Three-dimensional object and method for laminating and forming a three-dimensional object

Abstract

To provide a three-dimensional object capable of increasing a surface area of an inner surface of a flow path.SOLUTION: A three-dimensional object according to one embodiment has a periodic structure. The periodic structure has a plurality of unit objects, and the plurality of unit objects are connected to each other to form a plurality of stepped structures. In each of the plurality of stepped structures, the plurality of unit objects are connected to each other in a stepped manner along a polygonal spiral orbit around a unit central axis in each of the plurality of stepped structures. The unit central axis in each of the plurality of stepped structures extends in a first direction. A unit flow path is provided in each of the plurality of stepped structures along the plurality of unit objects connected to each other in a stepped manner. A flow path is provided in the periodic structure that includes the unit flow paths of the plurality of stepped structures and that is connected to an outside of the periodic structure.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present invention relate to three-dimensional objects and methods for additive manufacturing of three-dimensional objects.

Background Art

[0002] For example, for a catalyst, a gas-liquid separator, a radiator, or other applications, a three-dimensional object is manufactured in which a flow path through which a fluid can pass is provided and the surface area of the inner surface of the flow path is large. For example, a three-dimensional object provided with a complex flow path can be manufactured by additive manufacturing.

[0003] Additive manufacturing is performed by an additive manufacturing apparatus such as a three-dimensional printer. The additive manufacturing apparatus manufactures a three-dimensional object, for example, by forming a layer of a material and curing a part of the material for each layer of the material with a laser beam. The laser beam, for example, sinters a powdery material or cures a photocurable resin containing a powdery material.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] As a three-dimensional object provided with a complex flow path, for example, a lattice three-dimensional object is manufactured. However, a mere lattice three-dimensional object makes it difficult to increase the surface area of the inner surface of the flow path.

[0006] An example of the problem to be solved by the present invention is to provide a three-dimensional object capable of making the surface area of the inner surface of the flow path wider and a method for additive manufacturing of the three-dimensional object.

Means for Solving the Problems

[0007] The three-dimensional object according to one embodiment has a periodic structure. The periodic structure has a plurality of unit objects, and the plurality of unit objects form a plurality of stepped structures connected to each other. In each of the plurality of stepped structures, the plurality of unit objects are connected to each other stepwise along a polygonal spiral orbit around the unit central axis in each of the plurality of stepped structures. The unit central axis in each of the plurality of stepped structures extends in a first direction. In each of the plurality of stepped structures, a unit flow path is provided along the plurality of unit objects connected to each other stepwise. In the periodic structure, a flow path is provided that includes the unit flow paths of the plurality of stepped structures and communicates with the outside of the periodic structure.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Modes for Carrying Out the Invention

[0009] (Embodiment) Hereinafter, one embodiment will be described with reference to FIGS. 1 to 7. In this specification, basically, vertically upward is defined as the upward direction, and vertically downward is defined as the downward direction. Also, in this specification, the components according to the embodiment and the description of the components may be described in a plurality of expressions. The components and their descriptions are examples and are not limited by the expressions in this specification. The components may be specified by different names from those in this specification. Also, the components may be described by expressions different from those in this specification.

[0010] FIG. 1 is an exemplary perspective view showing a three-dimensional object 10 according to one embodiment. The three-dimensional object 10 is used, for example, as a catalyst, a gas-liquid separator, a radiator, or for other applications. The three-dimensional object 10 is manufactured, for example, by additive manufacturing. Note that the three-dimensional object 10 may be manufactured by other methods.

[0011] As shown in each drawing, in this specification, for convenience, the X-axis, Y-axis, and Z-axis are defined. The X-axis, Y-axis, and Z-axis are perpendicular to each other. The X-axis is provided along the width of the three-dimensional object 10. The Y-axis is provided along the length of the three-dimensional object 10. The Z-axis is provided along the height of the three-dimensional object 10.

[0012] Furthermore, in this specification, the X-direction, Y-direction, and Z-direction are defined. The X-direction is the direction along the X-axis, including the +X direction indicated by the arrow of the X-axis and the -X direction opposite to the arrow of the X-axis. The Y-direction is the direction along the Y-axis, including the +Y direction indicated by the arrow of the Y-axis and the -Y direction opposite to the arrow of the Y-axis. The Z-direction is the direction along the Z-axis, including the +Z direction indicated by the arrow of the Z-axis and the -Z direction opposite to the arrow of the Z-axis.

[0013] For convenience, the +X direction may be referred to as the right direction, the -X direction as the left direction, the +Y direction as the rear direction, the -Y direction as the front direction, the +Z direction as the upward direction, and the -Z direction as the downward direction. However, the expressions for the up, down, left, right, front, and rear directions in this embodiment do not limit the position, orientation, usage mode, and other conditions.

[0014] The +Z direction is an example of the first direction. The X direction (+X direction or -X direction) is a direction orthogonal to the +Z direction and is an example of the fourth direction. The Y direction (+Y direction or -Y direction) is a direction orthogonal to the +Z direction and also orthogonal to the X direction, and is an example of the fifth direction.

[0015] The three-dimensional object 10 is made of, for example, ceramics. Note that the three-dimensional object 10 may be made of other materials such as metal, resin, or metal oxide. The three-dimensional object 10 has a periodic structure 11. The three-dimensional object 10 may have other parts.

[0016] FIG. 2 is an exemplary perspective view showing a part of the periodic structure 11 of the present embodiment. FIG. 3 is an exemplary plan view showing a part of the periodic structure 11 of the present embodiment. As shown in FIGS. 2 and 3, the periodic structure 11 has a plurality of columnar bodies 21 and a plurality of connecting portions 22. The columnar body 21 is an example of a unit object and may also be referred to as a constituent unit.

[0017] Each of the plurality of columnar bodies 21 and the plurality of connecting portions 22 is formed in a substantially columnar shape extending in the substantially Z direction. Note that the shape of each of the columnar body 21 and the plurality of connecting portions 22 is not limited to this example. Also, the plurality of columnar bodies 21 and the plurality of connecting portions 22 may have different shapes from each other.

[0018] FIG. 4 is an exemplary cross-sectional view showing a part of the periodic structure 11 of the present embodiment. As shown in FIG. 4, each of the plurality of columnar bodies 21 has an upper surface 21a, a bottom surface 21b, and a side surface 21c. The upper surface 21a is an example of a plane.

[0019] The upper surface 21a is a substantially flat circular surface. Note that the upper surface 21a may be other shapes such as a quadrilateral. The upper surface 21a faces substantially in the +Z direction. The bottom surface 21b is located on the opposite side of the upper surface 21a. The side surface 21c is provided between the upper surface 21a and the bottom surface 21b.

[0020] The bottom surface 21b is a substantially circular surface. However, at least one bottom surface 21b of the plurality of columnar bodies 21 is a curved surface that protrudes in the substantially -Z direction. Note that the bottom surface 21b is not limited to this example. For example, the bottom surface 21b of the lowermost one of the plurality of columnar bodies 21 may be substantially flat.

[0021] The side surface 21c is a substantially cylindrical curved surface. However, at least one side surface 21c of the plurality of columnar bodies 21 is a curved surface that protrudes in a direction substantially orthogonal (intersecting) to the Z direction. Note that the side surface 21c is not limited to this example.

[0022] As shown in FIG. 2, the connecting portion 22 has an upper surface 22a. The upper surface 22a is, like the upper surface 21a of the columnar body 21, a substantially flat circular surface and faces in the +Z direction. Note that the shape of the connecting portion 22 is not limited to this example.

[0023] As shown in FIG. 1, the plurality of columnar bodies 21 form a plurality of stepped structures 31, 32. FIGS. 2 and 3 show the stepped structure 31 among the plurality of stepped structures 31, 32. The stepped structure 32 is formed symmetrically with respect to the stepped structure 31 in a direction orthogonal to the Z axis.

[0024] As shown in FIG. 2, in each of the plurality of stepped structures 31, 32, the plurality of columnar bodies 21 are connected to each other stepwise along a polygonal spiral orbit around the unit central axis Ax. The unit central axis Ax is the central axis of the spiral orbit in each of the plurality of stepped structures 31, 32. That is, the periodic structure 11 has a plurality of unit central axes Ax corresponding to the plurality of stepped structures 31, 32. The unit central axis Ax in each of the plurality of stepped structures 31, 32 extends in the Z direction (+Z direction). In other words, the plurality of unit central axes Ax extend substantially parallel in the Z direction.

[0025] In the present embodiment, the plurality of columnar bodies 21 are connected to each other stepwise along a double spiral orbit around the unit central axis Ax. Note that the plurality of columnar bodies 21 may be connected to each other along a single spiral orbit, or may be connected to each other along a triple or more spiral orbit.

[0026] As shown in FIG. 3, in the present embodiment, the plurality of columnar bodies 21 are connected to each other stepwise along a quadrangular spiral orbit. In other words, when viewed in the Z direction, the plurality of columnar bodies 21 are connected to each other along a quadrangular orbit. Note that the plurality of columnar bodies 21 are not limited to this example, and may be connected to each other stepwise along a hexagonal, octagonal, or other polygonal spiral orbit.

[0027] At least one of the plurality of columnar bodies 21 is connected to the upper surface 21a of another one of the plurality of columnar bodies 21. The upper surface 21a of the columnar body 21 is connected to the bottom surface 21b of another columnar body 21. As shown in FIG. 4, the upper surface 21a of one of the plurality of columnar bodies 21 located at the uppermost position may not be connected to another columnar body 21. Also, the bottom surface 21b of one of the plurality of columnar bodies 21 located at the lowermost position may not be connected to another columnar body 21.

[0028] Since the plurality of columnar bodies 21 are connected to each other stepwise, at least a part of the upper surfaces 21a of the plurality of columnar bodies 21 is not connected to other objects and other parts and is exposed. Also, at least a part of the bottom surfaces 21b of the plurality of columnar bodies 21 is not connected to other objects and other parts and is exposed.

[0029] As shown in FIG. 2, each of the stepped structures 31, 32 along the quadrangular spiral orbit has a plurality of stepped portions 41, 42, 43, 44. In other words, the plurality of columnar bodies 21 form a plurality of stepped portions 41, 42, 43, 44 in each of the plurality of stepped structures 31, 32. In each of the plurality of stepped portions 41, 42, 43, 44, the plurality of columnar bodies 21 are connected to each other stepwise.

[0030] As shown in FIG. 3, the plurality of columnar bodies 21 of the stepped portion 41 are arranged in the X direction when viewed in the Z direction (+Z direction or -Z direction). The plurality of columnar bodies 21 of the stepped portion 41 are arranged in an oblique direction (upper left direction) between the -X direction and the +Z direction. Therefore, in the stepped portion 41, the center of one columnar body 21 is spaced apart from the center of another columnar body 21 connected to the one upper surface 21a in the +X direction.

[0031] The plurality of columnar bodies 21 of the stepped portion 42 are arranged in the Y direction when viewed in the Z direction. The plurality of columnar bodies 21 of the stepped portion 42 are arranged in an oblique direction (oblique rear direction) between the +Y direction and the +Z direction. Therefore, in the stepped portion 42, the center of one columnar body 21 is spaced apart from the center of another columnar body 21 connected to the one upper surface 21a in the -Y direction.

[0032] The plurality of columnar bodies 21 of the stepped portion 43 are arranged in the X direction when viewed in the Z direction. The plurality of columnar bodies 21 of the stepped portion 43 are arranged in an oblique direction (upper right direction) between the +X direction and the +Z direction. Therefore, in the stepped portion 43, the center of one columnar body 21 is spaced apart from the center of another columnar body 21 connected to the one upper surface 21a in the -X direction.

[0033] The plurality of columnar bodies 21 of the stepped portion 44 are arranged in the Y direction when viewed in the Z direction. The plurality of columnar bodies 21 of the stepped portion 44 are arranged in an oblique direction (oblique front direction) between the -Y direction and the +Z direction. Therefore, in the stepped portion 44, the center of one columnar body 21 is spaced apart from the center of another columnar body 21 connected to the one upper surface 21a in the +Y direction.

[0034] In the stepped structure 31, the columnar body 21 located at the uppermost position in one stepped portion 41 is connected to the columnar body 21 located at the lowermost position in one stepped portion 42. The columnar body 21 located at the uppermost position in the stepped portion 42 is connected to the columnar body 21 located at the lowermost position in one stepped portion 43. The columnar body 21 located at the uppermost position in the stepped portion 43 is connected to the columnar body 21 located at the lowermost position in one stepped portion 44. The columnar body 21 located at the uppermost position in the stepped portion 44 may be connected to the columnar body 21 located at the lowermost position in another stepped portion 41.

[0035] In the stepped structure 32, the columnar body 21 located at the lowermost position in one stepped portion 41 is connected to the columnar body 21 located at the uppermost position in one stepped portion 42. The columnar body 21 located at the lowermost position in the stepped portion 42 is connected to the columnar body 21 located at the uppermost position in one stepped portion 43. The columnar body 21 located at the lowermost position in the stepped portion 43 is connected to the columnar body 21 located at the uppermost position in one stepped portion 44. The columnar body 21 located at the lowermost position in the stepped portion 44 may be connected to the columnar body 21 located at the uppermost position in another stepped portion 41.

[0036] The stepped portions 41, 42, 43, 44 connected to each other extend along a quadrangular spiral orbit. The quadrangular spiral orbit is, for example, an orbit that spirally extends along the outer peripheral surface of a virtual substantially quadrangular prism extending along the unit central axis Ax.

[0037] In the present embodiment, each of the stepped portions 41, 42, 43, 44 is formed by four of the plurality of columnar bodies 21. Note that the number of columnar bodies 21 forming the stepped portions 41, 42, 43, 44 is not limited to this example.

[0038] One of the columnar bodies 21 that form the stepped portion 41 also serves as one of the columnar bodies 21 that form the stepped portion 42. One of the columnar bodies 21 that form the stepped portion 42 also serves as one of the columnar bodies 21 that form the stepped portion 43. One of the columnar bodies 21 that form the stepped portion 43 also serves as one of the columnar bodies 21 that form the stepped portion 44. One of the columnar bodies 21 that form the stepped portion 44 may also serve as one of the columnar bodies 21 that form the stepped portion 41.

[0039] In each of the plurality of stepped structures 31, 32, two stepped portions 41 are arranged with a gap in the Z direction. The two stepped portions 41 extend substantially parallel to each other. The two stepped portions 42 are also arranged with a gap in the Z direction. The two stepped portions 42 extend substantially parallel to each other.

[0040] The two stepped portions 43 are also arranged with a gap in the Z direction. The two stepped portions 43 extend substantially parallel to each other. The two stepped portions 44 are also arranged with a gap in the Z direction. The two stepped portions 44 extend substantially parallel to each other.

[0041] As shown in FIG. 2, a plurality of unit flow paths 45, 46, 47, 48 are provided in each of the plurality of stepped structures 31, 32. The unit flow path 45 is located between two stepped portions 41. In other words, the unit flow path 45 is located between a plurality of columnar bodies 21 adjacent to each other in the Z direction (+Z direction). The unit flow path 45 extends substantially parallel to the stepped portion 41.

[0042] The unit flow path 46 is located between two stepped portions 42 and extends substantially parallel to the stepped portion 42. The unit flow path 47 is located between two stepped portions 43 and extends substantially parallel to the stepped portion 43. The unit flow path 48 is located between two stepped portions 44 and extends substantially parallel to the stepped portion 44.

[0043] One end of the unit flow path 45 is connected to one end of the unit flow path 46. The other end of the unit flow path 46 is connected to one end of the unit flow path 47. The other end of the unit flow path 47 is connected to one end of the unit flow path 48. The other end of the unit flow path 48 may be connected to one end of another unit flow path 45. The mutually connected unit flow paths 45, 46, 47, 48 extend along a square spiral orbit. That is, the unit flow paths 45, 46, 47, 48 are provided along a plurality of columnar bodies 21 that are connected to each other in a stepped manner.

[0044] As described above, the plurality of columnar bodies 21 are connected to each other in a stepped manner along a double spiral orbit around the unit central axis Ax. Therefore, in each of the plurality of stepped structures 31, 32, two columnar bodies 21 are arranged in a direction orthogonal to the Z direction. The two columnar bodies 21 are spaced apart from each other in a direction orthogonal to the Z axis.

[0045] In other words, in each of the plurality of stepped structures 31, 32, one upper surface 21a of the plurality of columnar bodies 21 and another upper surface 21a of the plurality of columnar bodies 21 are arranged at substantially the same position (height) in the Z direction. At least two of the plurality of columnar bodies 21 having the same upper surface 21a in the Z direction (+Z direction) are spaced apart from each other in a direction orthogonal to the Z direction.

[0046] The connecting portion 22 connects a plurality of columnar bodies 21 that are connected to each other in a stepped manner along one of the double spiral orbits and a plurality of columnar bodies 21 that are connected to each other in a stepped manner along the other of the double spiral orbits. For example, the connecting portion 22 connects two columnar bodies 21 located on the diagonal passing through the unit central axis Ax to each other. The upper surface 22a of the connecting portion 22 forms a single plane with the upper surfaces 21a of the two columnar bodies 21 connected by the connecting portion 22.

[0047] In this embodiment, the length of the connecting portion 22 in the Z direction is approximately twice the length of the columnar body 21 in the Z direction. The connecting portion 22 connects a pair of columnar bodies 21 arranged in a direction orthogonal to the Z direction to each other, and also connects another pair of columnar bodies 21 arranged in a direction orthogonal to the Z direction to each other. Note that the connecting portion 22 is not limited to this example.

[0048] As shown in FIG. 1, the plurality of stepped structures 31, 32 are arranged in a lattice pattern along the X-Y plane and are connected to each other in the X direction and the Y direction. In other words, one of the plurality of stepped structures 31, 32 is connected to another one of the plurality of stepped structures 31, 32 in the X direction and is connected to yet another one of the plurality of stepped structures 31, 32 in the Y direction.

[0049] In this embodiment, the stepped structures 31 and 32 are formed alternately. In the stepped structures 31, 32 adjacent in the X direction, the stepped portion 42 or the stepped portion 44 of the stepped structure 31 also serves as the stepped portion 42 or the stepped portion 44 of the stepped structure 32. Further, in the stepped structures 31, 32 adjacent in the Y direction, the stepped portion 41 or the stepped portion 43 of the stepped structure 31 also serves as the stepped portion 41 or the stepped portion 43 of the stepped structure 32.

[0050] As described above, the periodic structure 11 has mirror-symmetrical stepped structures 31, 32 formed alternately. In other words, in the periodic structure 11, the stepped structures 31, 32 are formed periodically.

[0051] As shown in FIG. 4, when the stepped structures 31, 32 are adjacent in the X direction, the unit flow path 45 of the stepped structure 31 and the unit flow path 47 of the stepped structure 32 are connected to each other. The unit flow path 45 is an example of a first unit passage. The unit flow path 47 is an example of a second unit passage.

[0052] The direction in which the unit flow path 45 extends and the direction in which the unit flow path 47 extends intersect each other. The direction in which the unit flow path 45 extends is a direction that intersects the Z direction (+Z direction) and is an example of a second direction. The direction in which the unit flow path 47 extends is a direction that intersects the Z direction (+Z direction) and is an example of a third direction. The direction in which the unit flow path 45 extends and the direction in which the unit flow path 47 extends intersect each other.

[0053] Similarly, by the stepped structures 31 and 32 being adjacent to each other in the X direction, the unit flow path 47 of the stepped structure 31 and the unit flow path 45 of the stepped structure 32 are connected to each other. By the stepped structures 31 and 32 being adjacent to each other in the Y direction, the unit flow path 46 of the stepped structure 31 and the unit flow path 48 of the stepped structure 32 are connected to each other. Further, by the stepped structures 31 and 32 being adjacent to each other in the Y direction, the unit flow path 48 of the stepped structure 31 and the unit flow path 46 of the stepped structure 32 are connected to each other.

[0054] In the present embodiment, the direction in which the unit flow path 45 extends and the direction in which the unit flow path 47 extends are orthogonal to each other. Also, the direction in which the unit flow path 46 extends and the direction in which the unit flow path 48 extends are orthogonal to each other. Note that the directions in which the unit flow paths 45, 46, 47, and 48 extend are not limited to this example.

[0055] By the unit flow paths 45, 46, 47, and 48 of the stepped structures 31 and 32 being connected to each other, a flow path 50 is provided in the periodic structure 11. The flow path 50 includes the unit flow paths 45, 46, 47, and 48 that are connected to each other. Note that the flow path 50 may include other portions.

[0056] The flow path 50 opens at the ends of the periodic structure 11 in each of the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction. That is, the flow path 50 communicates with the outside of the periodic structure 11. For this reason, the fluid can pass through the flow path 50. Note that the flow path 50 may open at the ends of the periodic structure 11 in at least two of the +X direction, -X direction, +Y direction, -Y direction, +Z direction, and -Z direction.

[0057] For example, when the three-dimensional object 10 is a catalyst, the target fluid passes through the flow path 50. At this time, the three-dimensional object 10 promotes the chemical reaction of the fluid in contact with the inner surface 50a of the flow path 50. The inner surface 50a is the surface of the columnar body 21 and the connecting portion 22 that is exposed in the flow path 50. Generally, the larger the surface area of the inner surface 50a of the three-dimensional object 10, the more the chemical reaction of the fluid is promoted.

[0058] In the stepped structures 31, 32, a plurality of columnar bodies 21 are connected to each other stepwise. For this reason, the inner surface 50a of the flow path 50 is formed in a stepped shape. Further, the bottom surface 21b and the side surface 21c of the columnar body 21 project outward. For this reason, the surface area of the inner surface 50a of the flow path 50 becomes larger than, for example, the case where the three-dimensional object has a smooth lattice or spiral portion.

[0059] Hereinafter, with reference to FIGS. 5 to 7, a part of the manufacturing method (laminated manufacturing method) of the three-dimensional object 10 will be exemplified. Note that the manufacturing method of the three-dimensional object 10 is not limited to the following method, and other methods may be used.

[0060] FIG. 5 is an exemplary cross-sectional view schematically showing the three-dimensional printer 100 of the present embodiment. The three-dimensional printer 100 is a device that laminates and forms the three-dimensional object 10 from the material M. The material M is, for example, a slurry having ceramic particles, a photocurable resin, and additives such as a dispersant. Note that the material M is not limited to this example.

[0061] The three-dimensional printer 100 of the present embodiment includes a stage 101, a material supply device 102, an optical device 103, and a control device 104. Note that the three-dimensional printer 100 is not limited to this example.

[0062] The stage 101 has a mounting table 111 and a peripheral wall 112. The mounting table 111 is, for example, a plate material extending along the X-Y plane. Note that the shape of the mounting table 111 is not limited to this. The mounting table 111 has an upper surface 111a. The upper surface 111a is a substantially flat surface facing in the substantially +Z direction. The peripheral wall 112 extends in the Z direction and is formed in a cylindrical shape surrounding the mounting table 111. The mounting table 111 can be moved in the Z direction inside the peripheral wall 112 by various devices such as a hydraulic elevator.

[0063] The material supply device 102 has a tank 121, a blade 122, and a moving device 123. The tank 121 stores the material M. The tank 121 can supply the material M to the upper surface 111a of the mounting table 111 from a slit provided in the tank 121. The blade 122 protrudes from the tank 121 toward the upper surface 111a. The blade 122 extends along the slit of the tank 121.

[0064] The moving device 123 has a rail 131 and a moving mechanism 132. The rail 131 extends, for example, in the X direction. The moving mechanism 132 is attached to the tank 121. The moving mechanism 132 can move the tank 121 and the blade 122 in parallel along the rail 131.

[0065] The moving device 123 changes the relative positions of the tank 121 and the blade 122 with respect to the stage 101. Note that the moving device 123 may, for example, move the stage 101 with respect to the tank 121 and the blade 122.

[0066] The optical device 103 has various components such as, for example, a light source having an oscillation element that emits laser light L, a conversion lens that converts the laser light L into parallel light, a converging lens that converges the laser light L, and a galvanometer mirror that moves the irradiation position of the laser light L. That is, the optical device 103 can emit the laser light L. The optical device 103 can change the power density of the laser light L.

[0067] The laser beam L is an example of light and energy rays. Note that light is not limited to visible light. For example, when the material M has an ultraviolet curable resin, the laser beam L may be an ultraviolet laser.

[0068] The optical device 103 is located above the stage 101. Note that the optical device 103 may be arranged in other places. The optical device 103 converts the laser beam L emitted by the light source into parallel light by a conversion lens. The optical device 103 reflects the laser beam L on a galvanometer mirror whose tilt angle can be changed, and converges the laser beam L by a converging lens, thereby irradiating the laser beam L to a desired position.

[0069] The control device 104 is electrically connected to the stage 101, the material supply device 102, and the optical device 103. The control device 104 is, for example, a computer and has various electronic components such as a CPU, a ROM, a RAM, and an external storage device.

[0070] The control device 104 controls the stage 101, the material supply device 102, and the optical device 103 by reading and executing a program stored in the ROM or the external storage device. The three-dimensional printer 100 forms a three-dimensional object 10 by layer manufacturing based on the control (program) of the control device 104. Further, the control device 104 can communicate with, for example, an external personal computer PC. The three-dimensional printer 100 and the personal computer PC may be included in a system for layer manufacturing.

[0071] In an example of layer manufacturing by the three-dimensional printer 100 described above, first, for example, a personal computer PC inputs STL data of the three-dimensional object 10 to the control device 104. The control device 104 generates manufacturing data of the three-dimensional object 10 by the three-dimensional printer 100 based on the STL data. The manufacturing data includes, for example, a movement command of the moving device 123, an irradiation command of the laser beam L by the optical device 103, and a lift command of the mounting table 111. The generated manufacturing data is stored, for example, in the RAM or the storage device of the control device 104.

[0072] Next, the moving device 123 of the material supply device 102 moves the tank 121 and the blade 122. Thereby, the tank 121 supplies the material M to the upper surface 111a of the mounting table 111. Further, the blade 122 levels the material M. Thereby, the layer ML of the material M is formed. The layer ML of the material M has a photocurable resin of the material M.

[0073] Next, the control device 104 controls the optical device 103 to irradiate the laser beam L of the optical device 103 onto the material M forming the layer ML. The control device 104 determines the irradiation position of the laser beam L based on the manufacturing data.

[0074] A part of the layer ML irradiated with the laser beam L is cured by the curing action of the photocurable resin. Thereby, at least one columnar body 21 is formed in the layer ML. Note that there may be a layer ML in which the columnar body 21 is not provided.

[0075] When the optical device 103 finishes irradiating the layer ML with the laser beam L, the mounting table 111 moves downward by a predetermined distance. The distance that the mounting table 111 moves is substantially equal to the thickness of the layer ML. Next, the moving device 123 moves the tank 121 and the blade 122 again. Thereby, a new layer ML is formed on the layer ML.

[0076] As described above, the material supply device 102 repeats the formation of the layer ML and the formation of the columnar body 21 in the layer ML by curing at least a part of the layer ML. Thereby, the three-dimensional printer 100 forms a three-dimensional object 10 including the periodic structure 11.

[0077] When the blade 122 levels the material M, a force in a direction orthogonal to the Z direction acts on the cured portion (columnar body 21) in the lower layer ML. However, in a plurality of layers ML, a plurality of columnar bodies 21 are connected to each other in a stepped manner. For this reason, the three-dimensional object 10 during additive manufacturing can have a strength capable of preventing deformation by the force of the blade 122.

[0078] The formed three-dimensional object 10 is embedded in the uncured material M. Therefore, the uncured material M is removed by cleaning. For example, the uncured material M is removed by a chemical solution such as ethanol.

[0079] In the formed three-dimensional object 10, the material M includes not only ceramic particles that are the material of the three-dimensional object 10 but also cured resin. Therefore, for example, the resin is removed from the three-dimensional object 10 by degreasing.

[0080] Next, the three-dimensional object 10 is transported to, for example, a furnace and heated in the furnace. Thereby, the ceramics of the material M are fired. Thus, the laminated manufacturing of the three-dimensional object 10 made of ceramics is completed.

[0081] FIG. 6 is an exemplary diagram schematically showing various data in the present embodiment. In the above-described laminated manufacturing, the control device 104 generates manufacturing data of the three-dimensional object 10 by the three-dimensional printer 100, for example, as described below. Note that the method for generating the manufacturing data is not limited to the following method. Also, a personal computer PC may generate the manufacturing data.

[0082] First, for example, a personal computer PC inputs model data D1 to the control device 104. The model data D1 is, for example, STL data. That is, the model data D1 is data representing the three-dimensional shape of the three-dimensional object 10 including the periodic structure 11. The model data D1 is not limited to STL data and may be other data such as CAD data.

[0083] In the model data D1, the plurality of columnar bodies 21 are represented as cylindrical. That is, in the model data D1, the bottom surface 21b of the columnar body 21 is flat, and the side surface 21c is a cylindrical curved surface. Note that the model data D1 is not limited to this example.

[0084] Next, the control device 104 divides (slices) the three-dimensional shape of the acquired model data D1 into a plurality of layers. The control device 104 converts the sliced three-dimensional shape into, for example, a collection of a plurality of points or cuboids (pixels) (rasterizes, pixelates) to generate slice data D2. The slice data D2 corresponds to the shape of a part (columnar body 21) of the three-dimensional object 10 in the plurality of layers ML. In this way, the control device 104 generates the slice data D2 based on the acquired model data D1.

[0085] Next, the control device 104 generates manufacturing data D3 having an instruction to irradiate the laser beam L in the plurality of layers ML based on the slice data D2. In the manufacturing data D3, the portion targeted by the instruction to irradiate the laser beam L is smaller than the columnar body 21 in the layer ML.

[0086] The manufacturing data D3 in FIG. 6 shows a part of the layer ML that is cured by the laser beam L according to the instruction in the manufacturing data D3. That is, if the laser beam L cures only the portion of the layer ML that is irradiated with the laser beam L, the three-dimensional object 10 is formed in the shape shown by the manufacturing data D3 in FIG. 6.

[0087] Before generating the manufacturing data D3 including the irradiation instruction of the laser beam L, the control device 104 may generate slice data in which the columnar body 21 is reduced, as exemplified by the manufacturing data D3 in FIG. 6. In this case, the control device 104 generates manufacturing data D3 having an instruction to irradiate the laser beam L in the plurality of layers ML from the slice data.

[0088] In the manufacturing data D3, the portion irradiated with the laser beam L in the layer ML is separated in a direction intersecting the Z direction (+Z direction) from the portion irradiated with the laser beam L in the next layer ML to be formed. In other words, in the manufacturing data D3, the portions irradiated with the laser beam L of two adjacent layers ML are separated from each other.

[0089] FIG. 7 is an exemplary plan view schematically showing a part of layer ML in the laminated manufacturing process of the present embodiment. FIG. 7 shows, for example, a layer ML in which two columnar bodies 21 and a connecting portion 22 are formed. Further, FIG. 7 shows, by a broken line, the columnar body 21 formed in the layer ML one layer below.

[0090] The formation of the columnar body 21 and the connecting portion 22 is performed based on the manufacturing data D3. For this reason, the portion PI irradiated with the laser beam L in the layer ML is smaller than each of the columnar body 21 and the connecting portion 22 to be formed. In other words, the area of the portion PI irradiated with the laser beam L in the layer ML is smaller than the area of the upper surface 21a of the columnar body 21 and smaller than the area of the upper surface 22a of the connecting portion 22.

[0091] When the layer ML is irradiated with the laser beam L, not only the portion PI irradiated with the laser beam L but also the portion PS around the portion PI is cured. By the curing of the portion PI and the curing (excessive curing) of the surrounding portion PS, the columnar body 21 and the connecting portion 22 are formed. That is, the formation of the columnar body 21 and the connecting portion 22 includes irradiating the portion PI of the layer ML with the laser beam L to cure the portion PI and the portion PS around the portion PI.

[0092] The control device 104 generates the manufacturing data D3 so that the difference between the outer diameter of the portion PS cured by excessive curing and the outer diameter of the corresponding columnar body 21 or connecting portion 22 is within a predetermined range. For example, the control device 104 calculates the outer diameter of the portion PI irradiated with the laser beam L by reducing the distance cured by excessive curing from the outer diameter of the columnar body 21 in the slice data D2.

[0093] As described above, in the manufacturing data D3, the portions irradiated with the laser beam L of two adjacent layers ML are separated from each other. However, due to excessive curing, the columnar bodies 21 of two adjacent layers ML partially overlap each other and are connected in a stepped manner.

[0094] Due to residual hardening, the bottom surface 21b and the side surface 21c of the columnar body 21 become curved surfaces protruding outward. Further, for example, the surface of the columnar body 21 may be worn due to cleaning. Therefore, the manufactured columnar body 21 shown in FIG. 4 and the shape of the columnar body 21 in the model data D1 shown in FIG. 6 are different from each other.

[0095] In the three-dimensional object 10 according to the present embodiment described above, the periodic structure 11 has a plurality of columnar bodies 21, and the plurality of columnar bodies 21 form a plurality of stepped structures 31, 32 connected to each other. In each of the plurality of stepped structures 31, 32, the plurality of columnar bodies 21 are connected to each other stepwise along a polygonal spiral orbit around the unit central axis Ax in each of the plurality of stepped structures 31, 32. The unit central axis Ax in each of the plurality of stepped structures 31, 32 extends in the +Z direction. In each of the plurality of stepped structures 31, 32, unit flow paths 45, 46, 47, 48 are provided along the plurality of columnar bodies 21 connected to each other stepwise. The periodic structure 11 includes the unit flow paths 45, 46, 47, 48 of the plurality of stepped structures 31, 32, and a flow path 50 communicating with the outside of the periodic structure 11 is provided. Since the plurality of columnar bodies 21 are connected stepwise, the surface area of the inner surface 50a of the flow path 50 can be provided wider. Further, since the plurality of columnar bodies 21 are connected to each other along a polygonal spiral orbit, the unit flow paths 45, 46, 47, 48 are formed in a spiral shape, and the plurality of unit flow paths 45, 46, 47, 48 can be regularly connected to each other. Therefore, the fluid can easily pass through the flow path 50. For example, when the three-dimensional object 10 is a catalyst, since the surface area is wide and the fluid can easily pass through the flow path 50, the performance of the catalyst can be improved. Further, for example, when the three-dimensional object 10 is manufactured by additive manufacturing, since the fluid can easily pass through the flow path 50, the three-dimensional object 10 can suppress the material M that has not been cured after the curing of the material M from staying in the flow path 50.

[0096] Generally, in a catalyst, a gas-liquid separator, a radiator, or other applications, the larger the surface area of the inner surface 50a of the flow path 50, the more effectively the three-dimensional object 10 functions. By narrowing the flow path 50, the three-dimensional object 10 can be provided with a large number of flow paths 50, and the surface area of the inner surface 50a of the flow path 50 can be increased. On the other hand, when the flow path 50 is narrow, the uncured material M tends to stay in the flow path 50. However, in the three-dimensional object 10 of the present embodiment, as described above, the fluid easily passes through the flow path 50. Therefore, the three-dimensional object 10 can suppress the uncured material M staying in the flow path 50 after the curing of the material M.

[0097] Each of the plurality of columnar bodies 21 has an upper surface 21a facing the +Z direction. At least one of the plurality of columnar bodies 21 is connected to the upper surface 21a of another one of the plurality of columnar bodies 21. Thereby, the inner surface 50a of the flow path 50 is more clearly formed in a stepped shape, and the surface area of the inner surface 50a of the flow path 50 can be provided wider.

[0098] Each of the plurality of columnar bodies 21 has a bottom surface 21b located on the opposite side of the upper surface 21a, and a side surface 21c provided between the upper surface 21a and the bottom surface 21b. The side surface 21c is a curved surface protruding in a direction intersecting the +Z direction. Thereby, the surface area of the inner surface 50a of the flow path 50 can be provided wider.

[0099] At least two of the plurality of columnar bodies 21 having the upper surfaces 21a at the same position in the +Z direction are spaced apart from each other in a direction orthogonal to the +Z direction. Thereby, each of the plurality of unit flow paths 45, 46, 47, 48 can be provided larger. Therefore, the fluid easily passes through the flow path 50.

[0100] The plurality of stepped structures 31, 32 are connected to each other in a direction intersecting the +Z direction. One of the unit flow paths 45, 46, 47, 48 among the plurality of stepped structures 31, 32 has a unit flow path 45 extending in the upper left direction intersecting the +Z direction. Another one of the unit flow paths 45, 46, 47, 48 among the plurality of stepped structures 31, 32 connected to the said one among the plurality of stepped structures 31, 32 has a unit flow path 47 extending in the upper right direction intersecting the +Z direction and intersecting the upper left direction. The unit flow path 45 is connected to the unit flow path 47. That is, the flow path 50 meanders at the unit flow path 45 and the unit flow path 47. Therefore, the surface area of the inner surface 50a of the flow path 50 can be provided more widely.

[0101] One of the plurality of stepped structures 31, 32 is connected to another one of the plurality of stepped structures 31, 32 in the X direction orthogonal to the +Z direction. The said one of the plurality of stepped structures 31, 32 is connected to still another one of the plurality of stepped structures 31, 32 in the Y direction orthogonal to the +Z direction and orthogonal to the X direction. That is, the plurality of stepped structures 31, 32 are connected to each other in a lattice shape. Thereby, a three-dimensional object 10 and a flow path 50 extending in the X direction and the Y direction can be provided.

[0102] In each of the plurality of stepped structures 31, 32, the plurality of columnar bodies 21 are connected to each other stepwise along a double helical orbit around the unit central axis Ax. The periodic structure 11 has a connection part 22. In each of the plurality of stepped structures 31, 32, the connection part 22 connects the plurality of columnar bodies 21 connected to each other stepwise along one of the double helical orbits and the plurality of columnar bodies 21 connected to each other stepwise along the other of the double helical orbits. Thereby, the surface area of the inner surface 50a of the flow path 50 can be provided more widely. Also, by the connection part 22 connecting two columnar bodies 21, the strength of the three-dimensional object 10 can be improved.

[0103] Also, in the three-dimensional object 10 stacking and forming method according to the present embodiment described above, the periodic structure 11 is formed by repeating the formation of the layer ML and the formation of at least one columnar body 21 in the layer ML by curing at least a part of the layer ML. That is, the periodic structure 11 is manufactured by stacking and forming. Since the periodic structure 11 can make the surface area of the inner surface 50a of the flow path 50 wider, it is possible to suppress the material M that has not been cured after the curing of the material M in the stacking and forming from staying in the flow path 50.

[0104] The layer ML has a photocurable resin. The formation of at least one columnar body 21 includes irradiating the portion PI of the layer ML with the laser beam L to cure the portion PI of the layer ML and the portion PS around the portion PI of the layer ML. That is, the columnar body 21 is formed not only by the curing by the irradiation of the laser beam L but also by the propagation (excessive curing) of the curing action around the portion PI irradiated with the laser beam L. Thus, since excessive curing is taken into account, the stacking and forming method of the present embodiment can suppress the flow path 50 from being blocked by excessive curing.

[0105] Based on the model data D1 representing the shape of the periodic structure 11, the manufacturing data D3 is created. The manufacturing data D3 has an instruction to irradiate the portion PI smaller than the columnar body 21 in the layer ML with the laser beam L. The formation of at least one columnar body 21 is performed based on the manufacturing data D3. That is, based on the model data D1 representing the shape of the periodic structure 11, the manufacturing data D3 in which excessive curing is taken into account is created. Thereby, the stacking and forming method of the present embodiment can reduce the capacity of the manufacturing data D3.

[0106] In the manufacturing data D3, the portion irradiated with the laser beam in the layer ML is separated from the portion irradiated with the laser beam L in the layer ML to be formed next in a direction intersecting the +Z direction. Thereby, since the portions irradiated with the laser beam L are dispersed, the stacking and forming method of the present embodiment can reduce the capacity of the manufacturing data D3.

[0107] (Modification example) In the above-described embodiment, the three-dimensional object 10 is made of ceramics, and the material M includes ceramic particles and a photocurable resin. On the other hand, in one modification, the three-dimensional object 10 is made of metal, and the material M includes powdered metal. In this case, the three-dimensional printer 100 irradiates the laser beam L onto the layer ML of the material M to sinter a part of the layer ML. Note that the three-dimensional printer 100 is not limited to the laser beam L, and a part of the layer ML may be sintered by other means such as microwaves.

[0108] Also in the modification, the formation of the columnar body 21 and the connection part 22 is performed based on the manufacturing data D3. For this reason, the portion PI irradiated with the laser beam L in the layer ML is smaller than each of the columnar body 21 and the connection part 22 to be formed.

[0109] When the layer ML is irradiated with the laser beam L, not only the portion PI irradiated with the laser beam L but also the portion PS around the portion PI is sintered. By sintering the portion PI and sintering (pre-sintering) the surrounding portion PS, the columnar body 21 and the connection part 22 are formed. That is, the formation of the columnar body 21 and the connection part 22 includes sintering the portion PI and the portion PS around the portion PI by irradiating the laser beam L onto the portion PI of the layer ML.

[0110] The control device 104 generates the manufacturing data D3 so that the difference between the outer diameter of the portion PS sintered by pre-sintering and the outer diameter of the corresponding columnar body 21 or connection part 22 falls within a predetermined range. For example, the control device 104 calculates the outer diameter of the portion PI irradiated with the laser beam L by reducing the distance sintered by pre-sintering from the outer diameter of the columnar body 21 in the slice data D2.

[0111] In the modification described above, the layer ML has powdered metal. The formation of at least one columnar body 21 includes sintering the portion PI of the layer ML and the portion PS around the portion PI of the layer ML by irradiating the portion PI of the layer ML with the laser beam L. That is, the columnar body 21 is formed not only by sintering due to the irradiation of the laser beam L but also by the propagation (pre-sintering) of sintering around the portion PI irradiated with the laser beam L. Thus, since pre-sintering is taken into account, the additive manufacturing method of the present embodiment can suppress the flow path 50 from being blocked by pre-sintering.

[0112] Manufacturing data D3 is created based on the model data D1 representing the shape of the periodic structure 11. The manufacturing data D3 has an instruction to irradiate a portion smaller than the columnar body 21 in the layer ML with the laser beam L. The formation of at least one columnar body 21 is performed based on the manufacturing data D3. That is, based on the model data D1 representing the shape of the periodic structure 11, manufacturing data D3 taking pre-sintering into account is created. Thereby, the additive manufacturing method of the present embodiment can reduce the capacity of the manufacturing data D3.

[0113] In the manufacturing data D3, the portion PI irradiated with the laser beam L in the layer ML is spaced apart from the portion PI irradiated with the laser beam L in the layer ML to be formed next in a direction intersecting the +Z direction. Thereby, since the portions PI irradiated with the laser beam L are dispersed, the additive manufacturing method of the present embodiment can reduce the capacity of the manufacturing data D3.

[0114] In the above description, suppression is defined as, for example, preventing the occurrence of an event, action, or influence, or reducing the degree of an event, action, or influence.

[0115] Although some embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalent scope thereof.

Explanation of Signs

[0116] 10…Three-dimensional object, 11…Periodic structure, 21…Columnar body, 21a…Upper surface, 21b…Bottom surface, 21c…Side surface, 22…Connection part, 31, 32…Step-like structure, 45, 46, 47, 48…Unit flow path, 50…Flow path, Ax…Unit central axis, L…Laser beam, ML…Layer, D1…Model data, D3…Manufacturing data, PI, PS…Parts.

Claims

1. A periodic structure having a plurality of unit objects, and forming a plurality of stepped structures in which the plurality of unit objects are connected to each other. comprising In each of the plurality of stepped structures, the plurality of unit objects are connected to each other stepwise along a polygonal spiral orbit around a unit central axis in each of the plurality of stepped structures. The unit central axes in each of the plurality of stepped structures extend in a first direction. In each of the plurality of stepped structures, a unit flow path is provided along the plurality of unit objects connected to each other stepwise. A three-dimensional object in which the periodic structure is provided with a flow path that includes the unit flow paths of the plurality of stepped structures and communicates with the outside of the periodic structure. A three-dimensional object.

2. Each of the plurality of unit objects has a plane facing the first direction. At least one of the plurality of unit objects is connected to the plane of another one of the plurality of unit objects. The three-dimensional object according to Claim 1.

3. Each of the plurality of unit objects has a bottom surface located on the opposite side of the plane, and a side surface provided between the plane and the bottom surface. The side surface is a curved surface protruding in a direction intersecting the first direction. The three-dimensional object according to Claim 2.

4. At least two of the plurality of unit objects in which the planes are in the same position in the first direction are spaced apart from each other in a direction orthogonal to the first direction. The three-dimensional object according to Claim 2 or Claim 3.

5. The plurality of stepped structures are connected to each other in a direction intersecting the first direction. One of the unit flow paths among the plurality of stepped structures has a first unit flow path extending in a second direction intersecting the first direction. Of the plurality of stepped structures, another one of the unit flow paths connected to one of them extends in a third direction that intersects the first direction and also intersects the second direction, and the first unit flow path is connected to the second unit flow path, A three-dimensional object according to any one of claims 1 to 4. **Claim 6** One of the plurality of stepped structures is connected to another one of the plurality of stepped structures in a fourth direction orthogonal to the first direction, and is further connected to yet another one of the plurality of stepped structures in a fifth direction orthogonal to the first direction and also orthogonal to the fourth direction, A three-dimensional object according to any one of claims 1 to 5. **Claim 7** In each of the plurality of stepped structures, the plurality of unit objects are connected to each other stepwise along a double helical orbit around the unit central axis, The periodic structure has, in each of the plurality of stepped structures, a connecting portion that connects the plurality of unit objects connected to each other stepwise along one of the double helical orbits and the plurality of unit objects connected to each other stepwise along the other of the double helical orbits, A three-dimensional object according to any one of claims 1 to 6. **Claim 8** Forming a periodic structure having a plurality of unit objects by repeating layer formation and formation of at least one unit object in the layer by curing at least a part of the layer, comprising The plurality of unit objects form a plurality of stepped structures connected to each other, In each of the plurality of stepped structures, the plurality of unit objects are connected to each other stepwise along a polygonal helical orbit around the unit central axis in each of the plurality of stepped structures, The unit central axis in each of the plurality of stepped structures extends in a first direction, In each of the plurality of stepped structures, unit flow paths are provided along the plurality of unit objects that are stepwise connected to each other. The periodic structure includes the unit flow paths of the plurality of stepped structures and is provided with a flow path that communicates with the outside of the periodic structure. A method for three-dimensional object additive manufacturing. Claim 9 The layer has a photocurable resin. The formation of the at least one unit object includes curing a part of the layer and a part around the part of the layer by irradiating light on the part of the layer. The method for three-dimensional object additive manufacturing according to claim 8. Claim 10 Based on the data representing the shape of the periodic structure, creating manufacturing data having an instruction to irradiate light on a portion of the layer that is smaller than the unit object. Further comprising The formation of the at least one unit object is performed based on the manufacturing data. The method for three-dimensional object additive manufacturing according to claim 9. Claim 11 In the manufacturing data, the portion of the layer irradiated with light is spaced apart in a direction intersecting the first direction from the portion of the next layer irradiated with light. The method for three-dimensional object additive manufacturing according to claim 10. Claim 12 The layer has a powdered metal. The formation of the at least one unit object includes sintering a part of the layer and a part around the part of the layer by irradiating the part of the layer with energy rays. The method for three-dimensional object additive manufacturing according to claim 8. Claim 13 Based on the data representing the shape of the periodic structure, creating manufacturing data having an instruction to irradiate the energy rays on a portion of the layer that is smaller than the unit object. Further comprising The formation of the at least one unit object is performed based on the manufacturing data. The method for three-dimensional object additive manufacturing according to claim 12.

14. In the manufacturing data, the portion irradiated with the energy beam in the layer is spaced apart from the portion irradiated with the energy beam in the layer to be formed next in a direction intersecting the first direction. The method for three-dimensional object additive manufacturing according to claim 13.

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