Molding method and support member

Abstract

To enhance a degree of freedom of engineering of a molded article.SOLUTION: A molding method includes: a step S4 of arranging a support member 2 including a molding support surface along a molding schedule region in which a lower surface of a second molding part is molded; and a step S5 of molding the second molding part continuing to a first molding part by supplying a powder material P and an energy beam E onto a molding support principal surface 22a of the support member 2. The support member 2 has a molding support part 22 including the molding support principal surface 22a, and a leg part 21 including a part not in contact with the first molding part, and determining a position of the molding support part 22 relative to the first molding part.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to a modeling method and a support member used in the modeling method.

Background Art

[0002] As one of methods for obtaining a hollow-shaped product, a so-called core is used, for example, in the field of casting. Patent Document 1 discloses a method for producing a resin-integrated core and a method for producing a mold using the resin-integrated core.

Prior Art Literature

Patent Literature

[0003]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0004] In a deposition-type modeling method, for example, energy is supplied to a powder material while supplying the powder material. The powder material is melted by the supply of energy and then solidified.

[0005] For example, a hollow-shaped product has an eave-shaped portion called a so-called overhang. When an attempt is made to model this overhang using a deposition-type modeling method, sagging of the molten powder material may occur. Therefore, when modeling a shape that cannot be realized by one deposition-type modeling operation, modeling is performed by dividing the shape into a plurality of modeled parts, which are then integrated by welding or the like. That is, in the deposition-type modeling method, there has been a predetermined restriction on shapes that can be modeled.

[0006] The present disclosure describes a modeling method capable of increasing the degree of freedom in designing a modeled object and a support member used in the modeling method.

Means for Solving the Problem

[0007] A molding method according to one aspect of the present disclosure is a molding method for molding an object having a first molding section and a second molding section that is continuous with the first molding section and extends in a direction intersecting the direction in which the first molding section extends. The molding method includes the steps of: positioning a support member including a molding support surface along the area to be molded on the lower surface of the second molding section; and molding the second molding section continuous with the first molding section by supplying material and an energy beam onto the molding support surface of the support member. The support member has a molding support section including a molding support surface, and a leg section including a portion that does not come into contact with the first molding section and which determines the position of the molding support section relative to the first molding section.

[0008] In this fabrication method, a second fabrication section, continuous with the first fabrication section, is fabricated on the fabrication support surface of a support member. The support member prevents sagging during the fabrication of the second section, thus enabling its fabrication. As a result, the design flexibility of the fabricated object can be increased.

[0009] The fabrication method further includes a step of fabricating the first fabrication section before the step of placing support members. In this case, no support members are placed during the fabrication of the first fabrication section. This improves the flexibility of the placement of the fabrication equipment, making it easier to fabricate the first fabrication section.

[0010] In the fabrication method, after the step of fabricating the second fabrication section, a hole is formed in the fabricated object that leads to a space defined by the inner surface of the first fabrication section and the portion of the support member that does not come into contact with the first fabrication section. The fabrication method further includes a step of removing the support member through the hole after the step of fabricating the second fabrication section. This makes it possible to fabricate a hollow structure. It also makes it possible to design the position of the hole considering the required strength of the fabricated object.

[0011] In the fabrication method, the fabrication support surface is flat. In this case, the surface roughness of the flat surface is transferred to the lower surface of the second fabrication section of the fabricated object. Therefore, by improving the surface roughness of the fabrication support surface, the surface roughness of the lower surface of the second fabrication section can be improved.

[0012] A support member according to another aspect of the present disclosure is a support member used in a molding method for molding an object having a first molding section and a second molding section that is continuous with the first molding section and extends in a direction intersecting the direction in which the first molding section extends. The support member comprises a leg portion extending in a predetermined direction and a molding support portion supported at the tip of the leg portion. The molding support portion has a molding reference surface spaced apart from the side surface of the leg portion between the tip of the leg portion and the base of the leg portion, along a direction perpendicular to the predetermined direction in which the leg portion extends; a molding support surface extending in a direction intersecting the predetermined direction in which the leg portion extends, so as to be continuous with the molding reference surface; and a molding corner portion formed in the portion where the molding reference surface and the molding support surface are continuous.

[0013] This support member is positioned so that the first part of the printed object and the printing reference surface are in contact. In this state, printing can be performed on the printing support surface. The printing reference surface, the printing support surface, and the printing corners prevent sagging from the printing support surface during printing. As a result, the design freedom of the printed object can be increased. [Effects of the Invention]

[0014] The molding method and support members used in the molding method of this disclosure can increase the degree of freedom in designing the molded object. [Brief explanation of the drawing]

[0015] [Figure 1] Figure 1 is a schematic diagram showing the configuration of the 3D printing apparatus. [Figure 2] Figure 2 shows an overview of the support member and an example of the cross-sectional structure of the material supply nozzle. [Figure 3] Figure 3 shows another example of the cross-sectional structure of a material supply nozzle. [Figure 4]FIG. 4 is a flowchart illustrating an example of a method for modeling a closed container. [Figure 5] FIG. 5 is a diagram illustrating an example of a cross-section of a closed container during modeling. (a) to (c) in FIG. 5 are diagrams each illustrating an example of a cross-section of the closed container corresponding to a modeling stage. [Figure 6] FIG. 6 is a diagram illustrating an example of a cross-section of a closed container during modeling. (a) to (c) in FIG. 6 are diagrams each illustrating an example of a cross-section of the closed container corresponding to a modeling stage. [Figure 7] FIG. 7 is a diagram illustrating an example of a conventional modeling method. (a) in FIG. 7 illustrates an example of modeling a modeled object without tilting the modeled object. (b) in FIG. 7 illustrates an example of modeling a modeled object while tilting the modeled object. (c) in FIG. 7 illustrates another example of modeling a modeled object while further tilting the modeled object. [Figure 8] FIG. 8 is a diagram illustrating an example of a comparison of cross-sections of closed containers. (a) in FIG. 8 is a diagram illustrating an example of a cross-section of a closed container manufactured by the modeling method of the present disclosure. (b) in FIG. 8 is a diagram illustrating an example of a cross-section of a closed container manufactured by a conventional modeling method. DETAILED DESCRIPTION OF EMBODIMENTS

[0016] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. In each of the drawings, the same or corresponding portions are denoted by the same reference numerals, and overlapping descriptions will be omitted.

[0017] The modeling apparatus 1 shown in FIG. 1 is a 3D (three-dimensional) printer. The modeling apparatus 1 manufactures a three-dimensional modeled object M. The modeled object M is, for example, a mechanical part or the like, and may also be another structure. The modeling apparatus 1 employs a so-called deposition method. For example, the modeling apparatus 1 supplies an energy beam E to powder material P while supplying the powder material P to a region to be modeled where a desired portion of the modeled object M is to be formed. The energy beam E is, for example, a laser, an electron beam, an arc, or the like.

[0018] The powder material P is, for example, a metal powder such as titanium-based metal powder, nickel powder such as Inconel powder, aluminum powder, or steel material powder such as stainless steel alloy. The powder material P is not limited to metal powders. The powder material P may be a powder containing carbon fiber and resin such as CFRP (Carbon Fiber Reinforced Plastics), for example. The powder material P may be another conductive powder. The powder material P in the present disclosure is not limited to those having conductivity. For example, when a laser is used as the energy beam E, the powder material P does not need to have conductivity.

[0019] The temperature of the powder material P rises due to the supply of the energy beam E, and the powder material P melts or sinters. The temperature of the powder material P decreases over time and solidifies. In the present disclosure, the expression "the powder material P solidifies" includes both an embodiment in which the powder material P, which has been heated to a temperature higher than its melting point and turned into a liquid, solidifies, and an embodiment in which the powder material P sinters when heated to a temperature lower than its melting point.

[0020] The material of the modeled object M may be, for example, a wire. The modeling apparatus 1 supplies an energy beam E to a wire or the like in a state where the wire or the like is placed against a region to be modeled, for example. Alternatively, the modeling apparatus 1 generates a plasma arc with the tip of the wire directed toward the region to be modeled, for example. The wire is melted by the plasma arc and then solidifies.

[0021] The modeling apparatus 1 includes an arm 11, a material supply nozzle 12, and a positioner 13. The arm 11 is, for example, a multi-axis robot or a Cartesian robot. The arm 11 adjusts the position of the material supply nozzle 12 so that the material supply nozzle 12 is located above the region to be modeled. The material supply nozzle 12 supplies the powder material P and the energy beam E to the region to be modeled. The positioner 13 is a work table for modeling the modeled object M. The positioner 13 adjusts the position, angle, and inclination of the region to be modeled. The modeling apparatus 1 may perform various controls in accordance with, for example, control signals transmitted from a control device (not shown).

[0022] A disc-shaped table 131 is attached to the positioner 13. The table 131 is located above the positioner 13 and faces the material supply nozzle 12. The positioner 13 changes the position and angle of the table 131. For example, the positioner 13 may rotate the table 131 around a rotation axis passing through the center of the table 131. The positioner 13 may raise and lower the table 131 along the rotation axis. The positioner 13 may tilt the table 131. The positioner 13 may move the table 131 along a direction intersecting the rotation axis. A base plate B, for example, made of metal, is placed on the table 131. The molded object M is continuously molded on the base plate B, which serves as the substrate for the molded object M.

[0023] The molding apparatus 1 modifies the object M while changing the relative position between it and the material supply nozzle 12. For example, the arm 11 positions the material supply nozzle 12 above the positioner 13. The positioner 13 changes the position and angle of the table 131. Accordingly, the position and angle of the base plate B on the table 131 and the object M on the base plate B are changed. As a result, the relative position between the object M and the material supply nozzle 12 changes. The material supply nozzle 12 supplies powder material P and energy beam E to the area to be molded. A molten pool, which is an accumulation of molten substrate and powder material P, is formed in the area to be molded. The powder material P solidifies over time, and the object M is molded. Once molding is complete in the entire area to be molded for the object M, the object M is manufactured.

[0024] Figure 2 shows an overview of the support member 2 and an example of the cross-sectional structure of the material supply nozzle 12. The material supply nozzle 12 is formed, for example, in a tubular shape. The material supply nozzle 12 has a nozzle tip 121 that tapers at one end. The nozzle tip 121 is directed toward the area to be fabricated. The area to be fabricated is located on the extension of the beam axis L, which is the central axis of the material supply nozzle 12. The material supply nozzle 12 is provided with a beam output hole 122 and a powder ejection hole 123.

[0025] The beam output hole 122 is a hole that passes through the beam axis L. The beam output hole 122 leads to the nozzle tip 121. On the opposite side of the nozzle tip 121, the beam output hole 122 leads to the energy beam source. When a laser is used as the energy beam, the energy beam source is an optical element such as a laser oscillator and a mirror. When an electron beam is used as the energy beam, the energy beam source may be an electron gun. The electron gun generates an electron beam corresponding to the potential difference between the cathode and the anode. When welding is used as the energy source, the molding device 1 generates a plasma arc between the wire and the molded object M.

[0026] The powder ejection holes 123 are holes provided around the beam axis L. The powder ejection holes 123 lead to the nozzle tip 121. Near the nozzle tip 121, the powder ejection holes 123 are inclined to approach the beam axis L. On the opposite side of the nozzle tip 121, the powder ejection holes 123 lead to a raw material tank or the like. The raw material tank stores the powder material P. The powder ejection holes 123 may be connected to the raw material tank through piping or the like.

[0027] The fabrication method of this disclosure uses a support member 2 in at least some of the steps. The support member 2 is, for example, a self-supporting base made of ceramics. The support member 2 is placed, for example, on an already fabricated surface of the fabricated object M, or on a base plate B, etc. The support member 2 has a main fabrication support surface 22a (fabrication support surface) that is aligned with the fabrication area in which the lower surface M1 of the fabricated object M is to be fabricated. The support member 2 has a shape that corresponds to, for example, its placement position and the fabrication area. The support member 2 is manufactured, for example, by a manufacturing method using a mold, or by a so-called binder jet type 3D printer, etc.

[0028] The material supply nozzle 12 supplies powder material P and an energy beam E onto the main surface 22a of the build support. For example, the material supply nozzle 12 outputs an energy beam E from the beam output hole 122 toward the outside of the nozzle tip 121. The material supply nozzle 12 ejects powder material P from the powder ejection hole 123 toward the outside of the nozzle tip 121. The ejection direction of the powder material P is adjusted along the slope of the powder ejection hole 123 so as to approach the beam axis L. The ejected powder material P is heated by the energy beam E on the beam axis L outside the material supply nozzle 12. The powder material P is heated to a temperature at which a build object M can be formed. A molten pool MP is formed on the main surface 22a of the build support by the substrate and the powder material P. In Figure 2, the substrate is a part of the already formed build object M. The molten pool MP solidifies over time, forming the build object M.

[0029] The molding apparatus 1 may be equipped with a material supply nozzle 12A, as shown in Figure 3, instead of the material supply nozzle 12. The material supply nozzle 12A differs from the material supply nozzle 12 in that it supplies powder material P from the nozzle center and energy beam E from the periphery of the nozzle center. The differences from the material supply nozzle 12 will be mainly described below. The material supply nozzle 12A has a nozzle tip 121A that tapers at one end. The material supply nozzle 12A is provided with a beam output hole 122A and a powder ejection hole 123A.

[0030] The beam output hole 122A is a hole located around the central axis of the material supply nozzle 12A. The beam output hole 122A leads to the nozzle tip 121A. On the opposite side of the nozzle tip 121A, the beam output hole 122A leads to the energy beam source. Near the nozzle tip 121A, the beam output hole 122A is inclined to approach the central axis of the material supply nozzle 12A.

[0031] The powder ejection hole 123A is a hole that passes through the central axis of the material supply nozzle 12A. The powder ejection hole 123A is connected to the nozzle tip 121A. On the opposite side of the nozzle tip 121A, the powder ejection hole 123A is connected to a raw material tank or the like.

[0032] The material supply nozzle 12A supplies powder material P and an energy beam E onto the main surface 22a of the build support. For example, the material supply nozzle 12A outputs an energy beam E from the beam output hole 122A toward the outside of the nozzle tip 121A. The material supply nozzle 12A ejects powder material P from the powder ejection hole 123A toward the outside of the nozzle tip 121A. The output direction of the energy beam E is adjusted along the inclination of the beam output hole 122A so as to approach the central axis of the material supply nozzle 12A.

[0033] An example of a method for fabricating a sealed container T will be explained with reference to Figures 4 to 6. The sealed container T is an example of a fabricated object M, such as a rectangular or round container with a lid. Figure 4 is a flowchart showing an example of a method for fabricating a sealed container T. Figures 5 and 6 show an example of a cross-section of the sealed container T during fabrication. In the following explanation, the sealed container T during fabrication will be referred to as the "intermediate product TA". For example, nickel-based alloy powder can be used as the material for the sealed container T.

[0034] The molding apparatus 1 fabricates the bottom 5 of the intermediate product TA having a hole H as shown in Figure 5(a) (step S1). The bottom 5 has a bottom upper surface 51 and a bottom lower surface 52. The bottom upper surface 51 faces the inside of the intermediate product TA. The bottom lower surface 52 is the surface opposite to the bottom upper surface 51. The hole H extends from the bottom upper surface 51 to the bottom lower surface 52 and penetrates a portion of the bottom 5. The molding apparatus 1 fabricates the bottom 5 on a base plate B, which is the substrate. The material supply nozzle 12 supplies powder material P and energy beam E to the area where the bottom 5 is to be fabricated. The material supply nozzle 12 fabricates the bottom 5 while avoiding the area where the hole H is to be made. The positioner 13 adjusts the position of the area to be fabricated, for example, by moving or rotating the table 131.

[0035] The molding apparatus 1 fabricates the side portion 6 of the intermediate product TA as shown in Figure 5(a) (step S2). The side portion 6 is continuous with the bottom portion 5 and extends wall-like along the central axis CL. The side portion 6 has a side inner surface 61, a side outer surface 62, a side base end 63, and a side tip end 64. The side inner surface 61 faces the inside of the intermediate product TA. The side outer surface 62 is the surface opposite to the side inner surface 61. The side base end 63 is the end that is continuous with the bottom portion 5. The side tip end 64 is the end opposite to the side base end 63. The molding apparatus 1 fabricates the side portion 6 so that it is continuous with the base portion 5. The material supply nozzle 12 supplies powder material P and energy beam E to the fabrication area where the side portion 6 will be fabricated. The positioner 13 adjusts the position of the fabrication area, for example, by lowering the table 131.

[0036] The molding apparatus 1 temporarily suspends the molding of the intermediate product TA (step S3). The material supply nozzle 12 temporarily suspends the supply of powder material P and energy beam E. Subsequently, in the molding method, a support member 2 as shown in Figure 5(b) is placed inside the intermediate product TA (step S4). If necessary, the intermediate product TA may be machined or otherwise processed before the support member 2 is placed inside the intermediate product TA (i.e., between steps S3 and S4). For example, the bottom upper surface 51, bottom lower surface 52, and side inner surface 61 of the intermediate product TA may be machined and polished.

[0037] The support member 2 comprises a leg portion 21 extending in a predetermined direction. The leg portion 21 is at least one columnar member. The leg portion 21 extends, for example, along the central axis CL of the intermediate product TA. The leg portion 21 determines the position of the molding support portion 22 relative to the side portion 6. The leg portion 21 has a leg tip portion 21a, a leg base end face 21b, and a leg side portion 21s. The leg tip portion 21a is one end of the leg portion 21. The leg base end face 21b is the other end of the leg portion 21. The leg side portion 21s is a side portion provided between the leg tip portion 21a and the leg base end face 21b.

[0038] The support member 2 includes a build support portion 22 supported by the leg tip portion 21a. The build support portion 22 has a build reference surface 22s spaced apart from the leg side surface 21s along a direction perpendicular to a predetermined direction in which the leg portion 21 extends. The build support portion 22 has a build support main surface 22a extending in a direction intersecting the predetermined direction in which the leg portion 21 extends, so as to be continuous with the build reference surface 22s. In the build support portion 22, the surface opposite to the build support main surface 22a is the build support back surface 22b. The build support portion 22 includes a build corner portion 22e formed in the portion where the build reference surface 22s and the build support main surface 22a are continuous. The build support main surface 22a is a plane. Here, "plane" is not limited to a flat surface. The build support main surface 22a may include curved surfaces, etc., within the allowable range indicated by geometric tolerances, as a plane.

[0039] As an example of the arrangement of the support member 2, the base end face 21b of the leg is in contact with the top bottom surface 51 of the bottom 5. The base end face 21b of the leg is positioned so as not to block the hole H. The side face 21s of the leg is spaced apart from the inner side surface 61 of the side. That is, the side face 21s of the leg does not come into contact with the side 6. In another example, the side face 21s of the leg may come into contact with the side 6. The molding reference surface 22s is in contact with the inner side surface 61 of the side. The molding corner 22e is in contact with the tip of the side 64.

[0040] The molding apparatus 1 fabricates the lid 7 of the intermediate product TA as shown in Figure 5(c) (step S5). The lid 7 is continuous with the side portion 6 and extends in a direction intersecting the direction in which the side portion 6 extends. More specifically, the lid 7 is continuous with the tip 64 of the side portion and extends over the side portion 6 in an overhang shape. The lid 7 has a lid surface 71 and a lid main surface 72. The lid surface 71 faces the main molding support surface 22a. The molding apparatus 1 fabricates the lid 7 on the main molding support surface 22a so as to be continuous with the tip 64 of the side portion 6 which is the base material. The main molding support surface 22a is along the planned molding area K (see Figure 5(b)) where the lid surface 71 of the lid 7 is fabricated. The material supply nozzle 12 supplies powder material P and energy beam E to the planned molding area K where the lid 7 is fabricated. The positioner 13 adjusts the position of the planned molding area K, for example, by moving or rotating the table 131. The surface roughness of the main molding support surface 22a is transferred to the back surface 71 of the molded lid 7.

[0041] The internal space A1 of the intermediate product TA after the lid portion 7 has been fabricated includes an area A11 not occupied by the support member 2 and an area A12 occupied by the support member 2. When viewed from the perspective of the support member 2, the support member 2 has a portion that is in contact with the inner surface of the intermediate product TA and a portion that is not in contact with the inner surface of the intermediate product TA. More specifically, the fabrication reference surface 22s of the support member 2 is in contact with the inner surface 61 of the side portion. The fabrication support main surface 22a is also in contact with the back surface 71 of the lid portion. The leg base end surface 21b is also in contact with the top surface 51 of the bottom portion. Conversely, the leg side surface 21s of the support member 2 is not in contact with the inner surface 61 of the side portion. The fabrication support back surface 22b is also not in contact with the top surface 51 of the bottom portion.

[0042] As a result, within the intermediate product TA, a non-contact space is formed, known as region A11, which is not occupied by the support member 2. This space is enclosed by the bottom upper surface 51, the inside of the leg side surface 21s, and the back surface 22b of the molding support. The hole H is connected to this region A11 that is not occupied by the support member 2.

[0043] Furthermore, the area not occupied by the support member 2 may be defined as a non-contact space enclosed by the inner surface 61 of the side, the upper surface 51 of the bottom, the outer surface of the leg side 21s, and the back surface 22b of the molding support.

[0044] In the molding process, a strong alkaline solution 100 is injected into the intermediate product TA as shown in Figure 6(a) (step S6). The intermediate product TA is inverted so that the bottom 5 is positioned above the lid 7. The strong alkaline solution 100 is injected into the intermediate product TA through the hole H. Examples of the strong alkaline solution 100 include aqueous solutions of sodium carbonate, sodium hydroxide, or potassium hydroxide. The support member 2 is then immersed in the strong alkaline solution 100.

[0045] In the fabrication process, the support member 2 dissolves (step S7). The support member 2, immersed in the strong alkaline solution 100, dissolves over time. The intermediate product TA, made from nickel-based alloy powder, does not dissolve because it has corrosion resistance to the strong alkaline solution 100.

[0046] The support member 2, excluding the molding support portion 22, may have at least a portion of a lattice structure. A lattice structure is the structure of a three-dimensional object in which a grid is periodically arranged. In a support member 2 with a lattice structure, the mass is reduced, and the surface area immersed in the strong alkaline solution 100 is increased. Therefore, the time required to dissolve the support member 2 is shortened.

[0047] In the molding process, the strong alkaline solution 101 containing the dissolved support member 2 is discharged from the intermediate product TA as shown in Figure 6(b) (step S8). The intermediate product TA is returned to its original orientation so that the lid 7 is positioned above the bottom 5. The strong alkaline solution 101 is discharged from the intermediate product TA through the hole H. This removes the dissolved support member 2 from the intermediate product TA.

[0048] In the fabrication process, the inside of the intermediate product TA is cleaned and dried (step S9). This removes any remaining strong alkaline solution 101 inside the intermediate product TA.

[0049] The molding apparatus 1 closes the hole H by forming a closing section 9 (step S10). This completes the sealing of the intermediate product TA, and a sealed container T is obtained. The closing section 9 may also be formed by welding a closing member, which is created as a separate component by machining or the like to match the size of the hole H, to the hole H.

[0050] The following describes the problems with conventional fabrication methods, followed by an explanation of the effects and benefits of the fabrication method disclosed herein.

[0051] Figure 7 shows an example of a conventional fabrication method. The conventional fabrication method differs from the fabrication method of this disclosure in that it does not use a support member 2. Figure 7(a) shows an example of fabricating an object M without tilting it. The positioner 13C lowers the table 131C along the beam axis L as the fabrication of the object M progresses, in response to the supply of powder material P from the material supply nozzle 12C.

[0052] Figure 7(b) shows an example of printing an object M at an angle. The printing apparatus 1C prints the object M at an angle θ1 (θ1>0°) with respect to the beam axis L. As the printing of the object M progresses, the positioner 13C moves the table 131C along the direction in which the object M is tilted.

[0053] Figure 7(c) shows another example of printing the object M at a further tilt. The printing apparatus 1C prints the object M at an angle θ2 (θ2 > θ1) with respect to the beam axis L. As the printing of the object M progresses, the positioner 13C moves the table 131C along the direction in which the object M is tilted. Due to the large tilt angle θ2, dripping D occurs from the molten pool MP. In other words, the deposition method cannot be used to print at an angle θ2 with respect to the beam axis L.

[0054] According to the above-described molding method, a sealed container TC as shown in Figure 8(b) can be manufactured. Figure 8(b) shows an example of a cross-section of a sealed container TC manufactured by a conventional molding method. The sealed container TC comprises a bottom 5C, side 6C, and lid 7C. In the sealed container TC, the lid 7C extends in a direction intersecting the side 6C. Inside the sealed container TC, the lid 7C and the side 6C form an angle θ4C (θ3 < θ4C).

[0055] Conventional deposition-based fabrication methods had limitations on the angle at which the beam axis L could be tilted. Therefore, it was difficult to fabricate overhang shapes using conventional methods. Conventional methods required, for example, manufacturing overhang members and other members separately and then integrating them by welding or other means to produce the final product. Such products were susceptible to quality degradation due to shrinkage, cracking, or residual stress associated with welding.

[0056] The present disclosure provides a method for fabricating an object M (sealed container T) having a first fabrication section (side section 6) and a second fabrication section (lid section 7) that is continuous with the first fabrication section and extends in a direction intersecting the direction in which the first fabrication section extends. The fabrication method includes steps S4 of positioning a support member 2 including a main fabrication support surface 22a along the fabrication area where the lower surface of the second fabrication section (back surface 71 of the lid section) will be fabricated, and step S5 of fabricating the second fabrication section continuous with the first fabrication section by supplying a material (powder material P) and an energy beam E onto the main fabrication support surface 22a of the support member 2. The support member 2 includes a fabrication support section 22 including the main fabrication support surface 22a, and leg sections 21 including a portion that does not contact the first fabrication section and which determine the position of the fabrication support section 22 relative to the first fabrication section.

[0057] In this fabrication method, a second fabrication section, continuous with the first fabrication section, is fabricated on the main fabrication support surface 22a of the support member 2. The support member 2 prevents sagging during the fabrication of the second section (step S2), thus enabling the fabrication of the second section. As a result, the design flexibility of the fabricated object M can be increased.

[0058] According to the fabrication method of this disclosure, a sealed container T as shown in Figure 8(a) can be fabricated. Figure 8(a) shows an example of a cross-section of a sealed container T manufactured by the fabrication method of this disclosure. In the sealed container T, the lid portion 7 extends in a direction intersecting the side portion 6. The lid portion 7 is continuous with the side portion 6 in an overhang-like manner. Inside the sealed container T, the lid portion 7 and the side portion 6 form an angle θ3 (for example, 90° < θ3). This angle θ3 is smaller than the angle θ4C of a sealed container TC fabricated by the conventional fabrication method shown in Figure 8(b). In other words, angle θ3 is closer to 90° than angle θ4C. This means that the fabrication method of this disclosure increases the degree of freedom in the shapes that can be fabricated.

[0059] Furthermore, the molding method further includes steps S1 and S2 for molding the first molding section before step S4 for placing the support members 2. In this case, the support members 2 are not placed during the molding of the first molding section. This improves the degree of freedom in the placement of the molding apparatus (molding apparatus 1), making it easier to mold the first molding section.

[0060] In the fabrication method, after step S5, in which the second fabrication section is fabricated, a hole H is formed in the fabricated object M that leads to a space defined by the inner surface of the first fabrication section and the portion of the support member 2 that does not come into contact with the first fabrication section. The fabrication method further includes step S6, in which the support member 2 is removed through the hole H, after step S5, in which the second fabrication section is fabricated. This makes it possible to fabricate a hollow structure M. Furthermore, it becomes possible to design the position of the hole H considering the required strength of the fabricated object M.

[0061] In the molding method, the main molding support surface 22a is flat. In this case, the surface roughness of the flat surface is transferred to the lower surface of the second molding section of the molded object M. Therefore, by improving the surface roughness of the main molding support surface 22a, the surface roughness of the lower surface of the second molding section can be improved.

[0062] The support member 2 of this disclosure is used in a molding method for molding an object M having a first molding section and a second molding section that is continuous with the first molding section and extends in a direction intersecting the direction in which the first molding section extends. The support member 2 comprises a leg portion 21 extending in a predetermined direction and a molding support portion 22 supported at the tip of the leg portion 21. The molding support portion 22 has a molding reference surface 22s spaced apart from the leg side surface 21s between the tip of the leg portion 21 (leg tip portion 21a) and the base end of the leg portion 21 (leg base end surface 21b) along a direction perpendicular to the predetermined direction in which the leg portion 21 extends, a molding support main surface 22a extending in a direction intersecting the predetermined direction in which the leg portion 21 extends so as to be continuous with the molding reference surface 22s, and a molding corner portion 22e formed in the portion where the molding reference surface 22s and the molding support main surface 22a are continuous.

[0063] The support member 2 is positioned so that the first molded portion of the molded object M and the molded reference surface 22s are in contact. In this state, it becomes possible to perform molding on the main molded support surface 22a (step S5). The molded reference surface 22s, the main molded support surface 22a, and the molded corners 22e prevent sagging from the main molded support surface 22a during molding. As a result, the design freedom of the molded object M can be increased.

[0064] It should be noted that the support member 2 of this disclosure is different from a core used in the field of casting. For example, a core enables the manufacture of hollow-shaped products by preventing the intrusion of molten metal. The entire surface of a core is in contact with the inner surface of the hollow-shaped product. In contrast, the entire surface of the support member 2 does not need to be in contact with the inner surface of the molded product M. For example, the base end surface 21b of the leg, the molding reference surface 22s, the main molding support surface 22a, and the molding corners 22e of the support member 2 are in contact with the inner surface of the molded product M, but the rest of the support member 2 is not in contact with the inner surface of the molded product M. In another example, the base end surface 21b of the leg, the molding reference surface 22s, the main molding support surface 22a, and the molding corners 22e of the support member 2 are in contact with the inner surface 61 of the side of the molded product M. When the intermediate product TA is fabricated at an angle, the support member 2 is supported by the inner surface 61 of the side portion, which helps to suppress displacement of the support member 2.

[0065] The angle θ3 in the sealed container T can be fabricated to be smaller than the angle θ4C in the sealed container TC. The lid 7 of the sealed container T can be said to be closer to horizontal than the lid 7C of the sealed container TC. The surface roughness of the main fabrication support surface 22a is transferred to the underside 71 of the lid. In contrast, on the lid 7C, the underside 71C of the lid that faces the inside of the sealed container TC cannot be processed by polishing or other methods.

[0066] The molding method and support member 2 of this disclosure are not limited to the embodiments described above, and various modifications are possible without departing from the spirit of this disclosure. For example, although the embodiments describe an example in which the support member 2 is placed after the side portion 6 is molded, the support member 2 may be placed before the side portion 6 is molded.

[0067] In this embodiment, an example was described in which the support member 2 inside the sealed container T is dissolved and removed, but the method for removing the support member 2 is not limited to this. For example, the support member 2 may be destroyed and removed inside the sealed container T. In one example, vibrations matching the natural frequency of the support member 2 may be applied to the sealed container T. The support member 2 resonates inside the sealed container T and then breaks. The destroyed support member 2 may be removed through the hole H.

[0068] In this embodiment, an example was described in which the hole H of the sealed container T is formed in conjunction with the molding of the bottom 5, but the method and location of forming the hole H are not limited to this. For example, the bottom 5 and side 6 may be molded without forming the hole H. The hole H may be formed in the bottom 5 or side 6 by drilling.

[0069] In the embodiments, a sealed container T is given as an example of a molded object M, but the examples of molded objects M are not limited to this. The molding method of this disclosure is applicable to molded objects M in general that have an overhang shape. If the molded object M is not a sealed container T, it is not necessary to provide a hole H.

[0070] In this embodiment, an example was described in which the molded object M is molded continuously on the base plate B, but the molded object M may also be molded continuously on other products, etc.

[0071] As another example, a surface plate may be used instead of the positioner 13. The surface plate fixes the position of the object M. The arm 11 changes the position of the material supply nozzle 12. The material supply nozzle 12 moves relative to the object M. [Explanation of symbols]

[0072] 1 Modeling equipment 2. Support members 5 Bottom 6 Side 7 Lid 11 Arms 12 Material supply nozzle 13 Positioner 21 Legs 22 Modeling support part 22s modeling reference surface 22a Printing support main surface (printing support surface) 22e shaped corner 71 Underside of the lid 72 Main surface of the lid 131 Tables 121 Nozzle tip 122 Beam output holes 123 Powder spout hole 21a Leg tip 21b Leg proximal surface 21s leg side B Base Plate E Energy Beam H hole M Modeled object P powder material T Closed container TA Intermediate Deliverables K: Planned area for design

Claims

1. A method for creating a molded object having a first molding section and a second molding section that is continuous with the first molding section and extends in a direction intersecting the direction in which the first molding section extends, The steps include: forming the first molding section, The steps include: positioning a support member including a build support surface that is aligned with the planned build area where the lower surface of the second build section will be built; The steps include: supplying powder material to the area to be fabricated on the fabrication support surface of the support member while supplying an energy beam to the powder material to fabricate the second fabrication section which is continuous with the first fabrication section; Includes, The support member is A molding support section including the molding support surface, A molding method comprising: a leg portion that includes a portion that does not come into contact with the first molding portion and determines the position of the molding support portion relative to the first molding portion.

2. After the step of forming the second molding section is carried out, the molded object has a hole formed in it that leads to a space defined by the inner surface of the first molding section and the portion of the support member that does not come into contact with the first molding section. The molding method according to claim 1, further comprising the step of removing the support member through the hole after the step of molding the second molding section.

3. The molding method according to claim 2, wherein the molding support surface is flat.

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