JP3095302B2 - Molding method for three-dimensional shaped objects - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a three-dimensionally shaped object, and more particularly to a method for forming a three-dimensionally shaped object using a photocurable resin which is cured by light irradiation. It relates to a manufacturing method.

[0002]

2. Description of the Related Art A method of molding a three-dimensional shaped object using a photocurable resin is to form a complicated three-dimensional shape easily and accurately without using a molding die or a special processing tool. It has been considered that the method can be used for manufacturing various product models and three-dimensional models. Specifically, for example, JP-A-61-114817, JP-A-63-141724, and JP-A-60-247515
There is a method disclosed in Japanese Unexamined Patent Publication (Kokai) No. H10-209.

For example, in the method disclosed in Japanese Patent Application Laid-Open No. 63-141724, a molding table which can be moved up and down submerged in a resin liquid is disposed immediately below the liquid surface of the resin liquid, and the liquid surface is irradiated with a laser beam. ,
The resin liquid layer on the molding table is light-cured to form a light-cured layer, and then, after the molding table is slightly sunk, the process of performing the same operation as described above is repeated, whereby a plurality of light-cured layers are formed. Is piled up. Other methods, first, to form a photo-cured layer by irradiating the photo-curable resin with light in a predetermined pattern,
It is common that such photocurable layers are sequentially stacked to obtain a shaped article having a desired three-dimensional shape.

[0004] In this method, for example, when the bottom surface of a modeled object has a curved surface or has complicated irregularities, if the modeled object is formed as it is on a flat molding table, the modeled object becomes stable. Therefore, there is a problem that the molded object moves or deforms on the molding table during the molding process. Also,
If the molded object is molded directly on the molding table, when removing the molded object from the molding table, part of the molded object remains attached to the molding table, or part of the molded object is broken or scratched. There is a problem to do.

[0005] Therefore, a method has been proposed in which a supporting member formed by the same method as that of a molded article, that is, a method of photo-curing a resin liquid, is formed on a molding table, and then the molded article is molded on the supporting member. Have been. Specifically, Japanese Patent Laid-Open No. 2-5
There is a method disclosed in Japanese Patent No. 2725. Further, FIG.
7 and the method shown in FIG. 18 are also considered. According to this method, a large number of through-holes a are formed in a molding table A, a lattice frame-shaped support member B is formed on the molding table A as shown in FIG. A molded object C is formed.
As shown in FIG. 18 (a), at the start of molding, when the upper surface of the molding table A is arranged on the liquid surface of the resin liquid D and is irradiated with the laser beam E, the resin liquid D is cured within the through hole a. b. FIG.
As shown in (b), when the support member B and the molded object C were formed while the forming table A was gradually lowered, the support member B was fitted into the through hole a of the forming table A on the bottom surface of the support member B. Because of the presence of the protruding portion b, the support member B can be reliably supported and fixed to the molding table A.

[0006]

However, in the above-described method using the supporting member, the molding table and the supporting member or the supporting member and the molded article are separated during the molding process. Therefore, the function of the support member is not sufficiently performed,
There was a problem that the modeled object was deformed or moved.

First, simply forming a support member on a flat molding table easily causes the support member to be displaced or peeled off from the molding table. In particular, it has been found that when the photocurable resin is cured, deformation due to curing shrinkage occurs. Also, when the support member and the molded article are molded, the deformation and warping of the shape occur due to the curing shrinkage. In addition, the molded object is easily peeled off from the molding table.

As shown in FIGS. 17 and 18 described above,
If a through hole is provided in the molding table and the projection of the support member is fitted into the through hole, it is possible to prevent the support member from shifting in the horizontal direction with respect to the molding table to some extent. If the projection moves or deforms, the projection easily comes out of the through hole, so that the deformation cannot be prevented.

In the above description, the case where the support member is separated from the molding table has been described. However, the support member and the object may be separated. Since the support member and the molded object are continuously molded with the same photocurable resin, they are less likely to be peeled off than between the support member and the molding table. It may be peeled off from the support member. In particular, the support member placed on the rigid molding table is restricted by the molding table and cannot be deformed much.However, since the molded article has no such restriction, deformation due to curing shrinkage appears greatly, and This is likely to cause displacement or peeling between members.

[0010] Next, there is a problem that when the shaped object is deformed due to curing shrinkage, the shape accuracy of the shaped object is reduced.
The support member also has a function of restricting deformation of the modeled object, but as described above, such a function cannot be exerted at all once the support member and the modeled object are separated. Therefore, there are three problems in the prior art: separation of the molding table and the support member, separation of the support member and the modeled object, and deformation of the modeled object, and these problems occur in relation to each other. However, this has a great adverse effect on the shape accuracy and quality of the molded object.

SUMMARY OF THE INVENTION It is an object of the present invention to solve the problems of the prior art as described above by preventing the molding table and the support member or the support member and the molded object from being separated or deformed. It is an object of the present invention to provide a method capable of improving the shape accuracy and quality of a product. Another object of the present invention is to provide a method capable of preventing the warpage or deformation of a modeled object and improving the shape accuracy and quality thereof.

[0012]

According to a third aspect of the present invention, there is provided a method of forming a three-dimensionally shaped object, the method comprising: irradiating a photocurable resin with light to form a photocurable layer. Is a method of forming a molded article having a desired three-dimensional shape by stacking a plurality of layers of the photocurable layer, on a molding table, molding a support member of the molded article in the same manner as the molded article, In the method of forming a molded article on the support member, the support member may be provided between a support member and a molding table .
By the vertical of the concavo-convex structure and the molding for the molding platform
Horizontal direction parallel to the surface of the table and vertical direction perpendicular to it
It is molded so that it can be hooked and fixed in any direction .

As the photo-curable resin, various photo-curable resins which are also used in a conventional method for forming a three-dimensionally shaped object are used. Specific examples include urethane, urethane-acrylate, epoxy, and epoxy-acrylate-based photocurable resins. Basic techniques for forming a three-dimensionally shaped object, such as a method of supplying a photocurable resin, a method of irradiating light, a method of forming a photocurable layer, and a method of stacking photocurable layers, are known in the art. Any ordinary method or apparatus can be applied as it is.

According to the present invention, a molded article is molded on a molding table via a support member. The basic shape structure of the support member is
It can be set freely according to the shape and structure of the modeled object, and the basic structure may be the same as the conventional molding method. As the basic structure of the supporting member, there are a pillar-shaped one, a wall-shaped one, a pedestal-shaped one, etc., which are erected on a molding table. By using the lattice frame-shaped support member arranged in the above, it is possible to surely support a model having various structures.

The fixing of the supporting member on the molding table means that the supporting member is fixed to the molding table in a direction parallel to the surface of the molding table and in a direction perpendicular thereto, that is, in both the horizontal direction and the vertical direction. It refers to being fixed by being hooked to each other by horizontal and vertical uneven structures so that it cannot be moved or deformed. For example, as in the prior art described above, the support member can be moved in the vertical direction only by fitting the protrusion of the support member into the vertical through hole of the molding table. Not applicable.

The methods of the second to eighth aspects are different from each other in that the specific locking means are different. The molding table is provided with a locking hole that extends beyond the surface side in a direction parallel to the surface of the molding table, and if the forming of the support member is started from the inside of the locking hole, the locking hole is formed. A support member having a hook corresponding to the shape is formed. The support member can be hooked and fixed to the molding table by the action of the hook between the hook portion and the hook hole.

The hook hole may penetrate from the front to the back of the molding table, or may be a bottomed hole formed only from the front to the middle. In the depth direction, when one horizontal cross section on the front side and one horizontal cross section on the rear side are compared in the depth direction, at least a part of the outer peripheral shape on the rear side is larger than the outer peripheral shape on the front side. It is only necessary to project outside. As long as there is only one protruding portion, the other portion may be exactly the same as the outer peripheral shape on the front side, or may be inside the outer peripheral shape on the front side.

The structure of the hook hole can be freely set in consideration of the strength of the hook fixing strength of the support member and the ease of processing. For example, the hook hole is inclined from the front side to the back side. It can be formed in a tapered hole, formed in a stepped hole, or formed in the side wall of the hooking hole with a radial recess. The center line of the hook hole may be simply inclined in the depth direction. The cross-sectional shape of the retaining hole may be a curved shape such as a circle or an ellipse, a linear shape such as a quadrangle or other polygons, or a shape combining a curved shape and a linear shape.

The amount of protrusion at the back side of the hook hole from the surface side is set such that light irradiated from the top of the molding table during photo-forming can also cure the resin at the above-mentioned protruding portion. Keep it. Since the photocurable resin undergoes photocuring in a certain range wider than the light irradiation range, photocuring can be caused even when the overhanging portion is not directly irradiated with light. However, in the case where the molding table is made of a non-translucent material, if the amount of overhang is too large, the resin at that portion cannot be light-cured. When the entire molding table or the portion of the retaining hole is made of a translucent material, the resin can be photocured even if the overhang amount is large.

The hook holes may be arranged at appropriate intervals on the entire molding table or only at the point where the support member is molded. The fixing force of the support member can be adjusted by the interval and the outer diameter of the locking holes. Next, instead of the above-mentioned hook hole, the molding table protrudes upward from the surface, and the tip side from the root side,
If a latching projection extending in a direction parallel to the surface of the molding table is provided, and the forming of the support member is started from the position of the latching projection, the latching portion and the latching projection formed between the latching projections are provided. In the same manner as described above, the support member can be hooked and fixed to the molding table.

The shape, arrangement, etc. of the hooking projections may be the same as those of the above-described hooking holes. As a specific shape of the locking projection, a shape in which the shape of the locking hole is reversed can be adopted. For example, an inverted truncated cone, an inverted truncated pyramid, an inclined columnar shape, an umbrella shape, and the like can be given. The height of the hooking projection may be a fixing force acting between the supporting member formed at the position of the hooking projection and the hooking projection, and the supporting member or the molded object may be securely supported and fixed.

When molding the support member, the formation of the photocurable layer, that is, the molding of the support member may be started from the surface of the molding table, that is, the root position of the latching projection. If it is on the side, the forming of the support member may be started halfway in the height direction of the engaging projection.
When light irradiation is performed while the molding table is immersed stepwise in the resin liquid, the molding start position of the support member is set at the depth of the molding table sunk from the liquid level of the resin liquid to the irradiation level of the light. That is, it can be freely adjusted by starting molding.

Next, a hook hole is provided on the molding table from the front surface to the back surface side, and if the support member is formed from the back surface side of the molding table, the hook hole is formed from the outside of the back side of the hole. A hook portion extending inside is formed, and the support member can be hooked and fixed to the shaping table by the hooking action of the hook portion of the supporting member and the back edge of the hook hole of the shaping table. In this case, the engaging hole does not need to have a protruding portion inside the hole as in the above-described engaging hole, and a normal vertical cylindrical hole or the like can be adopted. In order to start molding of the support member from the back side of the molding table, when irradiating light while gradually lowering the molding table in the resin liquid, the back surface of the molding table is placed almost on the liquid surface of the resin liquid. By irradiating the light in the arranged state, the support member can be formed from the rear edge of the retaining hole.

When the molding table is made of a non-translucent material made of metal, synthetic resin, ceramic, or the like, the resin liquid is light-cured to a depth hidden by the back surface of the molding table. Can not do. Therefore, if at least the periphery of the retaining hole is formed of a light-transmitting material and the molding of the support member is started from the rear surface side of the light-transmitting material, over a sufficiently wide range on the rear surface side of the light-transmitting material. The resin liquid is light-cured, and at this portion, the support member can be hooked and fixed to the molding table.

As the translucent material, a material having a high transmittance to a wavelength component of light used for photo-curing, such as a transparent synthetic resin or glass, can be used. The entire surface of the molding table may be formed of a light-transmitting material, or only the periphery of the hook hole of the molding table is formed of a light-transmitting material, and the remaining portion is formed of a non-light-transmitting material. You can also keep. Next, while providing a hooking hole in the forming table, and providing a mesh member crossing the hooking hole, and starting the forming of the support member from the back side of the mesh member, the inside of the hooking hole is formed. The hook of the support member is formed with the net member embedded, and the support member is hooked and fixed to the forming table. As the net member, any material or a net having a net structure can be used as long as there is a space or a gap through which the resin liquid can pass. Specifically, a material made of metal or synthetic resin, glass fiber, synthetic fiber, or the like and used for various screens can be used. The net member may be embedded and mounted inside each of the hook holes, but if a plate member with hook holes is attached to both sides of the planar net member, a forming table is formed. In addition, it is possible to easily manufacture a molding table provided with a net member in the middle of the retaining hole. A net member may be attached to the front or back surface of the molding table.

The above-described structures such as the locking holes, the locking projections, the translucent material, the net member, etc., can be used not only independently, but also some of them can be combined with each other. Next, as another method, the following method is combined.
Can be matched. In the method for molding a molded article in the same manner as in the first aspect, a separation preventing means is provided between the support member and the molded article .

First, as a separation preventing means, a support member is
It is possible to adopt a method in which the molded object is formed so as to be continuous from the entire bottom surface to a part of the side surface. Of the support members, the same structure as the conventional support members can be adopted on the bottom side of the modeled object. On the side surface of the modeled object, the support member is formed from the boundary with the bottom surface to a height that does not hinder the use of the modeled object. Specifically, the support member may be formed up to a height of about several mm from the bottom surface.

In order to form the support member up to a part of the bottom surface and side surface of the molded article, first, a support member having a constant thickness and a concave portion having a small depth in the center portion is formed. If the object is formed inside, the support member is arranged to the side of the object by the depth of the concave portion. The shape of the concave portion corresponds to the shape of the bottom portion of the modeled object. After the molded object is formed, the molded object including the portion that has entered the concave portion may be removed from the support member and taken out.

Next, as a separation preventing means, a surplus portion corresponding to the bottom shape of the modeled object is formed on the support member by the same method as the support member and the modeled object. A method of molding an object can be adopted. The extra part is
It is formed in the same or slightly wider range as the bottom shape of the object. Even when the support member has a surface shape different from the bottom shape of the modeled object, such as a lattice frame shape, the surface shape of the extra portion is formed in the same shape as the bottom shape of the modeled object. Is preferred. It is preferable that the extra bank is provided so as to be embedded in the upper part of the support member. The method of molding the molded article on the extra portion may be the same as the ordinary molding method. The extra portion and the bottom surface of the object are joined on the entire surface.

The structure of the separation preventing means described above can be used in combination with the means for hooking and fixing the above-mentioned support member to the molding table. Further, another method is a method of molding a shaped article in the same manner as in claim 1 , wherein a warp absorbing means for the shaped article is provided between the support member and the shaped article.
The warpage of a modeled object refers to the deformation of the modeled object such that the modeled object is wholly or partially lifted in the vertical direction due to the curing shrinkage stress generated in the modeled object when the photocured layers are stacked and molded. you say.

As the warp absorbing means, it is effective to form the support member so that the degree of curing becomes softer than that of the molded article. The degree of curing of the photocurable resin can be changed depending on the intensity of the light irradiation energy and the length of the irradiation time.If the light irradiation is stopped at a stage where the curing of the resin is not sufficiently progressing, a molded product with a soft curing degree can be obtained. Is obtained. The modeling object is
Depending on the purpose of use, the intensity of light irradiation energy and the irradiation time are set so as to cure to the required degree of curing. Light irradiation conditions may be set such that the degree becomes soft. However, if the degree of curing becomes too soft, it is not preferable because the support member cannot support the molded article. Specifically, the preferable degree of curing differs depending on the shape of the molded article and the shape of the support member.

As the warp absorbing means, it is also effective to form each photo-cured layer constituting the modeled object into a shape that can correct the amount of warpage generated in the modeled object to be finally formed.
The amount of warpage generated in the formed article can be determined by molding a shaped article by a usual method on a test basis and measuring the amount of warpage generated at that time. Back-calculated from the amount of warpage, the photocurable layer constituting the modeled object is formed in a shape slightly deviated from the shape of the target modeled object, and is formed of the photocured layer thus formed. When the modeled object warps, it is deformed to the intended shape of the modeled object. Such a corrected shape of the photocurable layer can be obtained empirically or by a dynamic theory, and based on the experience or the dynamic theory, arithmetic processing is performed by a computer or the like to form a modeled object. The corrected shape of each photocurable layer may be calculated, and the molded object may be formed based on the calculated shape.

As described above, when the shape of the molded object or the photocurable layer to be molded is molded with a correction shape in consideration of the amount of warpage, the surface shape of the support member is changed to the uneven shape corresponding to the amount of warpage of the molded object. When the object is warped, the supporting member can be deformed in accordance with the warpage of the object. The specific uneven shape of the support member is
At the same time as calculating the corrected shape of the molded article or the photocurable layer, the uneven shape required for the support member may be calculated. As described above, the support member is set to have a soft curing degree so that it can be easily deformed.

The configuration of the warp absorbing means described above can be used in combination with the means for hooking and fixing the support member to the molding table or the means for preventing separation.

[0035]

According to the first to eighth aspects of the present invention, the support member is hooked and fixed to the forming table by a so-called anchoring action in which the locking portion of the supporting member is hooked inside or on the back side of the locking hole of the forming table. Therefore, the support member cannot move or deform with respect to the molding table in any of the horizontal direction and the vertical direction. In addition, there is no possibility that the molding table is separated from the support member by being peeled off. As a result, problems caused by separation of the support member from the molding table can be solved,
It is possible to manufacture a shaped article having high shape accuracy and high quality.

In particular, in the method according to the second aspect, since the other materials and the forming process can be the same as those in the ordinary method, only the forming holes are formed in the forming table, the forming is easy and the work is efficient. I can do it. According to the method of the third aspect, since the other materials and the molding process are the same as those of the ordinary method only by attaching the latching projection on the molding table, the molding is easy and the work can be performed efficiently. Further, a conventional molding table can be used as it is.

In the method according to the fourth aspect, the hooking portion of the supporting member can be hooked on the hooking projection by a height sufficient to hook and fix the supporting member to the molding table. And no waste of the photocurable resin to be cured as the support member. According to the method of the fifth aspect, the shape of the hook hole can be made a relatively simple shape such as a vertical hole similar to the conventional one. It is also possible to use the table as it is.

In the method according to the sixth aspect, the resin can be light-cured by irradiating light through the translucent material to the inside of the protruding portion of the hooking hole or to the back edge of the hooking hole. The support member and the molding table can be securely locked and fixed, and the fixing force is also increased. In the method according to the seventh aspect, only the portions necessary for hooking and fixing the support member and the molding table may be formed of a translucent material, and the other portions are inexpensive in terms of cost or have low mechanical strength. Since a non-translucent material, which is a material of an excellent ordinary molding table, may be used, the production cost of the molding table does not increase and the function of the molding table does not decrease.

In the method according to the eighth aspect, since the mesh member is embedded in the hooking portion of the support member, the hooking and fixing of the support member and the forming table is reliable, and the fixing force is increased.
Next, in the method using the above-described separation preventing means, the molded article and the supporting member can be firmly joined by the separation preventing means, so that the problem caused by the separation of the molded article from the supporting member can be solved. In particular, the above claim 1
When the support member and the molding table are firmly fixed by the method described above, all the hardening deformation stress generated in the support member or the formed object acts between the formed object and the support member, and the formed object is supported by the support member. Since it is easy to be peeled off from the substrate, the advantage of providing the separation preventing means is great.

[0040] The supporting lifting member, molded to your fluff to be continuous over the entire bottom surface of the shaped article to a part of the side surface, the both of the bottom and side surfaces of the shaped article, the support can be fixed to wrap the supporting member Thus, vertical and horizontal movement and deformation of the modeled object can be reliably prevented. In addition, after the molded object is formed, if only a part of the bottom and side surfaces of the molded object are separated from the support member, the molded object can be easily removed without damaging the outer shape of the molded object.

The surplus portion can be securely supported and fixed to the support member, and the formed object can be supported and fixed by joining the entire bottom surface thereof to the surplus portion. As compared with the case where the object is partially joined to the support member, the deformation of the modeled object can be favorably prevented. Also,
After the molded object is formed, the molded object can be easily taken out if the molded object is separated from the surplus portion.

Next, by providing a warp absorption means forming shape thereof, it is possible to obtain a shaped product having excellent shape accuracy. Because soft support member than granulated form thereof will absorb the deformation stress, never excessive residual stress shaped object occurs. In addition, it is possible to prevent the joint between the modeled object and the support member from peeling or separating.

[0043] In view of the amount of warpage of the concrete form was lever to set the shape of the photocurable layer during molding, when the warpage occurs in the final molded shaped object, the exact shape of interest Can be obtained. Since the warpage is not forcibly suppressed, there is no large residual stress on the modeled object, and the modeled product removed from the molding table may undergo temporal deformation due to residual stress or cause inconvenience when using the modeled product Can be prevented.

The above SL how, the molded shape of the molded article, when that has been set in advance considering the amount of warpage, when the molded article causes the warp to an intended shape, also the support member The deformation can be smoothly performed according to the deformation of the modeled object, and the support member can be prevented from peeling off from the modeled object in the process of deformation.

[0045]

Next, an embodiment of the present invention will be described below with reference to the drawings. FIG. 1 shows an embodiment in which a retaining hole is provided in a molding table. The basic structure of the molding apparatus, the basic steps of the molding method, and the like are the same as those in the conventional method of molding a three-dimensionally shaped object, and a detailed description thereof will be omitted.

In the molding table 10, hook holes 12 are formed through the entire surface at regular intervals. The retaining hole 12 has a substantially truncated cone shape, and is formed so that the outer diameter of the back surface side is larger than the front surface side of the molding table 10. This molding table 10
Is submerged near the liquid surface of the photocurable resin liquid 20.
In this state, the liquid surface of the resin liquid 20 is irradiated with a laser beam 40 or the like to form the support member 30. As the entire structure of the support member 30, a lattice frame-shaped member as shown in FIG. 17 can be employed.

The laser beam 40 applied to the liquid surface penetrates from the surface of the molding table 10 to the inside of the retaining hole 12, and photo-cures the resin liquid 20 at that portion. That is, the molding table 1
At the lower part of the photo-cured layer 30 formed on the surface of the “0”, a projection-shaped engaging portion 32 having a constant thickness is formed along the inner diameter of the engaging hole 12. Thereafter, while the molding table 10 is immersed in the resin liquid 20 stepwise, a laser beam 40 is irradiated in a predetermined pattern to form a plurality of photo-cured layers in order, thereby forming the entire structure of the support member. The molding of the shaped article thereon is the same as the ordinary molding method.

In this manner, the locking holes 12 of the molding table 10
When the engaging portion 32 of the supporting member 30 is fitted into and fixed to the supporting member 30, the supporting member 30 can be supported even if a force is applied to the supporting member 30 in either the horizontal direction or the vertical direction. 30 does not peel off or slip from the molding table 10. Next, the embodiment shown in FIGS.
Are different from each other.

In the embodiment shown in FIG. 2, a trapezoidal pyramid-shaped hooking hole 12 is used. In the embodiment shown in FIG. 3, an inclined column-shaped latching hole 12 having a columnar shape and having a center line inclined from a vertical direction is used. In this case, the cross-sectional shape of the hook hole 12 is such that the back side protrudes in the horizontal direction from the front side in one direction, but the back side is recessed inward from the front side in the opposite direction. Thus, the hook hole 12
The target function can be exerted as long as there is a part of the part that extends beyond the surface side in the horizontal direction.

In the embodiment shown in FIG. 4, a stepped cylindrical locking hole 12 whose rear side is larger than its front side is used. In this case, the irradiation depth of the laser beam 40 or the depth position of the molding table 10 submerged below the liquid level is adjusted, and the resin liquid is light-cured to a position deeper than the step portion of the locking hole 12. In addition, it is necessary to ensure that the stepped engaging portion 32 is formed.

Next, the embodiment of FIGS. 5 and 6 shows a case in which a latching projection is provided on a molding table. As shown in FIG. 5, on the molding table 10, hooking protrusions 14 each having a shape of an inverted quadrangular pyramid are attached at regular intervals. The irradiation of the laser beam 40 is started in a state where the molding table 10 is slightly sunk below the liquid surface of the resin liquid 20. At a portion where the liquid surface of the resin liquid 20 is exposed in the gap portion of the hooking projection 14, the resin liquid 20 is light-cured to form a hooking portion 32 corresponding to the gap shape of the hooking projection 14. . The planar shape of the engaging portion 32 is a vertical or horizontal lattice shape or a net shape in which the portions of the engaging projections 14 are spaces at regular intervals.

Since the upper surface of the hooking projection 14 is larger than the lower surface, the laser beam 40
Is not applied to the resin liquid 20 near the side surface of the hooking projection 14. However, since the photo-curing resin causes photo-curing up to the peripheral portion of the portion directly irradiated with light, the locking projections 14
The resin liquid 20 can be light-cured to a position adjacent to the side surface of the first portion to form the hook portion 32.

When the irradiation of the laser beam 40 is repeated while the molding table 10 is gradually lowered, the support member 30 is molded above the hooking projections 14 as shown in FIG.
At the lower part of the support member 30, a lattice-shaped latching portion 32 fitted to the latching projection 14 is arranged. Also in this case, similarly to the above-described embodiment, the locking projections 14 of the molding table 10 are used.
In addition, since the hook 32 of the support member 30 is hooked and fixed,
The support member 30 does not separate from the molding table 10 or move and deform.

In the above embodiment, as shown in FIG. 5, the molding table 10 is moved from a position where it is slightly submerged below the liquid surface of the resin liquid 20.
The forming of the support member 30 has begun. However, the molding start position of the support member 30 may be performed in a state where the liquid surface is arranged at any position from the base to the tip of the hooking projection 14 of the molding table 10. For example, the molding of the support member 30 may be started from a state where the surface of the molding table 10 is arranged on the liquid surface.

FIGS. 7 and 8 show an embodiment in which the shape of the latching projection 14 is different from that of the above embodiment. In the embodiment shown in FIG. 7, a locking projection 14 having an umbrella-shaped disk provided at the upper end of a cylinder is used. In the embodiment shown in FIG. 8, an inclined column-shaped latching projection 14 is used. Next, the embodiment of FIG. 9 shows a case where the molding table 10 is formed of a translucent material.

As shown in FIG. 9A, the molding table 10 is formed of a light-transmitting material such as a transparent synthetic resin and has a vertical column-shaped engaging hole 16 formed at regular intervals. Keep it. The projecting portion as in the above embodiment is not provided in the hook hole 16. The back surface of the molding table 10 is
Irradiation of the laser light 40 is performed in a state where the laser light 40 is disposed on the liquid surface. The laser light 40 irradiates the resin liquid 20 not only through the hook holes 16 of the molding table 10 but also through the entire molding table 10 made of a translucent material. As a result, the molding table 1
The entire resin liquid 20 from the position of the 0 engaging hole 16 to the location covered by the surrounding molding table 10 is light-cured, and a plate-shaped engaging portion 34 is formed.

As shown in FIG. 9B, when the molding table 10 is slightly lowered, the resin liquid 20 enters the inside of the retaining hole 16. By irradiating the laser beam 40 in this state,
The hook 34 on the back side of the molding table 10 is formed to be continuous up to the inside of the hook hole 16. As shown in FIG. 9 (c), after the molding table 10 is further submerged so that the surface of the molding table 10 is lower than the liquid level, and the support member 30 is molded in a normal process, the support member At the lower part of the hook 30, a hook portion 34 extending from the inside of the hook hole 16 to the back side of the molding table 10 is formed.

In this case, since the support member 30 is formed so as to surround the latch hole 16 from the back surface of the molding table 10, the latching of the support member 30 to the molding table 10 can be performed more reliably. Done. Next, the embodiment of FIG.
In the above embodiment, a case where only the periphery of the hook hole 16 is made of a translucent material is shown.

As shown in FIG. 10A, the molding table 10
It is formed of a non-translucent material such as an opaque synthetic resin. A cylindrical light-transmissive member 18 made of quartz glass or the like having a very high transmissivity to ultraviolet rays is embedded in a place where the hook hole 16 is provided in the molding table 10. The molding process is performed in the same manner as in the embodiment of FIG. That is, the irradiation of the laser beam 40 is started in a state where the back surface of the molding table 10 is arranged on the liquid surface of the resin liquid 20, and the irradiation of the laser beam 40 is repeated while the molding table 10 is gradually lowered, so that the support member 30 molding is performed.

Then, as shown in FIG. 10B, on the back side of the molding table 10, the light transmitting member 1 around the hook hole 16 is formed.
The photo-curing of the resin liquid 20 is performed up to the area where 8 is provided, so that the hooking portion 34 having an umbrella-shaped protrusion that protrudes left and right on the back side of the molding table 10 is formed. In the above embodiment, since the translucent member 18 is formed of quartz glass, the transmissivity of the laser light 40 is very good, and the light is surely irradiated to the back side of the translucent member 18 so that the locking portion 34 is formed. Can be formed. Moreover, it is very expensive to manufacture the entire molding table 10 from quartz glass, but the cost is low because only the light transmitting member 18 needs to be formed from quartz glass.

Next, the embodiment shown in FIG. 11 shows a case where a mesh member is used. As shown in FIG.
The molding table 10 is divided into two members, an upper member 11 and a lower member 13. A vertical column-shaped locking hole 16 is formed through both members 11 and 13 at regular intervals. The two members 11 and 13 are intermediately provided with a screen-like mesh member 5.
It is joined and fixed with the “0” sandwiched therebetween. Therefore, each hook hole 16 is provided with a net-like member 50 in the middle of the hole so as to cross the hole.

Using such a molding table 10, the mesh member 5
The irradiation of the laser light 40 is started in a state in which 0 is arranged on the liquid surface of the resin liquid 20. The laser light 40 is applied to the locking hole 16.
Is irradiated to the lower resin liquid 20 through the mesh member 50. The mesh member 50 is made of a thin linear material, and the resin liquid 20 is photo-cured not only at the position where light is directly irradiated but also within a certain range around the position. When the resin liquid 20 is photo-cured by the laser light 40 applied to the resin liquid 20, the photo-curing of the resin liquid 20 also occurs at the back side of each wire of the mesh member 50, and Thus, photo-curing of the resin liquid 20 occurs. As a result, on the back side of the net-like member 50, the engaging portion 32 is formed along the internal shape of the engaging hole 16.

As shown in FIG. 11 (b), when the step of immersing the molding table 10 step by step and irradiating the laser beam 40 is repeated, the molding table 10 is removed from the inside of the hook hole 16 above the mesh member 50. The support member 30 extending upward is formed. In this embodiment, since the mesh member 50 is embedded in the support member 30, the individual wires of the mesh member 50 prevent the support member 30 from peeling or moving, and the formation of the support member 30 is prevented. The locking and fixing to the table 10 is performed strongly.

Next, the embodiment shown in FIG.
Of the molding is started from the back side of the molding table 10. The molding table 10 has a vertical column-shaped locking hole 16.
Is provided. As shown in FIG. 12A, irradiation of the laser beam 40 is started in a state where the back surface of the molding table 10 is arranged on the liquid surface of the resin liquid 20. The laser light 40 is applied to the locking hole 1
Since the liquid surface is irradiated only at the position 6, the resin liquid 20 in a range corresponding to the cross-sectional shape of the retaining hole 16 undergoes photocuring. At this time, as described above, the photo-curable resin has a property of causing photo-curing not only in the area directly irradiated with light but also in a peripheral portion thereof. 10 to a certain range on the back side of the resin liquid 2
0 photocuring occurs.

As shown in FIGS. 12 (b) and 12 (c), when the step of lowering the molding table 10 step by step and irradiating the laser beam 40 is repeated, the molding table 1
The support member 30 is molded above the zero. As a result, at the lower portion of the support member 30, a hook portion 32 is formed from the inside of the hook hole 16 so as to protrude outside the outer periphery of the hook hole 16 on the back side of the molding table 10. Become.

The structure of such a hook 32 is the same as that shown in FIG.
However, in this embodiment, the same one having the same vertical columnar locking hole 16 as the conventional one can be used as the molding table 10 in this embodiment. Equipment costs are low. However, in order to increase the amount of protrusion of the hanging portion 32 to the outside of the back surface of the molding table 10,
It is better to use the light transmitting member 18 as in the embodiment of FIG.

The above-mentioned method of starting the molding of the support member 30 from the state in which the back surface of the molding table 10 is arranged on the liquid surface of the resin liquid 20 is performed by the method of FIG. When using the locking hole 12 having
As in the embodiment of FIG. 11, when the mesh member 50 is used, it can be used together, and the fixing of the support member 30 to the forming table 10 can be more reliably performed.

Next, the embodiment of FIG. 13 shows a case in which separation preventing means is provided between the support member and the modeled object. As shown in FIG. 13 (a), forming the support member 30 on the forming table 10 submerged in the resin liquid 20 is the same as the usual forming method. The overall structure of the support member 30 is as follows:
This is a lattice frame shown in FIG.

As shown in FIG. 13B, a shallow concave portion 38 having a shape corresponding to the bottom shape of the object is formed at the center of the upper surface of the support member 30. Specifically, before the molding of the support member 30 is completed, the concave portions 38 are formed in several photocurable layer forming steps.
It is sufficient that the irradiation of the laser beam 40 is not performed only in the range corresponding to the above. The depth of the recess 38 may be about 0.5-1.0 mm.

As shown in FIG. 13C, a model 60 is formed on the concave portion 38 of the support member 30 by a predetermined process.
The modeled object 60 has a bottom surface and a part of the side surface that
It is molded in a state of being joined to the inner surface of the. As shown in FIG. 13D, after the molded object 60 and the support member 30 are removed from the molding table 10, the molded object 60 is
If it is removed from the concave portion 38 of 0, the manufacture of the modeled object 60 is completed.

According to the method of this embodiment, since the shaped object 60 is molded with a part of the bottom surface and a part of the side surface embedded in the concave portion 38 of the supporting member 30, the joining of the shaped object 60 to the supporting member 30 is performed. Fixation is performed firmly. Next, the embodiment shown in FIG. 14 shows a case where a marginal portion is formed on the support member.

As shown in FIG. 14A, the formation of the lattice frame-shaped support member 30 on the molding table 10 submerged in the resin liquid 20 is the same as in the above-described embodiment. FIG.
As shown in (b), a model 60
Is formed as a surplus portion 39 having the same surface shape as the bottom surface shape. The thickness of the extra bank 39 may be about 0.5 to 1.0 mm. The support member 30 in the form of a lattice frame is formed to extend on the outer periphery of the extra bank 39, and the extra bank 39 is embedded in the upper part of the support member 30.

As shown in FIG. 14C, a model 60 is formed on the extra bank 39. The bottom surface of the modeled object 60 is joined to the entire surface of the surplus portion 39 over the entire surface. As shown in FIG.
After the support member 30 is removed from the molding table 10 and the molded object 60 is separated from the support member 30 at the boundary between the molded object 60 and the extra portion 39, the molding of the molded object 60 is completed.

In the above-described embodiment, compared to the case where the modeled object 60 is formed directly on the support member 30 having a lattice frame shape and the modeled object 60 is partially fixed by the support member 30 having a lattice frame shape. And the modeling object 6 on the entire surface of the extra portion 39 having a much larger area.
0 can be fixedly bonded. Since the surplus portion 39 itself is formed in a form embedded in the upper portion of the support member 30, the joint fixing to the support member 30 is reliable. In other words, the molded object 60 is firmly fixed to the support member 30 by the intermediary of the extra bank 39.

Moreover, when removing the shaped object 60, only the boundary surface between the bottom surface of the shaped object 60 and the extra portion 39 has to be separated, so that the side surface of the shaped object 60 is not damaged and the like. Can be taken out. Next, the embodiment of FIG. 15 shows a case where the degree of curing of the support member is softened.

As shown in FIG. 15A, the formation of the support member 30 on the molding table 10 submerged in the resin liquid 20 is the same as in each of the above embodiments. However, by adjusting the irradiation conditions such as the energy intensity of the laser beam 40, the scanning speed, and the focal position when the support member 30 is formed, the degree of curing of the support member 30 formed by photocuring can be reduced. Is set so as to be softer than the degree of curing in molding.

As shown in FIG. 15 (b), a laser beam 40 is irradiated on the soft support member 30 as described above under ordinary light irradiation conditions to form a modeled object 60. When the photocurable layers are stacked to form the modeled object 60, both ends of the modeled object 60 are deformed such that both ends of the modeled object 60 are warped upward due to deformation stress caused by curing shrinkage. At this time, since the support member 30 is soft and can be easily deformed, the support member 30 is deformed so as to extend upward according to the warp deformation of the modeled object 60. As a result, the support member 30
There is no possibility that the boundary portion between the molded object 60 and the molded object 60 is peeled off or excessive deformation stress remains in the molded object 60.

However, in the above embodiment, the manufactured object 60 is still warped in the bottom shape and the like, and therefore, it is difficult to use it for applications requiring high shape accuracy in the bottom shape and the like. Next, the embodiment of FIG. 16 shows a case where the molding shapes of the support member and the modeled object are set so as to absorb the warpage of the modeled object.

As shown in FIG. 16 (a), a support member 30 is formed on a molding table 10, and the shape of the upper surface of the support member 30 is set to be a gentle spherical surface whose center portion is higher and lower toward the periphery. It is formed in a shape. The support member 30
As in the above-described embodiment, the degree of curing is set relatively soft. A model 60 is formed on the support member 30. When the light-cured layers 62 of the respective layers are sequentially formed on the support member 30, the lower light-cured layer 62 is formed only on the outer peripheral portion of the support member 30 according to the spherical shape of the support member 30, and the light layer of the upper layer is formed. When the cured layer 62 is formed, the support member 30
Is formed also on the central portion side of. Even during the formation of the photocurable layers 62 in a stacked manner, the deformation due to the curing shrinkage occurs, so that the spherical shape of the upper surface of the support member 30 is also sequentially deformed. Normally, the curing deformation of the stacked photo-cured layers 62 occurs such that both ends warp upward, and thus the upper surface of the support member 30 is deformed in a direction in which the spherical shape gradually becomes gentle.

As shown in FIG. 16B, at the stage where the photocured layers 62 are stacked to form the shaped object 60, the surface of the support member 30, which has been initially spherical, is substantially flat. It will be deformed into a flat shape. That is, in the molded article 60 thus molded, the entire shape including the bottom face shape forms a target three-dimensional shape,
Warpage due to curing shrinkage has been eliminated.

[0081]

According to the above-described method for forming a three-dimensionally shaped object according to the present invention, the molding table and the support member, or the support member and the object can be separated or moved and deformed. Can be satisfactorily prevented.
As a result, the shape accuracy and quality performance of the manufactured modeled object are improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a stage during molding in an embodiment of the present invention.

FIG. 2 is a sectional view showing another embodiment.

FIG. 3 is a sectional view showing another embodiment.

FIG. 4 is a sectional view showing another embodiment.

FIG. 5 is a sectional view showing another embodiment.

FIG. 6 is a sectional view showing another embodiment.

FIG. 7 is a sectional view showing another embodiment.

FIG. 8 is a sectional view showing another embodiment.

FIG. 9 is a sectional view showing another embodiment in a stepwise manner from (a) to (c).

FIG. 10 is a cross-sectional view showing a molding table (a) and a step (b) during molding in another embodiment.

FIG. 11 is a sectional view showing another embodiment in a stepwise manner from (a) to (b).

FIG. 12 is an enlarged sectional view showing another embodiment in a stepwise manner from (a) to (c).

FIG. 13 is a sectional view showing another embodiment in a stepwise manner from (a) to (d).

FIG. 14 is a sectional view showing another embodiment in a stepwise manner from (a) to (d).

FIG. 15 is a sectional view showing another embodiment in a stepwise manner from (a) to (b).

FIG. 16 is a sectional view showing another embodiment in a stepwise manner from (a) to (b).

FIG. 17 is a perspective view showing a conventional technique.

FIG. 18 is a cross-sectional view showing the prior art step by step from (a) to (b).

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Molding stand 12, 16 Hook hole 14 Hook projection 18 Translucent member 20 Resin liquid 30 Support member 32, 34, 36 Hook part 40 Laser beam 50 Mesh member 38 Depression 39 Excess part 60 Modeling object 62 Light hardening layer

Claims (8)

(57) [Claims] 1. A method of irradiating a photocurable resin with light to form a photocurable layer, and stacking a plurality of such photocurable layers to form a molded article having a desired three-dimensional shape. In the method of molding a support member of a modeled object in the same manner as the modeled object and molding the modeled object on the support member, the support member may be provided between a support member and a molding table .
By the vertical of the concavo-convex structure and the molding for the molding platform
Horizontal direction parallel to the surface of the table and vertical direction perpendicular to it
A method for forming a three-dimensionally shaped object, characterized in that the shape is formed so as to be hooked and fixed in any direction . 2. The method according to claim 1, wherein the molding table is provided with a retaining hole projecting in a direction parallel to the surface of the molding table on the back side from the surface side. A method for forming a three-dimensional object, in which the forming of a three-dimensional object is started and the supporting member is hooked and fixed to a forming table. 3. The method according to claim 1, wherein the forming table is provided with a locking projection that protrudes upward from the surface and protrudes in a direction parallel to the surface of the forming table on a tip side from a root side. A method for forming a three-dimensional object, in which molding of a support member is started from a position of a projection, and the support member is hooked and fixed to a molding table. 4. The method according to claim 3, wherein the forming of the supporting member is started at a point in the height direction of the hooking projection, and the supporting member is hooked and fixed to the forming table. 5. The method according to claim 1, wherein a hooking hole is provided in the molding table so as to penetrate from the front surface to the back surface, and molding of the support member is started from the back surface side of the molding table. A method for forming a three-dimensionally shaped object to be hooked and fixed on a workpiece. 6. The method according to claim 5, wherein at least the periphery of the engaging hole is formed of a light-transmitting material, and the supporting member is formed from the rear surface side of the light-transmitting material. A method of forming a three-dimensional object that is hooked and fixed on a table. 7. The three-dimensional object according to claim 6, wherein only the periphery of the engaging hole of the molding table is formed of a light-transmitting material, and the remaining portion is formed of a non-light-transmitting material. Molding method. 8. The method according to claim 1, wherein a retaining hole is provided in the molding table, and a mesh member is provided to cross the retaining hole, and molding of the support member is started from the back side of the mesh member. Then, the supporting member is hooked and fixed to the molding table to form a three-dimensionally shaped object.