JP7571475B2 - Recoater device and additive manufacturing device - Google Patents

Description

The present invention relates to a recoater device and an additive manufacturing device.

Patent Document 1 describes an additive manufacturing device that produces a model by solidifying a powder material. The additive manufacturing device includes a powder bed containing powder and a modeling table capable of holding a model, a laser light emitting unit that solidifies the powder held on the modeling table with a laser, a powder supply table that deposits the powder supplied to the modeling table, and a recoater device that scrapes the powder deposited on the powder supply table onto the modeling table.

JP 2007-307742 A

Metal additive manufacturing can be performed using an additive manufacturing device. Metal additive manufacturing is a technology in which metal powder is laid down to a thickness on the order of micrometers and then melted with a laser to form a product. In metal additive manufacturing, the metal powder is laid down evenly using a recoater that moves horizontally. However, when an object is formed by irradiating it with a laser, the object may warp. In this case, the recoater may come into contact with the warped object and be damaged. If the recoater is damaged, the surface to which the powder is applied may not be flat, which may result in a decrease in the quality of the object.

One aspect of the present invention aims to provide a recoater device and an additive manufacturing device that suppresses damage to the recoater.

A recoater device according to one embodiment of the present invention includes a recoater including multiple metallic recoater elements aligned in a first direction, and a holder extending in the first direction to hold the recoater. When the recoater is held by the holder, the multiple recoater elements cooperate to form a flat surface extending along the first direction, and adjacent recoater elements in the first direction are separated from each other at least at the position where they form the flat surface, and each recoater element is capable of being displaced independently of the other recoater elements in the second direction when pressed in a second direction intersecting the first direction.

According to the above recoater device, the flat surface formed by the multiple recoater elements moves over the surface to which the metal powder is applied, thereby leveling the metal powder. Because the recoater elements are made of metal, even if a warp in the molded object comes into contact with one of the recoater elements, the recoater element is prevented from being damaged by the warp. Furthermore, a recoater element that comes into contact with the warp is displaced in the direction pressed by the warp. This allows the recoater element to overcome the warp. As described above, the above recoater device prevents the recoater from being damaged.

The recoater element may be one pitch of a spiral having a central axis along the first direction, and the flat surface may be the outer peripheral surface of the spiral. In this configuration, by aligning the central axis of the spiral with the first direction, the outer peripheral surface of the spiral forms a flat surface along the first direction. Since multiple recoater elements are integrally formed, the recoater can be easily handled.

The multiple recoater elements may each be plate-shaped and aligned with the plate thickness direction as the first direction. In this configuration, by aligning the multiple recoater elements with the plate thickness direction aligned with the first direction, the peripheral surfaces of adjacent recoater elements form a flat surface along the first direction. Since each recoater element is separate from the others, interference between adjacent recoater elements is suppressed.

The multiple recoater elements have through holes along the plate thickness direction, and the recoater may include a flexible pole that is inserted into the through hole. In this configuration, the multiple recoater elements are held together by the pole, making the recoater easy to handle.

The holder may include a buffer material disposed between the holder and the recoater in the second direction. In this configuration, for example, even if any of the recoater elements is displaced toward the holder in the second direction due to warping, the buffer material can easily restore the recoater to its original position.

The multiple recoater elements may each be plate-shaped and aligned with the second direction as the plate thickness direction and the width direction intersecting the plate thickness direction as the first direction. In this configuration, the plate thickness direction of the plate-shaped recoater elements is the second direction, so that the surfaces of the recoater elements intersecting the plate thickness direction form flat surfaces along the first direction.

The recoater has a metal plate with multiple slits arranged in parallel and spaced apart from each other in the first direction, and the multiple recoater elements may be portions of the metal plate between adjacent slits. Since the multiple recoater elements are integrally formed, the recoater can be easily handled.

An additive manufacturing apparatus according to one embodiment of the present invention includes a chamber, a work table disposed within the chamber and holding a powder bed containing powder, an irradiation device that irradiates the powder held on the work table with an energy beam, and the above-mentioned recoater device disposed within the chamber and smoothing the surface of the powder bed.

According to one aspect of the present invention, a recoater device and an additive manufacturing device are provided that prevent damage to the recoater.

FIG. 1 is a vertical cross-sectional view showing an example of an additive manufacturing apparatus. FIG. 2 is a schematic diagram for explaining the structure of an example of a recoater apparatus. FIG. 2 is a front view of a recoater apparatus according to an exemplary embodiment. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. FIG. 13 is a front view showing a recoater apparatus according to another exemplary embodiment. 6 is a cross-sectional view taken along line VI-VI in FIG. 5. FIG. 13 is a front view showing a recoater apparatus according to still another exemplary embodiment. 8 is a cross-sectional view taken along line VIII-VIII in FIG. 7.

Embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the same or equivalent parts in each drawing are given the same reference numerals, and duplicated explanations will be omitted.

The additive manufacturing device shown in FIG. 1 is a so-called 3D (three-dimensional) printer. In the following description, the additive manufacturing device will be simply referred to as "modeling device 1." The modeling device 1 partially applies energy to metal powder 2 arranged in layers to sinter or melt the metal powder 2. The modeling device 1 manufactures a three-dimensional object 3 by repeatedly sintering or melting the metal powder 2.

The molded object 3 is, for example, a machine part. Note that the molded object 3 may be other structures. The metal powder 2 is, for example, titanium-based metal powder, Inconel (registered trademark) powder, aluminum powder, stainless steel powder, etc. The powder that is the material of the molded object 3 is not limited to metal powder. The powder may contain carbon fiber and resin, such as CFRP (Carbon Fiber Reinforced Plastics). The powder may also contain other materials. For example, the powder may contain a conductive material that is conductive.

The modeling apparatus 1 includes a vacuum chamber 4, a work table 5, a lifting device 6, a powder supplying device 7, an electron beam irradiation device 8 (irradiation device), a modeling tank 10, and a controller 18. The vacuum chamber 4 is a container capable of creating a vacuum (low pressure) state inside. A vacuum pump (not shown) is connected to the vacuum chamber 4. The shape of the work table 5 is, for example, a plate shape. The shape of the work table 5 is, for example, a circle in a plan view. The shape of the work table 5 is not limited to a circle. The shape of the work table 5 may be a rectangle. The shape of the work table 5 may also be another shape.

A substrate 15 is placed on the work table 5. Metal powder 2, which is the material of the molded object 3, is placed on the substrate 15. The metal powder 2 on the substrate 15 is placed, for example, in layers in multiple batches.

The working table 5 and the substrate 15 are disposed in the modeling tank 10 within the vacuum chamber 4. In the modeling tank 10, the working table 5 can move in the Z direction (up and down). The working table 5 descends sequentially according to the number of layers of the metal powder 2. The side wall 10a of the modeling tank 10 guides the movement of the working table 5. The shape of the side wall 10a corresponds to the outer shape of the working table 5. For example, when the shape of the working table 5 is a disk, the shape of the area surrounded by the side wall 10a is cylindrical. Also, when the shape of the working table 5 is rectangular, the shape of the area surrounded by the side wall 10a is a square tube. The side wall 10a of the modeling tank 10 and the working table 5 form a storage section that stores the metal powder 2 and the modeled object 3. The working table 5 may form the bottom of the modeling tank 10.

The lifting device 6 lifts and lowers the work table 5. When the lifting device 6 lifts and lowers the work table 5, the substrate 15 on the work table 5, the metal powder 2 on the substrate 15, and the molded object 3 are lifted and lowered. The lifting device 6 includes, for example, a rack-and-pinion type drive mechanism. With these mechanisms, the lifting device 6 moves the work table 5 in the Z direction. The lifting device 6 includes a vertical member 6a (rack) and a drive source 6b. The vertical member 6a is a rod-shaped member that is connected to the back surface of the work table 5 and extends downward. The drive source 6b drives the vertical member 6a. For example, an electric motor may be used as the drive source 6b. A pinion is provided on the output shaft of the electric motor. A tooth shape that meshes with the pinion is provided on the side of the vertical member 6a. When the electric motor is driven, the pinion rotates. Power is transmitted by the rotation of this pinion. As a result, the vertical member 6a moves in the vertical direction. When the rotation of the electric motor is stopped, the vertical member 6a is positioned. As a result, the position of the work table 5 in the Z direction is determined, and the position of the work table 5 is maintained. The lifting device 6 is not limited to a rack-and-pinion type drive mechanism. For example, the lifting device 6 may be equipped with other drive mechanisms such as a ball screw, a cylinder, etc.

The powder supplying device 7 includes a raw material tank 11. The raw material tank 11 is a storage unit that stores the raw material metal powder 2. The raw material tank 11 is disposed within the vacuum chamber 4. The raw material tank 11 is disposed above the work table 5 in the Z direction. The raw material tank 11 is disposed, for example, on both sides of the electron beam irradiation area D of the electron beam irradiation device 8 in the X direction that intersects with the Z direction. An outlet is provided at the bottom of the raw material tank 11. The outlet is continuous in, for example, the Y direction. The Y direction is a direction that intersects with the X direction and the Z direction.

Below the raw material tank 11, a protruding plate 12 is provided, which extends laterally from the upper end of the side wall 10a of the modeling tank 10. The protruding plate 12 forms a plane that intersects with the Z direction around the work table 5.

The powder supplying device 7 includes a recoater device 100, which is a powder application mechanism that evens out the metal powder 2. The recoater device 100 is equipped with a recoater 101. The recoater 101 is movable in the X direction above the work table 5 and the extension plate 12. By this movement, the recoater 101 scrapes the metal powder 2 deposited on the extension plate 12 onto the work table 5. Furthermore, by this movement, the recoater 101 evens out the surface 2a (upper surface) of the top layer of the stack of metal powder 2 on the work table 5. Hereinafter, the "stack of metal powder 2" is referred to as powder bed A. The recoater 101 abuts against the surface 2a of the powder bed A to make the height of the powder bed A uniform. The recoater 101 has a predetermined width in the Y direction. The length of the powder application mechanism in the Y direction corresponds to, for example, the total length of the work table 5 in the Y direction.

The recoater device 100 may include, for example, a rack-and-pinion type drive mechanism as a mechanism for moving the recoater 101 in the horizontal direction. The recoater device 100 may include, for example, a guide rail, an endless belt, a ball screw, an electric motor, a cylinder, etc. as a drive mechanism.

The electron beam irradiation device 8 includes an electron gun (not shown) that irradiates an electron beam (electron beam) as an energy beam. In FIG. 1, the irradiation area D through which the emitted electron beam passes is indicated by a two-dot chain line. The electron beam emitted from the electron gun is irradiated into the vacuum chamber 4. The electron beam heats the metal powder 2. In other words, the electron beam irradiation device 8 imparts energy to the metal powder 2. As a result, the metal powder 2 is heated and melts or sinters. The electron beam irradiation device 8 is a powder solidification section that solidifies the metal powder 2 in the powder bed A. The electron beam irradiation device 8 is also an energy imparting section that imparts energy to the powder bed A.

The electron beam irradiation device 8 may include a coil device that controls the irradiation of the electron beam. The coil device includes, for example, an aberration coil, a focus coil, and a deflection coil. The aberration coil is installed around the electron beam emitted from the electron gun and converges the electron beam. The focus coil is installed around the electron beam emitted from the electron gun and corrects the deviation of the focus position of the electron beam. The deflection coil is installed around the electron beam emitted from the electron gun and adjusts the irradiation position of the electron beam. The deflection coil performs electromagnetic beam deflection. With electromagnetic beam deflection, the scanning speed during irradiation of the electron beam is faster than with mechanical beam deflection. The electron gun and coil unit are arranged at the top of the vacuum chamber 4. The electron beam emitted from the electron gun is converged by the coil unit, the focus position is corrected, the scanning speed is controlled, and the electron beam reaches the irradiation position of the metal powder 2.

The controller 18, which is a control unit, controls the operation of the entire molding device 1. The controller 18 is a computer that includes hardware such as a CPU (Central Processing Unit), a ROM (Read Only Memory), and a RAM (Random Access Memory), and software such as programs stored in the ROM. The controller 18 includes an input signal circuit, an output signal circuit, a power supply circuit, etc. The controller 18 includes a calculation unit and a memory. The controller 18 is electrically connected to the electron beam irradiation device 8, the powder supply device 7, and the lifting device 6. The controller 18 can generate various command signals. The memory can store data necessary for various controls.

The controller 18 transmits a command signal to the electron beam irradiation device 8 to control the timing and position of irradiation of the electron beam (irradiation control). The controller 18 controls the irradiation of the electron beam when melting the metal powder 2. The controller 18 transmits a command signal to the powder supply device 7 to control the timing and amount of supply of the metal powder 2. The controller 18 may transmit a command signal to the recoater device 100 to control the operation timing of the recoater 101, etc.

Next, the recoater apparatus 100 will be described in more detail. FIG. 2 is a schematic diagram illustrating the structure of an example of the recoater apparatus 100. The recoater apparatus 100 includes a holder 103 and a recoater 101. The holder 103 functions as a holding section that holds the recoater 101. The holder 103 extends in a first direction D1. The first direction D1 is the Y direction in the drawing. For example, the length of the holder 103 in the Y direction may correspond to the overall length of the work table 5 in the Y direction.

The recoater 101 includes multiple recoater elements 102 made of metal. The type of metal used for the recoater 101 may vary depending on the material of the metal powder 2. For example, the type of metal used for the recoater 101 may be the same as the type of metal powder 2. In this case, even if the metal forming the recoater 101 is mixed into the metal powder 2 due to wear of the recoater 101, the adverse effects of such mixing can be suppressed. If the metal constituting the metal powder 2 cannot be used as the material for the recoater 101 from the viewpoint of tension and processability, a material with similar characteristics may be used. For example, if the metal powder 2 is an iron-based powder, the recoater 101 may be made of SUS material.

The recoater elements 102 are aligned along the first direction D1. When the recoater 101 is held by the holder 103, the recoater elements 102 cooperate to form a lower surface S1 (flat surface) extending along the first direction D1. The lower surface S1 is exposed downward from the holder 103. The lower surface S1 faces the upper surface of the work table 5. The lower surface S1 is a flat surface without any irregularities. A flat surface means a surface that is substantially flat within the range of the modeling accuracy required for the modeling device 1. In other words, when the surface 2a of the powder bed A is leveled by the lower surface S1, the surface 2a of the powder bed A becomes flat to a degree that is acceptable for the modeling accuracy of the modeling device 1.

Among the multiple recoater elements 102, adjacent recoater elements 102 in the first direction D1 are separated from each other at least at the position forming the lower surface S1. When each recoater element 102 is pressed along a second direction D2 intersecting the first direction D1, it is displaced independently of the other recoater elements 102 toward the second direction D2. Displacement independently includes displacement substantially independently. That is, when one recoater element 102 is displaced toward the second direction D2, the other adjacent recoater elements 102 may be stationary or may be displaced less than the displacement of the pressed recoater element 102. In the illustrated example, a state is shown in which one recoater element 102A of the multiple recoater elements 102 is pressed toward the second direction D2.

In the recoater device 100, the recoater 101 held by the holder 103 moves horizontally over the powder bed A in the X direction. As the recoater 101 moves, the lower surface S1 formed by the multiple recoater elements 102 moves over the coated surface of the metal powder 2. This makes the metal powder 2 flat and even. The electron beam irradiation device 8 irradiates the metal powder 2 with an electron beam in accordance with the shape of one layer of the molded object 3. The metal powder 2 irradiated with the electron beam is melted or sintered to form one layer of the molded object. Thereafter, the recoater 101 moves horizontally over the powder bed A again, and new metal powder 2 is placed on the molded object that has been formed.

When the electron beam from the electron beam irradiation device 8 melts or sinters the metal powder 2, a warp may be formed in the molded object 3. The warped portion of the molded object 3 may come into contact with the recoater moving in the X direction. For example, if the recoater is made of a material such as silicone rubber, the recoater can overcome the warp of the molded object 3. However, the recoater may be damaged when it comes into contact with the warp. Also, if the recoater is made of metal, damage to the recoater is suppressed. However, when the recoater comes into contact with the warp, it may not be able to overcome the warp, and the movement of the recoater in the X direction may stop.

In one example of the recoater device 100, the recoater element 102 is made of metal. Therefore, even if the warp in the model 3 comes into contact with the recoater element 102, the recoater element 102 is prevented from being damaged.

Furthermore, if the warpage of the model 3 comes into contact with any of the recoater elements 102, the recoater element 102 is pressed relatively by the warpage. In this case, there is a risk that the movement of the recoater 101 in the horizontal direction will stop. However, in the example recoater device 100, the recoater element 102 that comes into contact with the warpage will be displaced in the direction in which it is pressed by the warpage. If the model 3 warps upward, the recoater element 102 may be displaced upward. Therefore, when the recoater 101 moves in the X direction, the recoater element can overcome the warpage. In this way, in the example recoater device 100, damage to the recoater 101 is suppressed. Furthermore, the movement of the recoater device 100 in the X direction is suppressed from stopping.

Next, exemplary embodiments of an example recoater apparatus will be described. FIG. 3 is a front view showing an exemplary embodiment of the recoater apparatus. FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 3. The recoater apparatus 200 shown in FIGS. 3 and 4 can be used in the molding apparatus 1 in place of the recoater apparatus 100. The recoater apparatus 200 includes a holder 230 and a recoater 210.

The holder 230 holds the recoater 210. The holder 230 extends in the Y direction. For example, the length of the holder 230 in the Y direction may correspond to the overall length of the work table 5 in the Y direction. An example of the holder 230 includes a connecting portion 231 and a holding portion 233. The connecting portion 231 is connected to a drive mechanism for moving the holder 230 along the X direction. The holding portion 233 holds the recoater 210. The holding portion 233 forms a cylindrical space 233a. The axial direction of this space 233a is along the Y direction. The holding portion 233 has an opening 233b formed on the lower surface of the holder 230. The opening 233b is formed along the Y direction. The length of the opening 233b in the Y direction is at least longer than the recoater 210. The opening 233b is connected to the cylindrical space 233a.

The holding portion 233 is provided with a cushioning material 235. The cushioning material 235 is fixed to an inner peripheral surface 233c of the holding portion 233. The inner peripheral surface 233c defines a space 233a. In the illustrated example, the cushioning material 235 is disposed above the opening 233b on the inner peripheral surface 233c. In other words, the cushioning material 235 faces the opening 233b in the Z direction. The cushioning material 235 extends in the Y direction. In the Y direction, the length of the cushioning material 235 may be, for example, the same as the length of the opening 233b.

The recoater 210, as an example, is a metallic tension coil spring (helical body). The cross-sectional shape of the wire of the tension coil spring in the illustrated example is, for example, circular. The outer and inner diameters of the tension coil spring are not particularly limited. The tension coil spring constituting the recoater 210 has a central axis along the Y direction (first direction). The recoater element 211 constituting the recoater 210 can be defined as one pitch of the tension coil spring. Under this definition, adjacent recoater elements 211 are formed to be continuous with each other in the helical direction. In addition, adjacent recoater elements 211 are separated from each other in the Y direction at positions other than the portions where they are continuous with each other in the helical direction.

When viewed from the Y direction, the outer diameter 210L of the tension coil spring is smaller than the diameter 230L of the space 233a of the holding part 233. The outer diameter 210L of the tension coil spring is larger than the distance 233L of the opening 233b in the X direction. When the recoater 210 is placed in the space 233a of the holding part 233, the recoater 210 is prevented from falling off from the opening 233b. The cushioning material 235 is placed between the inner surface 233c of the holding part 233 and the outer surface of the recoater 210. The cushioning material 235 biases the recoater 210 toward the opening 233b.

The recoater elements 211 are aligned along the first direction D1. When the recoater 210 is held by the holder 230, the recoater elements 211 cooperate to form a lower surface S2 (flat surface) extending along the first direction D1. The lower surface S2 is formed by the outer peripheral surface of the tension coil spring that constitutes the recoater 210. The lower surface S2 is exposed downward from the opening 233b of the holder 230. The lower surface S2 faces the upper surface of the work table 5. The lower surface S2 is a flat surface that is substantially free of irregularities. The degree of flatness of the lower surface S2 can be determined by the wire diameter of the tension coil spring, so that when the grain size of the metal powder 2 is small, the wire diameter of the tension coil spring may also be small.

Of the multiple recoater elements 211, adjacent recoater elements 211 in the first direction D1 are separated from each other at least at the position that forms the lower surface S2. When pressed upward along the Z direction, each recoater element 211 is displaced upward independently of the other recoater elements 211.

In the recoater device 200, the recoater element 211 is made of metal. Therefore, even if the warp in the model 3 comes into contact with the recoater element 211, the recoater element 211 is prevented from being damaged.

Furthermore, in the recoater device 200, the recoater element 211 that comes into contact with the warp is displaced in the direction pressed by the warp. If the object 3 warps upward, the recoater element 211 can be displaced upward. Therefore, when the recoater 210 moves in the X direction, the recoater element 211 can overcome the warp.

The recoater element 211 is one pitch of a tension coil spring having a central axis along the Y direction. The flat lower surface S2 is formed by the outer peripheral surfaces of the multiple recoater elements 211. In this configuration, the multiple recoater elements 211 are integrally formed to form the tension coil spring (recoater 210), making it easy to handle the recoater.

The holder 230 also includes a buffer material 235 that is disposed between the holder 230 and the recoater 210 in the Z direction. In this configuration, even if any of the recoater elements 211 is displaced toward the holder in the Z direction due to warping, the buffer material 235 can easily restore the recoater elements 211 to their original positions.

Figure 5 is a front view showing a recoater apparatus according to another exemplary embodiment. Figure 6 is a cross-sectional view taken along line VI-VI in Figure 5. The recoater apparatus 300 shown in Figures 5 and 6 can be used in the molding apparatus 1 in place of the recoater apparatus 100. The recoater apparatus 300 includes a holder 330 and a recoater 310.

The holder 330 holds the recoater 310. The holder 330 extends in the Y direction. For example, the length of the holder 330 in the Y direction may correspond to the overall length of the work table 5 in the Y direction. An example of the holder 330 includes a connecting portion 331 and a holding portion 333. The connecting portion 331 is connected to a drive mechanism for moving the holder 330 along the X direction. The holding portion 333 holds the recoater 310. The holding portion 333 forms a cylindrical space 333a. The axial direction of this space 333a is along the Y direction. The holding portion 333 has an opening 333b formed on the lower surface of the holder 330. The opening 333b is formed along the Y direction. The length of the opening 333b in the Y direction is at least longer than the recoater 310. The opening 333b is connected to the cylindrical space 333a.

The holding portion 333 is provided with a cushioning material 335. The cushioning material 335 is fixed to an inner peripheral surface 333c of the holding portion 333. The inner peripheral surface 333c defines a space 333a. In the illustrated example, the cushioning material 335 is disposed above the opening 333b on the inner peripheral surface 333c. In other words, the cushioning material 335 faces the opening 333b in the Z direction. The cushioning material 335 extends in the Y direction. In the Y direction, the length of the cushioning material 335 may be, for example, the same as the length of the opening 333b.

The recoater 310 in one example includes a plurality of metal recoater elements 311 in the shape of a plate and a cylindrical pole 313. The recoater element 311 in the illustrated example has an annular plate shape. That is, the recoater element 311 has a pair of annular side surfaces and a cylindrical inner peripheral surface and an outer peripheral surface whose axis is in the Y direction. The plurality of recoater elements 311 are aligned with the plate thickness direction as the Y direction. In one example, the recoater element 311 has a circular through hole 311a along the plate thickness direction. The pole 313 is inserted into each of the through holes 311a of the plurality of recoater elements 311. When viewed from the Y direction, the diameter of the pole 313 may be approximately the same as the diameter of the through hole 311a of the recoater element 311. The pole 313 is formed of a material having heat resistance and flexibility, such as silicone or fluororubber. When the pole 313 is inserted, the recoater elements 311 adjacent to each other in the Y direction may be in contact with each other. Note that a fastener may be provided at the end of the pole 313 to prevent the recoater elements 311 from falling off the pole 313.

When viewed from the Y direction, the diameter 310L of the outer periphery of the recoater 310 is smaller than the diameter 330L of the space 333a of the holding part 333. In addition, the diameter 310L of the outer periphery of the recoater 310 is larger than the distance 333L of the opening 333b in the X direction. When the recoater 310 is placed in the space 333a of the holding part 333, the recoater 310 is prevented from falling out of the opening 333b. The cushioning material 335 is placed between the inner periphery 333c of the holding part 333 and the outer periphery of the recoater 310. The cushioning material 335 biases the recoater 310 toward the opening 333b.

The multiple recoater elements 311 are aligned along the first direction D1. When the recoater 310 is held by the holder 330, the multiple recoater elements 311 cooperate to form a lower surface S3 (flat surface) extending along the first direction D1. The lower surface S3 is formed by the outer peripheral surfaces of the multiple recoater elements 311 that constitute the recoater 310. The lower surface S3 is exposed downward from the opening 333b of the holder 330. The lower surface S3 faces the upper surface of the work table 5. The lower surface S3 is a flat surface without any irregularities. When pressed in the Z direction, each recoater element 311 is displaced independently of the other recoater elements 311 in the Z direction.

In the recoater device 300, the recoater element 311 is made of metal. Therefore, even if the warp in the model 3 comes into contact with the recoater element 311, the recoater element 311 is prevented from being damaged.

Furthermore, in the recoater device 300, the recoater element 311 that comes into contact with the warp is displaced in the direction pressed by the warp. If the shaped object 3 warps upward, the recoater element 311 can be displaced upward. Therefore, when the recoater 310 moves in the X direction, the recoater element 311 can overcome the warp.

The multiple recoater elements 311 are each plate-shaped and aligned with the plate thickness direction in the Y direction. In this configuration, the outer peripheral surfaces of adjacent recoater elements 311 form a lower surface S3 along the Y direction. Since each recoater element 311 is separate from the others, the displacement of adjacent recoater elements 311 is prevented from interfering with each other. When the displacement of any one of the recoater elements 311 is transmitted to the pole 313, the other recoater elements 311 may be displaced via the pole 313.

The multiple recoater elements 311 have through holes 311a along the plate thickness direction, and the recoater 310 includes a flexible pole 313 that is inserted into the through holes 311a. In this configuration, the multiple recoater elements 311 are bundled together by the pole 313, making the recoater 310 easy to handle.

The holder 330 also includes a cushioning material 335 that is placed between the holder 330 and the recoater 310 in the Z direction. In this configuration, even if any of the recoater elements 311 is displaced toward the holder in the Z direction due to warping, the cushioning material 335 can easily restore the recoater elements 311 to their original positions.

Figure 7 is a front view showing a recoater apparatus according to yet another exemplary embodiment. Figure 8 is a cross-sectional view taken along line VIII-VIII in Figure 7. The recoater apparatus 400 shown in Figures 7 and 8 can be used in the molding apparatus 1 in place of the recoater apparatus 100. The recoater apparatus 400 includes a holder 430 and a recoater 410.

The holder 430 holds the recoater 410. The holder 430 extends in the Y direction. For example, the length of the holder 430 in the Y direction may correspond to the overall length of the work table 5 in the Y direction. An example of the holder 430 includes a connecting portion 431 and a holding portion 433. The connecting portion 431 is connected to a drive mechanism for moving the holder 430 along the X direction. The holding portion 433 holds the recoater 410. The holding portion 433 includes a pair of grooves 434, 435. The pair of grooves 434, 435 extend along the Y direction. The pair of grooves 434, 435 open toward the work table 5 side. That is, the pair of grooves 434, 435 are formed in an upward concave shape on the lower surface of the holding portion 433. The length of the pair of grooves 434, 435 in the Y direction may be equal to or greater than the length of the recoater 410. One of the pair of grooves 434, 435, groove 434, is disposed on one side in the X direction when viewed from the Y direction. The other of the pair of grooves 434, 435, groove 435, is disposed on the other side in the X direction when viewed from the Y direction. Groove 434 and groove 435 are formed parallel to each other.

The recoater 410, as an example, is formed of a metal plate. The metal plate may have a thickness of, for example, about 0.02 mm to 0.1 mm, and is elastically deformable in the plate thickness direction. The recoater 410 has, for example, a rectangular shape. The recoater 410 has a plurality of slits 411 formed along the extension direction of the short side. The plurality of slits 411 are formed at the center of the extension direction of the short side. The plurality of slits 411 are arranged in parallel and spaced apart from each other in the extension direction of the long side. The recoater 410 is held by the holder 430 by inserting a pair of long side portions 412, 413 into a pair of grooves 434, 435, respectively. When the recoater 410 is held by the holder 430, the recoater 410 is curved in a U-shape when viewed from the Y direction. For example, the recoater 410 may be fixed to the holder 430 by a fixing member such as a bolt when held by the holder 430.

When the recoater 410 is held by the holder 430, the multiple slits 411 extend on a plane along the X and Z directions and are arranged in parallel and spaced apart from each other in the Y direction. The recoater 410 includes multiple recoater elements 415. The multiple recoater elements 415 are portions of the recoater 410 between adjacent slits 411. Each of the multiple recoater elements 415 is plate-shaped.

When the recoater 410 is held by the holder 430, the multiple recoater elements 415 cooperate to form a lower surface S4 extending along the Y direction. The multiple recoater elements 415 are aligned with the width direction intersecting the plate thickness direction as the Y direction. At the lowest end position of the lower surface S4, the multiple recoater elements 415 have the plate thickness direction in the Z direction. The lower surface S4 faces the upper surface of the work table 5. The lower surface S4 is a flat surface with substantially no irregularities. When pressed in the Z direction, each recoater element 415 is displaced in the Z direction independently of the other recoater elements 415.

In the recoater device 400, the recoater 410 is formed from a metal plate. Therefore, even if the warp generated in the model 3 comes into contact with the recoater element 415, the recoater element 415 is prevented from being damaged.

Furthermore, because the metal plate forming the recoater 410 is elastically deformable in the plate thickness direction, the recoater element 415 that comes into contact with the warp is displaced in the direction pressed by the warp. If the object 3 warps upward, the recoater element 415 can be displaced upward. Therefore, when the recoater 410 moves in the X direction, the recoater element 415 can overcome the warp.

The multiple recoater elements 415 are each plate-shaped, and are aligned in the Y direction across the slit 411, with the Z direction being the plate thickness direction. In this configuration, the plate thickness direction of the plate-shaped recoater elements 415 corresponds to the Z direction, so that the surface that intersects with the plate thickness direction of the recoater elements 415 forms a lower surface S4 that is aligned along the Y direction.

The recoater 410 is a metal plate with multiple slits 411 arranged in parallel and spaced apart from each other in the Y direction. The multiple recoater elements 415 are portions of the metal plate between adjacent slits 411. Because the multiple recoater elements 415 are integrally formed, the recoater 410 can be easily handled. In addition, the recoater 410 can be easily manufactured.

The above describes in detail one example of a recoater device, but the present invention is not limited to the above embodiment.

For example, although an example has been shown in which the cross-sectional shape of the wire of the tension coil spring that constitutes the recoater is circular, the cross-sectional shape of the wire of the tension coil spring may be a shape other than circular, such as a square shape.

In the above example, the recoater is moved in the X direction to level the surface 2a of the powder bed A, but the recoater may also be moved in other directions in the X-Y plane to level the surface 2a of the powder bed A. In addition, the recoater may be arranged along the radial direction of an imaginary circle centered on a base point, and the recoater may be rotated around the base point.

Furthermore, among the above-mentioned embodiments, the corresponding configurations may be substituted for each other, or the configurations may be reused. For example, the recoater device 200 may include the pole 313 included in the recoater device 300. Furthermore, in the recoater device 400, a cushioning material may be disposed between the lower surface of the holder 430 and the recoater 410.

Reference Signs List 1 Molding device 2 Metal powder 2a Surface 3 Molded object 4 Vacuum chamber 5 Working table 6 Lifting device 6a Vertical direction member 6b Driving source 7 Powder supply device 8 Electron beam irradiation device (irradiation device)
10 Modeling tank 10a Side wall 11 Raw material tank 12 Extension plate 15 Substrate 18 Controller 100 Recoater device 101 Recoater 102 Recoater element 102A Recoater element 103 Holder 200 Recoater device 210 Recoater 211 Recoater element 230 Holder 230L Diameter 231 Connection portion 233 Holding portion 233a Space 233b Opening 233c Inner surface 233L Distance 235 Cushioning material 300 Recoater device 310 Recoater 310L Diameter 311 Recoater element 311a Through hole 313 Pole 330 Holder 330L Diameter 331 Connection portion 333 Holding portion 333a Space 333b Opening 333c Inner surface 333L Distance 335 Cushioning material 400 Recoater device 410 Recoater 411 Slit 412 Long side portion 413 Long side portion 415 Recoater element 430 Holder 431 Connecting portion 433 Holding portion 434 Groove 435 Groove A Powder bed D Irradiation area D1 First direction D2 Second direction S1 Lower surface (flat surface)
S2 Bottom surface (flat surface)
S3 Bottom surface (flat surface)
S4 Bottom surface (flat surface)

Claims (6)

a recoater including a plurality of metallic recoater elements aligned in a first direction;
a holder extending in the first direction and holding the recoater,
With the recoater held by the holder,
the recoater elements cooperate to form a flat surface extending along the first direction;
Among the plurality of recoater elements, at least portions forming the flat surfaces of adjacent recoater elements in the first direction are separated from each other,
When each of the recoater elements is pressed in a second direction intersecting the first direction, the recoater elements are displaceable in the second direction independently of the other recoater elements ,
the recoater element corresponds to one pitch of a spiral body formed such that a wire is spirally formed around an axis line along the first direction,
A recoater apparatus , wherein the flat surface is formed by an outer peripheral surface of the spiral body . a recoater including a plurality of metallic recoater elements aligned in a first direction;
a holder extending in the first direction and holding the recoater,
With the recoater held by the holder,
the recoater elements cooperate to form a flat surface extending along the first direction;
Among the plurality of recoater elements, at least portions forming the flat surfaces of adjacent recoater elements in the first direction are separated from each other,
When each of the recoater elements is pressed in a second direction intersecting the first direction, the recoater elements are displaceable in the second direction independently of the other recoater elements,
The recoater device, wherein each of the plurality of recoater elements is plate-shaped and aligned with a plate thickness direction as the first direction. The plurality of recoater elements have through holes along the plate thickness direction,
The recoater apparatus according to claim 2 , wherein the recoater includes a flexible pole that is inserted into the through hole. the holder includes a buffer material disposed between the holder and the recoater in the second direction.
The recoater apparatus according to any one of claims 1 to 3 . a recoater including a plurality of metallic recoater elements aligned in a first direction;
a holder extending in the first direction and holding the recoater,
With the recoater held by the holder,
the recoater elements cooperate to form a flat surface extending along the first direction;
Among the plurality of recoater elements, at least portions forming the flat surfaces of adjacent recoater elements in the first direction are separated from each other,
When each of the recoater elements is pressed in a second direction intersecting the first direction, the recoater elements are displaceable in the second direction independently of the other recoater elements,
A recoater device in which the multiple recoater elements each have a curved plate shape that is convex on the opposite side to the holder when viewed from the first direction , and are aligned with the second direction as the plate thickness direction and the width direction that intersects the plate thickness direction as the first direction. A chamber;
a work table disposed within the chamber and holding a powder bed containing powder;
an irradiation device that irradiates the powder held on the work table with an energy beam;
and a recoater apparatus according to any one of claims 1 to 5 , disposed within the chamber and configured to level a surface of the powder bed.

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