Three-dimensional additive manufacturing apparatus and powder leveling member
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- JEOL LTD
- Filing Date
- 2022-06-27
- Publication Date
- 2026-05-11
Smart Images
Figure 0007856507000001 
Figure 0007856507000002 
Figure 0007856507000003
Abstract
Description
Technical Field
[0001] The present invention relates to a three-dimensional laminating apparatus and a powder leveling member.
Background Art
[0002] As one of the three-dimensional laminating technologies, a powder bed type forming method is known. In this forming method, a new powder material is supplied onto a previously formed cured layer and an uncured powder material, and a width plate-shaped regulating member that crosses the forming frame is horizontally moved at a position slightly higher than the forming frame to regulate the height position of the powder material and form a layer of powder material having a constant thickness as a whole. Next, an electron beam or a laser is irradiated onto the surface of the formed powder material layer. As a result, the whole or a part of the powder material is melted to integrally bond the powder materials to form a cured layer, and the newly formed cured layer is integrated with the cured layer laminated below. By repeating such a cured layer forming process, it is said that a three-dimensional laminated body in which a plurality of cured layers having a predetermined pattern shape are laminated can be obtained (see Patent Document 1 below).
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] Incidentally, there is a type of regulating member used to form layers of powder material that consists of multiple comb-shaped leveling plates stacked together. In such a regulating member, each leveling plate is positioned and fixed so that adjacent leveling plates block the slits in the comb teeth with each other. In a regulating member with this configuration, if the leveling plates expand due to thermal influences from the molding environment, a misalignment of the comb teeth between the leveling plates may occur, resulting in gaps between the comb teeth. In this case, it was not possible to align the height of the powder material, making it difficult to form a layer of powder material with a flat surface.
[0005] Therefore, the present invention aims to provide a three-dimensional molding apparatus having a powder leveling member that can form a powder layer with a flat surface regardless of the thermal influence of the molding environment, and a powder leveling member. [Means for solving the problem]
[0006] To achieve this objective, the present invention provides a three-dimensional additive manufacturing apparatus comprising a base plate and a powder leveling member for leveling powder supplied onto the base plate to form a powder layer, wherein the powder leveling member comprises a squeegee formed by stacking a plurality of comb-shaped leveling plates having a plurality of alignment holes, with the alignment holes overlapping, and an arm having a plurality of positioning pins that are fitted into the overlapping alignment holes, wherein the plurality of alignment holes are a first alignment hole for alignment in the direction of the arrangement of the comb teeth, and a second alignment hole for alignment in a direction perpendicular to the direction of the arrangement of the comb teeth, arranged on both sides of the first alignment hole and having an elongated opening shape in the direction of the arrangement of the comb teeth. [Effects of the Invention]
[0007] The present invention provides a three-dimensional molding apparatus having a powder leveling member that can form a powder layer with a flat surface regardless of the thermal influence of the molding environment, and a powder leveling member. [Brief explanation of the drawing]
[0008] [Figure 1] This is a schematic diagram of a three-dimensional additive manufacturing apparatus according to an embodiment of this invention. [Figure 2] This is a schematic diagram of the powder leveling member according to the embodiment. [Figure 3] This is an exploded perspective view of the squeegee that constitutes the powder leveling member according to the embodiment. [Figure 4] This is a plan view of the leveling plate that constitutes the squeegee according to the embodiment. [Figure 5] This diagram shows the deflection of the arms that make up the powder leveling member. [Figure 6] This diagram illustrates the problems of comparative examples compared to the embodiments. [Modes for carrying out the invention]
[0009] ≪Three-dimensional additive manufacturing equipment≫ Figure 1 is a schematic diagram of a three-dimensional additive manufacturing apparatus 1 according to an embodiment. The three-dimensional additive manufacturing apparatus 1 shown in Figure 1 is a powder bed type three-dimensional additive manufacturing apparatus 1, and includes a forming tank 11, a base plate 12, a powder supply device 13, a powder leveling member 14, a rail member 15, a dust box 16, and an energy ray irradiation unit 17 within a reduced pressure chamber 10. The three-dimensional additive manufacturing apparatus 1 also includes a control unit 18 and an input unit 19 for controlling the drive unit among these components. The following describes these components that constitute the three-dimensional additive manufacturing apparatus 1.
[0010] <Formation tank 11> The forming tank 11 is a cylindrical structure erected within the reduced pressure chamber 10, and a three-dimensional additively fabricated object is formed inside the cylindrical structure. The cylindrical structure constituting the forming tank 11 is, for example, cylindrical. Such a forming tank 11 is equipped with a flange-shaped table 11a that extends from the periphery of the upper opening toward the outer circumference.
[0011] <Base Plate 12> The base plate 12 is provided in contact with the inner circumferential wall of the forming tank 11 and constitutes the bottom surface of the forming tank 11. A flexible seal 12a is placed in the gap between the inner circumferential wall of the forming tank 11 and the edge of the base plate 12, ensuring the sliding and airtightness of the base plate 12 within the forming tank 11. Inside the forming tank 11, whose bottom surface is formed by the base plate 12, powder 100 is stored, and powder layers, each made by stacking the powder 100 to a predetermined thickness, are sequentially stacked.
[0012] The base plate 12 also includes a base plate drive unit 12b. The base plate drive unit 12b controls the raising and lowering of the base plate 12 within the forming tank 11, thereby making the depth of the forming tank 11 variable. This base plate drive unit 12b is connected to the control unit 18 and raises and lowers the base plate 12 based on instructions from the control unit 18.
[0013] <Powder supply device 13> The powder supply device 13 supplies powder 100 to the top of the table 11a. This powder supply device 13 comprises a powder tank 13a and a quantitative dispenser 13b connected to the bottom of the powder tank 13a, and supplies a predetermined amount of powder 100 onto the table 11a from a powder outlet 13c provided in the quantitative dispenser 13b. The powder supply device 13 supplies a predetermined amount of powder 100 in a line extending across the upper opening of the forming tank 11, near the starting position [ps] set near one edge of the table 11a, and on the upper opening side of the forming tank 11 from the starting position [ps]. This supply of powder 100 by the powder supply device 13 is carried out by instructions from the control unit 18. The starting position [ps] is the position where the powder leveling member 14, which will be described next, begins to move.
[0014] <Powder leveling member 14> The powder leveling member 14 is a long plate-shaped member that spans the upper opening of the forming tank 11. Such a powder leveling member 14 is movable along the upper opening of the table 11a and the forming tank 11 at a height position where one side of the plate-shaped member maintains a predetermined interval with respect to the table 11a. Further, after the powder 100 is supplied onto the table 11a from the powder supply device 13 according to an instruction from the control unit 18, the powder leveling member 14 moves from the movement start position [ps] set near one end edge of the table 11a toward the upper opening along the table 11a.
[0015] Furthermore, the powder leveling member 14 moves to the folding position [pr] so as to pass over the upper opening across the upper opening of the forming tank 11. The folding position [pr] is a position set near the other end edge of the table 11a. After reaching the folding position [pr], the powder leveling member 14 moves from the folding position [pr] toward the movement start position [ps]. Thereby, the powder leveling member 14 supplies the powder 100 supplied onto the table 11a into the forming tank 11 and makes the thickness of the powder 100 accommodated in the forming tank 11 uniform to form a powder layer 101.
[0016] Also, the powder leveling member 14 discharges the excess powder 100 that cannot be accommodated in the forming tank 11 and protrudes from the upper opening of the forming tank 11 to the outer periphery of the table 11a. The configuration of the powder leveling member 14 as described above will be described in detail hereinafter.
[0017] <Rail member 15> The rail member 15 is laid along the traveling direction of the powder leveling member 14, holds the end portion of the powder leveling member 14 slidably, and guides the movement of the powder leveling member 14. Such a rail member 15 may be arranged only at one end portion of the powder leveling member 14 and may be configured to cantilever the powder leveling member 14. Also, the rail member 15 may be arranged at both end portions of the powder leveling member 14 and may be configured to hold the powder leveling member 14 on both sides.
[0018] <Dust box 16> The dust boxes 16 are arranged below the table 11a on both sides in the moving direction of the powder leveling member 14. These dust boxes 16 are the dust box 16s on the moving start position [ps] side and the dust box 16r on the folding position [pr] side. These dust boxes 16 accommodate the surplus powder 100 discharged onto the outer periphery of the table 11a by the powder leveling member 14.
[0019] <Energy beam irradiation unit 17> The energy beam irradiation unit 17 is an irradiation unit for an energy beam capable of melting the powder 100. It is arranged to face the base plate 12 and irradiates an energy beam onto the powder layer 101 composed of the powder 100 laminated on the base plate 12. The energy beam is, for example, an electron beam, and the illustrated energy beam irradiation unit 17 is an electron beam irradiation device. Such an energy beam irradiation unit 17 irradiates the powder layer 101 composed of the powder 100 stored on the base plate 12 in the forming tank 11 while scanning the energy beam within a set irradiation range under the drive control by the control unit 18 described below.
[0020] <Control unit 18> The control unit 18 controls the driving of the above-described components and is composed of a computer. The computer is hardware used as a so-called computer. The computer includes a CPU (Central Processing Unit), a RAM (Random Access Memory), and a non-volatile storage unit such as a ROM (Read Only Memory) or an HDD (hard disk drive), and may further include a network interface. The control unit 18 composed of such a computer causes the CPU to execute the shaping program recorded in the ROM or RAM.
[0021] <Input unit 19> The input unit 19 is for inputting an instruction to start forming a three-dimensional laminated object and for inputting the shaping data necessary for forming a three-dimensional laminated object.
[0022] ≪Detailed configuration of the powder leveling member 14≫ Figure 2 is a schematic diagram of the powder leveling member 14 according to the embodiment. As shown in Figure 2, the powder leveling member 14 comprises an arm 14a and a squeegee 14b held by the arm 14a. Hereinafter, the extension direction of the arm 14a will be defined as the x-direction, the direction perpendicular to the x-direction within the arrangement plane of the powder leveling member 14 will be defined as the y-direction, and the direction perpendicular to both the x-direction and the y-direction will be defined as the z-direction, and the configuration of the arm 14a and the squeegee 14b will be described accordingly.
[0023] [Arm 14a] The arm 14a is equipped with two elongated crossbeams 141, and the squeegee 14b is sandwiched between the two crossbeams 141 and fixed between the two crossbeams 141 by bolts 142. In this type of arm 14a, the ends of the two crossbeams 141 are slidably fitted into the rail member 15, thereby guiding the movement of the powder leveling member 14 in the z direction to the rail member 15. The two crossbeams 141 constituting the arm 14a are made of metal or ceramic material.
[0024] One of these two crossbeams 141 has a plurality of positioning pins 143 that protrude in the z direction toward the other crossbeam 141. The other of the two crossbeams 141 that make up the arm 14a has a plurality of holes (not shown) that fit individually with each positioning pin 143.
[0025] The multiple positioning pins 143 and the holes that engage with the positioning pins 143 are, for example, arranged along the extension direction (x direction) of the crossbeam 141, and are provided, for example, near both ends and near the center. The multiple positioning pins 143 are also typically arranged at the same positions in the y direction.
[0026] [Squeegee 14b] Figure 3 is an exploded perspective view of the squeegee 14b that constitutes the powder leveling member according to the embodiment. As shown in Figures 2 and 3, the squeegee 14b is constructed by stacking multiple leveling plates 200. In the illustrated example, the squeegee 14b is constructed by stacking three leveling plates 201, 202, and 203 (see Figure 3) in order.
[0027] Each leveling plate 200 is comb-shaped, with the base end of the comb teeth 200a held by the arm 14a, with the height of the tips of the comb teeth 200a aligned. Multiple leveling plates 200 are arranged such that the extension direction (x direction) of the arm 14a is aligned with the arrangement direction of the comb teeth 200a, and adjacent leveling plates 200 are stacked on top of each other so that the slits 200b between the comb teeth 200a are closed. With this configuration, when leveling the powder 100 (see Figure 1), even if protrusions form on the edges of the molten part of the base powder layer 101, only the comb teeth 200a in contact with the protrusion deform, maintaining the height of the tip of the squeegee 14b, making it possible to spread and level the powder. Each leveling plate 200 is made of a metal material, a ceramic material, or a resin.
[0028] Figure 4 is a plan view of the leveling plate 200 that constitutes the squeegee according to the embodiment. As shown in Figures 2 to 4, each leveling plate 200 is comb-shaped with a plurality of comb teeth 200a. Each leveling plate 200 also has a first alignment hole 200h and a second alignment hole 200v. These first alignment hole 200h and second alignment hole 200v are provided on the base end side of each leveling plate 200 as through holes into which the positioning pin 143 of the arm 14a is fitted. Next, the comb teeth 200a, the first alignment hole 200h, and the second alignment hole 200v of the leveling plate 200 will be described in order, and then the details of the laminated structure of the leveling plate 200 will be described.
[0029] -Comb teeth 200a- The comb teeth 200a of each leveling plate 200 constituting the squeegee 14b are, for example, extended in a direction perpendicular to the arrangement direction of the comb teeth 200a (x direction) (y direction). However, the extension direction of the comb teeth 200a is not limited to this, and may be oblique to the arrangement direction of the comb teeth 200a (x direction). The comb teeth 200a are arranged, for example, at equal pitches, and the size of the slits 200b provided between the comb teeth 200a is such that they can be closed by the comb teeth 200a. In addition, in a plurality of comb teeth 200a, the width of at least one of the comb teeth 200a at both ends may be smaller (or larger) than the other comb teeth 200a. As a result, by stacking leveling plates 200 of the same design alternately front and back, a squeegee 14b can be constructed in which the slits 200b of the comb teeth 200a are closed by the adjacent stacked leveling plates 200.
[0030] In the example shown in Figure 4, the comb tooth 200a at the far right of the drawing is designated as an adjustment comb tooth 200aa, and the width of this adjustment comb tooth 200aa is approximately one-third that of the other comb teeth 200a. The width of the slit 200b between the comb teeth 200a is also approximately one-third that of the comb teeth 200a.
[0031] -First alignment hole 200h- The first alignment hole 200h is in the extending direction of the arm 14a and is a through hole for positioning the leveling plate 200 with respect to the arrangement direction (x direction) of the comb teeth 200a, i.e., for positioning the comb teeth 200a. The opening width [hx] of this first alignment hole 200h in the arrangement direction (x direction) of the comb teeth 200a may be approximately the same as the diameter of the positioning pin 143 that is fitted into this first alignment hole 200h. This opening width [hx] should be such that, with the positioning pin 143 passed through the first alignment hole 200h, there is no slack in the arrangement direction (x direction on the drawing) of the comb teeth 200a.
[0032] Furthermore, in the first alignment hole 200h, the opening width [hy] in the y direction should be large enough to accommodate the positioning pin 143. However, it is preferable that this opening width [hy] is large enough to absorb, for example, the deflection caused by thermal deformation of the arm 14a. In this case, the first alignment hole 200h will have an elongated opening shape in the y direction.
[0033] Figure 5 shows the deflection of the arm 14a that constitutes the powder leveling member 14. As shown in this figure, the powder leveling member 14, which is made of a metal material for example, becomes hot due to the thermal influence from the molding environment, and the internal stress of the material is released, causing thermal deformation such as deflection of the arm 14a, which changes the positional relationship of the positioning pins.
[0034] Therefore, the first alignment hole 200h of the leveling plate 200 is configured such that the opening width [hy] in the extension direction (y direction) of the comb teeth 200a is made sufficiently larger than the diameter of the positioning pin 143, thereby absorbing the thermal deformation of the arm 14a.
[0035] The first alignment hole 200h described above is preferably located near the center of each leveling plate 200 in the direction of arrangement of the comb teeth 200a (the x-direction in the drawing), and the most preferred location is the center. As a result, as shown in Figure 3, even if the stacked leveling plates 200 are of the same design, by stacking leveling plates 200 of the same design alternately with their front and back sides facing each other, a squeegee 14b can be formed in which adjacent stacked leveling plates 200 close the slits 200b of the comb teeth 200a. In this case, it is preferable that the y-direction, which is perpendicular to the direction of arrangement of the comb teeth 200a (the x-direction), is the direction in which the comb teeth 200a extend.
[0036] Furthermore, if the first alignment hole 200h is in the center of the alignment direction (x direction) of the comb teeth 200a, each leveling plate 200 expands from the center of the alignment direction (x direction) of the comb teeth 200a toward both sides, as shown by the arrow in Figure 3. Therefore, the amount of movement due to expansion can be minimized in the part where the amount of movement due to expansion is greatest at both ends of the leveling plate 200.
[0037] -Second alignment hole 200v- As shown in Figures 2 to 4, the second alignment hole 200v is a through hole for positioning the leveling plate 200 in the y-direction perpendicular to the extension direction (x-direction) of the arm 14a. The opening width [vy] in the y-direction of this second alignment hole 200v may be approximately the same as the diameter of the positioning pin 143 that is fitted into this second alignment hole 200v. This opening width [vy] should be such that there is no slack in the y-direction when the positioning pin 143 is passed through the second alignment hole 200v.
[0038] Furthermore, in the second alignment hole 200v, the opening width [vx] in the direction of arrangement of the comb teeth 200a (x direction) is large enough to absorb the thermal expansion of the leveling plate 200, which is made of, for example, a metal material, and the second alignment hole 200v has an elongated opening shape in the x direction.
[0039] The second alignment holes 200v described above are preferably arranged on both sides of the first alignment hole 200h in each leveling plate 200, and are located at both ends of the leveling plate 200. This makes it possible to stabilize the posture of the leveling plate 200 relative to the arm 14a. Furthermore, it is preferable that these two second alignment holes 200v are located at equal distances from the first alignment hole 200h. This makes it possible to construct a squeegee 14b in which adjacent stacked leveling plates 200s block the slits 200b of the comb teeth 200a by stacking leveling plates 200 of the same design alternately with their front and back sides facing each other.
[0040] -Laminated structure of leveling board 200- The leveling plates 200 having the first alignment holes 200h, the second alignment holes 200v, and the comb teeth 200a described above are stacked so that adjacent leveling plates 200 close the slits 200b between the comb teeth 200a. In this state, one positioning pin 143 is inserted into each of the multiple first alignment holes 200h that are stacked on top of each other, and then one positioning pin 143 is inserted into each of the second alignment holes 200v that are stacked on top of each other on either side.
[0041] Here, when stacking leveling plates 200 of the same design to form a single squeegee 14b, refer to Figure 3, and among the stacked leveling plates 200, the leveling plate 202, which is stacked in an even number of positions, is flipped over relative to the leveling plates 201 and 203, which are stacked in an odd number of positions. As a result, the arrangement of the adjustment comb teeth 200aa alternates in the stacking direction. In this state, one positioning pin 143, which is provided in the center of the arm 14a, is inserted into one of the multiple first alignment holes 200h located in the center of each leveling plate 200. In addition, one positioning pin 143 is inserted into each of the second alignment holes 200v, which are stacked on either side of the first alignment holes 200h.
[0042] <<Effects of the Embodiment>> According to the embodiment described above, the leveling plate 200 has a structure in which elongated second alignment holes 200v are arranged perpendicular to the first alignment hole 200h for aligning the comb teeth 200a in the alignment direction. As a result, when subjected to thermal influence from the molding environment, each of the stacked leveling plates 200 expands toward both sides starting from the first alignment hole 200h. Therefore, misalignment of the comb teeth between the leveling plates 200 is less likely to occur, and gaps between the comb teeth 200a can be prevented. Furthermore, friction between the leveling plates 200 and snagging between the comb teeth 200a can be prevented. As a result, it becomes possible to form a powder layer 101 with a flat surface regardless of the thermal influence of the molding environment.
[0043] Figure 6 illustrates the problems of a comparative example compared to the embodiment and is an exploded perspective view of the squeegee 14b' that constitutes the powder leveling member. The difference between the squeegee 14b' shown in this figure and the squeegee 14b of the embodiment lies in the arrangement of the first alignment holes 200h' and the second alignment holes 200v' provided on the leveling plate 200'. These leveling plates 200' are of the same design, and the comb teeth 200a have the same configuration as in the embodiment, with the comb teeth 200a at one end being designated as adjustment comb teeth 200aa, and the width of these adjustment comb teeth 200aa being smaller than that of the embodiment. In this configuration, the first alignment hole 200h' is located at one end (for example, the end on the side of the adjustment comb teeth 200aa). Furthermore, the second alignment hole 200v' is located in the center and at the other end.
[0044] Furthermore, these leveling plates 200' are stacked alternately on the front and back to form a squeegee 14b', and positioning pins 143 of an arm (not shown in the illustration) are fitted into the first alignment holes 200h' and the second alignment holes 200v' to form a powder leveling member.
[0045] In a powder leveling member having a squeegee 14b' with such a configuration, when subjected to thermal influence from the environment, each leveling plate 200' expands thermally with respect to the first alignment hole 200h' provided at its end, as shown by the arrow in Figure 6. As a result, adjacent leveling plates 200' expand in opposite directions, causing a misalignment of the comb teeth between the leveling plates 200' and creating a risk of gaps forming between the comb teeth 200a. Furthermore, the expansion of adjacent leveling plates 200' in opposite directions could cause the leveling plates 200' to rub against each other or the comb teeth 200a to catch on each other, potentially causing the leveling plates 200' to warp. In addition, if the arm deforms due to heat, a misalignment of the positioning pin 143 may occur, which could cause the leveling plates 200' to bend accordingly. In contrast, the configuration of the present embodiment makes it possible to prevent these problems as described above. [Explanation of Symbols]
[0046] 1…Three-dimensional additive manufacturing device 12…Base plate 14... Powder leveling member 14a...arm 14b... Squeegee 15… Rail components 100…powder 101…Powder layer 141...Horizontal beam 142... Volts 143…Positioning pin 200... leveling board 200a…comb teeth 200aa…Adjustment comb teeth 200b... Slit 200h...First alignment hole 200V...Second alignment hole 201, 203... odd-numbered leveling boards 202... Even-numbered leveling boards
Claims
1. A three-dimensional additive manufacturing apparatus comprising a base plate and a powder leveling member for leveling the powder supplied onto the base plate to form a powder layer, The aforementioned powder leveling member is A squeegee made by stacking multiple comb-shaped leveling plates, each having multiple alignment holes, with the alignment holes overlapping, The arm comprises a plurality of positioning pins that are fitted into the aforementioned overlapping alignment holes, The aforementioned plurality of alignment holes are A first alignment hole for aligning the comb teeth in the alignment direction of the leveling plate, Alignment holes for aligning the comb teeth in a direction perpendicular to the arrangement direction, and second alignment holes arranged on both sides of the first alignment hole, having an elongated opening shape in the direction of the arrangement direction of the comb teeth, The first alignment hole has an elongated opening shape in a direction perpendicular to the arrangement direction of the comb teeth, The aforementioned multiple leveling plates are arranged so that the comb teeth of adjacent leveling plates close the slits between the comb teeth. Three-dimensional additive manufacturing device.
2. The first alignment hole is provided in the center of the arrangement direction of the comb teeth on the leveling plate. The three-dimensional additive manufacturing apparatus according to claim 1.
3. The second alignment holes are provided at both ends of the leveling plate in the direction of arrangement of the comb teeth. The three-dimensional additive manufacturing apparatus according to claim 1.
4. A powder leveling member for leveling powder and forming a powder layer, A squeegee made by stacking multiple comb-shaped leveling plates, each having multiple alignment holes, with the alignment holes overlapping. The arm comprises a plurality of positioning pins that are fitted into the aforementioned overlapping alignment holes, The aforementioned plurality of alignment holes are A first alignment hole for aligning the comb teeth in the alignment direction of the leveling plate, Alignment holes for aligning the comb teeth in a direction perpendicular to the arrangement direction, and second alignment holes arranged on both sides of the first alignment hole, having an elongated opening shape in the direction of the arrangement direction of the comb teeth, The first alignment hole has an elongated opening shape in a direction perpendicular to the arrangement direction of the comb teeth, The aforementioned multiple leveling plates are arranged so that the comb teeth of adjacent leveling plates close the slits between the comb teeth. Powder leveling component.