JP6229155B2 - Manufacturing method of three-dimensional shaped object - Google Patents

Description

The present invention relates to a method for producing a three-dimensional shaped object by irradiating a light beam used in a method for producing a three-dimensional shaped article to form a molten layer and stacking the molten layers.

  Conventionally, this type of three-dimensional shaped object is made by melting and solidifying an inorganic powder (metal) or organic powder (resin) by irradiating, for example, a directional energy beam or a laser beam, and laminating the hardened layer. And what manufactured the three-dimensional shaped molded article is known (for example, refer patent document 1).

  Hereinafter, the manufacturing method of the three-dimensional shaped object (hereinafter, the three-dimensional shaped object will be described as a shaped object) will be described with reference to FIGS.

  As shown in FIG. 8, the modeled object 101 is irradiated with a laser beam to melt and solidify the powder material to form a modeled object. The model 101 is in close contact with the base plate 102 and is formed as an integral structure.

  Further, as shown in FIG. 9, a cured region 103 in which the powder material is melted and solidified by irradiation with the laser beam and a non-cured region 104 not irradiated with the laser beam are formed on the base plate 105. After the production of the predetermined shaped object is completed, the powder material is collected by the material collection holes 106 of at least one powder material provided in the base plate 105, and the usage amount of the powder material is reduced.

  However, in the process of manufacturing the modeled object shown in FIG. 9, as shown in FIG. 10A, the cured region 103 does not exist in the lower layer of the modeled object, and the non-cured region 104 is irradiated with a laser beam and melted. When the uppermost cured region 107 is formed as the solidified layer, when the next upper layer powder material is coated with the squeegee blade 108 as shown in FIG. Then, the uppermost cured region 107 is damaged and remains as a damaged object 109 of the modeled object.

  Therefore, normally, as shown in FIG. 11A, the non-hardened region 112 is formed in a conical shape in the hardened region 111, and each layer formed of the non-hardened region 112 approaches the upper layer when the model is manufactured. However, in order to collect the powder material for each conical shape, the base plate 113 needs to have a powder material collection hole 114. Moreover, when there are too many non-hardened areas, modeling strength will fall. (For example, see Patent Document 1)

JP 2002-249805 A

  In such a conventional modeling method, when hollowing a modeled object, it is difficult to recover the powder material, and the hollowing and strength are in conflict, so the more hollowed, It had the subject that securing of modeling strength was difficult and stable modeling was also difficult.

  SUMMARY OF THE INVENTION The present invention solves the above-described conventional problems, and an object of the present invention is to provide a shaped article that ensures strength and enables material recovery even when hollow.

In order to achieve this object, the present invention forms a cured layer that is cured after the powder is melted by irradiating a predetermined portion of the inorganic or organic powder layer with a light beam,
A layer of the powder is coated on the hardened layer, and a predetermined portion of the powder is irradiated with a light beam to melt and then cured to form a hardened layer integrated with the lower hardened layer. In the manufacturing method of a three-dimensional shaped object in which a plurality of cured layers are laminated and integrated by repeating,
The powder layer is formed on a base plate having recovery holes, and a plurality of layers of the powder are provided with a hardened region that is cured by irradiation with a light beam and then cured, and a non-hardening region that is not irradiated with the light beam. In addition, at least a part of the hardened region is composed of a hollow sphere or an assembly of polyhedrons, the spheres or polyhedrons have overlapping portions in the stacking direction, and the hollow spheres or polyhedrons have the powder in the non-hardened region. A through-hole that can be passed through is provided , and the powder that has passed through the through-hole is recovered through the recovery hole , thereby achieving the intended purpose.

According to the present invention, a predetermined layer of a powder layer made of inorganic or organic powder is irradiated with a light beam to form a cured layer that is melted and then cured, and the powder layer is coated on the cured layer. At the same time, by irradiating a predetermined portion of this powder with a light beam and melting it and curing it, a cured layer integrated with the lower cured layer is formed, and by repeating this, multiple cured layers are laminated and integrated In the three-dimensional shaped article manufacturing method, the powder layer is formed on a base plate provided with a recovery hole, and a plurality of layers of the powder are irradiated with a light beam and melted and then cured. and a non-hardening region not irradiated with the light beam is provided, at least a portion of the hardened zone is composed of an aggregate of hollow spheres or polyhedrons, the sphere or polyhedron an overlapping portion in the stacking direction As well as that, a through hole may pass through said powder of said non-hardening region in the hollow sphere or polyhedral provided, said powder having passed through the through hole has a configuration called recovered through the recovery hole Since the inside of the modeling is made hollow and the modeling strength and material recovery become possible, the effect of improving the modeling quality such as reduction of material cost, shortening of processing time, reduction of warpage, etc. is obtained with respect to ordinary modeling objects. be able to.

(A) The block diagram which shows the cross section of the hollow modeling shape of Embodiment 1 of this invention, (b) The hollow sphere partial side view (A) The hollow modeling partial perspective view, (b) The hollow sphere partial perspective view, (c) The hollow sphere partial plan view The block diagram which shows A cross section of the hollow modeling shape (A) The block diagram which shows B cross section of the same hollow shaping shape, (b) The flow chart of material recovery inside the hollow shaping shape sphere (A) The block diagram which shows the C cross section of the hollow modeling shape, (b) The flow chart of material recovery outside the sphere of the hollow modeling shape (A) The perspective view which shows the rib shape of the strength improvement in the same hollow sphere, (b) The block diagram which shows the cross section of the rib shape by the strength improvement in the same hollow sphere (A) The block diagram which shows the cross section of the hollow modeling shape of Embodiment 2 of this invention, (b) The block diagram which shows the cross section of the hollow modeling shape from which the same spherical diameter differs, (c) The hollow modeling shape where the same spherical diameter is small Diagram showing the cross section of the Schematic diagram of conventional three-dimensional shaped objects (not including non-hardened areas) Schematic diagram of conventional three-dimensional shaped objects (including non-hardened areas) (A) The block diagram which shows the cross section before the squeezing of the conventional three-dimensional shape molded article, (b) The block diagram which shows the cross section during the squeezing of the conventional three-dimensional shape molded article (A) The block diagram of the hardening area | region and non-hardening area | region of the conventional three-dimensional shape molded article, (b) The block diagram of the non-hardening area | region of the conventional three-dimensional shape molded article

A hardened layer is formed by irradiating a predetermined portion of the inorganic or organic powder layer according to claim 1 of the present invention with a light beam to melt the powder and then curing, and the powder layer is formed on the hardened layer. And a cured layer that is integrated with the lower cured layer is formed by irradiating a predetermined portion of the powder with a light beam and then melting and curing, and a plurality of cured layers are laminated by repeating this process. In the manufacturing method of the three-dimensional shaped object to be integrated, the powder layer is formed on a base plate having a recovery hole, and the plurality of layers of the powder are melted by irradiation with a light beam and then cured. a non-hardening region not irradiated with the curing area and a light beam is provided, at least a portion of the hardened zone is composed of an aggregate of hollow spheres or polyhedrons, the sphere or polyhedron sounds heavy in the stacking direction And has a section, a through hole may pass through said powder of said non-hardening region in the hollow sphere or polyhedral provided, said powder having passed through the through-holes have a structure that is recovered through the recovery hole . As a result, the inside of the modeling is hollowed, and the modeling strength and material recovery are possible, so that there is an effect of improving modeling quality such as reduction of material cost, shortening of processing time, and reduction of warpage.

  Further, the hollow sphere or polyhedron in the non-hardened region may be configured not only as a sphere or polyhedron of the same size but also as an aggregate of spheres or polyhedrons having different sizes. Thereby, even a complicated three-dimensional shaped object can be hollowed more effectively, and there is an effect of improvement in modeling quality such as reduction of material cost, shortening of processing time, and reduction of warpage.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
As shown in FIG. 1A, a three-dimensional shaped object 1 obtained by the manufacturing method of the present invention is applied to a predetermined portion of a layer of inorganic or organic powder formed on a modeling base plate 2. Forming a cured layer that is cured by irradiating a beam to melt the powder, coating the layer of the powder on the cured layer, and irradiating a predetermined portion of the powder with a light beam to melt and then curing Thus, a cured layer integrated with the lower cured layer is formed, and by repeating this, a plurality of cured layers are laminated and integrated.

  That is, a plurality of powder layers are provided with a hardened region 3 that is cured after being irradiated with a light beam and melted, and a non-hardened region 4 that is not irradiated with a light beam. The hardened region 3 includes an aggregate of hollow spheres 3a and an outer shell. 3b, the non-hardened region 4 is formed by a gap 4b between the hollow sphere 3a adjacent to the hollow portion 4a in the hollow sphere 3a.

  As shown in FIG. 1B, the hollow sphere 3a of each layer has an overlapping portion 5 in the laminating direction in a side view, and a through-hole 6 through which powder in an uncured region can pass through the top and bottom of the hollow sphere 3a. The base plate 2 is provided with a recovery hole 7.

  Here, the powder made of an inorganic material is a metal powder material.

  FIG. 2A shows a perspective view of only the hollow sphere 3 a in the hardened region 3.

  As shown in FIG. 2A, a plurality of hollow spheres 3a are arranged vertically and horizontally, and the strength of the three-dimensional shaped article 1 is ensured by contacting and closely contacting the maximum 12 hollow spheres 3a.

  2B is a partially enlarged perspective view of FIG. 2A, and FIG. 2C is a plan view thereof. 2B and 2C, the hollow sphere 3a is in contact with the three hollow spheres 3a at the top and bottom.

  Moreover, FIG. 3 represents the arrangement | sequence of the hollow sphere 3a in the A cross section of Fig.2 (a). From FIG. 3, the hollow spheres 3 a arranged outside the outer peripheral portion are surrounded by six pieces around each circumference and are in close contact with each other.

  From FIG. 2 and FIG. 3, the hollow spheres 3a are in contact with three in the vertical direction and six in the horizontal direction, and are in contact with a maximum of twelve as described above.

  Next, powder collection will be described with reference to FIGS. 4 and 5.

  FIG. 4A is a B cross section of FIG. 2A and shows a cross-sectional view of the center of the hollow sphere. As shown in FIG. 4B, the material of the non-hardened region in the hollow sphere 3a is discharged out of the hollow sphere 3a through the through-hole 6 provided in the lower part of the hollow sphere 3a as shown by the solid line. The hollow sphere 3a is inserted into the hollow sphere 3a through the through-hole 6 provided in the upper portion, and is again discharged from the through-hole 6 provided in the lower portion of the hollow sphere 3a to the outside of the hollow sphere 3a. Will be collected.

  Further, a part of the material of the non-cured region discharged from the hollow sphere 3a to the outside of the hollow sphere 3a through the through-hole 6 provided in the lower part of the hollow sphere 3a moves in the horizontal direction as it is along the outer surface of the hollow sphere 3a. While falling to the lowest layer, it passes through the collection hole 7 of the base plate 2 for modeling and is collected.

  Fig.5 (a) is C cross section of Fig.2 (a), and has shown sectional drawing in the contact part of hollow spheres. As shown in FIG. 5 (b), the material of the non-hardened region outside the hollow sphere 3a passes through the outside of the hollow sphere or the inside of the hollow sphere as shown by the solid line and the broken line, as in FIG. It falls to the lower layer and passes through the collection hole 7 of the base plate 2 for modeling and is collected.

  Here, in FIGS. 4 and 5, the two paths that directly fall into the collection hole 7 of the base plate 2 for modeling have been described, but there are other paths that do not fall directly into the collection hole 7, but the lowermost hollow sphere 3 a A continuous space is formed between the base plate 2 for modeling, and the through holes 6 are provided above and below the hollow sphere 3a, so that the material in the non-hardened region is recovered by the two recovery holes 7. can do.

  Further, in practice, the material of the non-cured region is collected by tilting or swinging the three-dimensional shaped object 1, and the through holes 6 are not necessarily provided above and below the hollow sphere 3a. It is only necessary that the material of the non-cured region in the hollow sphere 3a can be discharged out of the hollow sphere 3a by tilting or swinging.

  Further, as for the number of the recovery holes 7, the recovery time can be shortened by increasing the number of the recovery holes 7. However, in order to dispose parts for forming a mold, such as inclined pins, ejector pins, etc., on the base plate 2 for modeling. Therefore, it is not possible to arrange too much, and 2 to 4 are preferable. For the same reason, the hole diameter of the recovery hole 7 cannot be too large, and is preferably around 10 mm.

  Further, in order to improve the strength of the hollow sphere 3a, a plurality of ribs 8 may be attached to the inner wall surface as shown in FIG. In FIG. 6B, four are provided, but three or more are preferable, and it is better to reduce the number of materials and powders.

  As described above, the three-dimensional modeled object 1 obtained by the manufacturing method of the present invention has strength ensured by arranging a plurality of spherical shapes in the vertical and horizontal directions, so that the inside of the model is hollowed out. In addition, since the modeling strength can be ensured and the powder material can be collected, there is an effect of improving the modeling quality, such as reduction of material cost, shortening of processing time, reduction of warpage, etc. with respect to a normal modeled object.

In the present embodiment, the hollow shape has been described as a sphere, but the same effect can be achieved even with a polyhedral structure of icosahedron or more. As another shape, there is a honeycomb structure. However, since the honeycomb structure has a cylindrical shape and a hardened region cannot be formed in the height direction inside the cylinder, a restriction is imposed on the size of the cylinder diameter, and a honeycomb having a large cylinder diameter. There is a disadvantage that the shape cannot be formed. On the other hand, a hollow shape with a polyhedral structure of spheres or icosahedrons or more has a plurality of spheres or polyhedrons of 20 or more surfaces in the height direction, and can form a hardened region, so it can be formed even with a larger diameter than the honeycomb shape. There is an advantage that it is easy to change the size of the hollowed shape or to arrange it according to the improvement of modeling strength and the shape of modeling.

  The outer shape 3b of the modeled object is necessary for the mold, but may not be necessary depending on the three-dimensional modeled model other than the mold.

(Embodiment 2)
A configuration in the case where it is necessary to ensure strength with reference to FIGS. 7A, 7B, and 7C will be described.

  FIG. 7A shows a case where it is necessary to ensure the strength of the right half of the modeled object, for example, a case where an inclined pin and an ejector pin constituting a mold are arranged on the right half and a hardening region 11 is provided around the left side. In this example, only a half of the non-hardened region 12 includes hollow spheres.

  Similarly, FIG. 7 (b) shows an example in which hollow spheres having different sphere diameters are used. For example, when bosses, ribs, etc. are densely packed in the right half of the product shape, the hollow spheres having small sphere diameters are used. And strength is secured.

  FIG. 7C is an example in which all the spherical sphere diameters are reduced to improve the strength of the entire modeling.

  In the embodiment, the aggregates of the spheres shown in FIGS. 7A, 7B, and 7C may be mixed, and the above configuration can improve the strength partially or entirely. Play.

  The manufacturing method of the three-dimensional structure according to the present invention enables to improve the molding quality such as reduction of material cost, shortening of processing time, reduction of warpage, etc., compared with a normal structure. It is useful for nesting production of molds used for speed machining of parts production.

1 Three-dimensional shaped object 2 Base plate 3, 11 Curing region 3a Hollow sphere 3b Outer shell 4, 12 Non-curing region 4b Gap 5 Overlap 6 Through hole 7 Collection hole

Claims (2)

Forming a hardened layer that is cured after the powder is melted by irradiating a predetermined portion of the powder layer made of inorganic or organic with a light beam;
Forming a cured layer integrated with the lower cured layer by coating the layer of the powder on the cured layer and irradiating a predetermined portion of the powder with a light beam to melt and then curing,
In the manufacturing method of the three-dimensional shaped object in which a plurality of hardened layers are laminated and integrated by repeating this,
The layer of powder is formed on a base plate with collection holes;
A plurality of layers of the powder are provided with a cured region that is cured after being irradiated with a light beam and melted and a non-cured region that is not irradiated with the light beam,
At least a part of the hardened region is composed of a hollow sphere or an assembly of polyhedrons,
The sphere or polyhedron has an overlapping portion in the stacking direction, and a hollow sphere or polyhedron is provided with a through hole through which the powder in the non-cured region can pass ,
The method for producing a three-dimensional shaped article, wherein the powder that has passed through the through hole is recovered through the recovery hole . The method for producing a three-dimensional shaped object according to claim 1, wherein the hollow sphere or polyhedron in the non-hardened region is not only a sphere or polyhedron of the same size, but also an aggregate of spheres or polyhedrons having different sizes.

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