JP7746826B2 - Powder coating device and three-dimensional modeling device - Google Patents

Description

This disclosure relates to a powder coating device and a three-dimensional modeling device.

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

Japanese Patent Application Laid-Open No. 2007-307742

In a three-dimensional modeling device, a powder bed stacked on a work table can become very hot when irradiated with an electron beam, laser, or other light. In this case, the heat from the powder bed is transferred to a powder coating device (leveling member) such as a recoater. If this heat transfer causes the powder coating device to thermally expand, it is possible that deformation such as warping may occur in the powder coating device. If the powder coating device deforms, it becomes difficult to level the powder bed, which could result in a decrease in modeling quality.

The purpose of this disclosure is to provide a powder coating device and a three-dimensional modeling device that can suppress deterioration in modeling quality.

A powder application device according to one embodiment of the present disclosure includes a leveling member extending in one horizontal direction for leveling the surface of a powder bed, and a support mechanism for supporting the leveling member, and the leveling member is supported by the support mechanism in a state in which at least a portion of the leveling member is slidable in one direction relative to the support mechanism.

A three-dimensional modeling apparatus according to one embodiment of the present disclosure includes a chamber, a work table disposed within the chamber and holding a powder bed, an irradiation device that irradiates an energy beam onto the powder bed held on the work table, and the above-mentioned powder application device disposed within the chamber and leveling the surface of the powder bed.

When the leveling member extends in one horizontal direction, as in the powder coating device described above, the direction of thermal expansion of the leveling member when it becomes hot tends to be primarily along that one direction, the extension direction. In the powder coating device described above, the leveling member extending in one direction is supported by a support mechanism so that it can slide in that one direction. This allows the leveling member to slide in one direction by the amount of expansion. Therefore, warping and other problems caused by expansion in the leveling member are suppressed, and a decrease in modeling quality can be suppressed.

The support mechanism may include multiple support members, each of which may be spaced apart from one another in one direction. In this configuration, a space may be formed between adjacent support members.

The support mechanism may include a biasing member that biases the leveling member downward. This configuration allows the height position of the upper end of the leveling member to be maintained constant.

The device may further include a base frame that supports the support mechanism, and the thermal expansion coefficient of the base frame may be smaller than that of the leveling member. This configuration suppresses deformation of the base frame due to thermal expansion.

The device may further include a base frame that supports the support mechanism, and the base frame may include a cooling mechanism for cooling the base frame. This configuration prevents the base frame from becoming too hot.

According to one aspect of the present disclosure, a powder coating device and a three-dimensional modeling device are provided that can suppress deterioration in modeling quality.

FIG. 1 is a cross-sectional view schematically illustrating an example of a three-dimensional modeling apparatus equipped with a powder coating device. FIG. 2 is a plan view illustrating a processing section of an example three-dimensional modeling apparatus. FIG. 3 is a schematic diagram of a powder coating device of an example three-dimensional modeling apparatus, viewed from the radial direction of the work table. FIG. 4 is a schematic diagram of a powder coating device of an example three-dimensional modeling apparatus, viewed from the circumferential direction of the work table. FIG. 5 is a schematic diagram of a powder coating device of an example three-dimensional modeling apparatus, viewed from the circumferential direction of the work table. FIG. 6 is a cross-sectional view showing a schematic diagram of another example of a powder coating apparatus. FIG. 7 is a cross-sectional view showing a schematic diagram of a powder coating apparatus according to still another embodiment. FIG. 8 is a cross-sectional view showing a schematic diagram of a powder coating apparatus according to still another embodiment. FIG. 9 is a cross-sectional view showing a schematic diagram of a powder coating apparatus according to still another embodiment. FIG. 10 is a cross-sectional view showing a schematic diagram of a powder coating apparatus according to still another embodiment.

Embodiments of the present disclosure will be described below with reference to the drawings. In the description of the drawings, identical elements will be designated by the same reference numerals, and duplicate descriptions will be omitted where appropriate.

The three-dimensional modeling device 1 shown in Figure 1 is a so-called 3D (three-dimensional) printer. The three-dimensional modeling device 1 sinters or melts powder P by partially applying energy to powder P arranged in layers. The three-dimensional modeling device 1 produces a three-dimensional object M by repeatedly sintering or melting powder P.

The molded object M is, for example, a machine part. The molded object M may also be other structures. The powder P is composed of a large number of powder bodies. The powder P is, for example, metal powder. Examples of metal powder include titanium-based metal powder, Inconel (registered trademark) powder, aluminum powder, and stainless steel powder. The powder P is not limited to metal powder. The powder P may be, for example, resin powder, or powder containing carbon fiber and resin, such as CFRP (Carbon Fiber Reinforced Plastics). The powder P may also be other powders that are conductive. The powder P does not have to be conductive.

As shown in FIG. 1, the three-dimensional printing device 1 includes a housing (chamber) 5, a drive unit 10, a printing processing unit 30, and a control unit 50. The housing 5 is supported by multiple columns. The housing 5 forms a printing space S. The printing space S is an airtight space that can be depressurized for processing powder P by the printing processing unit 30. The housing 5 may be, for example, a vacuum chamber.

A work table 6 and a modeling tank 7 are arranged in the modeling space S. The work table 6 is a processing table on which the modeling process is carried out. The work table 6 is, for example, disk-shaped and is installed so that it can rotate around a rotation axis C. The rotation axis C extends, for example, vertically. Powder P, which is the raw material for the model M, is placed on the main surface 6a (upper surface) of the work table 6. The main surface 6a is formed so as to be perpendicular to the rotation axis C.

The work table 6 is disposed within the housing 5 and within the modeling tank 7. Within the modeling tank 7, the work table 6 is movable in a direction D1 along the vertical direction. The work table 6 descends sequentially according to the number of layers of powder P. The peripheral walls of the modeling tank 7 guide the movement of the work table 6. The shape of the peripheral walls of the modeling tank 7 may correspond to the outer shape of the work table 6. The peripheral walls of the modeling tank 7 and the work table 6 may form a storage section that stores the powder P and the modeled object M. The work table 6 may form the bottom of the modeling tank 7.

The drive unit 10 performs various operations required for modeling. For example, the drive unit 10 rotates and elevates the work table 6. The drive unit 10 may include a rotation unit 11 and an elevation unit 12. The rotation unit 11 rotates the work table 6 about the rotation axis C. The upper end of the rotation unit 11 may be connected to the work table 6. The lower end of the rotation unit 11 may be connected to a drive source (e.g., a motor). The elevation unit 12 elevates the work table 6 along direction D1. When the elevation unit 12 elevates the work table 6, the powder P and the model M on the work table 6 are elevated.

The modeling processing unit 30 processes the powder P to obtain a model M. The processing of the powder P includes, for example, a process of supplying the powder P, a process of preheating the powder P, and a process of modeling the powder P. The modeling processing unit 30 is arranged above the main surface 6a of the work table 6. As shown in FIG. 2, the modeling processing unit 30 has, for example, a first modeling processing unit 31A and a second modeling processing unit 31B. The first modeling processing unit 31A and the second modeling processing unit 31B are arranged side by side along the rotation direction D2 (circumferential direction) of the work table 6. The first modeling processing unit 31A and the second modeling processing unit 31B are formed, for example, to have a relationship of 180° rotational symmetry about the rotation axis C. The first modeling processing unit 31A and the second modeling processing unit 31B have, for example, the same components as each other. Hereinafter, unless the first formation processing unit 31A and the second formation processing unit 31B are specifically described separately, they will be collectively referred to simply as the "formation processing unit 31."

The modeling processing unit 31 has, for example, a supply unit 35, a heating unit 32, and an irradiation unit (irradiation device) 33. The supply unit 35 supplies powder P onto the main surface 6a of the work table 6. The supply unit 35 includes a raw material tank 34 and a powder coating device 100. The raw material tank 34 stores powder P therein. The raw material tank 34 also supplies the stored powder P onto the main surface 6a of the work table 6.

The powder coating device 100 levels the surface (top surface) of the top layer of a stack of powder P supplied onto the main surface 6a of the work table 6. Hereinafter, this stack of powder P will be referred to as the "powder bed PA." The powder bed PA may include a molded object M formed by melting or sintering the powder P. The powder coating device 100 is disposed so as to extend radially on the main surface 6a of the work table 6. In other words, the powder coating device 100 extends along a direction intersecting the direction of rotation of the work table 6. As the work table 6 rotates, the powder coating device 100 comes into contact with the surface of the powder bed PA and spreads and levels the powder bed PA. In this way, the powder bed PA is applied to a uniform thickness on the main surface 6a.

The heating unit 32 preheats the powder bed PA applied to the main surface 6a. The heating unit 32 may be, for example, a device that heats the powder bed PA below the heating unit 32 by radiant heat. The heating unit 32 may be, for example, an infrared heater or a heater that heats using another method.

The irradiation unit 33 irradiates the preheated powder bed PA with an electron beam (energy beam). The irradiation unit 33 is, for example, an electron gun. The irradiation unit 33 generates an electron beam corresponding to the potential difference generated between the cathode and anode. The irradiation unit 33 then irradiates the electron beam, which is focused by adjusting the electric field, at a desired position on the powder bed PA. The powder P heated by the irradiation of the electron beam is melted or sintered. When the irradiation unit 33 stops irradiating the powder P with the electron beam, the temperature of the powder P drops, causing it to solidify. As the work table 6 rotates, the electron beam is irradiated and stopped multiple times to form the molded object M.

As shown in FIG. 2, the supply unit 35, heating unit 32, and irradiation unit 33 are arranged in this order from upstream to downstream along the rotation direction D2 (counterclockwise in FIG. 2). With the supply unit 35, heating unit 32, and irradiation unit 33 arranged in this manner along the rotation direction D2, the work table 6 rotates in the rotation direction D2, whereby the supply process by the supply unit 35, the preheating process by the heating unit 32, and the modeling process by the irradiation unit 33 are carried out in parallel. As the work table 6 rotates, each process is repeated, and a model M is formed on the main surface 6a.

The control unit 50 is an electronic control unit that controls the entire 3D printing apparatus 1. The control unit 50 is a computer that includes hardware such as a CPU (Central Processing Unit), ROM (Read Only Memory), and RAM (Random Access Memory), as well as software such as programs stored in the ROM. There are no particular limitations on the form or location of the control unit 50. The control unit 50 is connected to the drive unit 10 and the printing processing unit 30 so that it can communicate with them. The control unit 50 controls the operation of the drive unit 10 and the printing processing unit 30 by the CPU executing the programs.

That is, the control unit 50 performs rotation control to rotate the work table 6. For example, the control unit 50 sets the rotation speed of the work table 6, etc. The control unit 50 performs elevation control to raise and lower the work table 6. For example, the control unit 50 sets the descent speed of the work table 6, etc. The control unit 50 performs supply control to supply powder P onto the main surface 6a of the work table 6. The control unit 50 performs preheat control to preheat the powder bed PA formed on the main surface 6a of the work table 6. For example, the control unit 50 sets the amount of heat to be applied to the powder bed PA, etc. The control unit 50 performs electron beam irradiation control when melting or sintering the powder P in the powder bed PA. For example, the control unit 50 sets the timing to start irradiation of the electron beam, the timing to end irradiation of the electron beam, and the irradiation position of the electron beam. In this way, the control unit 50 performs rotation control, elevation control, preheating control, irradiation control, and supply control of the work table 6, thereby executing a series of molding processes to form the molded object M.

The powder coating apparatus 100 will now be described in more detail. Figures 3 and 4 are schematic diagrams showing the powder coating apparatus 100. In Figure 3, the powder coating apparatus 100 is viewed from the radial direction of the work table 6. In Figure 4, the powder coating apparatus 100 is viewed from the circumferential direction of the work table 6. That is, in Figure 3, the left-to-right direction of the page corresponds to the rotation direction of the work table 6, and in Figure 4, the front-to-back direction of the page corresponds to the rotation direction of the work table 6. Also, in Figure 4, the right side of the page corresponds to the center of the work table 6, and the left side of the page corresponds to the outer periphery of the work table 6. As shown in Figures 3 and 4, an example powder coating apparatus 100 is provided downstream of the supply unit 35 and levels the powder P supplied from the supply unit 35.

The powder application device 100 includes a leveling member 110, a support mechanism 120, and a base frame 130. The leveling member 110 is a part that levels the powder P on the powder bed PA, and extends in one direction along the horizontal direction. In the following description, the direction in which the leveling member extends may be referred to as the longitudinal direction.

The leveling member 110 in the illustrated example extends linearly from the center of the work table 6 to near the outer edge of the work table 6 in a plan view along the radial direction of the work table 6, so as to intersect with the direction of movement of the powder bed PA. The leveling member 110 in the illustrated example includes a flat first portion 111 for leveling the powder bed PA, and a second portion 112 formed on the upper end of the first portion 111. The first portion 111 in the illustrated example has a rectangular flat plate shape. The first portion 111 and the second portion 112 may be formed integrally. As an example, the leveling member 110 is made of a metal such as stainless steel.

In one example, the thickness of the second portion 112 is greater than the thickness of the first portion 111. Note that the thicknesses of the first portion 111 and the second portion 112 are lengths in the horizontal direction intersecting the longitudinal direction. Because the second portion 112 protrudes from the first portion 111 in the thickness direction, if the powder P moves upward due to the smoothing operation of the first portion 111, the powder P may come into contact with the lower end of the second portion 112. This prevents the powder P from moving up to the position of the support mechanism 120.

The support mechanism 120 supports the leveling member 110 in a suspended state. When the leveling member 110 is supported by the support mechanism 120, the leveling member 110 is able to slide longitudinally relative to the support mechanism 120. For example, the leveling member 110 may be entirely slidable relative to the support mechanism 120. Alternatively, the leveling member 110 may be partially slidable relative to the support mechanism 120.

As shown in FIG. 4 , an example support mechanism 120 is composed of multiple support members 121. The multiple support members 121 are spaced apart from each other along the longitudinal direction. That is, a space is formed between adjacent support members 121. Any one of the multiple support members 121 may be fixed to the leveling member 110. In the illustrated example, of the three support members 121 (support members 121A, 121B, 121C), support member 121A, which is located on the outermost radial side of the work table 6, is fixed to the leveling member 110, and the other support members 121B and 121C slidably support the leveling member 110. For example, the support member 121 may be made of a material such as ceramic that has a lower thermal expansion coefficient and thermal conductivity than the leveling member 110.

The base frame 130 is a rectangular plate extending along the longitudinal direction of the leveling member 110 and the support mechanism 120. The base frame 130 supports the support mechanism 120. For example, the support mechanism 120 may be fixed to the lower end of the base frame 130 by a fastening member such as a bolt. The base frame 130 may be fixed to a frame constituting the housing 5, for example. In the illustrated example, one longitudinal end 130a of the base frame 130 (for example, the end on the outer edge side in the radial direction of the work table 6) is fixed to the frame of the housing 5. The base frame 130 may be formed, for example, from a material such as ceramic that has a lower thermal expansion coefficient and thermal conductivity than the leveling member 110.

As described above, one example of a powder application device 100 includes a leveling member 110 that extends in one horizontal direction to level the surface of the powder bed PA, and a support mechanism 120 that supports the leveling member 110. The leveling member 110 is supported by the support mechanism 120 in a state in which at least a portion of the leveling member 110 is slidable in one direction relative to the support mechanism 120.

Figure 5 illustrates the operation of such a powder coating apparatus 100. In one example of a three-dimensional modeling apparatus 1, the housing 5 is placed in a vacuum (reduced pressure) state, and three-dimensional modeling is performed. In this case, because convection does not occur within the housing 5, the powder coating apparatus 100 is heated by thermal radiation and conduction from the powder bed PA, which is heated by the electron beam irradiation. Therefore, the powder coating apparatus 100 is heated in order, starting from the side closest to the powder bed PA. That is, the leveling member 110, the support mechanism 120, and the base frame 130 are heated in that order, so the temperature tends to be higher the closer to the powder bed PA. For example, if the base frame, support mechanism, and leveling member are all formed from metal plates, the amount of deformation due to thermal expansion increases the closer to the powder bed PA, which could cause the leveling member to warp upward, for example. This could make it difficult to flatten the powder bed PA, potentially leading to a decrease in modeling quality. However, in the example described above, the leveling member 110 is supported so that it can slide longitudinally. In other words, the direction in which the leveling member 110 tends to expand and the sliding direction are the same. Therefore, as shown in Figure 5, the leveling member 110 can slide in the longitudinal direction by the amount of expansion. This prevents the leveling member 110 from warping up, thereby preventing a decrease in modeling quality.

The thermal expansion coefficient of the base frame 130 may be smaller than that of the leveling member 110. With this configuration, deformation of the base frame 130 due to thermal expansion is suppressed. For example, consider a case where the base frame deforms due to thermal expansion. The parts of the base frame closer to the powder bed PA are more likely to become hotter. In this case, the parts closer to the powder bed PA are more likely to deform, causing the base frame to warp upward. When the base frame deforms in this way, there is a possibility that the leveling member will deform and warp upward in response to this deformation. With the above configuration, deformation of the base frame 130 due to thermal expansion is suppressed, and therefore deformation of the leveling member 110 due to deformation of the base frame 130 is also suppressed.

The support mechanism 120 includes multiple support members 121, which may be spaced apart from one another in one direction. In this configuration, spaces can be formed between adjacent support members 121. In this case, heat conduction from the leveling member 110 to the base frame 130 via the support members 121 can be suppressed.

At least one support member 121 may be fixed to the leveling member 110. With this configuration, the sliding direction of the leveling member 110 due to thermal expansion can be controlled. That is, in the above example, the support member 121A, which is positioned radially outward of the work table 6, is fixed to the leveling member 110. In this case, only the support members 121B and 121C slide in response to the expansion of the leveling member 110, so the leveling member 110 slides radially inward of the work table 6.

Next, several more specific examples of the powder coating apparatus 100 will be described. Figures 6 to 10 are each schematic diagrams of the powder coating apparatus viewed from the radial direction of the work table 6. The powder coating apparatus 200 shown in Figure 6 includes a leveling member 210, a support mechanism 220, and a base frame 130. The leveling member 210 is a part that levels the powder P on the powder bed PA, and extends in one horizontal direction.

In a plan view, the leveling member 210 in the illustrated example extends linearly along the radial direction of the work table 6 from the center of the work table 6 to near the outer edge of the work table 6. The leveling member 210 in the illustrated example includes a flat first portion 211 for leveling the powder bed PA, and a second portion 212 formed on the upper end of the first portion 211.

The second portion 212 includes a lower portion 212a that is continuous with the first portion 211, and an upper portion 212b that is continuous with the lower portion 212a. In the illustrated example, the cross-sectional shape of the lower portion 212a is rectangular when viewed in the longitudinal direction.

When viewed in the longitudinal direction, the upper portion 212b has a pair of side surfaces 212b1, 212b2 that slope upwards and move away from each other, and a flat top surface 212b3 that connects the upper ends of side surfaces 212b1 and 212b2. In other words, when viewed in the longitudinal direction, the cross-sectional shape of the upper portion 212b is a trapezoid whose upper base is longer than its lower base. The first portion 211 and second portion 212 may be formed integrally.

The support mechanism 220 is fixed to the lower end of the base frame 130. The support mechanism 220 has a space 221 shaped to accommodate the upper portion 212b of the leveling member 210. That is, when viewed in the longitudinal direction, the support mechanism 220 has a pair of side surfaces 220a, 220b that slope away from each other as they extend upward, and a flat top surface 220c that connects the upper ends of side surfaces 220a and 220b. The space 221 opens downward. The angles of the pair of side surfaces 220a, 220b may be substantially the same as those of the pair of side surfaces 212b1, 212b2.

The support mechanism 220 supports the leveling member 210 by accommodating the upper portion 212b of the leveling member 210 within a space 221 defined by a pair of side surfaces 220a, 220b and a top surface 220c. When the leveling member 210 is supported by the support mechanism 220, the leveling member 210 is able to slide longitudinally relative to the support mechanism 220. Note that the support mechanism 220 may be composed of multiple support members spaced apart longitudinally, similar to how the support mechanism 120 is composed of multiple support members 121.

The powder application apparatus 300 shown in Figure 7 includes a leveling member 310, a support mechanism 320, and a base frame 130. The leveling member 310 is a part that levels the powder P on the powder bed PA, and extends in one direction along the horizontal direction.

In a plan view, the leveling member 310 in the illustrated example extends linearly along the radial direction of the work table 6 from the center of the work table 6 to near the outer edge of the work table 6. The leveling member 310 in the illustrated example includes a flat first portion 311 for leveling the powder bed PA, and a second portion 312 formed on the upper end of the first portion 311.

The second portion 312 includes a lower portion 312a that is continuous with the first portion 311, and an upper portion 312b that is continuous with the lower portion 312a. In the illustrated example, the cross-sectional shape of the lower portion 312a is rectangular when viewed in the longitudinal direction.

When viewed in the longitudinal direction, the upper portion 312b has a pair of side surfaces 312b1, 312b2 that slope upward so that they move away from each other, and a flat top surface 312b3 that connects the upper end of side surface 312b1 with the upper end of side surface 312b2. In other words, when viewed in the longitudinal direction, the cross-sectional shape of the upper portion 312b is a trapezoid whose upper base is longer than its lower base. The first portion 311 and second portion 312 may be formed integrally.

The support mechanism 320 is fixed to the lower end of the base frame 130. The support mechanism 320 has a space 321 shaped to accommodate the upper portion 312b of the leveling member 310. In one example, the support mechanism 320 has a pair of side surfaces 320a, 320b that slope upward as they move away from each other when viewed in the longitudinal direction; a pair of extending portions 320c, 320d that extend upward from the upper ends of side surfaces 320a and 320b; and a flat upper surface 320e that connects the upper ends of the pair of extending portions 320c, 320d. The angle of each of the pair of side surfaces 320a, 320b may be substantially the same as that of the pair of side surfaces 312b1, 312b2.

The support mechanism 320 supports the leveling member 310 by accommodating the upper portion 312b of the leveling member 310 within a space 321 defined by a pair of side surfaces 320a, 320b, a pair of extensions 320c, 320d, and a top surface 320e. When the leveling member 310 is supported by the support mechanism 320, a biasing member 325, such as a compression coil spring or a leaf spring, is accommodated in the space between the top surface 312b3 of the leveling member 310 and the top surface 320e of the support mechanism 320. The leveling member 310 is biased downward by the biasing member 325 and is therefore slidable longitudinally relative to the support mechanism 320. Multiple biasing members 325 may be arranged at equal intervals along the longitudinal direction. The downward biasing of the leveling member 310 maintains a constant height position of the top end of the leveling member 310. The biasing member 325 may be fixed to either the support mechanism 320 or the leveling member 310. Note that the support mechanism 320 may be composed of multiple support members spaced apart from each other in the longitudinal direction, similar to how the support mechanism 120 is composed of multiple support members 121.

The powder application apparatus 400 shown in Figure 8 includes a leveling member 410, a support mechanism 420, and a base frame 130. The leveling member 410 is a part that levels the powder P on the powder bed PA, and extends in one direction along the horizontal direction.

In a plan view, the leveling member 410 in the illustrated example extends linearly along the radial direction of the work table 6 from the center of the work table 6 to near the outer edge of the work table 6. The leveling member 410 in the illustrated example includes a flat first portion 411 for leveling the powder bed PA, and a second portion 412 formed on the upper end of the first portion 411.

The second portion 412 includes a lower portion 412a that is continuous with the first portion 411, and an upper portion 412b that is continuous with the lower portion 412a. In the illustrated example, the cross-sectional shape of the lower portion 412a is rectangular when viewed in the longitudinal direction.

The upper portion 412b includes a spline shaft 412c with circumferentially equally spaced concave and convex portions when viewed from the longitudinal direction. The width of the spline shaft 412c is greater than the width of the lower portion 412a. The first portion 411 and the second portion 412 may be integrally formed.

The support mechanism 420 is fixed to the lower end of the base frame 130. The support mechanism 420 has a space 421 that can accommodate the upper portion 412b of the leveling member 410 and that corresponds in shape to the upper portion 412b. In other words, the space 421 of the support mechanism 420 has a shape that corresponds to the spline shaft 412c, with uneven grooves formed at equal intervals around the circumference when viewed from the longitudinal direction.

The support mechanism 420 supports the leveling member 410 by accommodating the upper portion 412b of the leveling member 410 within a space 421 defined by multiple projections and recesses. When the leveling member 410 is supported by the support mechanism 420, the leveling member 410 is able to slide longitudinally relative to the support mechanism 420. Note that the support mechanism 420 may be composed of multiple support members spaced apart longitudinally, similar to how the support mechanism 120 is composed of multiple support members 121.

The powder application apparatus 500 shown in Figure 9 includes a leveling member 510, a support mechanism 520, and a base frame 130. The leveling member 510 is a part that levels the powder P on the powder bed PA, and extends in one direction along the horizontal direction.

In the illustrated example, the leveling member 510 extends linearly in the radial direction of the work table 6 from the center of the work table 6 to near the outer edge of the work table 6 in a plan view. The leveling member 510 in the example includes a flat first portion 511 for leveling the powder bed PA, and a second portion 512 formed on the upper end of the first portion 511.

The second portion 512 includes a lower portion 512a that is continuous with the first portion 511, and an upper portion 512b that is continuous with the lower portion 512a. In the illustrated example, the cross-sectional shape of the lower portion 512a is rectangular when viewed in the longitudinal direction.

The upper portion 512b has a groove 513 that extends in the longitudinal direction and opens upward. When viewed in the longitudinal direction, the groove 513 is defined by a pair of side surfaces 512b1, 512b2 that slope toward each other as they approach each other, and a flat bottom surface 512b3 that connects the lower end of side surface 512b1 with the lower end of side surface 512b2. In other words, when viewed in the longitudinal direction, the cross-sectional shape of the groove 513 is trapezoidal, with the upper base shorter than the lower base. The first portion 511 and second portion 512 may be formed integrally.

The support mechanism 520 is fixed to the lower end of the base frame 130. The support mechanism 520 has a shape that allows it to be housed in the groove 513 of the leveling member 510. That is, when viewed in the longitudinal direction, the support mechanism 520 has a pair of side surfaces 520a, 520b that slope upwards and approach each other, and a flat bottom surface 520c that connects the lower end of side surface 520a with the lower end of side surface 520b.

The support mechanism 520 is housed in the groove 513, thereby supporting the leveling member 510. When the leveling member 510 is supported by the support mechanism 520, the leveling member 510 is able to slide longitudinally relative to the support mechanism 520. Note that the support mechanism 520 may be composed of multiple support members spaced apart from each other in the longitudinal direction, similar to how the support mechanism 120 is composed of multiple support members 121.

In addition, although the drawing shows the upper end of the leveling member 510 and the lower end of the base frame 130 in contact, the leveling member 510 and the base frame 130 may be spaced apart from each other. If the support mechanism 520 is composed of multiple support members that are spaced apart from each other in the longitudinal direction, a gap is formed between the leveling member 510 and the base frame 130 by separating the leveling member 510 and the base frame 130 from each other.

The powder coating apparatus 600 shown in FIG. 10 includes a leveling member 110, a support mechanism 120, and a base frame 630. The base frame 630 is a rectangular plate extending along the longitudinal direction of the leveling member 110 and the support mechanism 120. The base frame 630 supports the support mechanism 120. For example, the support mechanism 120 may be fixed to the lower end of the base frame 630 by fastening members such as bolts. The base frame 630 may be fixed to a frame that constitutes the housing 5, for example. A pipe 631 (cooling mechanism) through which a fluid for cooling the base frame 630 flows is embedded inside the base frame 630. The fluid flowing through the pipe 631 is not particularly limited, but may be a liquid such as oil or water.

For example, multiple pipes 631 are provided. The multiple pipes 631 extend vertically at a distance from each other along the longitudinal direction of the base frame 630. For example, the pipes 631 may be evenly spaced vertically. Alternatively, the pipes 631 may be arranged so that they are denser toward the lower end, i.e., closer to the support mechanism. The base frame 630 may be formed, for example, from a material such as ceramic that has a lower thermal conductivity than the leveling member 110, or from the same metal as the leveling member 110. In a configuration in which the base frame 630 includes pipes 631 as a cooling mechanism for cooling the base frame 630, the base frame 630 is prevented from becoming too hot. In this case, even if the base frame 630 is formed from metal, excessive deformation of the base frame 630 is prevented.

This disclosure is not limited to the above-described embodiments, and various modifications are possible without departing from the spirit of the present invention.

For example, the shapes of the support mechanism and leveling member are not limited to the examples described above. While trapezoidal cross-sections, spline shapes, and the like have been shown as shapes for the upper part of the leveling member, the upper part of the leveling member may have any shape that corresponds to the support mechanism and can be supported by the support mechanism, and may also have other shapes, such as a circular cross-section or a rectangular cross-section.

Furthermore, although an example in which the support mechanism is composed of three support members has been shown, the support mechanism may be composed of two or fewer support members, or four or more support members.

Furthermore, while an example of single-end support in which one longitudinal end of the base frame is fixed to the housing has been shown, the base frame may also be double-end supported in which both longitudinal ends are supported. For example, the base frame of the first formation processing unit 31A and the base frame of the second formation processing unit 31B can support each other, thereby making each base frame double-end supported.

In addition, while an example has been shown in which the powder coating device is fixed above a rotating work table, the powder coating device may be provided so as to be movable relative to the work table. For example, the powder coating device may be disposed above a fixed work table so as to be able to move back and forth along a horizontal plane.

Furthermore, although an example of irradiating an electron beam as an energy beam has been shown, an energy beam other than an electron beam may also be irradiated. In other words, the energy beam may be any beam capable of supplying energy to the powder bed, and may be, for example, an ion beam or other charged particle beam, or a laser beam, etc.

1 Three-dimensional modeling device 6 Working table 100 Powder coating device 110 Leveling member 120 Support mechanism 121 Support member 130 Base frame 325 Urging member 631 Piping (cooling mechanism)
PA powder bed

Claims (5)

a leveling member extending in one direction along the horizontal direction and for leveling the surface of the powder bed;
a support mechanism for supporting the leveling member,
the leveling member is supported by the support mechanism in a state in which at least a portion of the leveling member is slidable relative to the support mechanism in the one direction ,
the support mechanism includes a plurality of support members that support the leveling member,
The powder coating apparatus , wherein each of the plurality of support members is spaced apart from one another along the one direction . The powder coating apparatus according to claim 1 , wherein the support mechanism includes a biasing member that biases the leveling member downward. a base frame supporting the support mechanism;
3. The powder coating apparatus according to claim 1 , wherein the base frame has a coefficient of thermal expansion smaller than that of the leveling member. a base frame supporting the support mechanism;
3. The powder coating apparatus according to claim 1, wherein the base frame includes a cooling mechanism for cooling the base frame. a chamber;
a work table disposed within the chamber and holding the powder bed;
an irradiation device for irradiating the powder bed held on the work table with an energy beam;
and the powder applying device according to any one of claims 1 to 4 , which is disposed in the chamber and levels the surface of the powder bed.