Method for producing structure, stereolithography method, and stereolithography device

Abstract

A region, of a forming surface (PP), corresponding to the inside of a structure to be formed is irradiated with promoting light (L1) for promoting the curing of a photocurable resin (RL) stored in a container (11), and a region (A2), of a region (A1) between the bottom plate of the container (11) and a forming table (12), on the forming table (12) side relative to the forming surface (PP) is irradated with inhibiting light (L3) for inhibiting the curing of the photocurable resin (RL). Thus, the forming resolution is improved.

Description

Structure manufacturing method, optical shaping method, and optical shaping device

[0001] The present invention relates to a stereolithography technique and a method for manufacturing a structure using the technique.

[0002] Stereolithography (also known as liquid vat polymerization) is known as one method for forming resin structures. Stereolithography uses a container that stores uncured photocurable resin and a modeling table that is immersed in the uncured photocurable resin. The bottom plate of the container is made of a light-transmitting material that allows the passage of accelerating light that accelerates the curing of the photocurable resin. An irradiation process in which accelerating light is irradiated onto the uncured photocurable resin present between the bottom plate of the container and the modeling table, and a lifting process in which the modeling table is lifted up are repeated, thereby forming a structure made of cured photocurable resin layer by layer. The formed structure is lifted up together with the modeling table while still attached to the modeling table. Patent Document 1, for example, is an example of a document disclosing the stereolithography method.

[0003] Japanese Patent Publication "JP-A-6-15749"

[0004] In stereolithography, the curing of the photocurable resin occurs on a build surface set between the bottom plate of the container and the build table. The area between this build surface and the build table contains both the built structure and uncured photocurable resin. Repeating the irradiation and lifting steps can unintentionally accelerate the curing of the photocurable resin in this area due to the cumulative effect of the accelerating light, resulting in a dulling of the shape of the built structure. This dulling means that the build resolution is lower than the resolution determined by the spot size of the accelerating light on the build surface.

[0005] One aspect of the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to improve the modeling resolution in a stereolithography technique or a method for manufacturing a structure using the technique.

[0006] A method for manufacturing a structure according to one aspect of the present invention includes an irradiation step of irradiating an area of ​​a modeling surface set between a bottom plate of the container and a modeling table with promotion light that promotes the hardening of photocurable resin stored in the container, the area corresponding to the inside of the structure to be modeled, and further irradiating an area of ​​the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface with inhibitory light that inhibits the hardening of the photocurable resin and that travels in a direction different from the direction of travel of the promotion light.

[0007] A photopolymerization method according to one aspect of the present invention includes an irradiation step of irradiating a region of a molding surface set between a bottom plate of the container and a molding table with promotion light that promotes the hardening of photocurable resin stored in the container, which corresponds to the inside of the structure to be molded, and further irradiating a region of the region between the bottom plate and the molding table that is closer to the molding table than the molding surface with inhibitory light that inhibits the hardening of the photocurable resin and that travels in a direction different from the direction of travel of the promotion light.

[0008] A photopolymerization apparatus according to one aspect of the present invention includes a container for storing photocurable resin, a modeling table immersed in the photocurable resin, a first irradiation unit that irradiates an area of ​​a modeling surface set between a bottom plate of the container and the modeling table with promotion light that promotes the hardening of the photocurable resin, the area corresponding to the inside of a structure to be modeled, and a second irradiation unit that further irradiates an area of ​​the area between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface with inhibition light that inhibits the hardening of the photocurable resin and that travels in a direction different from the direction of travel of the promotion light.

[0009] According to one aspect of the present invention, it is possible to improve the modeling resolution.

[0010] 1 is a cross-sectional view of a photo-fabrication apparatus according to one embodiment of the present invention; FIG. 2 is a flow diagram showing the flow of a photo-fabrication method (a method for manufacturing a structure) using the photo-fabrication apparatus shown in FIG. 1; FIG. 3 is a side view showing a structure obtained when the formation of the first, second, third, and fourth layers is completed, and a structure obtained when the formation of all layers is completed, when the photo-fabrication method according to a reference embodiment is carried out; FIG. 4 is a side view showing a structure obtained when the formation of the first, second, third, and fourth layers is completed, and a structure obtained when the formation of all layers is completed, when the photo-fabrication method shown in FIG. 2 is carried out; FIG. 5 is a plan view showing the configurations of a first irradiation unit and a second irradiation unit provided in the photo-fabrication apparatus shown in FIG. 1; FIG. 6 is a perspective view showing a specific example of an optical diffraction element formed by the photo-fabrication apparatus shown in FIG.

[0011] (Configuration of Optical Prototyping Apparatus) The configuration of an optical prototyping apparatus 1 according to one embodiment of the present invention will be described with reference to Fig. 1. Fig. 1(a) is a cross-sectional view of the optical prototyping apparatus 1.

[0012] 1, the optical shaping apparatus 1 is an apparatus for manufacturing a resin structure, and includes a container 11, a shaping table 12, a first irradiation unit 13, and a second irradiation unit 14. The optical shaping apparatus 1 also includes a lifting mechanism (not shown) that lifts the shaping table 12. Specific examples of the first irradiation unit 13 and the second irradiation unit 14 will be described later with reference to different drawings.

[0013] The container 11 is configured to store the photocurable resin (hereinafter also referred to as "photocurable resin RL") before curing. The container 11 is, for example, box-shaped or tub-shaped. The bottom plate of the container 11 is made of a light-transmitting material that transmits the accelerating light L1 and the inhibiting light L2 described below, and the side plates of the container 11 are made of a light-transmitting material that transmits the inhibiting light L3 described below. The modeling table 12 is configured to support the photocurable resin (hereinafter also referred to as "photocurable resin RS") after curing. The modeling table 12 has, for example, a rectangular prism or a cylindrical shape. The modeling table 12 is immersed in the photocurable resin RL so that its bottom surface faces the bottom plate of the container 11 in parallel.

[0014] The first irradiation unit 13 is configured to irradiate the region A1 between the bottom plate of the container 11 and the modeling table 12 with acceleration light L1. The acceleration light L1 is light that has the effect of accelerating the curing of the photocurable resin RL (e.g., the effect of initiating polymerization of the monomer). In this embodiment, visible light, for example, visible light (blue light) with a wavelength of 470 nm, is used as the acceleration light L1. The acceleration light L1 travels, for example, in a direction intersecting (or orthogonal in this embodiment) the modeling surface PP defined between the bottom plate of the container 11 and the modeling table 12 and is focused so that its intensity is maximized on the modeling surface PP. The acceleration light L1 is irradiated to a region of the modeling surface PP corresponding to the interior of the structure to be modeled, and is used to accelerate the curing of the photocurable resin RL present in that region.

[0015] The first irradiator 13 may also irradiate inhibitory light L2 along with the acceleration light L1. The inhibitory light L2 is light that inhibits the curing of the photocurable resin RL (e.g., stops the polymerization of the monomer). In this embodiment, ultraviolet light, e.g., ultraviolet light with a wavelength of 375 nm, is used as the inhibitory light L2. The inhibitory light L2 also travels in the same direction as the acceleration light L1, e.g., a direction intersecting the printing surface PP (in this embodiment, a direction perpendicular to the direction of travel of the acceleration light L1). The inhibitory light L2 is irradiated onto an area of ​​the printing surface PP that corresponds to the outside of the structure to be printed, and is used to inhibit the curing of the photocurable resin RL present in that area. By employing a configuration in which the inhibitory light L2 is irradiated from the first irradiator 13, it is possible to perform stereolithography with a resolution higher than the resolution determined by the spot size of the acceleration light L1 on the printing surface PP.

[0016] The first irradiator 13 may be configured as either (1) or (2) below. (1) The irradiator 13 irradiates the entire area of ​​the printing surface PP that corresponds to the interior of the structure to be printed with the accelerating light L1. (2) The irradiator 13 irradiates a portion of the area of ​​the printing surface PP that corresponds to the interior of the structure to be printed with the accelerating light L1. When the irradiator 13 employs the configuration (1), the printing of each point constituting each layer of the structure is carried out all at once. On the other hand, when the latter configuration is employed, the irradiation point of the accelerating light L1 is moved so as to scan the area of ​​the printing surface PP that corresponds to the interior of each layer of the structure. As a result, the printing of each point constituting each layer of the structure is carried out sequentially. The same can be said for the irradiator 13 using the inhibitory light L2.

[0017] The second irradiation unit 14 is configured to irradiate an area A2, which is located closer to the modeling table 12 than the modeling surface PP, with the inhibitory light L3, within the area A1 between the bottom plate of the container 11 and the modeling table 12. The inhibitory light L3, like the inhibitory light L2, is light that inhibits the curing of the photocurable resin RL (e.g., stops the polymerization of the monomer). The inhibitory light L3 travels in a direction different from the traveling direction of the acceleration light L1, for example, a direction along the modeling surface PP (in this embodiment, a direction parallel to the modeling surface PP). The inhibitory light L3 is irradiated onto at least a portion of the area A2, which is located closer to the modeling table 12 than the modeling surface PP, within the area A1 between the bottom plate of the container 11 and the modeling table 12, and is used to inhibit the curing of the photocurable resin RL present in that area.

[0018] It is preferable that the second irradiator 14 shapes the inhibiting light L3 into a sheet and irradiates it, which makes it possible to more uniformly inhibit the curing of the photocurable resin RL present in an area A2 that is closer to the modeling table 12 than the modeling surface PP in the area A1 between the bottom plate of the container 11 and the modeling table 12.

[0019] (Flow of the optical shaping method) The flow of the optical shaping method S1 using the optical shaping apparatus 1 will be described with reference to Fig. 2. Fig. 2 is a flow diagram showing the flow of the optical shaping method S1. The optical shaping method S1 can also be rephrased as a method for manufacturing a structure.

[0020] The optical shaping method S1 includes a pre-processing step S11, an irradiation step S12, a pulling-up step S13, and a post-processing step S14. The irradiation step S12 and the pulling-up step S13 are repeated a predetermined number of times. For example, when a structure is divided into n layers (n is any natural number) and each layer is shaped, the irradiation step S12 and the pulling-up step S13 are repeated n times.

[0021] The pre-processing step S11 is a step of storing the photocurable resin RL in the container 11 and immersing the modeling table 12 in the photocurable resin RL. Here, the modeling table 12 is immersed in the photocurable resin RL so that its bottom surface faces and is parallel to the bottom plate of the container 11. The storing of the photocurable resin RL and the immersion of the modeling table 12 may be performed manually by an operator or automatically by the optical modeling apparatus 1 or another device.

[0022] In the irradiation step S12, the first irradiation unit 13 irradiates the accelerating light L1, and the second irradiation unit 14 irradiates the inhibiting light L3. The accelerating light L1 irradiated from the first irradiation unit 13 travels, for example, in a direction intersecting the printing surface PP (in this embodiment, perpendicular to the printing surface PP) to promote the curing of the photocurable resin RL in a region of the printing surface PP corresponding to the interior of the structure to be printed. The inhibiting light L3 irradiated from the second irradiator 14 travels in a direction different from the traveling direction of the accelerating light L1, for example, in a direction parallel to the printing surface PP (in this embodiment, parallel to the printing surface PP), to suppress the curing of the photocurable resin RL in at least a portion of the region A2. The region A2 is a region of the region A1 between the bottom plate of the container 11 and the printing table 12 that is closer to the printing table 12 than the printing surface PP. The first irradiating unit 13 and the second irradiating unit 14 may be controlled manually by an operator or automatically by the optical shaping apparatus 1 or another device.

[0023] In the irradiation step S12, the first irradiation unit 13 may irradiate the inhibitory light L2 in addition to the acceleration light L1. The inhibitory light L2 irradiated from the first irradiation unit 13 travels in the same direction as the acceleration light L1, for example, in a direction intersecting the printing surface PP (in this embodiment, perpendicular to the direction of travel), and inhibits the curing of the photocurable resin RL in an area of ​​the printing surface PP that corresponds to the outside of the structure to be printed. In this case, it is possible to perform photolithography with a resolution higher than the resolution determined by the spot size of the acceleration light L1 on the printing surface PP.

[0024] The lifting process S13 is a process in which the lifting mechanism lifts the modeling table 12. Here, the direction in which the modeling table 12 is lifted is a direction in which the modeling table 12 moves away from the bottom plate of the container 11, and the amount by which the modeling table 12 is lifted is approximately equal to the thickness of one layer of the structure. The lifting mechanism may be controlled manually by an operator or automatically by the optical modeling apparatus 1 or another device.

[0025] In the lifting step S13, the photocurable resin RS that has been hardened in the irradiation step S12 of the current cycle is lifted up together with the modeling table 12, and the photocurable resin RL that will be hardened in the irradiation step S12 of the next cycle is replenished around the modeling surface PP.

[0026] When the formation of the structure is completed by repeating the irradiation step S12 and the pulling-up step S13, a post-processing step S14 is carried out. The post-processing step S14 is a step of removing the formed structure from the container 11 and performing processes such as exposure and / or cleaning on the structure removed from the container 11. For example, uncured photocurable resin RL adhering to the structure removed from the container 11 is removed in the post-processing step S14.

[0027] (Effects of the stereolithography method using the stereolithography device) The effects of the stereolithography method S1 using the stereolithography device 1 will be described with reference to Figures 3 and 4. Here, an embodiment and a reference embodiment in which three pillars P1 to P3 are formed on a substrate B will be given as examples. The stereolithography method S0 according to the reference embodiment differs from the stereolithography method S1 according to the embodiment in that irradiation of the inhibitory light L3 by the second irradiator 14 is omitted.

[0028] Fig. 3 is a side view showing a structure obtained when the first, second, third, and fourth layers are formed and the structure obtained when all layers are formed when the optical shaping method S0 according to the reference embodiment is performed. Fig. 4 is a side view showing a structure obtained when the first, second, third, and fourth layers are formed and the structure obtained when all layers are formed when the optical shaping method S1 according to the embodiment is performed.

[0029] In both the optical shaping method S0 according to the reference embodiment and the optical shaping method S1 according to the embodiment, each time the irradiation step S12 is performed, the promotion light L1 is irradiated onto the region of the shaping surface PP corresponding to the interior of the pillars P1 to P3 to be shaped. Therefore, each time the irradiation step S12 is performed, the photocurable resin RL present in the region of the shaping surface PP corresponding to the interior of the pillars P1 to P3 to be shaped is cured. Therefore, each time the irradiation step S12 and the pulling-up step S13 are performed, the pillars P1 to P3 are shaped one layer at a time.

[0030] Incidentally, when focusing on the region A2 of the region A1 between the bottom plate of the container 11 and the modeling table 12, which is closer to the modeling table 12 than the modeling surface PP, the accelerating light L1 also spreads between the modeled pillars P1 to P3. Therefore, when the optical shaping method S0 according to the reference embodiment is employed, repeatedly performing the irradiation step S12 causes the cumulative effect of the accelerating light L1 to progress the curing of the photocurable resin RL present between the modeled pillars P1 to P3. Therefore, when the optical shaping method S0 according to the reference embodiment is employed, even after performing the post-processing step S14, it is likely that cured or semi-cured photocurable resin RL will remain between the modeled pillars P1 to P3. In other words, the shapes of the modeled pillars P1 to P4 will easily become dull. This problem occurs regardless of whether or not the inhibiting light L2 is irradiated in the irradiation step S12.

[0031] On the other hand, when the optical shaping method S1 according to this embodiment is employed, the inhibitory light L3 is irradiated onto at least a portion of the region A2, which is located closer to the shaping table 12 than the shaping surface PP, within the region A1 between the bottom plate of the container 11 and the shaping table 12. This suppresses the curing of the photocurable resin RL present between the shaped pillars P1 to P3. Therefore, when the optical shaping method S1 according to this embodiment is employed, even after the post-processing step S14 is performed, it is less likely that cured or semi-cured photocurable resin RL will remain between the shaped pillars P1 to P3. In other words, the shapes of the shaped pillars P1 to P4 will be less likely to become dull. Note that this effect occurs regardless of whether or not the inhibitory light L2 is irradiated in the irradiation step S12.

[0032] (Configuration Example of First Irradiation Unit and Second Irradiation Unit) A configuration example of the first irradiating unit 13 and the second irradiating unit 14 will be described with reference to Fig. 5. Fig. 5 is a plan view showing a configuration example of the first irradiating unit 13 and the second irradiating unit.

[0033] The first irradiation unit 13 includes an optical system 13a used to irradiate the promotion light L1, an optical system 13b used to irradiate the inhibition light L2, and an optical system 13c used in common to irradiate the promotion light L1 and the inhibition light L2.

[0034] 5, the optical system 13a used to irradiate the acceleration light L1 includes an LED (Light Emitting Diode) 13a1, a diffuser 13a2, a first collecting lens 13a3, a second collecting lens 13a4, a first aperture stop 13a5, a second aperture stop 13a6, a condenser lens 13a7, a mirror 13a8, and a DMD (Digital Mirror Device) 13a9. The diffuser 13a2, the first collecting lens 13a3, the second collecting lens 13a4, the first aperture stop 13a5, the second aperture stop 13a6, the condenser lens 13a7, the mirror 13a8, and the DMD 13a9 are arranged in this order along the optical path of the acceleration light L1 output from the LED 13a1.

[0035] 5, the optical system 13b used to irradiate the inhibition light L2 includes an LED (Light Emitting Diode) 13b1, a diffuser 13b2, a first collector lens 13b3, a second collector lens 13b4, a first aperture stop 13b5, a second aperture stop 13b6, a condenser lens 13b7, a mirror 13b8, and a DMD (Digital Mirror Device) 13b9. The diffuser 13b2, the first collector lens 13b3, the second collector lens 13b4, the first aperture stop 13b5, the second aperture stop 13b6, the condenser lens 13b7, the mirror 13b8, and the DMD 13b9 are arranged in this order along the optical path of the inhibition light L2 output from the LED 13b1.

[0036] The optical system 13c commonly used for irradiating the promotion light L1 and the inhibition light L2 includes a dichroic mirror 13c1, a tube lens 13c2, an aperture stop 13c3, a beam splitter 13c4, and an objective lens 13c5, as shown in Fig. 5. The tube lens 13c2, the aperture stop 13c3, the beam splitter 13c4, and the objective lens 13c5 are arranged in this order along the optical paths of the promotion light L1 and the inhibition light L2 reflected by the dichroic mirror 13c1.

[0037] The configuration of the first irradiating unit 13 illustrated in FIG. 5 is publicly known, and therefore further detailed description thereof will be omitted here.

[0038] 5, the second irradiation unit 14 includes a linear light source 141 and a plano-convex cylindrical lens 142. The linear light source 141 may be, for example, a laser device such as an argon ion laser, or an LED bar with multiple light-emitting diodes (LEDs) arranged in a straight line. The second irradiation unit 14 shapes the wedge-shaped inhibitory light L3 emitted from the linear light source 141 into a sheet using the plano-convex cylindrical lens 142. This allows the inhibitory light L3 to be uniformly irradiated onto an area A2, which is located closer to the modeling table 12 than the modeling surface PP, within the area A1 between the bottom plate of the container 11 and the modeling table 12.

[0039] (Specific Example of Structure) Using the optical shaping device 1, an optical diffraction element (a specific example of the above-mentioned "structure") having an optical calculation function and composed of multiple microcells whose thicknesses are set independently of each other can be manufactured. When signal light is incident on such an optical diffraction element, the signal light beams with different phases that have passed through each microcell interfere with each other, thereby performing a predetermined optical calculation. In this specification, the term "microcell" refers to a cell with a cell size of less than 10 μm. In this specification, the term "cell size" refers to the square root of the area of ​​the cell. For example, if the planar shape of the microcell is square, the cell size is the length of one side of the cell. The lower limit of the cell size is not particularly limited, but is, for example, 1 nm.

[0040] A specific example of such an optical diffraction element is shown in Fig. 6. Fig. 6 is a perspective view of an optical diffraction element 100 according to this example.

[0041] The optical diffraction element 100 according to this example has a square effective area with sides of 1.0 mm. This effective area is composed of 100 x 100 microcells arranged in a matrix. Each microcell is composed of a rectangular pillar having a square base with sides of 1 μm and formed on a substrate with a thickness of 100 μm. The height of each pillar is, for example, 0 nm, 100 nm, 200 nm, ..., 1100 nm, or 1200 nm (13 levels in 100 nm steps), and is determined so that the amount of phase change of light passing through the microcell composed of the pillar is a desired value.

[0042] If the optical diffraction element 100 is fabricated without using the inhibiting light L3, the photocurable resin RL may unintentionally harden in the region between the tall pillars due to the cumulative effect of the accelerating light L1. This may cause the thickness of each microcell to deviate from the design value, which may result in the optical diffraction element 100 being unable to perform the intended optical calculation function.

[0043] In contrast, when the optical diffraction element 100 is formed using the inhibiting light L3, unintended curing of the photocurable resin RL due to the cumulative effect of the promoting light L1, which may occur in the region sandwiched between tall pillars, is suppressed. This makes it less likely that the thickness of each microcell will deviate from the design value, and as a result, it becomes less likely that the optical diffraction element 100 will be unable to perform the intended optical calculation function.

[0044] (Summary) The method for manufacturing a structure according to aspect 1 of the present invention includes an irradiation step of irradiating a region of a modeling surface set between a bottom plate of the container and a modeling table with promotion light that promotes the hardening of photocurable resin stored in the container, which corresponds to the interior of the structure to be modeled, and irradiating an inhibitory light that inhibits the hardening of the photocurable resin, the inhibitory light traveling in a direction different from the traveling direction of the promotion light, onto at least a portion of a region of the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface.

[0045] According to the above configuration, it is possible to suppress unintended curing of the photocurable resin due to the cumulative effect of the accelerating light, which may occur in the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface, thereby improving modeling resolution.

[0046] A method for manufacturing a structure according to a second aspect of the present invention is the method for manufacturing a structure according to the first aspect, wherein in the irradiating step, the inhibiting light is shaped into a sheet and irradiated.

[0047] According to the above configuration, it is possible to more uniformly suppress unintended curing of the photocurable resin due to the cumulative effect of the accelerating light in the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface, thereby further improving modeling resolution.

[0048] The method for manufacturing a structure according to aspect 3 of the present invention is a method for manufacturing a structure according to aspect 1 or 2, wherein in the irradiation step, other inhibiting light that inhibits the hardening of the photocurable resin and that travels in a direction that intersects with the modeling surface is irradiated onto an area of ​​the modeling surface that corresponds to the outside of the structure to be modeled.

[0049] According to the above configuration, it is possible to suppress unintended curing of the photocurable resin that may occur in an area of ​​the modeling surface that corresponds to the outside of the structure to be modeled, thereby further improving modeling resolution.

[0050] The method for manufacturing a structure according to aspect 4 of the present invention is a method for manufacturing a structure according to any one of aspects 1 to 3, and further includes a lifting step of lifting the modeling table in a direction away from the bottom plate, and by repeating the irradiation step and the lifting step, the structure to be modeled is formed layer by layer.

[0051] According to the above configuration, it is possible to form a structure in which the cross-sectional shape differs for each layer.

[0052] The method for manufacturing a structure according to aspect 5 of the present invention is a method for manufacturing a structure according to any one of aspects 1 to 4, wherein the direction of travel of the promotion light is a direction that intersects with the modeling surface, and the direction of travel of the inhibition light is a direction that follows the modeling surface.

[0053] According to the above configuration, promotion light can be effectively irradiated onto the modeling surface, and inhibition light can be effectively irradiated onto the area between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface.

[0054] The optical molding method according to aspect 5 of the present invention includes an irradiation step of irradiating a region of a molding surface set between a bottom plate of the container and a molding table with promotion light that promotes the hardening of photocurable resin stored in the container, which corresponds to the inside of the structure to be molded, and irradiating an area of ​​the molding surface set between the bottom plate and the molding table with inhibitory light that inhibits the hardening of the photocurable resin, the inhibitory light traveling in a direction different from the direction of travel of the promotion light, onto a region of the region between the bottom plate and the molding table that is closer to the molding table than the molding surface.

[0055] According to the above configuration, it is possible to suppress unintended curing of the photocurable resin due to the cumulative effect of the accelerating light, which may occur in the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface, thereby improving modeling resolution.

[0056] The optical molding apparatus according to aspect 6 of the present invention comprises a container for storing photocurable resin, a molding table immersed in the photocurable resin, a first irradiation unit that irradiates a region of a molding surface set between a bottom plate of the container and the molding table with promotion light that promotes the hardening of the photocurable resin, the region corresponding to the inside of the structure to be molded, and a second irradiation unit that irradiates an inhibitory light that inhibits the hardening of the photocurable resin, the inhibitory light traveling in a direction different from the traveling direction of the promotion light, onto a region of the region between the bottom plate and the molding table that is closer to the molding table than the molding surface.

[0057] According to the above configuration, it is possible to suppress unintended curing of the photocurable resin due to the cumulative effect of the accelerating light, which may occur in the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface, thereby improving modeling resolution.

[0058] (Summary 2) A method for manufacturing a structure according to aspect 1 of the present invention includes irradiating an area of ​​a modeling surface set between a bottom plate of the container and a modeling table with promotion light that promotes the hardening of photocurable resin stored in the container, the area corresponding to the inside of the structure to be modeled, and, when irradiating the promotion light, irradiating an area of ​​the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface with inhibition light that inhibits the hardening of the photocurable resin and travels in a direction different from the direction of travel of the promotion light.

[0059] A method for manufacturing a structure according to a second aspect of the present invention is the method for manufacturing a structure according to the first aspect, further comprising shaping the inhibiting light into a sheet shape.

[0060] A method for manufacturing a structure according to aspect 3 of the present invention is a method for manufacturing a structure according to aspect 1, further comprising, when irradiating the accelerating light and the inhibiting light, irradiating another inhibiting light that inhibits the hardening of the photocurable resin and travels in the direction of travel of the accelerating light onto an area of ​​the forming surface that corresponds to the outside of the structure.

[0061] A method for manufacturing a structure according to aspect 4 of the present invention is a method for manufacturing a structure according to aspect 1, further comprising: forming the structure layer by layer by repeating the steps of lifting the modeling table away from the bottom plate, irradiating the facilitating light and the inhibiting light, and lifting the modeling table.

[0062] A method for manufacturing a structure according to aspect 5 of the present invention is a method for manufacturing a structure according to aspect 1, wherein the traveling direction of the promotion light is a direction that intersects with the modeling surface, and the traveling direction of the inhibition light is a direction that runs along the modeling surface.

[0063] The optical molding method according to aspect 6 of the present invention comprises irradiating an area of ​​a molding surface set between a bottom plate of the container and a molding table with promotion light that promotes the hardening of photocurable resin stored in the container, the area corresponding to the inside of the structure to be molded, and, when irradiating the promotion light, irradiating an area of ​​the area between the bottom plate and the molding table that is closer to the molding table than the molding surface with inhibition light that inhibits the hardening of the photocurable resin and travels in a direction different from the direction of travel of the promotion light.

[0064] The optical molding apparatus of aspect 7 of the present invention comprises a container for storing photocurable resin, a molding table immersed in the photocurable resin, a first illuminator that irradiates an area of ​​the molding surface set between the bottom plate of the container and the molding table with promotion light that promotes the hardening of the photocurable resin, which corresponds to the inside of the structure to be molded, and a second illuminator that irradiates an area of ​​the region between the bottom plate and the molding table that is closer to the molding table than the molding surface with inhibition light that inhibits the hardening of the photocurable resin and travels in a direction different from the direction of travel of the promotion light.

[0065] (Additional Notes) The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in the above-described embodiments are also included in the technical scope of the present invention.

[0066] REFERENCE SIGNS LIST 1 Optical molding device 11 Container 12 Molding table 13 First irradiation unit 14 Second irradiation unit L1 Promotion light L2, L3 Inhibition light

Claims

1. A method for manufacturing a structure, comprising an irradiation step of irradiating an area of ​​a modeling surface set between a bottom plate of the container and a modeling table with promotion light that promotes the hardening of photocurable resin stored in the container, the area corresponding to the inside of the structure to be modeled, and irradiating an inhibitory light that inhibits the hardening of the photocurable resin, the inhibitory light traveling in a direction different from the traveling direction of the promotion light, onto an area of ​​the area between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface.

2. The method for manufacturing a structure according to claim 1, wherein in the irradiation step, the inhibiting light is shaped into a sheet and then irradiated.

3. A method for manufacturing a structure as described in claim 1 or 2, wherein in the irradiation process, another inhibitory light that inhibits the hardening of the photocurable resin and travels in the same direction as the promotion light is irradiated onto an area of ​​the modeling surface that corresponds to the outside of the structure to be modeled.

4. A method for manufacturing a structure described in any one of claims 1 to 3, further comprising a pulling-up process of pulling up the modeling table in a direction away from the bottom plate, and forming the structure to be modeled layer by layer by repeating the irradiation process and the pulling-up process.

5. A method for manufacturing a structure described in any one of claims 1 to 4, wherein the traveling direction of the promotion light is a direction that intersects with the modeling surface, and the traveling direction of the inhibition light is a direction that runs along the modeling surface.

6. A photopolymerization method including an irradiation step of irradiating an area of ​​a printing surface set between a bottom plate of the container and a printing table, the area corresponding to the inside of a structure to be printed, with promotion light that promotes the hardening of photopolymerizable resin stored in the container, and irradiating an area of ​​the printing surface set between the bottom plate and the printing table with inhibition light that inhibits the hardening of the photopolymerizable resin and that travels in a direction different from the direction of travel of the promotion light, the area being on the side of the printing table rather than the printing surface, the area being on the side of the printing table.

7. A photopolymerization device comprising: a container for storing photocurable resin; a modeling table immersed in the photocurable resin; a first irradiation unit for irradiating a region of a modeling surface set between a bottom plate of the container and the modeling table with promotion light for promoting the hardening of the photocurable resin, the region corresponding to the inside of a structure to be modeled; and a second irradiation unit for irradiating an inhibitory light that inhibits the hardening of the photocurable resin, the inhibitory light traveling in a direction different from the traveling direction of the promotion light, onto a region of the region between the bottom plate and the modeling table that is closer to the modeling table than the modeling surface.

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