JP7192615B2 - POWDER SUPPLY DEVICE, THREE-DIMENSIONAL MODELING APPARATUS, AND METHOD FOR MODELING THREE-DIMENSIONAL PRODUCT - Google Patents

Description

The present disclosure relates to a powder supply device, a three-dimensional modeling device, and a method of modeling a three-dimensional modeled object.

Patent Documents 1 to 7 disclose techniques related to three-dimensional modeling apparatuses. A three-dimensional modeling apparatus spreads a powdery material evenly and irradiates an energy beam to a predetermined region of the spread material. The material in the area irradiated with the energy beam melts and then solidifies. Then, the powdery material is spread evenly again. In this way, the three-dimensional modeling apparatus obtains a three-dimensional model by repeating the spreading of the powdery material and the irradiation of the energy beam.

WO2017/188152 WO2017/002926 Utility Model Registration No. 3190955 JP-A-2004-175093 JP 2015-150825 A JP 2016-55625 A JP 2018-20521 A

The powder material is supplied from the area where it is stored to the area irradiated with the energy beam by a predetermined supply mechanism. This feeding mechanism has a portion that directly contacts the powder material. As a result, the powder material may adhere to the touched portion. If such residual powder falls on the untreated powder material spread over the build area, it will affect the quality of the build.

Therefore, the present disclosure describes a powder supply device capable of reliably removing residual powder, a three-dimensional modeling apparatus including the powder supply device, and a method of modeling a three-dimensional object.

One aspect of the present disclosure is a powder supply device used in a three-dimensional modeling apparatus that forms a modeled object by processing evenly spread powder, comprising: a powder storage unit that stores powder; and a powder removing unit for removing residual powder adhering to the applying unit. And, the application unit includes an application pressing unit that presses the powder in a first direction toward the modeling area from the powder storage unit, and an application pressing unit that projects in a second direction that intersects the first direction. an application body for gripping the pressing portion, and the powder removal portion has a pressing removal surface facing the application pressing portion and a body removal surface facing the application body.

The application unit moves the powder to the modeling area by an application pressing unit that presses the powder. This powder may adhere to the application pressing portion and the application body in the vicinity of the application pressing portion and become residual powder. Since the powder supply device has a pressure removing surface facing the application pressing portion, it is possible to remove residual powder adhering to the application pressing portion by bringing the pressure removal surface relatively close to the application pressing portion. is. Furthermore, since the powder feeder has a body removal surface facing the application body, it is possible to remove residual powder adhering to the application body by bringing the body removal surface relatively close to the application body. be. That is, the powder supply device can remove residual powder in the application pressing part and the application main body.

The shape of the press-removal surface in the powder feeder described above follows the shape of the application pressing portion facing the press-removal surface, and the shape of the main body removal surface follows the shape of the application main body that the main body-removal surface faces. good too. According to this configuration, residual powder in the application pressing portion and the application body can be reliably removed.

The powder removing part in the above powder supply device has a body removing part including a body removing surface, the elastic modulus of the body removing part is smaller than the elastic modulus of the applying body, and the body removing part is pressed against the applying body. Sometimes, the body removing part may be deformed so as to follow the shape of the application body. According to this configuration, when the body-removing part comes close to the application body, the force of the body-removing part pressing the residual powder adhering to the application body against the application body is reduced. Therefore, residual powder adhering to the applicator body can be more reliably removed.

The powder removing section in the powder supply device has a pressure removing section including a pressure removing surface, the elastic modulus of the pressure removing section is smaller than the elastic modulus of the coating pressing section, and the pressure removing section presses the coating pressing section. When applied, the pressure removing portion may be deformed to follow the shape of the application pressing portion. According to this configuration, when the pressure removing part comes close to the applying pressure part, the force of the pressure removing part pressing the residual powder adhering to the applying pressure part against the applying pressure part is reduced. Therefore, it is possible to more reliably remove the residual powder in the application pressing portion.

The powder removal section in the powder feeder described above may be fixed. According to this configuration, the remaining powder is removed by moving the applying section and approaching the powder removing section. That is, since a configuration for moving the powder removing section is unnecessary, the configuration of the powder supply device can be simplified.

The powder removing unit in the powder supply device includes a movable piece including a pressure removing surface and a body removing surface, and a moving mechanism for moving the movable piece in a third direction intersecting the first direction and the second direction. , may have According to this configuration, residual powder can be removed more reliably.

Another aspect of the present disclosure is a three-dimensional modeling apparatus that processes evenly spread powder to form a modeled object, wherein the modeling area in which the powder is evenly spread and the modeled object is formed by processing the powder. and a powder supply unit that evenly spreads the powder in the modeling area. , an application section for moving the powder from the powder storage section to the modeling area section, and a powder removal section for removing residual powder adhering to the application section. It has an application pressing part that presses the powder in one direction, and an application body that holds the application pressing part so that the application pressing part protrudes in a second direction that intersects with the first direction. It has a pressing removal surface facing the application pressing part and a body removal surface facing the application body.

The three-dimensional modeling apparatus has a powder supply section having the same configuration as the powder supply apparatus described above. Therefore, residual powder in the application pressing part and the application body is reliably removed.

According to still another aspect of the present disclosure, a three-dimensional modeling apparatus includes a modeling area section in which powder is evenly spread and a modeled object is formed by processing the powder, and a powder supply section in which the powder is evenly spread in the modeling area section. and a step of spreading the powder evenly over the modeling area by moving the coating portion of the powder supply portion in a predetermined direction; and a step of processing the spread powder to form a three-dimensional model and a step of removing the residual powder by bringing the powder removing portion for removing the residual powder adhering to the applying portion and the applying portion relatively close to each other, and the step of removing the residual powder includes removing the powder. It includes a step of removing residual powder adhering to the application body that grips the application pressing portion to be pressed, and a step of removing residual powder adhering to the application pressing portion.

According to this method of forming a three-dimensional structure, the residual powder can be reliably removed in the step of removing the residual powder. As a result, the influence of the residual powder on the quality of the model can be suppressed.

According to the powder supply device of the present disclosure, the three-dimensional modeling apparatus including the powder supply device, and the method of modeling a three-dimensional modeled object, residual powder can be reliably removed.

FIG. 1 is a diagram showing a three-dimensional modeling apparatus of the present disclosure. FIG. 2 is an enlarged view of the main part of the three-dimensional modeling apparatus shown in FIG. 3 is a plan view of the main part shown in FIG. 2. FIG. FIG. 4 is a diagram showing the structure of the recoater. FIG. 5 is a perspective view showing a removing mechanism and a coating mechanism. FIG. 6 is a flowchart showing the operation of the 3D modeling apparatus. Parts (a), (b) and (c) of FIG. 7 are diagrams for explaining the removal operation. FIG. 8 is a perspective view showing a removing mechanism and a coating mechanism of Modification 1. FIG. 9A and 9B are diagrams showing a removing mechanism and a coating mechanism according to Modification 2. FIG. Parts (a) and (b) of FIG. 10 are diagrams showing the configuration and operation of the removal mechanism and the coating mechanism of Modification 3. FIG. 11A and 11B are diagrams showing a removing mechanism and a coating mechanism according to Modification 4. FIG. FIG. 12 is a diagram showing a three-dimensional modeling apparatus of modification 5. As shown in FIG.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and overlapping descriptions are omitted.

The 3D modeling apparatus 1 shown in FIG. 1 obtains a 3D model 100 . The three-dimensional modeling apparatus 1 first supplies the powder 101 to the modeling area. Then, the three-dimensional modeling apparatus 1 irradiates the powder 101 with a laser beam (hereinafter simply “laser L”) as an energy beam. The powder 101 is melted by this irradiation. When the irradiation of the laser L is stopped, the melted powder 101 is solidified. That is, the three-dimensional modeling apparatus 1 repeats the supply of the powder 101 and the irradiation of the laser L. FIG.

In the following description, X-axis, Y-axis, and Z-axis may be used. The X-axis is the in-plane direction of the main surface 11a of the workbench and is the direction in which the recoater 24 moves (first direction). The Y-axis is the in-plane direction of the main surface 11a of the workbench and is a direction (third direction) perpendicular to the X-axis. The Z-axis is the normal direction of the main surface 11a of the workbench and is the direction in which the laser L is irradiated (second direction).

The three-dimensional structure 100 is, for example, a machine part. Also, the three-dimensional structure 100 may be another structure. Powder 101 is composed of a large number of powder bodies. The material of the powder 101 is metal, such as titanium-based metal powder, Inconel (registered trademark) powder, aluminum powder, and stainless steel powder. The material of the powder 101 is not limited to metallic materials. The material of the powder 101 may be a material containing carbon fiber and resin, such as CFRP (Carbon Fiber Reinforced Plastics). Also, the material of the powder 101 may be another material. The material of the powder 101 may be a material having conductivity. Moreover, the powder 101 may be any material as long as it can be melted by the laser L irradiation. For example, as the powder 101, granules having a larger particle size than the powder may be used.

The three-dimensional modeling apparatus 1 has a modeling section 2, a laser emitting section 3, and a control section 4 as main components. The modeling unit 2 is a part that models a three-dimensional modeled object 100 that is a desired object. The laser emitting section 3 emits a laser L toward the powder 101 . The control unit 4 is an electronic control unit that controls the entire three-dimensional modeling apparatus 1 . The control unit 4 includes a computer configured from hardware such as a CPU (Central Processing Unit), ROM (Read Only Memory), and RAM (Random Access Memory), and software such as programs stored in the ROM. may be

The laser emitting unit 3 is a laser emitting device that melts and solidifies the powder 101 . The laser L emitted from the laser emitting portion 3 is irradiated into the chamber 9 to heat the powder 101 . The laser emitting unit 3 can apply energy to the powder 101 to heat and melt the powder 101 . The laser emitting section 3 is an energy imparting section that imparts energy to the powder 101 . The laser emission unit 3 may include optical components such as a mirror for polarizing the laser L, a mirror driving unit for moving the mirror, and a condenser lens for condensing the laser L.

The control unit 4 executes emission control of the laser L in the laser emission unit 3 and operation control of the mirror driving unit and the like. For example, the controller 4 controls the irradiation position of the laser L by outputting a control signal to the mirror driving section as operation control of the laser emitting section 3 . Three-dimensional CAD (Computer-Aided Design) data of a three-dimensional modeled object 100, which is an object to be modeled, is input to the control unit 4. FIG. The control unit 4 generates two-dimensional slice data based on this three-dimensional CAD data. The slice data is, for example, horizontal cross-sectional data of the three-dimensional structure 100, and is a collection of a large number of data corresponding to vertical positions. Based on this slice data, the area irradiated with the laser L is determined, and a control signal is output to the mirror driving section according to the area. The control unit 4 also executes supply control of the powder 101, which will be described later.

The modeling unit 2 forms a space for modeling a three-dimensional modeled object 100, which is a desired object, and accommodates several devices required for modeling. The modeling section 2 has a chamber 9, a workbench 11, a modeling tank 12, and a powder supply device 13 (powder supply section).

The chamber 9 forms a modeling space S that accommodates a work table 11 , a modeling tank 12 (modeling area section), and a powder supply device 13 . The chamber 9 is a container whose interior can be evacuated (low pressure), and is connected to a vacuum pump (not shown). The interior of the chamber 9 is filled with argon gas, for example.

The workbench 11 has a workbench main surface 11a. The main surface 11a of the workbench is provided with an opening of a modeling tank 12, openings of storage tanks 17A and 17B, and openings of collection tanks 18A and 18B, which will be described later.

As shown in FIG. 2, the modeling tank 12 extends in the direction of the Z-axis. The modeling tank 12 includes, for example, a circular tank hole 12a in which a modeling piston 14 is arranged.

The modeling piston 14 has a flat plate member arranged in the modeling tank 12 and a shaft member provided on the rear surface of the flat plate-shaped member. The modeling tank 12 and the modeling piston 14 are arranged concentrically. The shape of the build piston 14 corresponds to the shape of the build area. The shape of the modeling area may be, for example, the shape of the opening of the modeling tank 12 provided on the main surface 11a of the workbench. The build piston 14 has a flat plate main surface (build table). The plate main surface supports the three-dimensional structure 100 and the powder 101 . The modeling piston 14 is arranged on the extension line of the emission direction of the laser L, and provided parallel to the horizontal XY plane, for example.

Since the powder 101 arranged on the modeling piston 14 is irradiated with the laser L, the main surface of the modeling piston 14 may be regarded as a region irradiated with the laser L (see FIG. 3). In other words, the opening of the modeling tank 12 may be regarded as the modeling area M. The modeling area M may be a range larger than the main surface of the modeling piston 14 or the opening of the modeling tank 12, or may be a part of the main surface of the modeling piston 14 or the opening of the modeling tank 12. .

A piston drive 16 is attached to the shaping piston 14 . The piston drive device 16 supports the modeling piston 14 and vertically moves the modeling piston 14 within the modeling tank 12 . The piston drive device 16 is electrically connected to the controller 4 and operates upon receiving a control signal from the controller 4 . The piston drive 16 moves the building piston 14 upward at the beginning of building the object and lowers the building piston 14 each time the powder 101 is deposited on the building piston 14 .

The shapes of the modeling tank 12 and the modeling piston 14 described above may be appropriately changed according to the shape of the three-dimensional modeled object 100 and the like. In the three-dimensional modeling apparatus 1 of the present disclosure, the modeling tank 12 and the modeling piston 14 are rectangular, and the modeling tank 12 is rectangular. Because the build piston 14 is placed in the build tank 12 and the build surface is formed on the build piston 14, in plan view they have equal shape and size. The shapes of the modeling tank 12 and the modeling piston 14 in plan view are not limited to squares, and may be circular, for example. The shape of the modeling tank 12 may be cylindrical.

Hereinafter, the powder feeder 13 will be described in detail with reference to FIGS. 2 and 3. FIG. The powder supply device 13 supplies powder 101 to the modeling tank 12 . The supply of the powder 101 includes an operation of moving the powder 101 from the outside of the modeling tank 12 to the modeling tank 12 and an operation of leveling the powder 101 to a predetermined thickness in the modeling tank 12 (specifically, on the modeling piston 14). and including.

The powder supply device 13 includes a pair of storage tanks 17A and 17B (powder storage units), a pair of recovery tanks 18A and 18B, an application mechanism 19 (application unit), and a pair of removal mechanisms 21A and 21B (powder removal units). and have

A pair of storage tanks 17A and 17B store the unsolidified powder 101, respectively. A pair of storage tanks 17A and 17B are arranged on both sides of the modeling tank 12 so as to sandwich the modeling tank 12 therebetween. The storage tanks 17A and 17B have a rectangular shape in plan view (see FIG. 3). Storage tanks 17A and 17B each have a tank hole 17a and a feed piston 22 . The tank hole 17a is a hole having an opening on the main surface 11a of the workbench. The tank holes 17a constitute side walls of the storage tanks 17A and 17B, respectively. The feed piston 22 has the same shape as the tank hole 17a in a plan view, and is arranged so as to be vertically movable inside the tank hole 17a. The feed piston 22 constitutes the bottom surface of the storage tanks 17A and 17B. The feed piston 22 is provided with a piston driving device 23 for moving the feed piston 22 in the vertical direction (in the axial direction of the tank hole 17a).

The powder 101 is moved from the storage tanks 17A, 17B onto the modeling tank 12 by the application mechanism 19 . At this time, in order to reliably supply the required powder 101, the feed piston 22 pushes out more powder 101 than required. Then, the extruded powder 101 is moved onto the modeling tank 12 by the application mechanism 19 . Excess powder is then produced. Collection tanks 18A and 18B collect this surplus powder.

The recovery tanks 18A, 18B are arranged so as to sandwich a pair of storage tanks 17A, 17B. For example, collection tank 18A is adjacent to storage tank 17A. The collection tank 18B is adjacent to the storage tank 17B. That is, the collection tank 18A, the storage tank 17A, the modeling tank 12, the storage tank 17B, and the collection tank 18B are arranged in this order along the moving direction of the coating mechanism 19 (eg, the negative X direction). The recovery tanks 18A and 18B have a recovery opening 18a formed in the main surface 11a of the workbench and a recovery area 18b communicating with the recovery opening 18a. The recovery opening 18a extends along the Y direction and is at least longer than the length of the modeling tank 12 in the Y direction.

Application mechanism 19 moves powder 101 to modeling tank 12 . Furthermore, the coating mechanism 19 evens out the powder 101 . This leveling may be defined as an operation for making the thickness of the unsolidified powder 101 constant with respect to the main surface 11a of the workbench. The coating mechanism 19 has a recoater 24 and a recoater driving section 26 . The recoater 24 is movable along the positive X direction and also movable in the negative X direction. That is, the recoater drive unit 26 reciprocates the recoater 24 along the X direction. Further, the recoater driving section 26 moves the recoater 24 above the collection openings 18a in the collection tanks 18A and 18B in accordance with the control signal provided from the control section 4. As shown in FIG.

The recoater 24 extends in the Y direction. The length of the recoater 24 in the longitudinal direction (Y direction) is at least longer than the diameter of the modeling tank 12 . Then, when the recoater 24 moves along the X direction, the recoater 24 passes through the entire area of the opening of the modeling tank 12 .

As shown in FIG. 4, the recoater 24 has a recoater body 27 (application body) and a scraper 28 (application pressing portion).

The recoater main body 27 is, for example, a rigid component made of a metal material. The rigidity (strength) of the recoater body 27 is at least higher than that of the scraper 28 . Both ends of the recoater main body 27 are connected to the recoater driving section 26 . The recoater body 27 grips the scraper proximal end 28a. The recoater main body 27 has a recoater main surface 27a facing the workbench main surface 11a. The recoater main body 27 holds the scraper 28 so that the scraper 28 protrudes in the Z direction (downward) from the recoater main surface 27a.

The scraper 28 moves the powder 101 and smoothes the powder 101 . The scraper 28 is made of a relatively flexible soft material. For example, the scraper 28 may be made of silicone resin. The scraper 28 has a scraper proximal end 28a, a scraper distal end 28b, and a scraper main surface 28c.

The scraper base end 28a is gripped by the recoater body 27 as described above. The scraper tip 28b is an end opposite to the scraper base end 28a and faces the main surface 11a of the workbench. The scraper tip 28b is closer to the workbench main surface 11a than the recoater main surface 27a. The scraper main surface 28 c is the surface that comes into direct contact with the powder 101 . The scraper main surface 28c is a surface that intersects the moving direction of the scraper 28 (positive or negative X direction). The scraper main surface 28c rises downward (in the Z direction) from the recoater main surface 27a. The angle formed by the recoater main surface 27a and the scraper main surface 28c may be approximately a right angle. The angle formed by the recoater main surface 27a and the scraper main surface 28c is not limited to a right angle, and may be an obtuse angle larger than the right angle.

As the scraper 28 moves in the positive X direction, one scraper major surface 28c contacts the powder 101. As shown in FIG. As the scraper 28 moves in the negative X direction, the other scraper main surface 28c contacts the powder 101. As shown in FIG. When the scraper 28 moves, a space surrounded by the recoater main surface 27a, the scraper main surface 28c, and the surface of the powder 101 is formed. Then, the powder 101 present in the vicinity of the scraper main surface 28c is easily pressed as the scraper 28 moves. In particular, the powder 101 tends to stay at the boundary between the recoater main surface 27a and the scraper main surface 28c. The stagnant powder 101 may stick to each other, form clumps, and adhere to the scraper main surface 28c and the recoater main surface 27a. Such powder 101 is called residual powder 200 (see FIG. 7).

The removal mechanism 21A, 21B shown in FIGS. 3-5 removes the residual powder 200. FIG. The removal mechanisms 21A, 21B are arranged above the recovery opening 18a. The removal mechanisms 21A and 21B have a plate-like removal plate 29 and a support portion 31 that supports the removal plate 29 . That is, the removing plate 29 is fixed so as not to move relative to the main surface 11a of the workbench. The thickness (length in the Z direction) of the removal plate 29 may be shorter than the length of the scraper main surface 28c. Further, the width (length in the X direction) of the removing plate 29 extends from the scraper main surface 28c to the side surface of the recoater body 27 (the side surface located on the positive side in the X direction in the case of the removing mechanism 21A, and the negative side in the case of the removing mechanism 21B). longer than the length to the side located on the side). According to this configuration, the tips of the removing mechanisms 21A and 21B can be brought into contact with the scraper main surface 28c. Furthermore, the depth (the length in the Y direction) of the removing mechanisms 21A and 21B is at least longer than the depth of the scraper 28 .

Next, the operation of the 3D modeling apparatus 1 will be described with reference to FIG.

First, the powder 101 is spread evenly (coating operation). For example, the recoater 24 is positioned between the removal mechanism 21B on one side and the storage tank 17B on one side. The controller 4 moves the recoater 24 in the positive X direction. This movement causes the powder 101 to move from one storage tank 17B onto the modeling piston 14 (modeling table). As a result, a powder layer is formed on the modeling piston 14 (step S1).

The powder layer is then processed (melting operation). The control unit 4 controls the laser emitting unit 3 to irradiate the powder 101 on the modeling piston 14 with the laser L (step S2). The irradiation of the laser L causes the powder 101 to melt. Note that the powder 101 may be preheated by the laser L before the powder 101 is melted, if necessary. After the irradiation of the laser L is completed, the controller 4 controls the piston driving device 16 to lower the modeling piston 14 by the thickness of one layer of the powder layer.

Excess powder is recovered before or in parallel with the above treatment. In moving the recoater 24, the control unit 4 moves the recoater 24 from one storage tank 17B to the recovery tank 18A via the modeling piston 14. As shown in FIG. As a result, powder that has not been applied by the modeling piston 14 (hereinafter referred to as "surplus powder") passes through the storage tank 17A and moves to the recovery opening 18a of the recovery tank 18A. That is, the surplus powder is recovered in the recovery tank 18A through the recovery opening 18a. After that, the controller 4 further moves the recoater 24 in the positive X direction. As a result, the removing mechanism 21A performs a removing operation (step S3), which will be described later. The removal operation will be described later in detail.

After the application operation of the powder 101, the operation of melting the powder 101 (the shaping process), and the operation of removing the powder 101 are performed, the recoater 24 may be positioned between the other removal mechanism 21A and the other storage tank 17A. Then, the control unit 4 moves the recoater 24 in the negative X direction. This movement causes the powder 101 to move from the other storage tank 17A onto the modeling piston 14 . As a result, the powder 101 is evenly spread on the modeling piston 14 (step S1).

Next, the control unit 4 controls the laser emitting unit 3 to irradiate the powder 101 on the modeling piston 14 with the laser L (step S2). The irradiation of the laser L causes the powder 101 to melt. After the irradiation of the laser L is completed, the controller 4 controls the piston driving device 16 to lower the modeling piston 14 by the thickness of one layer of the powder layer.

Then, when moving the recoater 24, the control unit 4 moves the recoater 24 from the other storage tank 17A to the recovery tank 18B via the modeling piston 14. As shown in FIG. As a result, the surplus powder passes through the storage tank 17B and moves to the recovery opening 18a of the recovery tank 18B. That is, the surplus powder is recovered in the recovery tank 18B. After that, the controller 4 further moves the recoater 24 in the negative X direction. As a result, the removal operation (step S3), which will be described later, is performed by the removal mechanism 21B.

By repeating the steps S1, S2, and S3 as described above, the three-dimensional structure 100 is laminated and manufactured.

Hereinafter, a more detailed configuration of the removing mechanism 21A and a removing operation by the removing mechanism 21A will be described with reference to parts (a), (b), and (c) of FIG. Note that the configuration and removal operation of the removal mechanism 21B are the same as those of the removal mechanism 21A, except that the structure and movement direction are symmetrical (opposite) with respect to the YZ plane. Accordingly, a detailed description of the removal mechanism 21B is omitted in place of the description of the removal mechanism 21A.

As shown in part (a) of FIG. 7, the recoater 24 that has finished the coating operation approaches the recovery opening 18a. In this illustration, the recoater 24 moves in the positive X direction. Surplus powder that has not been applied onto the modeling tank 12 is moved beyond the storage tank 17A by the recoater 24 and is collected in the collection tank 18A through the collection opening 18a. Residual powder 200 adheres to the recoater 24 . Residual powder 200 adheres to recoater main surface 27a and scraper main surface 28c.

As shown in part (b) of FIG. 7, the removal mechanism 21A has a removal tip surface 29a (press removal surface) and a removal main surface 29b (main body removal surface). The removal tip surface 29a faces the scraper main surface 28c. Further, the removal plate 29 is held by the support portion 31 so that the removal tip surface 29a is arranged above the recovery opening 18a. The removal main surface 29b faces the recoater main surface 27a at a position where the recoater 24 is close to the removal mechanism 21A. The removing mechanism 21A is held so that a slight gap is formed between the removing main surface 29b and the recoater main surface 27a.

The recoater 24 approaches the removal mechanism 21A from the storage tank 17A while maintaining the movement direction (positive X direction) (see FIG. 7A). At this time, as shown in part (a) of FIG. 7, residual powder 200 may adhere to the recoater main surface 27a and the scraper main surface 28c. In this state, when the recoater 24 moves further in the positive X direction, the removal tip surface 29a comes into contact with the residual powder 200. As shown in FIG. Also, the removing main surface 29b of the removing mechanism 21A faces the recoater main surface 27a. In this state, a portion 201 of the residual powder 200 adhering to the recoater main surface 27a facing the removal main surface 29b is removed (see FIG. 7B, step S3a: Residual powder adhering to the coating body ).

As shown in part (c) of FIG. 7, the recoater 24 moves further. This movement is stopped just before the removal tip surface 29a contacts the scraper main surface 28c. That is, the removal tip surface 29a does not contact the scraper main surface 28c. note that. The removal tip surface 29a may slightly contact the scraper main surface 28c. Along with this movement, residual powder 200 adhering to recoater main surface 27a facing removal main surface 29b is further removed. In addition, since the removal main surface 29b is close to the scraper main surface 28c, the residual powder 200 on the scraper main surface 28c is also stimulated, so that a portion 202 of the residual powder 200 adhering to the scraper main surface 28c is also removed. (Step S3b: Step of removing residual powder adhering to the application pressing portion).

That is, the removing mechanism 21A removes not only the residual powder 200 adhering to the scraper main surface 28c but also the residual powder 200 adhering to the recoater main surface 27a. As a result, it becomes possible to reliably remove the residual powder 200 .

In short, application mechanism 19 moves powder 101 by scraper 28 . This powder 101 may adhere to the scraper 28 and the recoater body 27 in the vicinity of the scraper 28 resulting in residual powder 200 . Since the removal plate 29 of the powder supply device 13 has a removal tip surface 29a facing the scraper 28, by bringing the removal tip surface 29a relatively close to the scraper 28, the residual powder 200 adhering to the scraper 28 is removed. can be removed. Furthermore, since the removal plate 29 of the powder supply device 13 has a main removal surface 29 b facing the recoater body 27 , the removal main surface 29 b is brought relatively close to the recoater body 27 , so that the recoater body 27 can be It is possible to remove the adhering residual powder 200 . That is, the removing mechanisms 21A and 21B can reliably remove the residual powder 200 on the scraper 28 and the recoater main body 27. FIG. Residual powder 200 removed from recoater 24 can be collected into collection tanks 18A, 18B through collection opening 18a.

After performing the step S3 of removing the residual powder 200, the controller 4 moves the recoater 24 in the negative X direction from the position shown in part (c) of FIG. Then, the control unit 4 moves the recoater 24 so as to move the powder 101 from the other storage tank 17A onto the modeling piston 14 (step S1). At this time, the residual powder 200 has been removed from the recoater 24 . As a result, it is possible to prevent the residual powder 200 from falling onto the modeling piston 14 (powder bed) (irradiation area of the energy beam).

The present disclosure is not limited to the embodiments described above, and various modifications such as those described below are possible without departing from the gist of the present disclosure.

<Modification 1>
The removal mechanisms 21A and 21B have a fixed removal plate 29, and the relative positional relationship between the recoater 24 and the removal plate 29 is changed by the movement of the recoater 24. FIG. For example, as shown in FIG. 8 , the powder supply device 13A according to Modification 1 may include a removal mechanism 21C having a movable piece 32 (movable piece portion) that moves with respect to the recoater 24 . Specifically, the removing mechanism 21C has a movable piece 32 and a movable piece driving section 33 (moving mechanism). Like the removal plate 29, the movable piece 32 has a removal tip surface 29a and a removal main surface 29b. On the other hand, the movable piece 32 has a depth length shorter than that of the removal plate 29 . Then, the movable piece 32 is reciprocated in the depth direction (direction along the Y-axis) by the movable piece drive section 33 . This action preferably removes residual powder adhering to the recoater 24 .

<Modification 2>
For example, as shown in FIG. 9, the removal plate 34 of the removal mechanism 21D of the powder supply device 13B according to the second modification includes a removal tip surface 34a following the shape of the scraper main surface 28c and a recoater main surface 27a. and a conforming removal major surface 34b. As illustrated in FIG. 9, when the cross-sectional shape of the recoater main surface 27a is arcuate, the cross-sectional shape of the removal main surface 34b may also be arcuate. With such a configuration, it is possible to bring the removal tip surface 34a closer to the scraper main surface 28c, and similarly, to bring the removal main surface 34b closer to the recoater main surface 27a. is possible. That is, when the recoater main surface 27a and the removal main surface 34b are close to each other, no large gap is formed. Therefore, residual powder adhering to the recoater 24 can be removed more reliably.

<Modification 3>
For example, as shown in part (a) of FIG. 10, the removal plate 35 of the removal mechanism 21E of the powder supply device 13C according to Modification 3 may be made of two different materials. Specifically, the removal plate 35 may have a body removal portion 36 including a removal tip surface 35a and a pressing removal portion 37 including a removal main surface 35b. The body removal portion 36 is made of a relatively hard material. For example, the modulus of elasticity of the body removal portion 36 may be greater than the modulus of elasticity of the pressure removal portion 37 . On the other hand, the pressure removing portion 37 is made of a relatively soft material. The term "softness" refers to a material that can be easily deformed so as to follow the shape of the recoater main surface 27a when the pressure removing portion 37 is pressed against the recoater main surface 27a (see FIG. 10(b)). . In other words, the pressure removing portion 37 is made of a flexible material. Further, the elastic modulus of the pressure removing portion 37 is smaller than the elastic modulus of the recoater main body 27 . Note that the main body removing portion 36 may also be deformable so as to follow the shape of the scraper main surface 28c, similarly to the pressing removing portion 37. As shown in FIG. According to this configuration, since the pressing removing portion 37 is deformable, the force with which the removing main surface 29b presses the recoater main surface 27a is reduced. Therefore, residual powder adhering to the recoater main surface 27a can be more reliably removed.

<Modification 4>
For example, as shown in FIG. 11, the removal plate 38 of the removal mechanism 21F of the powder supply device 13D according to Modification 4 may have an L shape when viewed from the side. In this case, the area of the removal tip surface 38a can be made larger than the removal main surface 36b. Further, the removal plate 38 having such a shape may be fixed to the support portion 31 as shown in FIG. 11, or may be movable in the positive and negative Z directions by a driving mechanism (not shown). good.

<Modification 5>
A three-dimensional modeling apparatus is not limited to a modeling apparatus to which a laser melting method is applied. For example, the 3D modeling apparatus may be a modeling apparatus using an electron beam. That is, the beam (energy beam) with which the powder 101 is irradiated in the three-dimensional modeling apparatus may be an electron beam. The beam (energy beam) with which the powder 101 is irradiated in the three-dimensional modeling apparatus may be a charged particle beam, which is a concept including an electron beam and an ion beam.

For example, a three-dimensional modeling apparatus 1A shown in FIG. 12 has an electron beam emitting section 3A instead of the laser emitting section 3. The electron beam emitting section 3A has an electron gun section 6, a converging coil 7, and a deflection coil 8. As shown in FIG. The electron gun section 6 is electrically connected to the control section 4 and operates upon receiving a control signal provided from the control section 4 . The electron gun unit 6 emits an electron beam B downward, for example. The converging coil 7 is electrically connected to the control section 4 and operates upon receiving a control signal provided from the control section 4 . A converging coil 7 is installed around the electron beam B emitted from the electron gun section 6 . A converging coil 7 converges the electron beam B. FIG. The deflection coil 8 is electrically connected to the control section 4 and operates upon receiving a control signal provided from the control section 4 . A deflection coil 8 is installed around the electron beam B emitted from the electron gun section 6 . The deflection coil 8 adjusts the irradiation position of the electron beam B according to the control signal. The electron gun section 6, the converging coil 7 and the deflection coil 8 are installed, for example, in a cylindrical column.

Incidentally, the electron beam emitting part 3A may be used for preheating the powder 101. FIG. Preheating refers to an operation of irradiating the powder 101 with the electron beam B to heat the powder 101 to a predetermined temperature before molding an object.

Furthermore, the three-dimensional modeling apparatus of the present disclosure can also have the following aspects in addition to the above modifications 1 to 5.

The three-dimensional modeling apparatus 1 of the embodiment employs a so-called powder bed fusion method (PBF). For example, the three-dimensional modeling apparatus to which the removal mechanism is applied may employ a so-called binder injection method.

In the above embodiment, the three-dimensional modeling apparatus 1 includes two storage tanks 17A and 17B and two removal mechanisms 21A and 21B. The storage tank 17A and the removal mechanism 21A were arranged on the positive X direction side with respect to the modeling piston 14 . The storage tank 17B and the removal mechanism 21B are arranged on the negative X direction side with respect to the modeling piston 14 . This configuration allows powder to be applied from both sides of the build piston 14 (powder bed). Furthermore, according to this configuration, the removal operation can be performed by the removal mechanism on both sides of the modeling piston 14 . However, the three-dimensional modeling apparatus to which the powder supply device is applied is not limited to such a configuration.

For example, the three-dimensional modeling apparatus may apply powder to the modeling piston only from one side. Also, the three-dimensional modeling apparatus may perform the removal operation only on one side of the modeling piston.

For example, the 3D modeling apparatus may include one storage tank and one removal mechanism. In this case, the storage tank may be arranged on the negative X direction side with respect to the build piston and the removal mechanism may be arranged on the positive X direction side with respect to the build piston. In other words, the storage tank is not located on the positive X direction side with respect to the build piston, and the removal mechanism is not located on the negative X direction side with respect to the build piston. That is, the storage tank and the removal mechanism are arranged so as to sandwich the modeling piston. Also in this case, the residual powder adhering to the recoater (the portion on the positive X direction side) due to powder application from the storage tank can be removed by the removal mechanism.

In this configuration, the removal mechanism is positioned forward in the direction of movement of the coating operation of the recoater. As a result, the removing mechanism can remove residual powder adhering to the front side of the recoater. Therefore, when the recoater returns to the storage tank after applying the powder, it is possible to prevent the residual powder adhering to the recoater from dropping onto the modeling piston. In other words, when the recoater moves in the direction opposite to the direction of movement during powder coating, it is possible to prevent the residual powder from falling onto the energy beam irradiation region, which is the powder bed.

Moreover, in said embodiment, whenever performing powder application|coating process S1 once, the form which performs removal operation|movement S3 was illustrated. For example, the timing of performing the removal operation S3 is not necessarily limited to this. For example, the removal operation S3 may be performed after performing the powder application step S1 a plurality of times. Further, when a certain amount or more of the residual powder 200 adheres to the recoater 24, the removing operation S3 may be performed.

1, 1A Three-dimensional modeling apparatus 2 Modeling unit 3 Laser emission unit 3A Electron beam emission unit 4 Control unit 6 Electron gun unit 7 Convergence coil 8 Deflection coil 9 Chamber 11 Workbench 11a Main surface of workbench 12 Modeling tanks 13, 13A, 13B , 13C, 13D powder supply device (powder supply unit)
14 modeling piston (modeling area)
16 piston driving device 17A, 17B storage tank (powder storage unit)
18A, 18B recovery tank 19 coating mechanism (coating section)
21A, 21B, 21C, 21D, 21E, 21F removal mechanism (powder removal section)
22 Feed piston 23 Piston driving device 24 Recoater 26 Recoater driving unit 27 Recoater main body (application main body)
27a recoater main surface 28 scraper (application pressing portion)
28a Scraper base end 28b Scraper tip 28c Scraper main surface 29 Removal plate 29a Removal tip surface (press removal surface)
29b removal main surface (main body removal surface)
31 support portion 32 movable piece (movable piece portion)
33 Movable piece drive unit (moving mechanism)
34 Removal plate 34a Removal tip surface 34b Removal main surface 35 Removal plate 36 Body removal part 37 Press removal part 38 Removal plate 100 Three-dimensional model 101 Powder 200 Residual powder B Electron beam (energy beam)
S modeling space M modeling area

Claims (6)

A powder supply device for use in a three-dimensional modeling device that processes spread powder to form a modeled object,
a powder storage unit that stores the powder;
a coating unit arranged movably between the powder containing unit and a modeling area in which the modeled object is formed by processing the powder, and for moving the powder from the powder containing unit to the modeling area;
and a powder removing unit that removes residual powder adhering to the applying unit,
The application part is
an application pressing portion that presses the powder in a first direction from the powder containing portion toward the modeling region;
an application body that holds the application pressing part so that the application pressing part protrudes in a second direction that intersects with the first direction;
The powder removing unit is
a pressing removal surface facing the application pressing portion;
a body removal surface facing the applicator body;
a body removal portion including the body removal surface ;
The elastic modulus of the main body removal portion is smaller than the elastic modulus of the application main body,
The powder feeder according to claim 1, wherein when the main body removing part is pressed against the applying main body, the main body removing part deforms to follow the shape of the applying main body . The powder removing section has a pressure removing section including the pressure removing surface,
The elastic modulus of the pressure removing portion is smaller than the elastic modulus of the application pressing portion,
2. The powder supply device according to claim 1 , wherein when said pressure removing part is pressed by said applying pressure part, said pressure removing part deforms so as to follow the shape of said applying pressure part. The powder supply device according to claim 1 or 2 , wherein the powder removal section is fixed. The powder removing portion includes a movable piece portion including the pressing removal surface and the main body removal surface;
The powder feeder according to any one of claims 1 to 3 , further comprising a moving mechanism for moving the movable piece portion in a third direction that intersects with the first direction and the second direction. A three-dimensional modeling apparatus that forms a modeled object by processing the evenly spread powder,
a modeling region where the powder is evenly spread and the modeled object is formed by processing the powder;
a powder supply unit that evenly spreads the powder on the modeling area;
with
The powder supply unit is
a powder storage unit that stores the powder;
an application unit arranged movably between the powder storage unit and the modeling area unit to move the powder from the powder storage unit to the modeling area unit;
a powder removal unit for removing residual powder adhering to the application unit;
The application part is
an application pressing unit that presses the powder in a first direction from the powder storage unit toward the modeling area;
an application body that holds the application pressing part so that the application pressing part protrudes in a second direction that intersects with the first direction;
The powder removing unit is
a pressing removal surface facing the application pressing portion;
a body removal surface facing the applicator body;
a body removal portion including the body removal surface ;
The elastic modulus of the main body removal portion is smaller than the elastic modulus of the application main body,
The three-dimensional modeling apparatus , wherein when the main body removing part is pressed against the applying main body, the main body removing part deforms so as to follow the shape of the applying main body . A method for modeling a three-dimensional object with a three-dimensional modeling apparatus, comprising:
The three-dimensional modeling apparatus includes a modeling area section in which powder is evenly spread and the modeled object is formed by processing the powder, and a powder supply section that spreads the powder evenly in the modeling area section,
a step of spreading the powder evenly over the modeling area by moving the coating portion of the powder supply portion in a predetermined direction;
a step of processing the evenly spread powder to form the three-dimensional model;
removing the residual powder by bringing a powder removing unit that removes the residual powder adhering to the applying unit and the applying unit relatively close to each other;
The step of removing the residual powder comprises:
a step of removing the residual powder adhering to the coating body that grips the coating pressing part that presses the powder;
and removing the residual powder adhering to the application pressing part ,
The powder removal section has a body removal section including a body removal surface facing the application body,
In the step of removing the residual powder adhering to the application main body, the main body removal portion having an elastic modulus smaller than that of the application main body is pressed against the application main body so that the main body removal portion is removed from the application main body. A method of forming a three-dimensional object that deforms so as to follow the shape of the object.

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