined by the combination of the two, the laser will also hit the powder (modeling material) after it flies, and the powder will easily disperse. This tendency is more pronounced when the beam diameter overlaps two or more times, and there is little powder dispersion when the beam diameter overlaps 1.2 to 1.7 times.

[0048] In this embodiment, the laser light source 115 can also irradiate the pulsed laser light 116a for melting, which functions as a means for heating the surface of the model 200. Therefore, the laser light source 115 also corresponds to an example of a melting means for melting at least one of the model 200 or the modeling material 201 that has flown onto the surface of the model 200.

[0049] The melting pulse laser beam 116a heats and melts at least one of the surface of the object 200 to be formed on the build plate 101 and the modeling material 201 that has flown onto the surface of the object 200. The melting pulse laser beam 116a having a wavelength of 2300 nm to 2500 nm can impart stable melting energy.

[0050] The pulsed laser beam 115a for flying and the pulsed laser beam 116a for melting are both beams emitted by the laser light source 115 and have the same wavelength, pulse width, optical energy, etc., but are used for flying and melting differently.

[0051] The laser light source 115 irradiates the melting pulse laser light 116a aiming at the position where the flying pulse laser light 115a is irradiated (the landing position of the modeling material 201). The positions where the flying pulse laser light 115a and the melting pulse laser light 116a are irradiated are adjustable, and it is also possible to switch the adjustment positions depending on the type of material, modeling speed, etc.

[0052] The laser light source 115 irradiates the material layer containing the modeling material 201 that has flown onto the surface of the model 200 with a melting pulse laser light 116 a, melting the modeling material 201 and causing it to adhere to the model 200.

[0053] Alternatively, the laser light source 115 causes the modeling material 201 to fly and land on the surface of the modeled object 200 that has been melted by the melting pulsed laser beam 116a, thereby adhering to the modeled object 200.

[0054] The timing of the flight of the modeling material 201 and the start of melting of the modeled object 200 is not particularly limited. That is, the surface of the modeled object 200 may be melted before the flight of the modeling material 201. Alternatively, the surface of the modeled object 200 may be melted after the flight of the modeling material 201, and the flying modeling material 201 may land on the molten surface.

[0055] The variation in the impact position and the excess or deficiency can be adjusted between layers, and the laser light source 115 may differ from the shape of the object. The shape of the object is determined by the pulsed laser light 116a for melting.

[0056] For example, the three-dimensional modeling apparatus 500 irradiates a material layer formed by flying the modeling material 201 by irradiating it with the flying pulsed laser beam 115a with the melting pulsed laser beam 116a to solidify the material layer with heat, and starts forming the next layer. At that time, the build plate 101 is lowered by the thickness of the layer that has been stacked, and the gap between the support 111 and the model 200 at the position of the modeling guide 155 is kept uniform.

[0057] A deviation of the gap between the support 111 and the object 200 at the position of the modeling guide 155 from a desired value affects the variation in the flight position of the modeling material 201, so it is desirable to make this as small as possible.

[0058] In this embodiment, a configuration in which the laser light source 115 functions as both the flying means and the melting means is illustrated, but the present invention is not limited to this, and the flying means and the melting means may be configured separately.

[0059] In this case, the flying means may be a laser light source, or may be one that blows air onto the modeling material 201 to fly it, or one that uses electrostatic force to fly it.

[0060] Furthermore, when a laser light source other than the projectile means is used as the melting means, it is not necessary to actively use pulsed laser light, and a continuous wave laser is suitable. Furthermore, as long as the melting state is achieved by energy, ultrasonic waves, convection, lamps, lasers, induction heating, dielectric heating, etc. can be applied in addition to laser heating. Furthermore, the "surface" in this case can be one layer formed in one molding operation, or multiple layers such as two or three layers. It can also be a part of each layer, or the entire layer. In other words, it is important that a part of the outermost layer is included.

[0061] Moreover, since it is preferable to maintain the temperature of the object 200 during modeling at a high temperature, the three-dimensional modeling apparatus 500 is provided with a chamber 104, and the build plate 101, the modeling guide 155, and a part of the support 111 are housed in the chamber 104. By controlling the inside of the chamber 104 to be at a high temperature, the temperature of the object 200 during modeling can be maintained at a high temperature.

[0062] The verify scanner 117 includes a camera and captures an image of the object 200 being formed. The verify scanner 117 outputs the captured image to the control unit 400. If the object 200 being formed has a dimensional error or the like, the control unit 400 controls the forming unit 100 so as to correct the dimensional error based on the captured image.

[0063] Although Figure 1 shows the main components of the 3D modeling apparatus 500, in addition to the components in Figure 1, the 3D modeling apparatus 500 can also have a stage heating heater for heating the Y-axis stage 102, a cleaning blade for cleaning the carrier, or a recovery case for recovering the modeling material scraped off by the cleaning blade.

[0064] 1, various modifications are possible. The angle at which the modeling material 201 is jetted, the angle at which the jetting pulsed laser beam 115a is irradiated, and the angle at which the melting pulsed laser beam 116a is irradiated can be appropriately selected with respect to the build plate 101.

[0065] <Configuration of control unit 400> Next, the control unit 400 will be described.

[0066] The control unit 400 is a control device that controls the modeling by the modeling unit 100 based on slice data generated from three-dimensional data received from an external device. The control unit 400 also controls the laser light source 115 to selectively eject the modeling material 201 onto a stationary support among the multiple supports 111a to 111e.

[0067] (Example of hardware configuration of control unit 400) The hardware configuration of the control unit 400 will be described with reference to Fig. 2. Fig. 2 is a block diagram illustrating an example of the hardware configuration of the control unit 400.

[0068] As shown in FIG. 2, the control unit 400 is constructed by a computer and has a CPU (Central Processing Unit) 501, a ROM (Read Only Memory) 502, a RAM (Random Access Memory) 503, a HD (Hard Disk) 504, and a HDD (Hard Disk Drive) controller 505.

[0069] It also includes a display 506 , an external device connection I / F (Interface) 508 , a network I / F 509 , a data bus 510 , a keyboard 511 , a pointing device 512 , a DVD-RW (Digital Versatile Disk Rewritable) drive 514 , and a media I / F 516 .

[0070] Of these, the CPU 501 controls the overall operation of the control unit 400. The ROM 502 stores programs such as an IPL (Initial Program Loader) used to drive the CPU 501. The RAM 503 is used as a work area for the CPU 501.

[0071] The HD 504 stores various data such as programs. The HDD controller 505 controls reading and writing of various data from and to the HD 504 under the control of the CPU 501. The display 506 displays various information such as a cursor, a menu, a window, characters, or an image.

[0072] The external device connection I / F 508 is an interface for connecting various external devices. In this case, the external devices are a USB (Universal Serial Bus) memory, a printer, etc. The network I / F 509 is an interface for data communication using the network N. The data bus 510 is an address bus, a data bus, etc. for electrically connecting each component such as the CPU 501.

[0073] The keyboard 511 is a type of input means having a plurality of keys for inputting characters, numbers, various instructions, etc. The pointing device 512 is a type of input means for selecting and executing various instructions, selecting a processing target, moving a cursor, etc.

[0074] A DVD-RW drive 514 controls reading and writing of various data from and to a DVD-RW 513 as an example of a removable recording medium. Note that the medium is not limited to a DVD-RW, and may be a DVD-R, etc. A media I / F 516 controls reading and writing (storing) of data from and to a recording medium 515 such as a flash memory.

[0075] (Example of functional configuration of control unit 400) Next, the functional configuration of the control unit 400 will be described with reference to Fig. 3. Fig. 3 is a block diagram illustrating an example of the functional configuration of the control unit 400.

[0076] 3, the control unit 400 includes a communication unit 401, a data generation unit 402, an error detection unit 403, and a modeling control unit 404. The modeling control unit 404 also includes a transport control unit 41, a selection unit 42, a flight control unit 43, a melting control unit 44, and a movement control unit 45.

[0077] Each of these units is a function or a means for performing a function that is realized when any of the components shown in Fig. 3 operates in response to an instruction from CPU 501 in accordance with a program loaded from ROM 502 onto RAM 503. Note that Fig. 3 shows the main components of control unit 400, but control unit 400 may also include other components.

[0078] The communication unit 401 communicates with an external device such as a PC (Personal Computer), etc. For example, the communication unit 401 receives three-dimensional data that is used as source data for forming a three-dimensional object from the external device, and outputs the received three-dimensional data to the data generation unit 402.

[0079] The data generating unit 402 slices the three-dimensional data in the stacking direction, generates slice data by calculation, which is used by the three-dimensional modeling apparatus 500 to form material layers one by one, and provides the slice data to the modeling control unit 404 .

[0080] The error detection unit 403 detects errors, such as dimensional errors, in the object 200 being modeled based on the captured image input from the verify scanner 117, and provides the errors to a modeling control unit 404.

[0081] The modeling control unit 404 uses the transport control unit 41, selection unit 42, flight control unit 43, melting control unit 44, movement control unit 45, etc. to perform control for stacking material layers formed based on slice data to form a model.

[0082] The transport control unit 41 controls the transport of the modeling material 201 by each of the carriers 111a to 111e via the carrier driving unit 411. For example, some of the carriers 111a to 111e are driven to transport the modeling material 201, and the other carriers are stopped.

[0083] The selection unit 42 selects a stationary carrier from among the plurality of carriers 111a to 111e, and provides the flight control unit 43 with a signal indicating the selected carrier.

[0084] The flight control unit 43 controls the laser light source 115 based on the slice data, irradiates the stopped support selected by the selection unit 42 with the flight pulse laser light 115a, and causes the modeling material 201 supported on the support to fly. This control includes intensity control and on / off control of the flight pulse laser light 115a. The flight control unit 43 can also drive and control a scanning unit such as a galvanometer mirror for scanning the flight pulse laser light 115a.

[0085] The melting control unit 44 controls the laser light source 115 based on the slice data, irradiates the material layer formed on the model 200 with the modeling material 201 jetted by the flight control unit 43 with the melting pulsed laser beam 116a, and solidifies the material layer with heat. This control includes control of the intensity of the melting pulsed laser beam 116a and control of whether it is on or off. The melting control unit 44 can also drive and control a scanning unit such as a galvanometer mirror for scanning the melting pulsed laser beam 116a.

[0086] The movement control unit 45 controls the Z-axis stage 103 to lower the build plate 101 by an amount equivalent to the thickness of the material layer after the material layer has solidified, thereby uniforming the gap between the modeling guide 155 and the model 200. In addition, the movement control unit 45 controls the Y-axis stage 102 based on the slice data to move the build plate 101 in the Y-axis direction to form the next material layer.

[0087] The modeling control unit 404 executes control using the conveying control unit 41, the selection unit 42, the flight control unit 43, the melting control unit 44, and the movement control unit 45, etc., for each material layer, and by repeating this process, a three-dimensional object can be formed.

[0088] <Example of the configuration of the modeling guide 155> Next, the configuration of the shaping guide 155 will be described with reference to Fig. 4 to Fig. 6. Fig. 4 is a diagram showing an example of the configuration of the shaping guide 155. Fig. 4 is a plan view of the shaping guide 155 as viewed from the +Z direction side. Since the shaping guides 155a to 155e all have the same configuration, they are collectively referred to as the shaping guide 155 in Fig. 4.

[0089] 4, the shaping guide 155 is a rectangular plate-like member whose longitudinal direction is along the conveying direction 210, and includes a slit portion 156. The slit portion 156 is a rectangular through-hole that extends in the conveying direction 210 and allows the laser light emitted by the laser light source 115 to pass through the through-hole.

[0090] Next, Fig. 5 is a diagram showing an example of the configuration of the shaping guide 155. Fig. 5 is a diagram showing one of the shaping guides 155a to 155e and one of the supports 111a to 111e as viewed from the positive direction of the X-axis.

[0091] The Y-axis direction corresponds to the width direction of the support 111, and the support region 111A of the support 111 in the width direction is a region that supports the modeling material 201. The non-supporting regions 111B arranged on both sides of the support region 111A in the width direction are regions where the modeling material 201 is not supported.

[0092] 5, the shaping guide 155 has two air suction holes 155A and two liquid passage holes 155B on both sides of the support region 111A in the width direction. The shaping guide 155 has the air suction hole 155A on the bottom surface side of the support 111, and adsorbs the support 111 to the bottom surface by sucking air through the air suction hole 155A.

[0093] Since the bottom surface of the shaping guide 155 has a relatively high flatness within the shaping guide 155, the support 111 runs along the bottom surface while being attracted to the bottom surface, thereby improving the flatness of the portion of the support 111 that runs along the bottom surface of the shaping guide 155. This makes it possible to keep the gap between the shaping object 200 and the support 111 constant, thereby improving the shape precision of the shaping object 200.

[0094] The modeling guide 155 is provided with a liquid passage hole 155B, which is a hole for passing a cooling liquid, on the +Z direction side of the air suction hole 155A. The support 111 becomes hot due to the temperature control by the chamber 104, but by passing the liquid through the liquid passage hole 155B, the temperature of the support 111 can be prevented from exceeding the heat resistance temperature of the support 111.

[0095] Fig. 6 is a diagram showing an example of a configuration around a plurality of shaping guides. Fig. 6 is a diagram showing shaping guides 155a to 155c among the shaping guides 155a to 155e and supports 111a to 111c among the supports 111a to 111e, as viewed from the positive direction of the X axis.

[0096] 6, the shaping guides 155a to 155c and the supports 111a to 111c are arranged at approximately equal intervals along the Y-axis direction. The configurations of the shaping guides 155a to 155c are the same as those of the shaping guide 155 shown in FIG. 5, and the configurations of the supports 111a to 111c are the same as those of the support 111 shown in FIG.

[0097] Fig. 7 is a diagram showing another example of the configuration around a plurality of shaping guides. The way of viewing the figure is the same as Fig. 6. As shown in Fig. 7, four infrared heaters 118 are provided around the shaping guides 155a to 155c. The infrared heaters 118 heat the surface on the +Z direction side of the shaped object 200, thereby making the temperature of the surface on the +Z direction side of the shaped object 200 constant before the laser light source 115 irradiates the melting pulse laser beam 116a.

[0098] Here, if a material layer is formed over the entire irradiation range of the flying pulsed laser beam 115a in the X direction, the modeling material 201 contained in the material layer outside the region where modeling is to be performed becomes unnecessary, and the modeling material 201 may be wasted.

[0099] 5 to 7, the modeling material 201 is supported on the carriers 111 corresponding to the necessary regions among the carriers 111, so that it is not necessary to form a material layer over the entire irradiation range of the flying pulsed laser light in the X direction. This makes it possible to reduce waste of the modeling material 201. In addition, the amount of the modeling material 201 transported by the carriers 111 and the amount of the modeling material 201 removed from the carriers 111 by cleaning can also be reduced.

[0100] <Example of irradiation of the flight pulse laser light 115a> Next, irradiation of the flight pulse laser beam 115a by the laser light source 115 will be described with reference to Fig. 8. Fig. 8 is a diagram for explaining an example of irradiation of the flight pulse laser beam 115a, showing the support 111 as viewed from the +Z direction side.

[0101] 8, the laser light source 115 irradiates the stationary support 111 with the flying pulse laser beam 115a while performing two-dimensional scanning along a scanning line 115A. Of the modeling materials 201 held by the support 111, the modeling materials 201 held at the irradiation position of the flying pulse laser beam 115a fly and land on the surface of the modeled object 200 to form a material layer.

[0102] Since the support 111 is stationary, the modeling material 201 can be made to fly under conditions with fewer error factors compared to when the flying pulsed laser light 115a is irradiated while the support 111 is moving, thereby ensuring the shape accuracy of the three-dimensional object.

[0103] The pattern of the scanning lines of the flying pulsed laser light 115a is not limited to the scanning lines 115A, and any pattern can be applied.

[0104] <Example of lamination method for material layers> Next, a method for stacking material layers will be described with reference to Fig. 9. Fig. 9 is a diagram for explaining a method for stacking material layers according to an embodiment, in which Fig. 9(a) is a diagram showing a comparative example, and Fig. 9(b) is a diagram showing an example of the embodiment.

[0105] 9(a), the material layers are stacked by arranging and stacking rectangular parallelepiped blocks 81X that are long in the X-axis direction in the XY plane. In this stacking method, the seams 82X of the blocks 81X in the Y-axis direction are aligned in the Z-axis direction, and the tensile strength of the resulting three-dimensional object in the Y-axis direction is weakened.

[0106] 9(b), the blocks 81 are stacked in the Z-axis direction while shifting the positions of the blocks 81 in the XY plane for each layer. This causes the seams to not be aligned in the Z-axis direction, increasing the tensile strength of the resulting three-dimensional object.

[0107] <Effects of the 3D modeling apparatus 500> Next, the effects of the three-dimensional object forming apparatus 500 will be described.

[0108] Conventionally, in a three-dimensional modeling device that stacks material layers containing modeling material, the modeling material is stacked by sandwiching the modeling material carried on a carrier together with the carrier between the stacking surface of a stage or between a model on the stacking surface and a pressing member, and a configuration has been disclosed in which the carrier is pressed against the model by adjusting the parallelism of the carrier and the model.

[0109] However, in the conventional configuration, the supporting powder that has not completely solidified around the object being modeled may collapse, making it impossible to ensure the shape accuracy of the three-dimensional object. In order to prevent such collapse of the supporting powder, it is necessary to make the supporting powder large so that it can withstand pressure from above or to erect walls to prevent collapse, which may reduce the productivity of modeling.

[0110] In addition, in an apparatus that forms a shape by stacking material layers formed by flying the modeling material carried by a carrier, there is variation in the landing position of the flying modeling material, and when attempting to melt the landing position with a melting pulsed laser beam, the modeling material before it lands may block the melting pulsed laser beam, preventing the melting pulsed laser beam from reaching the intended location, making it impossible to form the intended object.

[0111] For this reason, it is preferable to arrange the flying means and the melting means separately along the moving direction of the build plate. For example, if a 100 mm square model is to be created with a build plate speed of 50 mm / sec, it takes 2 seconds to fly and melt the material for one layer of the model, and 2 seconds to return to the initial build plate position, totaling 4 seconds, which may reduce the productivity of the model.

[0112] Because there is a deviation in the position where the modeling material flies and hits the build plate, the flying position and the melting position cannot be in the same position. Therefore, the melting position is shifted in the Y direction from the flying position. Therefore, in order to model the next layer, the build plate needs to return to its original position after one layer is modeled.

[0113] In this embodiment, there are multiple carriers 111 that carry and transport the modeling material 201, and a laser light source 115 (flying means) that causes the modeling material 201 carried by the carriers 111 to fly onto the surface of the modeled object 200, and the laser light source 115 causes the modeling material 201 carried by a carrier 111 that is stationary among the multiple carriers 111 to fly.

[0114] Since the support 111 is stationary, the modeling material 201 can be sent out with fewer error factors than when the support 111 is irradiated with the pulsed laser beam 115a for sending out the modeling material 201 while it is moving. This ensures the shape accuracy of the three-dimensional object. In addition, since it is not necessary to make the support powder larger or to erect walls to prevent the material layer from collapsing, the productivity of modeling can be ensured.

[0115] Furthermore, in a three-dimensional modeling apparatus using one carrier, if the carrier is stopped to fly the modeling material in order to ensure shape accuracy, stopping the carrier may reduce modeling productivity. In this embodiment, only some of the carriers 111 are stopped, while the other carriers continue to operate. This makes it possible to suppress a decrease in modeling productivity caused by stopping the carriers.

[0116] The effect of the three-dimensional object forming apparatus 500 will be described more specifically. For example, of the multiple carriers 111 and modeling guides 155, three carriers 111 and modeling guides 155 are always used, and the width of the carriers 111 carrying the modeling material 201 is 10 [mm]. In addition, the carriers 111 and modeling guides 155 that do not carry the modeling material 201 on both sides of the three carriers 111 are brought into contact with each other, the width carried by the carriers 111 is 10 [mm], and the melting region between the adjacent modeling guides is 10 [mm].

[0117] The object 200 is divided into four regions: the flight region, the regions at both ends of the flight region, and the melting region. Since there are three of these regions, the object 200 is divided into 12 regions in the direction of movement of the build plate 101.

[0118] In the flying process, the build plate 101 is stopped for one out of every 12 flying pieces, and the flying pulse laser light 115a is two-dimensionally scanned. The scanning speed is, for example, 0.17 [sec].

[0119] Next, the build plate 101 is moved by 1 / 12th of a block, and the next modeling material is jetted. Next, the first jetted material enters the melting area, and the modeling material 201 is melted by the melting pulse laser light 116a while moving (0.17 [sec]). Next, the third jetting is performed, and this is repeated to model one layer. The modeling time for one layer is 1.67 [sec].

[0120] Furthermore, in this embodiment, since the support 111 and the build plate 101 are stopped during flight, it is possible to increase the speed of the build plate 101. The movement speed of the build plate 101 is, for example, 100 [mm / sec], and the modeling time can be shortened (1.17 [sec]) by the amount corresponding to the increased movement speed.

[0121] The fact that the flying pulsed laser beam 115a and the melting pulsed laser beam 116a are irradiated simultaneously to three locations is effective in shortening the modeling time using the three-dimensional modeling apparatus 500. Therefore, calculations were performed in the case where the flying pulsed laser beam 115a and the melting pulsed laser beam 116a are irradiated in sequence to three locations using one laser light source 115.

[0122] As a result, the printing time for one layer was 4.67 [sec]. Considering that the moving speed of the build plate 101 was 100 [mm / sec], the printing time for one layer was 2.92 [sec].

[0123] In addition, since the timing of the flying pulse laser beam 115a and the melting pulse laser beam 116a does not need to be synchronized, the flying pulse laser beam 115a and the melting pulse laser beam 116a can be irradiated using the same laser light source 115. In addition, the flying of the next layer also starts before the final melting operation, so there is no need to return the build plate 101 to the initial position.

[0124] Furthermore, since the movement distance of the build plate 101 during modeling of a single layer is short, the device can be made smaller.

[0125] In addition, in this embodiment, the flying means causes the modeling material 201 to fly by irradiating it with a pulsed laser light 115a for flying emitted by the laser light source 115 (light source), and the melting means melts at least one of the modeled object 200 or the modeling material 201 that has flown onto the surface of the modeled object 200 by irradiating it with a pulsed laser light 116a for melting emitted by the laser light source 115 (light source).

[0126] The functions of the flying means and the melting means can be realized using a single laser light source 115, and the three-dimensional modeling apparatus 500 can be made smaller and manufacturing costs can be reduced compared to when the flying means and the melting means are realized using separate configurations.

[0127] In this embodiment, the multiple carriers 111 are arranged in the Y-axis direction (predetermined direction) and are belt-like members that transport the modeling material 201 in a transport direction intersecting the Y-axis direction. The multiple carriers 111 are also provided with multiple modeling guides 155 (guide members) that support the multiple carriers 111, respectively. The modeling guide 155 is a rectangular plate-like member that extends in the transport direction and includes a slit portion 156 that passes the flight pulse laser beam 115a emitted by the laser light source 115, and is elongated in the transport direction.

[0128] With this configuration, the support 111 at rest can be irradiated with the flying pulse laser light 115a by two-dimensional scanning, thereby improving the productivity of modeling.

[0129] In this embodiment, among the multiple supports 111, a first support supports a first modeling material, and a second support supports a second modeling material that is different in type from the first modeling material. This allows the objects 200 to be modeled in parallel using different modeling materials 201.

[0130] In this embodiment, the first modeling material is resin-coated sand, and the second modeling material is amorphous resin. This allows the resin-coated sand to be used as a support (mold), making it possible to model using amorphous resin, which is difficult to control the temperature.

[0131] In this embodiment, the plurality of carriers 111 are belt-shaped members having a predetermined width along the Y-axis direction (predetermined direction). This allows the modeling material 201 to be transported with a predetermined width, thereby improving modeling productivity.

[0132] In this embodiment, the multiple supports 111 each have a Y-axis stage 102 (moving means) that places the object 200 thereon and moves the object 200 in a direction along the Y-axis direction (predetermined direction). The Y-axis stage 102 moves the object 200 to a position corresponding to a stopped support 111. This allows selective three-dimensional modeling using a stopped support 111, thereby ensuring the shape accuracy of the object and improving modeling productivity.

[0133] [Second embodiment] Next, a 3D modeling apparatus 500a according to the second embodiment will be described. Note that the same components as those described in the first embodiment will be given the same part numbers, and duplicated descriptions will be omitted as appropriate.

[0134] 10 is a diagram illustrating an example of the configuration of a 3D modeling apparatus 500a. As shown in FIG 10, the 3D modeling apparatus 500a includes a rotation stage 105 and a control unit 400a.

[0135] The rotation stage 105 is an example of a rotation means for rotating the model 200 around a rotation axis E parallel to the stacking direction of the material layers (Z-axis direction). The rotation stage 105 can rotate the placed build plate 101 and Z-axis stage 103, and the model 200 on the build plate 101, together around the rotation axis E. The rotation stage 105 is placed on the Y-axis stage 102 and is movable in the Y-axis direction. The control unit 400a includes a rotation control unit that controls the rotation of the rotation stage 105.

[0136] Here, FIG. 11 is a diagram for explaining an example of a method for stacking material layers by the three-dimensional modeling apparatus 500a, and FIG. 11(a) to FIG. 11(d) are diagrams showing modeling steps.

[0137] The 3D modeling apparatus 500a rotates the build plate 101 around the rotation axis E each time a material layer is stacked, leaving a gap in the direction of the rectangular parallelepiped blocks to be stacked, and stacks them by changing the angle by 90 degrees.

[0138] 11(a), for example, rectangular parallelepiped blocks 91 with their longitudinal direction in the X-axis direction are formed on the surface of the +Z direction of the object 200 so as to be arranged along the Y-axis direction. After the object 200 is rotated from this state around the rotation axis E, as shown in FIG 11(b), rectangular parallelepiped blocks 92 with their longitudinal direction in the X-axis direction are formed on the surface of the object 200 in the +Z direction so as to be arranged along the Y-axis direction.

[0139] In this state, the object 200 is rotated around the rotation axis E, and then, as shown in Fig. 11(c), a rectangular parallelepiped block 93 with its elongated direction in the X-axis direction is formed on the surface of the object 200 on the +Z direction side so as to be arranged along the Y-axis direction. In the same manner, rectangular parallelepiped blocks 94 and 95 are formed on the surface of the object 200 on the +Z direction side.

[0140] In this way, the rectangular parallelepiped blocks 91 to 95 can be stacked seamlessly in the X-axis and Y-axis directions, improving the tensile strength in the X-axis and Y-axis directions. In addition, because the rectangular parallelepiped blocks 91 to 95 are stacked in an uneven shape, the surface area for bonding between the blocks increases, improving the tensile strength in the Z-axis direction as well.

[0141] Although the embodiments have been described above, the present invention is not limited to the above specifically disclosed embodiments, and various modifications and changes are possible without departing from the scope of the claims.

[0142] Each function of the above-described embodiments can be realized by one or more processing circuits. Here, the term "processing circuit" in this specification includes a processor programmed to execute each function by software, such as a processor implemented by an electronic circuit, and a device such as an ASIC (Application Specific Integrated Circuit), a DSP (digital signal processor), an FPGA (field programmable gate array), or a conventional circuit module designed to execute each function described above. [Explanation of symbols]

[0143] 100 Modeling Department 101 Build Plate 102 Y-axis stage (an example of a moving means) 103 Z-axis stage 104 Chamber 105 Rotating stage (rotating means) 111 Support 112 Supply section 115 Laser light source (an example of a flying means, an example of a melting means) 115a Pulsed laser light for flight 116a Pulsed laser light for melting 117 Verify Scanner 155 Modeling guide (an example of a guide member) 155A Air suction hole 155B Liquid passage hole 156 Slit section 200 Sculptures 201 Modeling materials 400 Control section 401 Communications Department 402 Data Generation Department 403 Error detection unit 404 Modeling Control Unit 41 Transport control section 42 Selection section 43 Flight Control Unit 44 Melting control section 45 Movement control section 500 Three-dimensional modeling equipment [Prior art documents] [Patent documents]

[0144] [Patent Document 1] JP 2018-24187 A

Claims

1. A three-dimensional modeling apparatus that models a model by stacking material layers containing a modeling material that is scattered on a surface of the model, comprising: A plurality of carriers that carry and transport the modeling material; a flying means for flying the modeling material carried by the carrier onto a surface of the model; a rotation means for rotating the object around a rotation axis parallel to a lamination direction of the material layers, the rotating means rotates for each layer of the material to be laminated, The flying means causes the modeling material carried by the stationary carrier among the plurality of carriers to fly, and stacks the material layers of the same layer with gaps between them; Among the plurality of carriers, a first carrier carries a first modeling material, and a second carrier carries a second modeling material that is different in type from the first modeling material; the first modeling material is resin-coated sand; The second modeling material is an amorphous resin.

2. The three-dimensional object forming apparatus according to claim 1 , wherein each of the plurality of carriers is a belt-like member arranged in a predetermined direction, transports the object in a transport direction intersecting the predetermined direction, and has a predetermined width along the predetermined direction.

3. A light source that emits light; A melting means, The flying means causes the modeling material to fly by irradiating the light, The three-dimensional object fabrication apparatus according to claim 1 , wherein the melting means melts at least one of the object and the modeling material flying onto a surface of the object by irradiating the object with the light.

4. Each of the plurality of carriers is a belt-like member that is arranged in a predetermined direction and transports the modeling material in a transport direction that intersects with the predetermined direction, a plurality of guide members for supporting the plurality of carriers, The three-dimensional modeling apparatus according to claim 3 , wherein the guide member is a rectangular plate-like member extending in a direction along the transport direction, including a slit portion that passes the light emitted by the light source, and whose longitudinal direction is along the transport direction.

5. Each of the plurality of carriers is a belt-like member that is arranged in a predetermined direction and transports the modeling material in a transport direction that intersects with the predetermined direction, a moving means for placing the object on the substrate and moving the object in a direction along the predetermined direction, The three-dimensional object forming apparatus according to claim 1 , wherein the moving means moves the object to a position corresponding to the support that is stopped.

6. The three-dimensional object fabrication apparatus according to claim 1 , wherein only some of the plurality of holders stop operating, and the remaining holders continue operating.

7. a carrier transport step in which the transport control unit transports some of the plurality of carriers; a flying step in which a flying means causes the modeling material held by the carrier to fly and form a material layer; A step of heating the modeling material that was flown in the flying step with a melting pulse laser; a rotating step of rotating the material layer around a rotation axis parallel to a lamination direction of the material layer each time the rotating means laminates the material layer, The flying means causes the modeling material carried by the stationary carrier among the plurality of carriers to fly, and stacks the material layers of the same layer with gaps between them; Among the plurality of carriers, a first carrier carries a first modeling material, and a second carrier carries a second modeling material that is different in type from the first modeling material; the first modeling material is resin-coated sand; The method for manufacturing a three-dimensional object, wherein the second modeling material is an amorphous resin.

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