JP6950780B2 - Manufacturing method of 3D model - Google Patents

Description

The present invention relates to a method for manufacturing a three-dimensional model.

Conventionally, various methods for manufacturing a three-dimensional model have been implemented. Among these, a method of forming a three-dimensional model using a fluid composition is disclosed.
For example, in Patent Document 1, a layer is formed using a metal paste as a fluid composition, and a three-dimensional model is manufactured while sintering or melting by irradiating a corresponding region of the three-dimensional model with a laser. The manufacturing method is disclosed.

Japanese Unexamined Patent Publication No. 2008-184622

However, when a three-dimensional molded product is manufactured while sintering or melting the corresponding region of the three-dimensional molded product, the heat generated during the sintering or melting causes the portion other than the corresponding region of the three-dimensional molded product to be sintered or melted. It melts, and there are cases where the load of separation work when removing the three-dimensional model and molding work after removal is heavy. That is, the conventional manufacturing method for manufacturing a three-dimensional model has not been able to sufficiently reduce the post-treatment steps of the three-dimensional model to be manufactured.

Therefore, an object of the present invention is to reduce the number of post-treatment steps after forming a three-dimensional model.

The method for producing a three-dimensional model according to the first aspect of the present invention for solving the above problems is a method for forming a fluid composition containing particles of constituent materials of the three-dimensional model and the three-dimensional model. A layer forming step of forming a layer using a fluid composition containing support part forming particles forming a support part supporting the three-dimensional model, and energy is applied to the constituent material particles and the support part forming particles. The energy applying step includes an energy applying step in which the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the melting point of the constituent material particles and lower than the melting point of the supporting portion forming particles. As such, it is characterized by imparting energy.

According to this aspect, energy is applied so that the temperatures of the constituent material particles and the support forming particles are equal to or higher than the melting point of the constituent material particles and lower than the melting point of the supporting portion forming particles. Therefore, it is possible to suppress the melting of the support portion while melting the constituent materials of the three-dimensional model. Therefore, by melting the portion other than the corresponding region of the three-dimensional modeled object, it is possible to suppress an increase in the load such as the separation work when removing the three-dimensional modeled object and the molding work after the removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

In the method for producing a three-dimensional model according to the second aspect of the present invention, in the first aspect, the layer forming step is a fluidity composition containing the constituent material particles and the fluidity including the support portion forming particles. The composition is discharged in the form of droplets to form the layer.

According to this aspect, the fluid composition containing the constituent material particles and the fluid composition containing the support portion forming particles are discharged in the form of droplets to form a layer. Therefore, by forming the layer, a three-dimensional model can be easily formed.

The method for producing a three-dimensional model according to a third aspect of the present invention is characterized in that, in the first or second aspect, there is a laminating step in which the layer forming step is repeated.

According to this aspect, it has a laminating step of repeating a layer forming step. Therefore, by repeating the layer forming step, a three-dimensional model can be easily formed.

In the method for producing a three-dimensional model according to the fourth aspect of the present invention, in any one of the first to third aspects, the energy applying step is the temperature of the constituent material particles and the support portion forming particles. Is characterized by applying energy so that the temperature is equal to or higher than the sintering temperature of the support portion forming particles.

According to this aspect, energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the support portion forming particles. That is, the constituent material particles are melted and the support forming particles are sintered. Since the sintered portion can be easily separated from the molten portion, the post-treatment step after forming the three-dimensional model can be reduced.

The method for producing a three-dimensional model according to a fifth aspect of the present invention is in any one of the first to fourth aspects, wherein the layer forming step is composed of the constituent material particles after the energy applying step. It is characterized in that the thickness of the formed layer and the thickness of the layer composed of the support portion forming particles corresponding to the layer are adjusted to be the same.

According to this aspect, after the energy application step, the thickness of the layer composed of the constituent material particles and the thickness of the layer composed of the support portion forming particles corresponding to the layer are adjusted to be the same. Therefore, it is not necessary to adjust the layer thickness due to the difference in layer thickness between the support layer and the constituent layer, and a highly accurate three-dimensional model can be easily manufactured.

In the method for producing a three-dimensional model according to the sixth aspect of the present invention, in any one of the first to fifth aspects, the energy applying step executes the layer forming step for one layer or a plurality of layers. It is characterized in that it is executed after it is executed.

According to this aspect, the energy applying step is executed after the layer forming step is executed for one layer or a plurality of layers. For example, by executing the energy application step after executing the multi-layer separation forming step, the number of times of the constituent layer forming step can be reduced, and the three-dimensional model can be quickly manufactured. Further, by executing the energy application step for each layer, even if one material covers the other material on a slope or the like, both materials are exposed on the same surface in each layer. , It becomes possible to appropriately apply energy to each material.

In the method for producing a three-dimensional model according to the seventh aspect of the present invention, in any one of the first to sixth aspects, the energy applying step is the same for the constituent material particles and the support forming particles. It is characterized by giving energy.

According to this aspect, the same energy is applied to the constituent material particles and the support forming particles. Therefore, the energy application step can be easily executed.

In the method for producing a three-dimensional model according to an eighth aspect of the present invention, in any one of the first to sixth aspects, the energy applying step has different energies for the constituent material particles and the support forming particles. Is characterized by giving.

According to this aspect, different energies are applied to the constituent material particles and the support forming particles. For this reason, effectively, the portion other than the corresponding area of the three-dimensional modeled object is also melted or excessively sintered, so that the load such as the separation work when removing the three-dimensional modeled object and the molding work after the removal is applied. It is possible to suppress the increase.

The method for producing a three-dimensional model according to a ninth aspect of the present invention is the porosity of the layer composed of the constituent material particles after the energy application step in any one of the first to eighth aspects. Is adjusted to be smaller than the porosity of the layer composed of the support-forming particles corresponding to the layer.

According to this aspect, after the energy application step, the porosity of the layer composed of the constituent material particles is adjusted to be smaller than the porosity of the layer composed of the support portion forming particles corresponding to the layer. .. Therefore, it is possible to prevent the porosity of the layer composed of the support portion-forming particles from becoming too small and increasing the load of the separation work when removing the three-dimensional model and the molding work after removal.

In the method for producing a three-dimensional model according to the tenth aspect of the present invention, in any one of the first to ninth aspects, the porosity of the layer composed of the support portion forming particles is the energy applying step. The latter is characterized in that it is adjusted to be smaller than that before the energy application step.

According to this aspect, the porosity of the layer composed of the support portion forming particles is adjusted so as to be smaller after the energy application step than before the energy application step. Therefore, there is an advantage that the strength of the support portion is improved and the structure can be reliably held in the process of performing the separation work when removing the three-dimensional structure.

In the method for producing a three-dimensional model according to the eleventh aspect of the present invention, in any one of the first to tenth aspects, the constituent material particles are aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel. It is a particle containing at least one component of aging steel, and the support forming particle is a particle containing at least one component of silica, alumina, titanium oxide, and zircon oxide.

According to this aspect, the constituent material particles can be melted by the energy application step, and the support member forming particles can be easily controlled to have a low sintering density, while ensuring the strength of the three-dimensional molded product. It is possible to suppress an increase in load such as separation work when removing a three-dimensional model and molding work after removal.

The device for producing a three-dimensional model according to a twelfth aspect of the present invention includes a discharge unit that discharges a fluid composition containing particles of constituent materials of the three-dimensional model, and the tertiary when forming the three-dimensional model. A discharge portion that discharges a fluid composition containing support portion-forming particles that form a support portion that supports the original model, a fluid composition that includes the constituent material particles, and a fluid composition that includes the support portion-forming particles. It has a control unit that controls the formation of a layer by using It is characterized in that energy is applied so that the temperature of the support portion forming particles is equal to or higher than the melting point of the constituent material particles and lower than the melting point of the supporting portion forming particles.

According to this aspect, energy is applied so that the temperatures of the constituent material particles and the support forming particles are equal to or higher than the melting point of the constituent material particles and lower than the melting point of the supporting portion forming particles. Therefore, it is possible to suppress the melting of the support portion while melting the constituent materials of the three-dimensional model. Therefore, by melting the portion other than the corresponding region of the three-dimensional modeled object, it is possible to suppress an increase in the load such as the separation work when removing the three-dimensional modeled object and the molding work after the removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

(A) is a schematic configuration diagram showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention, and (b) is an enlarged view of part C shown in (a). (A) is a schematic configuration diagram showing the configuration of a three-dimensional model manufacturing apparatus according to one embodiment of the present invention, and (b) is an enlarged view of the C'part shown in (a). The external view of the head base according to one embodiment of the present invention from the D direction shown in FIG. 1 (b). FIG. 3 is a cross-sectional view of the EE portion shown in FIG. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The schematic diagram which shows the example of other arrangement of the head unit arranged in a head base. The schematic diagram which shows the manufacturing process of the 3D model | object which concerns on one Example of this invention. The flowchart of the manufacturing method of the 3D model which concerns on one Example of this invention. The schematic diagram which shows the manufacturing process of the 3D model | object which concerns on one Example of this invention. The flowchart of the manufacturing method of the 3D model which concerns on one Example of this invention.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.
1 and 2 are schematic configuration diagrams showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention.
Here, the three-dimensional model manufacturing apparatus of the present embodiment includes two types of material supply units (head bases), but FIGS. 1 and 2 each represent only one material supply unit. It is a figure, and the other material supply part is omitted. Further, the material supply unit of FIG. 1 is a material supply unit that supplies a fluid composition (constituent material) containing constituent material particles of a three-dimensional model. Then, the material supply unit of FIG. 2 provides a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional model when forming the three-dimensional model. It is a material supply unit to be supplied. In addition, although the fluid composition containing the constituent material particles of this example and the fluid composition containing the support portion forming particles both contain a solvent and a binder, those which do not contain these may be used. ..
In addition, "three-dimensional modeling" in this specification indicates that a so-called three-dimensional model is formed, and for example, even if it is a flat plate shape, a so-called two-dimensional shape, a shape having a thickness is formed. It also includes doing. Further, "supporting" means supporting from the lower side, supporting from the side, and in some cases, supporting from the upper side.

The three-dimensional model manufacturing apparatus 2000 (hereinafter referred to as the forming apparatus 2000) shown in FIGS. 1 and 2 includes the base 110 and the X, Y, illustrated by the driving device 111 as the driving means provided in the base 110. The stage 120 is provided so as to be movable in the Z direction or to be driven in the rotation direction about the Z axis.
Then, as shown in FIG. 1, a head base 1100 holding a plurality of head units 1400 having one end fixed to the base 110 and having a constituent material discharging portion for discharging the constituent material to the other end. It includes a head base support 130 that is held and fixed.
Further, as shown in FIG. 2, a head unit 1400'having a support portion forming material discharge portion having one end fixed to the base 110 and discharging the support portion forming material to the other end portion is provided. It is provided with a head base support portion 130'in which a plurality of head bases 1100' are held and fixed.
Here, the head base 1100 and the head base 1100'are provided in parallel on the XY plane.
The constituent material discharge portion 1230 and the support portion forming material discharge portion 1230'have the same configuration except that the discharged materials (constituent material and support portion forming material) are different. However, it is not limited to such a configuration.

Layers 501, 502, and 503 are formed on the stage 120 in the process of forming the three-dimensional model 500. Further, in the region facing the stage 120, the heating unit controller 1710 connected to the control unit 400, which will be described later, controls the on / off of the irradiation of heat energy, and the heating unit 1700 capable of heating the entire region of the stage 120 is provided. It is provided.
Since the heating unit 1700 irradiates (energizes) heat energy to form the three-dimensional model 500, a sample plate 121 having heat resistance is used to protect the stage 120 from heat. A three-dimensional model 500 may be formed on the 121. By using, for example, a ceramic plate as the sample plate 121, high heat resistance can be obtained, and the reactivity with the constituent materials of the three-dimensional model to be melted is low, preventing deterioration of the three-dimensional model 500. can do. In addition, in FIG. 1A and FIG. 2A, for convenience of explanation, three layers 501, 502 and 503 are illustrated, but up to the desired shape of the three-dimensional model 500 (FIGS. 1A and 1A and FIG. (Up to the layer 50n in FIG. 2A) is laminated.
Here, the layers 501, 502, 503, ... 50n are the support layer 300 formed of the support forming material discharged from the support forming material discharge portion 1230'and the constituent material discharging portion 1230, respectively. It is composed of a constituent layer 310 (a layer corresponding to a constituent region of the three-dimensional modeled object 500) formed of the constituent materials discharged from the vehicle. Further, after forming one layer of the constituent material discharged from the constituent material discharging portion 1230 and the supporting portion forming material discharged from the supporting portion forming material discharging portion 1230', the entire layer is covered. Thermal energy can be irradiated from the heating unit 1700 to melt each layer. Furthermore, the shape of the three-dimensional model is completed by forming a plurality of layers of the constituent layer 310 and the support layer 300, and this is melted in a constant temperature bath (heating part) provided separately from the forming device 2000. It is also possible to let it.

Further, FIG. 1B is an enlarged conceptual diagram of part C showing the head base 1100 shown in FIG. 1A. As shown in FIG. 1B, the head base 1100 holds a plurality of head units 1400. Although the details will be described later, one head unit 1400 is configured by holding the component material discharge unit 1230 provided in the component material supply device 1200 by the holding jig 1400a. The component material discharge unit 1230 includes a discharge nozzle 1230a and a discharge drive unit 1230b that discharges the component material from the discharge nozzle 1230a by the material supply controller 1500.

Further, FIG. 2B is an enlarged conceptual diagram of a C'part showing the head base 1100'shown in FIG. 2A. As shown in FIG. 2B, the head base 1100'holds a plurality of head units 1400'. The head unit 1400'is configured by holding the support portion forming material discharge portion 1230' provided in the support portion forming material supply device 1200' by the holding jig 1400a'. The support portion forming material discharge unit 1230' includes a discharge nozzle 1230a'and a discharge drive unit 1230b' that discharges the support portion forming material from the discharge nozzle 1230a'by the material supply controller 1500.

In the present embodiment, the heating unit 1700 will be described by an energy irradiation unit that irradiates electromagnetic waves as heat energy. By using electromagnetic waves for the heat energy to be irradiated, it is possible to efficiently irradiate the target supply material with energy, and it is possible to form a high-quality three-dimensional model. Further, for example, the amount of irradiation energy (power, scanning speed) can be easily controlled according to the type of material to be discharged, and a three-dimensional model of desired quality can be obtained. However, the configuration is not limited to such a configuration, and a configuration in which heating may be performed by another method may be used. Needless to say, it is not limited to being melted by electromagnetic waves.

As shown in FIG. 1, the constituent material discharge unit 1230 is connected to the constituent material supply unit 1210 and the supply tube 1220, which accommodate the constituent materials corresponding to the head units 1400 held by the head base 1100. .. Then, a predetermined constituent material is supplied from the constituent material supply unit 1210 to the constituent material discharge unit 1230. The constituent material supply unit 1210 is provided with a material (a paste-like constituent material containing metal particles (constituent material particles)) containing a raw material of the three-dimensional model 500 formed by the forming apparatus 2000 according to the present embodiment as a supply material. It is housed in the component material accommodating unit 1210a, and each component material accommodating unit 1210a is connected to the individual component material discharge unit 1230 by the supply tube 1220. As described above, by providing the individual constituent material accommodating portions 1210a, a plurality of different types of materials can be supplied from the head base 1100.

As shown in FIG. 2, the support portion forming material discharge portion 1230'is a support portion forming material containing a support portion forming material corresponding to each of the head units 1400' held by the head base 1100'. It is connected to the supply unit 1210'by the supply tube 1220'. Then, a predetermined support portion forming material is supplied from the support portion forming material supply unit 1210'to the support portion forming material discharge portion 1230'. The support portion forming material supply unit 1210'is a paste-like support portion forming material containing ceramic particles (support portion forming particles) constituting the support portion forming the support portion when modeling the three-dimensional model 500. ) Is housed in the support material accommodating portion 1210a'as a supply material, and the individual support portion forming material accommodating portions 1210a' are connected to the individual support portion forming material discharge portions 1230' by the supply tube 1220'. Has been done. As described above, by providing the individual support portion forming material accommodating portions 1210a', a plurality of different types of support portion forming materials can be supplied from the head base 1100'.

As the constituent material, for example, a single powder of magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or A slurry containing a mixed powder of an alloy containing one or more of these metals (malaging steel, stainless steel, cobalt chrome molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chrome alloy), a solvent, and a binder. It can be used as a mixed material in the form (or paste form).
Further, general-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can be used. In addition, engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyallylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
As described above, the constituent materials are not particularly limited, and metals other than the above metals, ceramics, resins, and the like can also be used.
Examples of the solvent include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, and acetate. Acetate esters such as iso-propyl, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, acetyl acetone Ketones such as; alcohols such as ethanol, propanol and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine solvents such as pyridine, γ-picolin and 2,6-rutidine; tetra Examples thereof include ionic liquids such as alkylammonium acetate (for example, tetrabutylammonium acetate), and one or a combination of two or more selected from these can be used.
Examples of the binder include acrylic resin, epoxy resin, silicone resin, cellulose resin or other synthetic resin, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide) or other thermoplastic resin.

In the present embodiment, the material for forming the support portion contains ceramics. As the material for forming the support portion, for example, it can be used as a slurry-like (or paste-like) mixed material containing a mixed powder of a metal oxide, a metal alkoxide, a metal or the like, a solvent, and a binder.
However, the material for forming the support portion is not particularly limited, and metals and resins other than ceramics as in the above example of the constituent materials can also be used.

The forming device 2000 includes a component material discharge unit 1230 provided in the above-mentioned stage 120 and the component material supply device 1200 based on modeling data of a three-dimensional modeled object (not shown), for example, output from a data output device such as a personal computer. , The heating unit 1700, and the control unit 400 as a control means for controlling the support unit forming material discharge unit 1230' provided in the support unit forming material supply device 1200' are provided. Although not shown, the control unit 400 includes a stage 120, a component material discharge unit 1230, and a control unit that controls the stage 120 and the support unit forming material supply device 1200'to drive and operate in cooperation with each other. ing.

The stage 120 movably provided on the base 110 is a signal that controls the movement start and stop, the movement direction, the movement amount, the movement speed, etc. of the stage 120 in the stage controller 410 based on the control signal from the control unit 400. Is generated and sent to the drive device 111 provided in the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The component material discharge unit 1230 provided in the head unit 1400 controls the material discharge amount from the discharge nozzle 1230a in the discharge drive unit 1230b provided in the component material discharge unit 1230 in the material supply controller 1500 based on the control signal from the control unit 400. A predetermined amount of the constituent material is discharged from the discharge nozzle 1230a by the generated signal.
Similarly, in the support portion forming material discharge unit 1230' provided in the head unit 1400', the discharge drive unit 1230 b provided in the support portion forming material discharge unit 1230' in the material supply controller 1500 based on the control signal from the control unit 400. A signal for controlling the amount of material discharged from the discharge nozzle 1230a'in' is generated, and a predetermined amount of material for forming a support portion is discharged from the discharge nozzle 1230a' by the generated signal.

Further, in the heating unit 1700, a control signal is sent from the control unit 400 to the heating unit controller 1710, and an output signal for irradiating the heating unit 1700 with an electromagnetic wave is transmitted from the heating unit controller 1710.

Next, the head unit 1400 will be described in more detail. The head unit 1400'has the same configuration as the head unit 1400, in which the support portion forming material discharge portion 1230'is configured in the same arrangement instead of the constituent material discharge portion 1230. Therefore, a detailed description of the configuration of the head unit 1400'will be omitted.
3 and 4 show an example of a holding form of the head unit 1400 held by the head base 1100 and the component material discharging unit 1230 held by the head unit 1400, and FIG. 3 shows an arrow shown in FIG. 1 (b). The external view of the head base 1100 from the D direction, FIG. 4 is a schematic cross-sectional view of the EE portion shown in FIG.

As shown in FIG. 3, a plurality of head units 1400 are held on the head base 1100 by fixing means (not shown). In the head base 1100 of the forming apparatus 2000 according to the present embodiment, the head units 1401 and 1402 in the first row, the head units 1403 and 1404 in the second row, and the head units 1405 and 1406 in the third row from the lower part of the drawing. It also includes eight head units 1400 of the fourth row head units 1407 and 1408. Although not shown, the component material discharge unit 1230 provided in each of the head units 1401 to 1408 is connected to the component material supply unit 1210 via the discharge drive unit 1230b by a supply tube 1220 and is held by the holding jig 1400a. It is composed.

As shown in FIG. 4, the component material discharge unit 1230 discharges the material M, which is a component material of the three-dimensional model, from the discharge nozzle 1230a toward the sample plate 121 placed on the stage 120. The head unit 1401 exemplifies a discharge form in which the material M is discharged in the form of droplets, and the head unit 1402 exemplifies a discharge form in which the material M is supplied in the form of a continuum. The ejection form of the material M in the forming apparatus 2000 of the present embodiment is in the form of droplets. However, a discharge nozzle 1230a having a continuous shape and capable of supplying a constituent material can also be used.

The material M discharged in the form of droplets from the discharge nozzle 1230a flies in the substantially gravitational direction and lands on the sample plate 121. Then, the landed material M forms the landing portion 50. The aggregate of the landing portions 50 is formed as a constituent layer 310 (see FIG. 1) of the three-dimensional model 500 formed on the sample plate 121.

5, 6 and 7 are plan views (viewing in the D direction shown in FIG. 1) that conceptually explain the relationship between the arrangement of the head unit 1400 and the formation form of the landing portion 50. First, as shown in FIG. 5A, at the modeling starting point q1 on the sample plate 121, the material M is discharged from the discharge nozzles 1230a of the head units 1401 and 1402, and the material M landed on the sample plate 121 causes the landing portion 50a. And 50b are formed. For convenience of explanation, although it is a plan view, the impacted portion 50 is hatched, and the constituent layer 310 of the first layer 501 formed on the upper surface of the sample plate 121 will be described as an example.

First, as shown in FIG. 5A, at the modeling starting point q1 of the constituent layer 310 of the layer 501 on the sample plate 121, from the constituent material discharge unit 1230 provided in the head units 1401 and 1402 in the first row below the drawing. Material M is discharged. The landing portions 50a and 50b are formed by the discharged material M.

FIG. 5 (b) shows the sample plate 121 in the Y (+) direction relative to the head base 1100 while continuing to discharge the material M from the constituent material discharge portions 1230 of the head units 1401 and 1402. The modeling start point q1 is moved to the position corresponding to the head units 1403 and 1404 in the second row. As a result, the landing portions 50a and 50b are extended while maintaining the width t from the modeling start point q1 to the position q2 after the relative movement of the sample plate 121. Further, the material M is discharged from the head units 1403 and 1404 in the second row corresponding to the modeling start point q1, and the landing portions 50c and 50d begin to be formed.

As shown in FIG. 5B, the landing portions 50c and 50d begin to be formed, and the sample plate 121 is attached to the head base 1100 while continuing to eject the material M from the constituent material ejection portions 1230 of the head units 1403 and 1404. On the other hand, the modeling starting point q1 shown in FIG. 5C is moved relatively in the Y (+) direction to the position corresponding to the head units 1405 and 1406 in the third row. As a result, the landing portions 50c and 50d are extended while maintaining the width t from the modeling start point q1 to the position q2 after the movement of the sample plate 121. At the same time, the landing portions 50a and 50b are extended while maintaining the width t from the modeling start point q1 to the position q3 after the relative movement of the sample plate 121. The material M is discharged from the head units 1405 and 1406 in the third row corresponding to the modeling start point q1, and the landing portions 50e and 50f begin to be formed.

As shown in FIG. 5C, the landing portions 50e and 50f begin to be formed, and the sample plate 121 is attached to the head base 1100 while continuing to eject the material M from the constituent material ejection portions 1230 of the head units 1405 and 1406. On the other hand, the modeling starting point q1 shown in FIG. 6D is moved relatively in the Y (+) direction to the position corresponding to the head units 1407 and 1408 in the fourth row. As a result, the landing portions 50e and 50f are extended while maintaining the width t from the modeling start point q1 to the position q2 after the movement of the sample plate 121. At the same time, the landing portions 50a and 50b maintain the width t from the modeling start point q1 to the position q4 after the relative movement of the sample plate 121, and the landing portions 50c and 50d from the modeling start point q1 to the position q3 after the relative movement of the sample plate 121. Will be extended. The material M is discharged from the head units 1407 and 1408 in the fourth row corresponding to the modeling start point q1, and the landing portions 50 g and 50 h begin to be formed.

When the position q5 is set as the modeling end position (hereinafter, the position q5 is referred to as the modeling end point q5), as shown in FIG. 6 (e), the head units 1401 and 1402 relatively reach the modeling end point q5 of the sample plate 121. By moving to, the landing portions 50g and 50h are extended. Then, at the head units 1401 and 1402 that have reached the modeling end point q5, the discharge of the material M from the constituent material discharge unit 1230 of the head units 1401 and 1402 is stopped. Further, while relatively moving the sample plate 121 in the Y (+) direction, the material M is discharged from the constituent material discharge unit 1230 until the head units 1403, 1404, 1405, 1406, 1407, and 1408 reach the modeling end point q5. Will be done. Then, as shown in FIG. 7, the landing portions 50a, 50b, 50c, 50d, 50e, 50f, 50g and 50h are formed from the modeling start point q1 to the modeling end point q5 while maintaining the width t. In this way, while moving the sample plate 121 from the modeling start point q1 to the modeling end point q5, the material M is sequentially discharged and supplied from the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408. In the example of this embodiment having a width T and a length J, a substantially rectangular landing portion 50 can be formed. Then, the constituent layer 310 of the first layer 501 can be formed and configured as an aggregate of the landing portions 50.

As described above, the forming apparatus 2000 according to the present embodiment synchronizes with the movement of the stage 120 including the sample plate 121, and discharges the constituent materials provided for the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407, and 1408. By selectively discharging and supplying the material M from the portion 1230, the constituent layer 310 having a desired shape can be formed on the sample plate 121. Further, as described above, in this example, the stage 120 is moved only in one direction along the Y-axis direction, and the landing portion having a desired shape within the region of width T × length J shown in FIG. 50, and the constituent layer 310 as an aggregate of the landing portions 50 can be obtained.

Further, the material M discharged from the constituent material discharge unit 1230 is a constituent material different from the other head units from any one unit of the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408, or two or more units. Can also be discharged and supplied. Therefore, by using the forming apparatus 2000 according to the present embodiment, a three-dimensional model formed from different materials can be obtained.

In the first layer 501, before or after forming the constituent layer 310 as described above, the support portion forming material is discharged from the support portion forming material discharge portion 1230', and the same method as described above is performed. Therefore, the support layer 300 can be formed. Then, when the layers 502, 503, ... 50n are formed by being laminated on the layer 501, the constituent layer 310 and the support layer 300 can be formed in the same manner.

The number and arrangement of the head units 1400 and 1400' provided in the forming apparatus 2000 according to the above-described embodiment is not limited to the above-mentioned number and arrangement. FIG. 8 schematically shows an example of other arrangements of the head unit 1400 arranged on the head base 1100 as an example.

FIG. 8A shows a form in which a plurality of head units 1400 are arranged in parallel on the head base 1100 in the X-axis direction. FIG. 8B shows a form in which the head units 1400 are arranged in a grid pattern on the head base 1100. The number of head units arranged in each case is not limited to the illustrated example.

Next, an example of a method for manufacturing a three-dimensional model performed by using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 9 is a schematic view showing an example of a manufacturing process of a three-dimensional modeled object performed by using the forming apparatus 2000. In this example, using the heating unit 1700 provided in the forming apparatus 2000, the constituent material and the supporting portion forming material are discharged from the constituent material discharging portion 1230 and the supporting portion forming material discharging portion 1230'for one layer. This is an example of a method for manufacturing a three-dimensional model, in which the layer is heated each time a layer is formed to produce the three-dimensional model. Further, in the method for manufacturing a three-dimensional model of the present embodiment, a three-dimensional model in a molten state is manufactured.
In FIG. 9, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the constituent layer 310 can be easily understood.

First, as shown in FIG. 9A, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first layer is formed. In the eye layer 501, the constituent layer 310 and the support layer 300 are formed. Here, the support layer 300 is formed in a region other than the three-dimensional model formation region (region corresponding to the constituent layer 310) in the layer.
Next, as shown in FIG. 9B, the layer 501 of the first layer is heated by the heating unit 1700 to melt the constituent layer 310 of the layer and to sinter the support layer 300. The heating temperature of the heating unit 1700 in this embodiment is the temperature at which the metal particles (constituent material particles) contained in the constituent material melt (above the melting point), and the ceramics contained in the material for forming the supporting portion. The temperature (less than the melting point) at which the particles (support forming particles) are sintered is set.

Hereinafter, the operation represented by FIG. 9A and the operation represented by FIG. 9B are repeated to complete the three-dimensional modeled object.
Specifically, as shown in FIG. 9C, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first In the second layer 502, the constituent layer 310 and the support layer 300 are formed. Then, as shown in FIG. 9D, the second layer 501 is heated by the heating unit 1700.
Further, the constituent layer 310 and the support layer 300 are formed in the third layer layer 502 as shown in FIG. 9 (e), and the third layer layer 501 is formed as shown in FIG. 9 (f). Is heated by the heating unit 1700 to form the constituent layer 310 and the support layer 300 in the fourth layer 502 as shown in FIG. 9 (g), and as shown in FIG. 9 (h), the constituent layer 310 and the support layer 300 are formed. The fourth layer 501 is heated by the heating unit 1700 to complete the three-dimensional model (constituent layer 310 in a molten state).

Next, an embodiment of the method for manufacturing the three-dimensional model represented by FIG. 9 will be described with reference to a flowchart.
Here, FIG. 10 is a flowchart of a method for manufacturing a three-dimensional model according to the present embodiment.

As shown in FIG. 10, in the method of manufacturing the three-dimensional model of the present embodiment, first, in step S110, the data of the three-dimensional model is acquired. Specifically, for example, data representing the shape of a three-dimensional model is acquired from an application program executed on a personal computer or the like.

Next, in step S120, data for each layer is created. Specifically, in the data representing the shape of the three-dimensional modeled object, slices are made according to the modeling resolution in the Z direction, and bitmap data (cross-section data) is generated for each cross-section.
At this time, the generated bitmap data is data that is distinguished by the formed region of the three-dimensional modeled object and the non-formed area of the three-dimensional modeled object.

Next, in step S130, the constituent material is discharged (supplied) from the constituent material discharge unit 1230 based on the data for forming the formation region of the three-dimensional modeled object, and the constituent layer 310 is formed.

Next, in step S140, the support portion forming material is discharged (supplied) from the support portion forming material discharge portion 1230'based on the data for forming the non-forming region of the three-dimensional modeled object, and is configured in step S130. The support layer 300 corresponding to the same layer as the constituent layer 310 is formed.
The order of steps S130 and S140 may be reversed or may be simultaneous.

Next, in step S150, the layers corresponding to the constituent layer 310 composed of step S130 and the support layer 300 composed of step S140 are irradiated with electromagnetic waves (heat energy is applied) from the heating unit 1700. The constituent layer 310 in the layer is melted and the support layer 300 is sintered.
In this step, the constituent layer 310 is melted and the support layer 300 is sintered, but the support layer 300 may not be sintered.

Then, in step S160, steps S130 to S160 are repeated until the modeling of the three-dimensional modeled object based on the bitmap data corresponding to each layer generated in step S120 is completed.

Then, when the modeling of the three-dimensional model is completed, in step S170, the development of the three-dimensional model (the region corresponding to the constituent layer 310, which is the region for forming the three-dimensional model, is the non-formed region of the three-dimensional model. The portion corresponding to the support layer 300 is removed, that is, the three-dimensional model is cleaned), and the method for manufacturing the three-dimensional model of this embodiment is completed.

Next, another embodiment of the method for manufacturing a three-dimensional model formed by using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 11 is a schematic view showing an example of a manufacturing process of a three-dimensional modeled object performed by using the forming apparatus 2000. In this example, the heating unit 1700 provided in the forming apparatus 2000 is not used, and in a constant temperature bath (heating portion) (not shown) provided separately from the forming apparatus 2000, the constituent material discharge portion 1230 and the support portion are formed. After the constituent material and the material for forming the support portion are discharged from the material discharge portion 1230'and the formation of the shape of the three-dimensional model is completed, the formation of the three-dimensional model is heated to manufacture the three-dimensional model. This is an example of a method for manufacturing a three-dimensional model. Further, in the method for manufacturing a three-dimensional model of the present embodiment, a three-dimensional model in a molten state is manufactured.
In FIG. 11, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the constituent layer 310 can be easily understood.

First, as shown in FIG. 11A, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first layer is formed. In the eye layer 501, the constituent layer 310 and the support layer 300 are formed. Here, the support layer 300 is formed in a region other than the three-dimensional model formation region (region corresponding to the constituent layer 310) in the layer.
Next, as shown in FIG. 11B, the constituent material is discharged from the constituent material discharging portion 1230, the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the second layer is formed. In the eye layer 502, the constituent layer 310 and the support layer 300 are formed.
Then, as shown in FIGS. 11 (c) and 11 (d), the operations shown in FIGS. 11 (a) and 11 (b) are repeated to complete the shape of the three-dimensional modeled object.
Then, as shown in FIG. 11 (e), the formation of the three-dimensional model is heated in a constant temperature bath (not shown) to melt the constituent layer 310 of the formation of the three-dimensional model and the support layer. 300 is sintered to complete a three-dimensional model (constituent layer 310 in a molten state). The heating temperature in the constant temperature bath in this embodiment is the temperature at which the metal particles (constituent material particles) contained in the constituent material melt (above the melting point), and the ceramics contained in the material for forming the support portion. The temperature (less than the melting point) at which the particles (support forming particles) are sintered is set.

Next, an embodiment of the method for manufacturing the three-dimensional model represented by FIG. 11 will be described with reference to a flowchart.
Here, FIG. 12 is a flowchart of a method for manufacturing a three-dimensional model according to the present embodiment.
Since steps S110 to S140 and step S170 in FIG. 12 are the same as steps S110 to S140 and step S170 in FIG. 9, description thereof will be omitted.

As shown in FIG. 12, in the method for manufacturing a three-dimensional model of the present embodiment, after the end of step S140, the process proceeds to step S160.
Then, in step S160, steps S130 to S160 are repeated until the modeling of the three-dimensional modeled product based on the bitmap data corresponding to each layer generated in step S120 is completed, and the three-dimensional modeled product is repeated. When the molding of the formed product is completed, the process proceeds to step S165.
In step S165, the constituent layer 310 and the support layer 300 are sintered in a constant temperature bath (not shown) for the formed body of the three-dimensional model formed by repeating steps S130 to S160. In this step, the constituent layer 310 is melted and the support layer 300 is sintered, but the support layer 300 may not be sintered. Then, after the end of this step, step S170 is executed to end the method of manufacturing the three-dimensional modeled object of this embodiment.

As represented by the above two examples, the method for manufacturing a three-dimensional model of the present embodiment forms a fluid composition (constituent material) containing particles of the constituent material of the three-dimensional model and the three-dimensional model. A layer forming step (step S130 and step) of forming a layer using a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional modeled object. S140). Then, it has an energy applying step (step S150 and step S165) of applying energy to the constituent material particles and the support portion forming particles. Further, in the energy application step, energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the melting point of the constituent material particles and lower than the melting point of the support portion forming particles.
For this reason, it is possible to suppress the melting of the support portion while melting the constituent materials of the three-dimensional model, and by melting the part other than the corresponding region of the three-dimensional model, when removing the three-dimensional model. It is possible to suppress an increase in load such as separation work and molding work after removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

In other words, the three-dimensional model manufacturing apparatus (forming apparatus 2000) of this embodiment is a discharge unit (constituting material) that discharges a fluid composition (constituting material) containing the constituent material particles of the three-dimensional modeling. Discharge unit 1230) and a discharge unit that discharges a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional model when forming the three-dimensional model. A control unit (control unit 400) that controls the formation of a layer by using (support portion forming material discharge portion 1230'), a fluid composition containing constituent material particles, and a fluid composition containing support portion forming particles. ), And an energy imparting portion (heating portion 1700) that imparts energy to the constituent material particles and the support portion forming particles. The energy applying portion is adjusted to apply energy so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the melting point of the constituent material particles and lower than the melting point of the supporting portion forming particles.
For this reason, it is possible to suppress the melting of the support portion while melting the constituent materials of the three-dimensional model, and by melting the part other than the corresponding region of the three-dimensional model, when removing the three-dimensional model. It is possible to suppress an increase in load such as separation work and molding work after removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

Further, in the layer forming step (step S130 and step S140) in the method for producing the three-dimensional model of the present embodiment, the fluid composition containing the constituent material particles and the fluid composition containing the support portion forming particles are droplets. Discharge in the state to form a layer. Therefore, a three-dimensional model can be formed by a simple method of forming a layer.

Further, the method for manufacturing a three-dimensional model of the present embodiment includes a laminating step (step S130 to step S160) in which the layer forming step (step S130 and step S140) is repeated. Therefore, by repeating the layer forming step, a three-dimensional model can be easily formed.

Further, in the energy application step (step S150 and step S165) in the method for manufacturing the three-dimensional model of the present embodiment, the temperature of the constituent material particles and the support portion forming particles becomes a temperature equal to or higher than the sintering temperature of the support portion forming particles. So, give energy. That is, the constituent material particles are melted and the support forming particles are sintered. Since the sintered portion can be easily separated from the molten portion, the post-treatment step after forming the three-dimensional model can be reduced.

Further, the layer forming step (step S130 and step S140) in the method for manufacturing the three-dimensional model of the present embodiment includes the thickness of the layer composed of the constituent material particles after the energy applying step (step S150 and step S165). The thickness of the layer and the thickness of the layer composed of the corresponding support forming particles are adjusted to be the same. Specifically, the change in the thickness of the constituent layer (degree of decrease) due to melting and the change in the thickness of the support layer (degree of decrease) due to sintering are calculated in advance, and the difference between the two changes is calculated. The thickness of each layer (droplet discharge amount) is adjusted. Therefore, it is not necessary to adjust the layer thickness due to the difference in layer thickness between the support layer and the constituent layer, and a highly accurate three-dimensional model can be easily manufactured.

Further, the energy application step (step S150) in the method for manufacturing the three-dimensional model of the present embodiment shown in FIG. 10 is executed every time the stacking step (steps S130 to S160) for one layer is completed. Then, the energy application step (step S165) in the method for manufacturing the three-dimensional model of the present embodiment represented by FIG. 12 is executed after all the laminating steps (steps S130 to S160) are completed. In other words, the energy applying step in the method for manufacturing the three-dimensional model of the present embodiment is executed after the layer forming step (step S130 and step S140) is executed for one layer or a plurality of layers. For example, by executing the energy application step after executing the multi-layer separation forming step, the number of times of the constituent layer forming step can be reduced, and the three-dimensional model can be quickly manufactured. Further, by executing the energy application step for each layer, even if one material covers the other material on a slope or the like, both materials are exposed on the same surface in each layer. , It becomes possible to appropriately apply energy to each material.

Further, in the energy application step (step S150 and step S165) in the method for manufacturing the three-dimensional model of the present embodiment, the same energy is applied to the constituent material particles and the support portion forming particles (in step S150, the constituent material particles and the support). Both the part-forming particles are irradiated with electromagnetic waves from the heating unit 1700, and in step S165, the constituent material particles and the support portion-forming particles are collectively heated in a constant temperature bath (not shown). Therefore, the energy application step can be easily executed.

However, in the energy application step, different energy may be applied to the constituent material particles and the support portion forming particles. By applying different energies, the parts other than the corresponding area of the 3D model are effectively melted, which increases the load of separation work when removing the 3D model and molding work after removal. This is because it is possible to suppress the increase.

Further, in the method for producing a three-dimensional model of the present embodiment, after the energy application step (step S150 and step S165), the porosity of the layer composed of the constituent material particles is the support portion forming particles corresponding to the layer. It is adjusted to be smaller than the porosity of the constituent layers. Therefore, it is possible to prevent the porosity of the layer composed of the support portion-forming particles from becoming too small and increasing the load of the separation work when removing the three-dimensional model and the molding work after removal.

Further, in the method for producing a three-dimensional model of the present embodiment, the porosity of the layer composed of the support portion forming particles is smaller after the energy application step (step S150 and step S165) than before the energy application step. It is adjusted to be. Therefore, there is an advantage that the strength of the support portion is improved and the structure can be reliably held in the process of performing the separation work when removing the three-dimensional structure.

Further, the constituent material particles are particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel, and the support forming particles are silica, alumina, titanium oxide, and zircon oxide. It is preferable that the particles contain at least one of the components. By the energy application process, the constituent material particles can be melted and the support member forming particles can be easily controlled to have a low sintering density, and the 3D model is removed while ensuring the strength of the 3D model. This is because it is possible to suppress an increase in load such as separation work at the time and molding work after removal.

The present invention is not limited to the above-described embodiment, and can be realized with various configurations within a range not deviating from the gist thereof. For example, the technical features in the examples corresponding to the technical features in each form described in the column of the outline of the invention may be used to solve some or all of the above-mentioned problems, or one of the above-mentioned effects. It is possible to replace or combine as appropriate to achieve part or all. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

50, 50a, 50b, 50c, 50d, 50e, 50f, 50g and 50h landing parts,
110 bases, 111 drives, 120 stages (supports),
121 sample plate, 130, 130'head base support,
300 support layer (support part), 310 constituent layer, 400 control unit (control part),
410 stage controller, 430 laser controller,
500 three-dimensional model, 501, 502 and 503 layers,
1100, 1100'head base,
1200 component material supply device, 1200'support part forming material supply device,
1210 Constituent material supply unit, 1210'Support unit forming material supply unit,
1210a Constituent material accommodating part, 1210a'Support part forming material accommodating part,
1220, 1220'feed tube,
1230 Constituent material discharge part, 1230'Support part formation material discharge part,
1230a, 12330a'Discharge nozzle, 1230b, 1230b' Discharge drive unit,
1400, 1400'head unit,
1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408 head units,
1400a, 1400a'holding jig, 1500 material supply controller,
1600, 1600'head base, 1700 heating part (energy applying part),
1710 Heating unit controller, 2000 forming device (manufacturing device for 3D model),
L laser, M material (constituent material)

Claims (5)

Constituent material A process of forming a constituent layer by ejecting a constituent material containing particles in a continuous shape, and
A step of forming a support layer that supports the three-dimensional modeled object when the support portion forming material containing the support portion forming particles is discharged in a continuous shape to generate the three-dimensional modeled object.
A laminating step of repeating the step of forming the constituent layer and the step of forming the support layer, and
It has an energy applying step of applying energy to the constituent layer and the support layer.
The melting point of the support forming particles is higher than the melting point of the constituent material particles.
In the energy applying step, energy is applied to the constituent layer and the support layer at a temperature equal to or higher than the melting point of the constituent material particles and lower than the melting point of the support portion forming particles.
In the laminating step, after the energy applying step, the constituent layer and the support layer are formed so that the thickness of the constituent layer and the thickness of the support layer corresponding to the constituent layer are equal to each other.
A method for producing a three-dimensional model, wherein after the energy application step, the porosity of the constituent layer becomes smaller than the porosity of the support layer corresponding to the constituent layer. In the method for manufacturing a three-dimensional model according to claim 1,
The energy applying step is characterized in that energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the support portion forming particles. Production method. In the method for manufacturing a three-dimensional model according to any one of claims 1 or 2.
The energy applying step is a method for producing a three-dimensional model, characterized in that the same energy is applied to the laminated constituent material particles and the support portion forming particles after the completion of the laminating step. In the method for manufacturing a three-dimensional model according to any one of claims 1 to 3.
A method for producing a three-dimensional model, wherein the porosity of the support layer is smaller after the energy application step than before the energy application step. In the method for manufacturing a three-dimensional model according to any one of claims 1 to 4.
The constituent material particles are particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel, and the support forming particles are of silica, alumina, titanium oxide, and zircon oxide. A method for producing a three-dimensional model, characterized in that the particles contain at least one of the components.

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