Optical molding device and method for manufacturing molded object

Abstract

To provide an optical shaping device and a method for manufacturing a shaped article which can accurately mold a shaped article.SOLUTION: An optical shaping device 10 includes: a shaping tank 11 which stores a photocurable resin 1, and has a light transmission plate 14 provided on the bottom surface; a light irradiation part 20 which emits light L for curing the photocurable resin 1; a platform 12 capable of moving up and down with respect to the shaping tank 11; a partition wall 13 which is liftable with respect to the platform 12, is formed in a cylindrical shape and is arranged outside the platform 12 through an airtight member 17, and forms an airtight space 3 by cooperating with the platform 12; a lifting control part 31 which forms a photocurable resin layer having a predetermined thickness between a lower surface 13A of the partition wall 13 and the lower surface of the space 3, and the light transmission plate 14; and an irradiation control part 32 which irradiates the photocurable resin layer with light L corresponding to a cross-sectional shape at a predetermined height position of the shaped article 2, and forms a curable layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a photolithography apparatus and a method for manufacturing a model. [Background technology]

[0002] Generally, a photo-lithography technique is known in which a liquid photo-curable resin is irradiated with light such as ultraviolet light to form a three-dimensional object made of the cured resin. Patent Document 1 discloses a photo-lithography technique, as a so-called regulated liquid level method, in which light corresponding to a cross section (predetermined cross section) of the object at a predetermined height position is irradiated through a light-transmitting window provided on the bottom surface of a liquid vat storing the photo-curable resin toward a base placed opposite the light-transmitting window, and a step of forming a layer of cured resin (cured layer) having the same shape as the predetermined cross section on the underside of the base is repeated, and a step of lifting the base up by a predetermined height relative to the liquid vat is repeated, thereby stacking the cured layers to form the desired object. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-62841 Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional liquid level control method, the object formed by stacking curable layers is immersed in the photocurable resin in the liquid tank, and the irradiated light can cure excess photocurable resin, leaving room for improvement in terms of forming the object with high precision.

[0005] The present invention has been made in view of the above, and has an object to provide a stereolithography apparatus and a method for manufacturing a model that can accurately form a model. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems and achieve the object, the optical molding apparatus of the present invention comprises a modeling tank that stores photocurable resin and has a light-transmitting section on its bottom surface; a light irradiation section that irradiates light that hardens the photocurable resin through the light-transmitting section; a platform that faces the light-transmitting section and can be raised and lowered relative to the modeling tank; a partition wall that can be raised and lowered relative to the platform, is cylindrically formed, and is arranged outside the platform via an airtight member, and cooperates with the platform to form an airtight space; a lifting and lowering control section that raises and lowers the platform and the partition wall, respectively, to form a photocurable resin layer of a predetermined thickness between the bottom surface of the partition wall and the underside of the airtight space and the light-transmitting section; and an irradiation control section that irradiates the photocurable resin layer from the light irradiation section with light that corresponds to the cross-sectional shape of the desired model at a predetermined height position, thereby forming a hardened layer.

[0007] The present invention also provides a method for manufacturing a molded object using a photo-polymerization device that includes a molding tank that stores photocurable resin and has a light-transmitting section on its bottom surface, a light irradiation section that irradiates light that hardens the photocurable resin through the light-transmitting section, a platform that faces the light-transmitting section and is capable of rising and lowering relative to the molding tank, and a partition wall that is capable of rising and lowering relative to the platform, is cylindrically formed, and is arranged outside the platform via an airtight member, and cooperates with the platform to form an airtight space.The method repeatedly performs the following steps: raising and lowering the platform and the partition wall to form a photocurable resin layer of a predetermined thickness between the bottom surface of the partition wall and the underside of the airtight space and the light-transmitting section; irradiating the photocurable resin layer from the light irradiation section with light that corresponds to the cross-sectional shape of the desired molded object at a predetermined height position, to form a hardened layer; and lowering the partition wall by a predetermined thickness relative to the platform. [Effects of the Invention]

[0008] According to the present invention, an effect is achieved in that a shaped object can be formed with high precision. [Brief explanation of the drawings]

[0009] [Figure 1]FIG. 1 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the first embodiment. [Figure 2] FIG. 2 is a diagram for explaining the steps of the method for manufacturing a shaped object according to the first embodiment. [Figure 3] FIG. 3 is a diagram for explaining the steps of the method for manufacturing a shaped object according to the first embodiment. [Figure 4] FIG. 4 is a diagram for explaining the steps of the method for manufacturing a shaped object according to the first embodiment. [Figure 5] FIG. 5 is a diagram for explaining the procedure of the method for manufacturing a shaped object according to the first embodiment. [Figure 6] FIG. 6 is a diagram for explaining the steps of the method for manufacturing a shaped object according to the first embodiment. [Figure 7] FIG. 7 is a diagram illustrating the steps of the method for manufacturing a shaped object according to the first embodiment. [Figure 8] FIG. 8 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the second embodiment. [Figure 9] FIG. 9 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the third embodiment. [Figure 10] FIG. 10 is a diagram illustrating the steps of the method for manufacturing a shaped object according to the third embodiment. [Figure 11] FIG. 11 is a diagram for explaining the procedure of the method for manufacturing a shaped object according to the third embodiment. [Figure 12] FIG. 12 is a diagram illustrating the steps of the method for manufacturing a shaped object according to the third embodiment. [Figure 13] FIG. 13 is a diagram illustrating the steps of the method for manufacturing a shaped object according to the third embodiment. [Figure 14] FIG. 14 is a diagram illustrating the steps of the method for manufacturing a shaped object according to the third embodiment. [Figure 15] FIG. 15 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the fourth embodiment. [Figure 16] FIG. 16 is a diagram for explaining the operation of the suction mechanism of the optical shaping apparatus according to the fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to these embodiments, and when there are multiple embodiments, the present invention also includes configurations that combine the embodiments. In the following embodiments, the same components are designated by the same reference numerals, and redundant explanations will be omitted.

[0011] In the following description of the embodiments, unless otherwise specified, uncured liquid photocurable resin will be simply referred to as photocurable resin. Furthermore, a photo-fabricated object formed by curing a liquid photocurable resin will be referred to as a three-dimensional object or simply a model. This three-dimensional object is not limited to a finished product in which all of the cured layers to be molded are stacked, but also includes an unfinished product in which only intermediate cured layers have been stacked.

[0012] [First embodiment] Fig. 1 is a schematic diagram showing the basic configuration of a photo-lithography apparatus according to the first embodiment. As shown in Fig. 1, the photo-lithography apparatus 10 includes a modeling tank 11, a platform 12, a partition wall 13, a light irradiation unit 20, and a control unit 30. In this embodiment, the photo-lithography apparatus 10 also includes a chamber 40 and a chamber internal pressure adjustment unit 41.

[0013] The modeling tank 11 has a dish shape with an open top, and is capable of storing the liquid photocurable resin 1. The modeling tank 11 has a light-transmitting plate (light-transmitting portion) 14 on the bottom. This light-transmitting plate 14 transmits light that cures the photocurable resin 1.

[0014] The photocurable resin 1 is a raw material for the three-dimensional object 2, and contains a polymerizable compound such as an acrylic compound or a vinyl compound. The photocurable resin 1 also preferably contains a polymerization initiator that generates radical species and the like upon irradiation with light.

[0015] The platform 12 holds the object 2 formed from the cured photocurable resin 1, and is disposed above the modeling tank 11, facing the light-transmitting plate 14. The platform 12 is formed in a polygonal plate shape, such as a circular or rectangular plate, and is disposed so that its lower surface 12A is substantially parallel to the light-transmitting plate 14. The platform 12 is also connected to a platform lifting mechanism 15, and is provided so that it can be raised and lowered relative to the modeling tank 11 by the operation of the platform lifting mechanism 15. Specifically, the platform 12 can move toward and away from the light-transmitting plate 14, and holds the object 2 formed on the lower surface 12A facing the light-transmitting plate 14.

[0016] The partition wall 13 is disposed on the outside of the platform 12, and houses the platform 12 and the model 2 inside. The partition wall 13 is formed in a tubular shape (cylindrical or polygonal tubular shape such as a rectangular tubular shape) corresponding to the shape of the platform 12. The partition wall 13 is also connected to a partition wall lifting mechanism 16, and is provided so as to be able to rise and fall with respect to the platform 12 by the operation of this partition wall lifting mechanism 16. In other words, the partition wall 13 can rise and fall relative to the platform 12.

[0017] Additionally, an airtight member 17 is disposed on the outer periphery of the platform 12 to seal the gap between the platform 12 and the partition wall 13. The airtight member 17 is an O-ring made of an elastic material such as rubber. The airtight member 17 is biased against the inner surface of the partition wall 13 by the restoring force generated when elastically deformed, thereby sealing the gap between the platform 12 and the partition wall 13. The airtight member 17 ensures airtightness between the platform 12 and the partition wall 13. Therefore, when the platform 12 and the partition wall 13 are lowered into the photocurable resin 1, a space 3 (airtight space) is formed that is partitioned by the platform 12, the partition wall 13, and the photocurable resin 1.

[0018] The light irradiation unit 20 is disposed below the modeling tank 11, i.e., on the opposite side of the platform 12 across the light-transmitting plate 14. The light irradiation unit 20 irradiates the photocurable resin 1 with light L, which cures the photocurable resin 1, through the light-transmitting plate 14. The irradiated light L may be any light that can cure the photocurable resin 1, and may be, for example, ultraviolet light or short-wavelength visible light. The light irradiation unit 20 includes a light source 21 such as an ultraviolet lamp, an image forming element 22, a reflecting mirror 23, a projection lens 24, and the like.

[0019] The light source 21 emits light to be irradiated onto the image-forming element 22, and may be, for example, an ultraviolet lamp. The image-forming element 22 modulates the light in accordance with shape data for each layer of the object 2 to be formed, and may be, for example, an LCOS (Liquid Crystal On Silicon) device, a Digital Mirror Device (DMD), or a liquid crystal device. The reflecting mirror 23 reflects the light modulated by the image-forming element 22 toward the projection lens 24. The projection lens 24 forms an image using the light reflected by the reflecting mirror 23. Note that the light irradiation unit 20 is not limited to this, and may alternatively be, for example, a laser scanning device using a laser light source and mirror drive, or an optical device using a reflective optical system or a refractive optical system.

[0020] The chamber 40 is a container that houses at least the modeling tank 11, the platform 12, the partition wall 13, the light irradiation unit 20, and the lifting mechanisms 15 and 16, and seals the internal environment from the outside. The chamber internal pressure adjustment unit 41 adjusts the internal pressure of the chamber 40 by introducing a gas (e.g., air or nitrogen) into the chamber 40 or discharging the gas to the outside of the chamber 40 through a pipe 42. By finely adjusting the internal pressure of the chamber 40, it becomes possible to freely adjust the position of the lower surface of the above-mentioned space 3.

[0021] The control unit 30 is an arithmetic processing device including, for example, a CPU (Central Processing Unit), and is connected to and controls the operations of each part of the optical shaping apparatus 10. The control unit 30 stores a program related to a manufacturing method for manufacturing the object 2, loads the program into memory, and executes the instructions included in the program. The control unit 30 includes an internal memory (not shown), which is used for temporary storage of data such as the program in the control unit 30.

[0022] The control unit 30 includes a lift control unit 31, an irradiation control unit 32, and a chamber internal pressure control unit 33. The lift control unit 31 controls the operation of the platform lifting mechanism 15 and the partition wall lifting mechanism 16 to control the height positions of the platform 12 and the partition wall 13, respectively. That is, the lift control unit 31 can raise and lower the platform 12 and the partition wall 13 in conjunction with each other with respect to the modeling tank 11, or raise and lower the platform 12 relative to the partition wall 13. The lift control unit 31 raises and lowers the platform 12 and the partition wall 13, respectively, to form a photocurable resin layer of a predetermined thickness between the light-transmitting plate 14 and the lower surfaces of the partition wall 13 and the space 3.

[0023] The irradiation control unit 32 calculates a light irradiation pattern that indicates the cross-sectional shape of the object at predetermined height intervals, for example, based on the three-dimensional shape data, and controls the light source 21, the image forming element 22, etc. to irradiate the photocurable resin with light. Therefore, the irradiation control unit 32 can form a cured layer of a predetermined thickness by irradiating the photocurable resin layer between the lower surface of the space 3 and the light-transmitting plate 14 with light that corresponds to the cross-sectional shape of the object at a predetermined height position. The chamber internal pressure control unit 33, for example, monitors the position of the lower surface of the space 3 inside the partition wall 13 (the liquid level of the photocurable resin) and adjusts the internal pressure of the chamber 40 based on the monitoring result. Therefore, the position of the lower surface of the space 3 can be aligned with the lower surface of the partition wall 13, and the thickness of the photocurable resin layer between the lower surface of the space 3 and the light-transmitting plate 14 can be accurately determined.

[0024] Next, a method for manufacturing a molded object according to the first embodiment will be described with reference to FIGS. 2 to 7. These figures schematically illustrate a portion of the optical molding apparatus 10 shown in FIG. 1. First, as shown in FIG. 2, the elevation control unit 31 adjusts the height positions of the platform 12 and the partition wall 13 so that the lower surface 12A of the platform 12 and the lower surface (bottom surface) 13A of the partition wall 13 are flush with each other. Next, the elevation control unit 31 lowers the platform 12 and the partition wall 13, which are positioned higher than the molding tank 11 storing the photocurable resin 1, into the molding tank 11, and positions them so that the lower surface 13A of the partition wall 13 and the light-transmitting plate 14 are spaced a predetermined distance T apart. Here, the predetermined distance T is set to the thickness of one layer of the cured layer to be molded (for example, several μm to approximately 100 μm). In this case, a photocurable resin layer 1a having a predetermined thickness T, which is the same as the predetermined distance T, is formed between the platform 12 and the light-transmitting plate 14.

[0025] Next, the irradiation control unit 32 calculates an irradiation pattern that indicates the cross-sectional shape of the object 2 at a predetermined height, based on the three-dimensional shape data of the object 2 to be molded, and irradiates the photocurable resin layer 1a with light L that corresponds to the cross-sectional shape of the first layer through the light-transmitting plate 14. As a result, the photocurable resin layer 1a is cured to have the same cross-sectional shape as the first layer. Therefore, as shown in FIG. 3, a cured layer 2a of a predetermined thickness T that will become the first layer is held on the platform 12.

[0026] 4, the lifting control unit 31 raises the platform 12 and the partition wall 13 to a position higher than the modeling tank 11. Next, the lifting control unit 31 lowers the partition wall 13 by a predetermined thickness T relative to the platform 12, as shown in FIG. 5. As a result, the lower surface 13A of the partition wall 13 becomes flush with the lower surface 2aA of the hardened layer 2a, and a space (airtight space) 3 partitioned by the platform 12 and the partition wall 13 is formed around the hardened layer 2a.

[0027] Next, the lifting control unit 31 vertically lowers the platform 12 and the partition wall 13 into the modeling tank 11 until the distance between the lower surface 13A of the partition wall 13 and the light-transmitting plate 14 becomes a predetermined distance T. In this case, the space 3 partitioned by the platform 12 and the partition wall 13 becomes an airtight space, and therefore, as shown in FIG. 6, a photocurable resin layer 1a of a uniform predetermined thickness T is formed between the lower surface 3A of the space 3 and the light-transmitting plate 14.

[0028] Here, the lower surface 3A of the space 3 coincides with the liquid level of the photocurable resin layer 1a. The height of the liquid level of the photocurable resin layer 1a may vary depending on the depth and surface area of ​​the photocurable resin 1 in the region stored around the partition wall 13. For this reason, in this embodiment, the height of the liquid level of the photocurable resin layer 1a is appropriately adjusted using a chamber internal pressure adjustment unit 41 shown in FIG. 1. The chamber internal pressure control unit 33, for example, monitors the liquid level of the photocurable resin layer 1a inside the partition wall 13 and, based on the results, adjusts the internal pressure of the chamber 40 so that the photocurable resin layer 1a has a predetermined thickness T. For example, the chamber internal pressure control unit 33 can lower the chamber internal pressure from the initial state to lower the lower surface 3A of the space 3 and thereby reduce the thickness of the photocurable resin layer 1a. By adjusting the internal pressure of the chamber 40 in this manner, the position of the lower surface 3A of the space 3 can be aligned with the lower surface 13A of the partition wall 13, and the photocurable resin layer 1a can be brought into contact only with the lower surface 2aA of the cured layer 2a.

[0029] Next, as shown in FIG. 6, the irradiation control unit 32 irradiates the photocurable resin layer 1a with light L corresponding to the cross-sectional shape of the second layer through the light-transmitting plate 14. As a result, the photocurable resin layer 1a is cured into the same shape as the cross-sectional shape of the second layer, as shown in FIG. 7. The second layer having a predetermined thickness T is stacked on the first layer to form the cured layer 2a. In this manner, in this embodiment, the photocurable resin layer 1a having a predetermined thickness T is formed between the lower surface 13A of the partition wall 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14. This photocurable resin layer 1a is cured into a predetermined shape. This allows the thickness of the cured layer 2a to be precisely shaped, and ultimately allows the object 2 to be precisely shaped. Furthermore, in this embodiment, the space 3 can be provided around the previously formed cured layer 2a, thereby preventing the light L irradiated through the light-transmitting plate 14 from curing excess photocurable resin 1.

[0030] In this way, the lifting control unit 31 and the irradiation control unit 32 alternately perform the formation of the photocurable resin layer 1a and the formation of the hardened layer 2a, and can form the object 2 by stacking the nth (n is a natural number) hardened layer 2a on the nth+1th hardened layer 2a.

[0031] As described above, the optical molding apparatus 10 according to the first embodiment includes a molding tank 11 that stores photocurable resin 1 and has a light-transmitting plate 14 on its bottom surface, a light irradiation unit 20 that irradiates light L through the light-transmitting plate 14 to cure the photocurable resin 1, a platform 12 that faces the light-transmitting plate 14 and can be raised and lowered relative to the molding tank 11, and a cylindrically shaped airtight member 17 that can be raised and lowered relative to the platform 12. The apparatus includes a partition 13 that cooperates with the platform 12 to form an airtight space 3, a lifting control unit 31 that raises and lowers the platform 12 and the partition 13, respectively, to form a photocurable resin layer 1a of a predetermined thickness T between the lower surface 13A of the partition 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14, and an irradiation control unit 32 that irradiates the photocurable resin layer 1a from the light irradiation unit 20 with light L that corresponds to the cross-sectional shape of the target object 2 at a predetermined height position, thereby forming a hardened layer 2a.

[0032] According to this configuration, a photocurable resin layer 1a of a predetermined thickness T is formed between the lower surfaces 13A of the partition wall 13 and the lower surfaces 3A of the spaces 3 and the light-transmitting plate 14, and this photocurable resin layer 1a is cured into a predetermined shape, so that the thickness of the cured layer 2a can be precisely formed, and therefore the object 2 can be precisely formed. Furthermore, according to this configuration, the space 3 can be provided around the previously formed cured layer 2a, which prevents the problem of excess photocurable resin 1 being cured by light L irradiated through the light-transmitting plate 14, and therefore the object 2 can be precisely formed.

[0033] Furthermore, the lifting control unit 31 lowers the partition 13 by a predetermined thickness T relative to the platform 12 each time the formation of the hardened layer 2a is completed, so that when the platform 12 and the partition 13 are lowered into the modeling tank 11, a photo-curable resin layer 1a of the predetermined thickness T can always be formed between the lower surface 13A of the partition 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14. Therefore, the thickness of the hardened layer 2a can be precisely formed, and thus the model 2 can be precisely formed.

[0034] Furthermore, the lifting control unit 31 temporarily lifts the platform 12 and the partition wall 13 above the photocurable resin 1 each time the formation of the cured layer 2a is completed, thereby introducing gas into the inside of the platform 12 and the partition wall 13 and forming an airtight space. This allows the thickness of the cured layer 2a to be precisely shaped, and ultimately allows the model 2 to be precisely shaped.

[0035] In addition, the lifting control unit 31 and the irradiation control unit 32 alternately form the photocurable resin layer 1a and the hardened layer 2a, and form the object 2 by stacking multiple hardened layers 2a on the platform 12, so that the object 2 can be formed with high precision.

[0036] Furthermore, the optical shaping apparatus 10 includes a chamber 40 that houses at least the shaping tank 11, the platform 12, the partition wall 13, and the light irradiation unit 20, a chamber internal pressure adjustment unit 41 that adjusts the internal pressure of the chamber 40, and a chamber internal pressure control unit 33 that controls the chamber internal pressure adjustment unit 41. Therefore, by adjusting the internal pressure of the chamber 40, the position of the lower surface 3A of the space 3 can be aligned with the lower surface 13A of the partition wall 13, and the photocurable resin layer 1a can be accurately defined to a predetermined thickness T. This allows the thickness of the cured layer 2a to be precisely shaped, and ultimately allows the shaped object 2 to be precisely shaped.

[0037] [Second embodiment] Next, a description will be given of a photo-fabrication apparatus according to a second embodiment. Fig. 8 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the second embodiment. The same components as those in the above-described embodiment are given the same reference numerals, and the description will be omitted.

[0038] As in the first embodiment of the optical molding apparatus described above, in a configuration in which a platform 12 and a partition 13 cooperate to create a space (airtight space) 3 in a molding tank 11 that stores photocurable resin 1 to accommodate a molded object 2 made of stacked cured layers 2a, and a photocurable resin layer 1a of a predetermined thickness T corresponding to one layer is formed between the lower surface 3A of this space 3 and a light-transmitting plate 14, the molded object 2 can be molded with high precision.However, if there is a discrepancy in height between the lower surface 13A of the partition 13 that forms the space 3 and the lower surface 2A of the cured object 2, the cured object 2 and the photocurable resin layer 1a will not be able to come into contact, which could result in defective molding.

[0039] 8, the optical shaping apparatus 110 includes a shaping tank 11, a platform 12, a partition wall 13, a light irradiation unit 20, an air cylinder (air supply / exhaust unit) 50, and a control unit 130. The control unit 130 also includes an elevation control unit 31, an irradiation control unit 32, and an air supply / exhaust control unit 133.

[0040] The air cylinder 50 is in communication with the space 3 partitioned by the platform 12 and the partition wall 13 via a hose 51. The air cylinder 50 has, for example, a cylindrical cylinder body with a piston inside. The air supply and exhaust control unit 133, for example, monitors the position of the liquid surface of the photocurable resin layer 1a inside the partition wall 13, and depending on the result, varies the position of the piston in the axial direction to introduce gas into or exhaust gas from the cylinder. The air supply and exhaust control unit 133 operates the air cylinder 50 to bring the liquid surface of the photocurable resin layer 1a into contact with the underside 2A of the model 2.

[0041] Next, a method for manufacturing a molded object according to the second embodiment will be described. Here, the operation of the air cylinder 50 will be mainly described. As described above, the lifting control unit 31 and the irradiation control unit 32 alternately form the photocurable resin layer 1a and the cured layer 2a, and form the molded object 2 by stacking the (n+1)th cured layer 2a on the nth (n is a natural number) cured layer 2a.

[0042] Once the photocurable resin layer 1a of a predetermined thickness T is formed between the lower surface 13A of the partition wall 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14, the air supply / exhaust control unit 133 operates the air cylinder 50, as shown in FIG. 8 . Specifically, the air supply / exhaust control unit 133 monitors the liquid level of the photocurable resin layer 1a using a sensor or the like, and expels a predetermined amount of gas from the space 3 using the air cylinder 50, slightly raising the liquid level of the photocurable resin layer 1a and bringing the photocurable resin layer 1a into contact with the lower surface 2A of the already cured object 2. Next, the air supply / exhaust control unit 133 supplies a predetermined amount of gas into the space 3 using the air cylinder 50, thereby reducing the thickness of the photocurable resin layer 1a to the predetermined thickness T. In this case, the photocurable resin layer 1a maintains contact with the lower surface 2A of the already cured object 2 due to surface tension.

[0043] Therefore, even if the irradiation control unit 32 is operated in this state to form a new hardened layer 2a, this hardened layer 2a is stacked to form the object 2, so that defective molding can be suppressed and an object 2 can be molded with high precision.

[0044] As described above, the optical molding apparatus 110 according to the second embodiment includes the molding tank 11 that stores the photocurable resin 1 and has the light-transmitting plate 14 on its bottom surface, the light irradiation unit 20 that irradiates the photocurable resin 1 with light L to cure the photocurable resin 1 through the light-transmitting plate 14, the platform 12 that faces the light-transmitting plate 14, is movable up and down relative to the molding tank 11, and holds the molded object 2 that is formed by stacking layers 2 a cured by irradiation with the light L, and the airtight member 17 that is movable up and down relative to the platform 12, is formed in a cylindrical shape, and is disposed outside the platform 12 via the airtight member 17, and cooperates with the platform 12 to form the airtight space 3 an air cylinder 50 for supplying or discharging gas into or from the space 3; an elevation control unit 31 for raising and lowering the platform 12 and the partition 13, respectively, to form a photocurable resin layer 1a of a predetermined thickness T between the lower surface 13A of the partition 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14; an air supply and exhaust control unit 133 for bringing the liquid surface of the photocurable resin layer 1a into contact with the lower surface 2A of the model 2 by the operation of the air cylinder 50; and an irradiation control unit 32 for irradiating the photocurable resin layer 1a from the light irradiation unit 20 with light L corresponding to the cross-sectional shape of the model 2 at a predetermined height, to form a hardened layer 2a.

[0045] According to this configuration, a photocurable resin layer 1a of a predetermined thickness T is formed between the lower surface 13A of the partition wall 13 and the lower surface 3A of the space 3 and the light-transmitting plate 14. This photocurable resin layer 1a is then cured into a predetermined shape, thereby enabling the thickness of the cured layer 2a to be precisely controlled, and ultimately enabling the object 2 to be precisely molded. Furthermore, according to this configuration, the space 3 can be provided around the previously formed cured layer 2a, preventing the problem of excess photocurable resin 1 being cured by light L irradiated through the light-transmitting plate 14. This configuration also enables the object 2 to be precisely molded. Furthermore, according to this configuration, the air cylinder 50 is provided to supply and exhaust gas to the space 3 partitioned by the platform 12 and the partition wall 13. This allows the liquid level of the photocurable resin layer 1a to be adjusted, thereby maintaining contact between the photocurable resin layer 1a and the lower surface 2A of the already cured object 2. This prevents molding defects and allows the object 2 to be precisely molded.

[0046] In addition, the lifting control unit 31, the air supply / exhaust control unit 133, and the irradiation control unit 32 repeatedly perform the formation of the photocurable resin layer 1a, the contact of the liquid surface of the photocurable resin layer 1a with the underside 2A of the object 2, and the formation of the hardened layer 2a, thereby reducing molding defects and accurately molding the object 2.

[0047] [Third embodiment] Next, a description will be given of a photo-fabrication apparatus according to a third embodiment. Fig. 9 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the third embodiment. The same components as those in the above-described embodiments are given the same reference numerals, and the description will be omitted.

[0048] In the optical shaping apparatuses of the first and second embodiments described above, a platform 12 and a partition wall 13 cooperate to provide a space (airtight space) 3 in a shaping tank 11 that stores a shaped object 2 formed by stacking cured layers 2a, and a photocurable resin layer 1a of a predetermined thickness T corresponding to one layer is formed between the lower surface 3A of this space 3 and a light-transmitting plate 14. In this configuration, it is necessary to lower the partition wall 13 by the predetermined thickness T relative to the platform 12 each time a cured layer 2a is formed. In this case, the predetermined thickness T is set to, for example, about several μm, which may pose a problem in that a precise lifting mechanism is required.

[0049] 9, the optical shaping apparatus 210 according to the third embodiment includes a shaping tank 11, a platform 12, a light irradiation unit 20, and a control unit 230. The control unit 230 also includes a lift control unit 231 and an irradiation control unit 232.

[0050] In this third embodiment, the optical shaping apparatus 210 is configured such that, instead of providing a partition wall as a device configuration, a cylindrical partition wall 213 is molded around the object 2 on the platform 12 together with the object 2. The platform 12 forms a space (airtight space) 3 in cooperation with the molded partition wall 213.

[0051] The lifting control unit 231 also controls the operation of the platform lifting mechanism 15 to control the height position of the platform 12. The lifting control unit 231 raises and lowers the platform 12 on which the partition wall 213 is formed, thereby forming a photocurable resin layer of a predetermined thickness between the bottom surface of the partition wall 213, the lower surface of the space 3, and the light-transmitting plate 14.

[0052] The irradiation control unit 232 calculates a light irradiation pattern that indicates the cross-sectional shapes of the object 2 and the partition wall 213 at predetermined height intervals based on, for example, the three-dimensional shape data, and controls the light source 21, the image forming element 22, etc. to irradiate the light onto the photocurable resin. The irradiation control unit 232 irradiates the photocurable resin layer between the lower surface of the space 3 and the light-transmitting plate 14 with light that corresponds to each cross-sectional shape at a predetermined height position of the object 2 and the partition wall 213, thereby forming a cured layer of a predetermined thickness.

[0053] Next, a method for manufacturing a molded object according to the third embodiment will be described with reference to Figs. 10 to 14. These figures schematically show a portion of the optical molding apparatus 10 shown in Fig. 9. First, as shown in Fig. 10, the elevation control unit 231 lowers the platform 12, which is positioned higher than the molding tank 11 in which the photocurable resin 1 is stored, into the molding tank 11, and positions the platform 12 at a position where a predetermined distance T is between the lower surface 12A of the platform 12 and the light-transmitting plate 14. In this case, a photocurable resin layer 1a having a predetermined thickness T, which is the same as the predetermined distance T, is formed between the platform 12 and the light-transmitting plate 14.

[0054] Next, the irradiation control unit 232 calculates an irradiation pattern that indicates the cross-sectional shapes of the object 2 and the partition wall 213 at a predetermined height, based on three-dimensional shape data of the object 2 to be molded and the cylindrical partition wall 213 that can accommodate the object 2, and irradiates the photocurable resin layer 1a with light L that corresponds to the cross-sectional shapes of the first layer of the object 2 and the partition wall 213 through the light-transmitting plate 14. As a result, the photocurable resin layer 1a is cured to have the same shape as the cross-sectional shapes of the first layer of the object 2 and the partition wall 213. Therefore, as shown in FIG. 11 , cured layers 2a and 213a with a predetermined thickness T that will become the first layers of the object 2 and the partition wall 213 are held on the platform 12.

[0055] 12, the lifting control unit 231 raises the platform 12 and temporarily positions it at a position higher than the modeling tank 11. Here, the hardened layer 2a of the model 2 and the hardened layer 213a of the partition wall 213 are formed to the same height and a predetermined thickness T. As a result, the lower surface 2aA of the hardened layer 2a of the model 2 and the lower surface 213aA of the hardened layer 213a of the partition wall 213 are flush with each other, and a space (airtight space) 3 partitioned by the platform 12 and the partition wall 213 (hardened layer 213a) is formed around the model 2 (hardened layer 2a).

[0056] Next, the lifting control unit 231 vertically lowers the platform 12 into the modeling tank 11 until the distance between the lower surface 213A of the partition wall 213 and the light-transmitting plate 14 becomes a predetermined distance T. In this case, the space 3 partitioned by the platform 12 and the partition wall 213 becomes an airtight space, and therefore, as shown in FIG. 13 , a photocurable resin layer 1a of a uniform predetermined thickness T is formed between the lower surface 3A of the space 3 and the light-transmitting plate 14.

[0057] Next, the irradiation control unit 232 irradiates the photocurable resin layer 1a with light L that corresponds to the cross-sectional shapes of the object 2 and the second layer of the partition wall 213 through the light-transmitting plate 14. As a result, the photocurable resin layer 1a is cured into a shape identical to the cross-sectional shape of the second layer, as shown in FIG. 14 , and the second layer having a predetermined thickness T is stacked on the first layer to form the cured layers 2a, 213a. In this manner, in this embodiment, the photocurable resin layer 1a having a predetermined thickness T is formed between the light-transmitting plate 14 and the lower surfaces 213aA of the partition wall 213 and the lower surfaces 3A of the spaces 3, which are molded together with the object 2, and the photocurable resin layer 1a is cured into a predetermined shape. This allows the thicknesses of the cured layers 2a, 213a of the object 2 and the partition wall 213 to be precisely shaped, and ultimately allows the object 2 to be precisely shaped. Furthermore, in this embodiment, a space 3 can be provided around the previously molded cured layer 2a, which prevents the problem of the light L irradiated through the light-transmitting plate 14 curing excess photocurable resin 1. Furthermore, in this embodiment, the partition 213 is molded together with the object 2, so there is no need to provide a separate partition around the platform 12, and the configuration of the optical molding apparatus 210 can be simplified.

[0058] In addition, the lifting control unit 231 and the irradiation control unit 232 alternately perform the formation of the photocurable resin layer 1a and the formation of each hardened layer 2a, 213a of the model 2 and the partition wall 213, and can form the model 2 and the partition wall 213 by stacking the nth (n is a natural number) hardened layer 2a, 213a on the nth+1th hardened layer 2a, 213a.

[0059] As described above, the optical molding apparatus 210 according to the third embodiment includes the modeling tank 11 that stores the photocurable resin 1 and has the light-transmitting plate 14 on its bottom surface, the light irradiation unit 20 that irradiates the photocurable resin 1 with light L through the light-transmitting plate 14 to cure the photocurable resin 1, and the light irradiation unit 20 that faces the light-transmitting plate 14 and is capable of moving up and down relative to the modeling tank 11, holds the cylindrical partition wall 213 that is formed around the model 2 together with the model 2 by irradiation with the light L, and cooperates with the partition wall 213 to form the air gap. The apparatus includes a platform 12 that forms a dense space 3, an elevation control unit 231 that raises and lowers the platform 12 to form a photocurable resin layer 1a of a predetermined thickness T between the lower surface 213A of the partition 213 and the lower surface 3A of the space 3 and the light-transmitting plate 14, and an irradiation control unit 232 that irradiates the photocurable resin layer 1a from the light irradiation unit 20 with light L that corresponds to the cross-sectional shape of the model 2 and the partition 213 at a predetermined height, thereby forming each hardened layer 2a, 213a.

[0060] According to this configuration, a photocurable resin layer 1a having a predetermined thickness T is formed between the light-transmitting plate 14 and the lower surfaces 213aA and 3A of the partition walls 213 and the space 3, which are molded together with the object 2. The photocurable resin layer 1a is then cured into a predetermined shape. This allows the thicknesses of the cured layers 2a and 213a of the object 2 and the partition walls 213 to be precisely shaped, and ultimately allows the object 2 to be precisely shaped. Furthermore, in this embodiment, the space 3 can be provided around the previously molded cured layer 2a, which prevents the problem of light L irradiated through the light-transmitting plate 14 curing excess photocurable resin 1. Furthermore, in this embodiment, because the partition walls 213 are molded together with the object 2, there is no need to provide a separate partition around the platform 12, which simplifies the configuration of the optical shaping apparatus 210.

[0061] Furthermore, the elevation control unit 231 temporarily raises the platform 12 above the photocurable resin 1 each time the formation of the cured layers 2a, 213a is completed, so that gas is introduced inside the partition wall 213 formed on the platform 12, forming an airtight space. This allows the thickness of the cured layers 2a, 213a to be formed with high precision, and ultimately allows the model 2 to be formed with high precision.

[0062] Furthermore, the lifting control unit 231 and the irradiation control unit 232 alternately perform the formation of the photocurable resin layer 1a and the formation of the cured layers 2a and 213a, and form the object 2 and the partition wall 213 by stacking multiple cured layers 2a and 213a on the platform 12, respectively, so that the object 2 can be formed with high precision while simplifying the device configuration of the optical molding device 210.

[0063] Furthermore, the lower surface 2A of the object 2 and the lower surface 213A of the partition wall 213 are always flush with each other, so that the object 2 can be easily molded with high precision.

[0064] [Fourth embodiment] Next, a photo-fabrication apparatus according to a fourth embodiment will be described. Fig. 15 is a schematic diagram showing the basic configuration of the photo-fabrication apparatus according to the fourth embodiment. Fig. 16 is a diagram for explaining the operation of the suction mechanism of the photo-fabrication apparatus according to the fourth embodiment. The same components as those in the above-mentioned embodiments are given the same reference numerals and their description will be omitted.

[0065] As in the first and second embodiments of the optical molding apparatus described above, in a configuration in which a platform 12 and a partition 13 cooperate to provide a space (airtight space) 3 in a molding tank 11 storing photocurable resin 1 to accommodate a molded object 2 having stacked cured layers 2a, and a photocurable resin layer 1a of a predetermined thickness T corresponding to one layer is formed between the underside 3A of this space 3 and a light-transmitting plate 14, the molded object 2 can be molded with high precision.However, if, for example, uncured or semi-cured photocurable resin remains in the previously cured molded object 2, a problem may arise in that when the next cured layer is cured, the remaining uncured photocurable resin itself will harden along with the next cured layer, making it impossible to mold with high precision.

[0066] 15, the optical molding apparatus 310 in the fourth embodiment includes a molding tank 11, a platform 12, a light irradiation unit 20, a suction mechanism 60, and a control unit 330. The control unit 330 also includes a lift control unit 231, an irradiation control unit 232, and a suction control unit 333.

[0067] The suction mechanism 60 generates negative pressure to suck and remove uncured photocurable resin adhering to the model 2. As shown in Fig. 15, the suction mechanism 60 includes a dish 61 with an open top, a suction unit 62 connected to the dish 61 via a hose 63 to generate negative pressure within the dish 61, and a movement mechanism 64 to move the dish 61, for example, horizontally.

[0068] In the fourth embodiment, similarly to the third embodiment, the optical shaping apparatus 310 does not include a partition wall as an apparatus configuration, but is configured to mold a cylindrical partition wall 313 around the object 2 on the platform 12 together with the object 2. The platform 12 cooperates with the molded partition wall 313 to form a space (airtight space) 3. The partition wall 313 is molded integrally with the object 2. The molding procedure for the object 2 and the partition wall 313 is the same as that described in the third embodiment. Note that, because the partition wall 313 is integral with the target object 2, a final step is required to separate the partition wall 313 from the object 2.

[0069] On the other hand, the dish portion 61 of the suction mechanism 60 is formed to have the same size as the partition wall 313 described above, and as shown in Figure 16, when the suction mechanism 60 is placed below the platform 12 and the platform 12 is lowered, the partition wall 313 is sandwiched between the platform 12 and the dish portion 61. As described above, the partition wall 313 is molded integrally with the model 2, and therefore the model 2 is supported by the platform 12 and the dish portion 61 via the partition wall 313. Therefore, the partition wall 313 also functions as a support for supporting the model 2.

[0070] Furthermore, in this configuration, when the partition wall 313 is sandwiched between the platform 12 and the dish portion 61, the edge of the dish portion 61 abuts against the lower surface (bottom surface) 313A of the partition wall 313, forming a closed space. Therefore, by operating the suction unit 62, a negative pressure can be created within this closed space, and the uncured photocurable resin 70 adhering to the model 2 can be easily sucked and removed.

[0071] As described above, the optical molding apparatus 310 according to the fourth embodiment includes the molding tank 11 that stores the photocurable resin 1 and has the light-transmitting plate 14 on its bottom surface, the light irradiation unit 20 that irradiates the photocurable resin 1 with light L that cures the photocurable resin 1 through the light-transmitting plate 14, the platform 12 that faces the light-transmitting plate 14 and can be raised and lowered relative to the molding tank 11, holds the cylindrical partition wall 313 that is formed around the object 2 together with the object 2 by irradiation with light L, and forms the airtight space 3 in cooperation with the partition wall 313, and sucks and removes the uncured photocurable resin 70 that has adhered to the object 2. The apparatus includes a suction mechanism 60, a lifting control unit 231 that raises and lowers the platform 12 to form a photocurable resin layer 1a of a predetermined thickness T between the bottom surface 313A of the partition 313 and the lower surface 3A of the space 3 and the light-transmitting plate 14, an irradiation control unit 232 that irradiates the photocurable resin layer 1a from the light irradiation unit 20 with light L that corresponds to the cross-sectional shape of the object 2 and the partition 313 at a predetermined height to form a single cured layer, and a suction control unit 333 that is positioned below the platform 12 and activates the suction mechanism 60 when the platform 12 is positioned above the photocurable resin 1a.

[0072] According to this configuration, a photocurable resin layer 1a of a predetermined thickness T is formed between the lower surface 313A of the partition wall 313 and the lower surface 3A of the space 3 and the light-transmitting plate 14, and this photocurable resin layer 1a is cured into a predetermined shape. This allows the thickness of each cured layer of the object 2 and the partition wall 313 to be precisely shaped, and ultimately allows the object 2 to be precisely shaped. Furthermore, according to this configuration, the space 3 can be provided around the cured layer of the previously molded object 2, which prevents the light L irradiated through the light-transmitting plate 14 from curing excess photocurable resin 1, and allows the object 2 to be precisely shaped. Furthermore, when the platform 12 is positioned above the photocurable resin 1, the suction mechanism 60, which is disposed below the platform 12 and sucks and removes uncured photocurable resin 70 adhering to the object 2, is activated. This prevents the uncured photocurable resin 70 adhering to the object 2 from being cured separately, allowing the object 2 to be precisely shaped.

[0073] The partition wall 313 is molded integrally with the object 2, and is sandwiched between the dish part 61 of the suction mechanism 60 and the platform 12 while the suction mechanism 60 is in operation, functioning as a support for the object 2. This makes it possible to easily prevent the object 2 from detaching from the platform 12 at least during the suction operation.

[0074] The suction mechanism 60 has a dish portion 61 with an open top surface, which abuts against the lower surface 313A of the partition wall 313 to form a closed space. When the suction portion 62 is activated, a negative pressure can be created within this closed space, and the uncured photocurable resin 70 adhering to the model 2 can be easily sucked and removed.

[0075] Furthermore, the lifting control unit 231, the irradiation control unit 232, and the suction control unit 333 repeatedly perform the formation of the photocurable resin layer 1a, the formation of the cured layer, and the suction of the uncured photocurable resin 70, stacking multiple cured layers on the platform 12 to form the object 2 and the partition wall 313, thereby simplifying the device configuration of the photopolymerization device 310 and enabling the object 2 to be formed with high precision.

[0076] The optical shaping apparatus and the method for manufacturing a shaped object according to the present invention have been described above. However, they may be embodied in various other forms in addition to the above-described embodiments. Furthermore, the configurations of these embodiments may be combined as appropriate. For example, the chamber 40, the chamber pressure adjusting unit 41, and the chamber pressure control unit 33 of the first embodiment may be combined with the optical shaping apparatuses according to the second to fourth embodiments. The air cylinder 50 and the air supply / exhaust control unit 133 of the second embodiment may be combined with the optical shaping apparatuses according to the first, third, or fourth embodiments. Furthermore, the suction mechanism 60 and the suction control unit 333 of the fourth embodiment may be combined with the optical shaping apparatuses according to the first to third embodiments.

[0077] Furthermore, each component of the illustrated optical shaping device is a functional concept and does not necessarily have to be physically configured as shown in the drawing. In other words, the specific form of each device is not limited to that shown in the drawing, and all or part of the device may be functionally or physically distributed or integrated in any unit depending on the processing load and usage status of each device.

[0078] The configuration of the control unit of the optical shaping apparatus is realized, for example, as software, by a program loaded into memory. In the above embodiment, the functional blocks are described as being realized by the cooperation of these hardware and software. In other words, these functional blocks can be realized in various forms, using only hardware, only software, or a combination of both. [Explanation of symbols]

[0079] 1 Photocurable resin 1a Photocurable resin layer 2 Three-dimensional objects (modeled objects) 2a hardened layer 3. Space (airtight space) 3A Bottom 10, 110, 210, 310 stereolithography equipment 11 Modeling tank 12 Platform 13, 213, 313 Bulkhead 13A, 213A, 313A Lower surface (bottom surface) 14 Light-transmitting plate (light-transmitting part) 15 Platform lifting mechanism 16 Bulkhead lifting mechanism 17 Airtight materials 20 Light irradiation unit 21 Light source 22 Image forming element 23 Reflective mirror 24 Projection lens 30, 130, 230, 330 Control unit 31, 231 Lift control section 32, 232 Irradiation control unit 33 Chamber internal pressure control unit 40 Chamber 41 Chamber internal pressure adjustment unit 50 Air cylinder (intake and exhaust section) 60 Suction mechanism 61 Dish section 62 Suction part 63 Hose 64 Moving mechanism 70 Uncured photocurable resin 133 Air intake and exhaust control unit 333 Suction control unit

Claims

1. a modeling tank that stores a photocurable resin and has a light-transmitting portion on its bottom surface; a light irradiation unit that irradiates light that cures the photocurable resin through the light transmission unit; a platform facing the light transmitting unit and capable of moving up and down relative to the modeling tank; a partition wall that is movably raised and lowered relative to the platform, that is formed in a cylindrical shape, that is disposed outside the platform via an airtight member, and that cooperates with the platform to form an airtight space; a lifting control section that lifts and lowers the platform and the partition wall, respectively, to form a photocurable resin layer of a predetermined thickness between the light transmitting section and a bottom surface of the partition wall and a lower surface of the airtight space; an irradiation control unit that irradiates the photocurable resin layer with the light corresponding to a cross-sectional shape at a predetermined height position of a target object from the light irradiation unit to form a cured layer; A photolithography device comprising:

2. The lift control unit, each time the formation of the hardened layer is completed, The optical shaping apparatus according to claim 1 , wherein the partition wall is lowered by the predetermined thickness relative to the platform.

3. The optical shaping apparatus according to claim 2 , wherein the elevation control unit temporarily raises the platform and the partition wall above the photocurable resin.

4. The optical molding device according to any one of claims 1 to 3, wherein the lifting control unit and the irradiation control unit alternately form the photocurable resin layer and the hardened layer, and stack multiple hardened layers on the platform to form the object.

5. A method for manufacturing a shaped object using a photo-lithography device including: a modeling tank that stores photocurable resin and has a light-transmitting section on its bottom surface; a light irradiation section that irradiates light that cures the photocurable resin through the light-transmitting section; a platform that faces the light-transmitting section and is movable up and down relative to the modeling tank; and a partition wall that is movable up and down relative to the platform, is formed in a cylindrical shape, and is disposed outside the platform via an airtight member, and forms an airtight space in cooperation with the platform, raising and lowering the platform and the partition wall, respectively, to form a photocurable resin layer of a predetermined thickness between the bottom surface of the partition wall, the lower surface of the airtight space, and the light transmitting portion; irradiating the photocurable resin layer with the light corresponding to a cross-sectional shape at a predetermined height position of a target object from the light irradiation unit to form a cured layer; and lowering the partition wall by the predetermined thickness relative to the platform.

Images