JP2008184623A - Method for producing three-dimensional molding, and material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a three-dimensional molding where the material is composed of fine powder, and has good fluidity and satisfactory molding precision, and also, the treatability of the raw material is satisfactory, and to provide the material used therefor. <P>SOLUTION: As the material, a mixture of metal powder and a highly volatile solvent is used, the material is fed onto a plate 31 for molding, so as to form a material layer 22, the highly volatile solvent in the material layer 22 is volatilized, thereafter, the material layer 22 is irradiated with an optical beam L, and a sintered layer 81 or a melted layer is formed. The formation of the material layer 22, the volatilization of the highly volatile solvent and the irradiation of the optical beam L are repeated, thus each sintered layer 81 or melted layer is stacked on the plate 31 for molding. Since the fluidity of the material is satisfactory, the material layer 22 can be uniformly thinly formed, and a three-dimensional molding 82 having satisfactory precision can be produced. Further, the metal powder is not stirred up, and the treatability of the material is satisfactory. Since the highly volatile solvent volatilizes and impurities are reduced, the three-dimensional molding 82 having high density and strength can be obtained. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a manufacturing method and a material for a three-dimensional shaped object in which a metal material is irradiated with a light beam.

  Conventionally, a material layer formed of a metal material is irradiated with a light beam (directional energy beam, for example, laser light) to form a sintered layer or a molten layer, and a new material is formed on the sintered layer or the molten layer. A technique for manufacturing a three-dimensional shaped object by repeating the formation of a sintered layer or a molten layer by forming a layer and irradiating a light beam is known. A feature of this technique is that a complicated three-dimensional shape can be manufactured in a short time. By irradiating a light beam with high energy density, the metal material is almost completely melted and then solidified, that is, the material density after melting is almost 100%, and the surface of this high-density model is finished. Thus, a smooth surface can be formed, which is applied to a plastic mold or the like.

  In this technique called metal stereolithography, the metal material normally used is used in a powder state. By making the material to be laminated a metal powder, the surface area of the material increases and the absorption rate of the laser beam also increases, so it is possible to sinter or melt the material even under irradiation conditions with low energy density, improving the modeling speed To do.

  In order to obtain a modeled object having a certain level of strength, in the material layer to which the laser beam is irradiated, the adhesion strength between the modeled part adjacent to the laser beam scanning position is increased, and the modeled layer that is irradiated and the modeled layer underneath it Adhesion strength with must also be increased. If the material to be laminated is a metal powder, the lower modeling layer is irradiated with laser light through a gap between the powders, and the lower modeling layer is also heated to improve the adhesion strength.

  Furthermore, the upper surface of the laser-irradiated portion should not rise so much. When the next material layer for modeling the next layer is formed, if the raised height is equal to or greater than the thickness for laminating the metal powder, formation of the material layer itself becomes difficult.

  Of course, the appearance of the shaped object must not be cracked, and it is desirable that the internal structure be free of microcracks.

  Here, a part or all of the metal material irradiated with the laser is once melted and then cooled and solidified to form a modeled object. If the wettability at the time of the melting is large, it is possible to join the adjacent modeled part. If the area is large and the fluidity is large, the rise is small. Therefore, it is desirable that the fluidity when melted is large and the wettability is good.

  From such a viewpoint, as shown in Patent Document 1, the present applicant proposed a mixed powder for metal stereolithography made of iron-based powder made of chromium molybdenum steel, nickel powder, and phosphorous copper or manganese copper powder. did. Chrome molybdenum steel powder is adopted from the viewpoint of hardness and strength, nickel powder is adopted from the viewpoint of strength, toughness and workability, and phosphorous copper or manganese copper powder is adopted from the viewpoint of wettability and fluidity.

  It is difficult to produce a high-density three-dimensional shaped object by irradiating only iron-based powder with laser light. This is because it is difficult to integrate the next modeling layer into the previously formed iron modeling layer without creating a gap. Even if the chromium molybdenum steel itself has high hardness and excellent mechanical strength, the modeling density of the three-dimensional structure obtained by laser irradiation with only the chromium molybdenum steel powder is low and its strength is also weak.

  In the case where the iron-based powder is an alloy containing a large amount of nickel component, the above-mentioned problem becomes serious because a strong oxide film formed on the surface of the powder hinders fusion integration of the iron-based powders. Inclusion of nickel in an iron-based metal has the advantage of improving the toughness, strength, and corrosion resistance of the iron-based metal, but when used for the production of three-dimensional structures by laser irradiation, the advantage is demonstrated. It is hard to be done.

  If the energy of laser irradiation is increased, even iron-based powders containing chromium-molybdenum steel and nickel components can be sufficiently fused and integrated. In this case, however, the laser irradiation device becomes too large or excessive power is required. In addition to the disadvantage that the manufacturing cost is high and the manufacturing cost is high, the scanning speed of the laser beam cannot be increased, and the manufacturing efficiency is lowered. In addition, a shaped article made with an excessive amount of irradiation energy tends to warp or deform due to thermal stress.

  Copper is a metal material that has good fluidity when melted, good wettability with an iron-based material in a molten state, and hardly deteriorates in characteristics even when alloyed with an iron-based material. When the mixed powder composed of iron-based powder and copper alloy powder is irradiated with laser light, the copper alloy is melted first to fill the gap between the iron-based powders, and at the same time, this becomes a binder and is fused and integrated. When the laser beam irradiation energy is high, the iron-based powder and copper alloy powder forming the mixed powder are melted to form an alloy.

  The fluidity of the molten metal becomes better as the difference between the melting temperature and the melting point increases. Phosphorous copper alloys and manganese copper alloys have lower melting points than pure copper, and the fluidity when irradiated with the same energy is better for phosphorous copper alloys and manganese copper alloys than for pure copper.

  The conventional iron-based powder material for metal stereolithography also includes nickel powder. As described above, when the iron-based powder is an alloy containing a nickel component, fusion integration between the powders is hindered by a strong oxide film formed on the powder surface. When nickel powder is mixed with a copper alloy as a separate powder, fusion and integration of these powders are performed well. And the hardened layer which consists of an iron-type component, nickel, and a copper alloy component has the high sintered density, As a result, toughness and intensity | strength become high.

  Particularly preferable results can be obtained when the amount of chromium molybdenum steel is 60 to 90 wt%, the amount of nickel powder is 5 to 35 wt%, and the amount of copper manganese alloy powder is 5 to 15 wt%.

  In the metal stereolithography using the above-described metal powder as a material, a generally preferable result can be obtained in that a complicated three-dimensional shaped object is obtained by laser irradiation and its lamination.

  However, in order to obtain a highly accurate three-dimensional shaped object, it is necessary to spread the powder material as thinly and uniformly as possible, and for this purpose, the particle size of the metal powder must be made fine. As the powder becomes finer, the powders agglomerate with each other. As a result, the fluidity of the metal powder itself is lowered, and the metal powder cannot be spread thinly and uniformly.

In addition, dry fine powder is very easy to fly and not only is poor in handleability, but if the material is a mixed powder, the components may fluctuate and the fine powder may not be able to achieve high-precision modeling. There is.
JP-A-2005-48234

  The present invention has been made in order to solve the above-mentioned problems, and the production of a three-dimensional shaped object having a fine powder, good fluidity, good modeling accuracy, and good material handling properties. It is an object to provide methods and materials.

  In order to achieve the above object, the invention according to claim 1 is a material layer forming step of supplying a material for three-dimensional shape modeling onto a modeling plate to form a material layer, and irradiating the material layer with a light beam. Then, an irradiation process for forming a sintered layer or a melted layer, and a laminating process for laminating the sintered layer or the melted layer on the modeling plate by repeating the material layer forming process and the irradiation process. In the method for manufacturing a three-dimensional shaped object provided, the material is a mixture of metal powder and a highly volatile solvent, and the light beam irradiation in the irradiation step is a material formed in the material layer forming step. This is performed after the highly volatile solvent in the layer has volatilized.

  Invention of Claim 2 is the manufacturing method of the three-dimensional shape molded article of Claim 1, The said material is a metal powder of 50 vol% or more and 70 vol% or less, and a highly volatile solvent of 30 vol% or more and 50 vol% or less, , Has.

  A third aspect of the present invention is the method for producing a three-dimensional shaped article according to the first or second aspect, wherein the average particle size of the metal powder is 1 μm or more and 100 μm or less.

  Invention of Claim 4 is a manufacturing method of the three-dimensional shape molded article according to any one of Claims 1 to 3, wherein the metal powder has a composition ratio of iron-based powder of 60 wt% or more and 90 wt% or less. The composition ratio of either or both of the nickel powder and the nickel-based alloy powder is 5 wt% or more and 35 wt% or less, and the composition ratio of either or both of the copper powder and the copper-based alloy powder is 5 wt% or more and 15 wt%. % Or less.

  A fifth aspect of the present invention is the method for producing a three-dimensional shaped article according to any one of the first to fourth aspects, wherein the thickness of the material layer is 1 μm or more and 200 μm or less.

  Invention of Claim 6 is a manufacturing method of the three-dimensional shape molded article as described in any one of Claim 1 thru | or 5, In the said material layer formation process, the said material layer is heated and the said highly volatile property The solvent is volatilized.

  The invention of claim 7 provides the highly volatile solvent that volatilizes from the material layer in the material layer forming step in the method of manufacturing a three-dimensional shaped article according to any one of claims 1 to 6. It is collected by suction.

  The invention of claim 8 is the method for producing a three-dimensional shaped article according to any one of claims 1 to 7, wherein the material layer has a wire mesh formed of a metal wire.

  The invention of claim 9 is the method for producing a three-dimensional shaped article according to any one of claims 1 to 8, wherein after the formation of the sintered layer or the melted layer, the layers are laminated up to that point. A cutting process for cutting and removing the surface portion and / or unnecessary portion of the three-dimensional shaped object thus obtained is further provided.

  The invention of claim 10 is a material for three-dimensional shape modeling, and is used in the method for producing a three-dimensional shape molded product according to any one of claims 1 to 4, wherein the metal powder and the highly volatile solvent are used. And are mixed.

  According to the first aspect of the present invention, since the fluidity is good even if the metal powder is made into a fine powder, the material layer can be formed uniformly and thinly, and an accurate three-dimensional shaped object can be manufactured. In addition, the metal powder does not soar and the material is easy to handle. Moreover, since the highly volatile solvent is volatilized and there are few impurities, a three-dimensional shaped article with high density and high strength can be obtained.

  According to the second aspect of the present invention, it is possible to obtain appropriate fluidity and viscosity in the material, and further to form the material layer uniformly and thinly, and it is possible to manufacture an accurate three-dimensional shaped object. .

  According to the invention of claim 3, since the particle size of the metal powder is small, the material layer can be formed evenly and thinly, and an accurate three-dimensional shaped object can be manufactured.

  According to the invention of claim 4, it is possible to produce a high-strength three-dimensional shaped article without cracks.

  According to the invention of claim 5, since the thickness of the material layer is thin, it is possible to manufacture an accurate three-dimensional shaped object.

  According to the invention of claim 6, since the volatilization rate of the highly volatile solvent is fast, the waiting time of the light beam irradiation is shortened, and the manufacturing time can be shortened.

  According to the seventh aspect of the present invention, it is possible to prevent contamination of the lens through which the light beam is transmitted, so that the light beam is stable and an accurate three-dimensional shaped article can be manufactured. By sucking, the volatilization rate of the highly volatile solvent is increased, and the waiting time of the light beam irradiation can be shortened. Moreover, environmental pollution can be prevented and the safety of production can be improved.

  According to the invention of claim 8, since the metal material is supplied at a high density, it is possible to manufacture a three-dimensional shaped object with good accuracy, high density and high strength.

  According to the ninth aspect of the present invention, the surface roughness of the manufactured three-dimensional shaped object becomes fine, and the dimensional accuracy is improved.

  According to the invention of claim 10, it is possible to manufacture a three-dimensional shaped article with high accuracy, no cracks, high density and high strength.

(First embodiment)
A method for manufacturing a three-dimensional shaped object according to the first embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a configuration of a metal stereolithography machine used for manufacturing a three-dimensional shaped object, and FIG. 2 shows an SEM photograph of metal powder used for the material. The metal stereolithography machine 1 is a modeling plate 31 on which a material layer 22 of a metal paste 21 as a material is laid, a modeling table 32 that holds the modeling plate 31 and moves up and down, and a metal paste 21 for modeling. A cylindrical container 41 supplied to the plate 31, a wiper 42 that moves in the direction of arrow A to form the material layer 22, a light beam transmitter 51 that emits a light beam L, and a light beam L on the material layer 22. The galvanometer mirror 52 for scanning, the milling head 61 for cutting the periphery of the modeled object, the XY drive mechanism 62 for moving the milling head 61 to the cutting location, the heater 71 for heating the material layer 22, and the fumes generated from the material layer 22 And a suction device 72 for sucking. The light beam transmitter 51 is, for example, a carbon dioxide laser or fiber laser transmitter. The milling head 61 has a tool (ball end mill) having a diameter of 0.6 mm (effective blade length 1 mm).

  The metal paste 21 contains 50 to 70 vol% metal powder and 30 to 50 vol% highly volatile solvent. The metal powder has a substantially spherical shape and an average particle diameter of 1 to 100 μm, preferably 1 to 20 μm. The metal powder is composed of, for example, iron-based powder that is SCM440 powder, nickel powder and / or nickel-based alloy powder, and copper powder and / or copper-based alloy powder that is, for example, CuMnNi powder. The composition ratio of the iron-based powder in the metal powder is 60 to 90 wt%, the composition ratio of the nickel powder and / or the nickel-based alloy powder is 5 to 35 wt%, and the copper powder and / or the copper-based alloy powder The composition ratio is 5 to 15 wt%. The highly volatile solvent is, for example, an alcohol solvent such as xylene or toluene, and the fluidity of the metal paste 21 is improved. It also volatilizes and leaves no impurities.

  FIG. 3 shows the operation of the method for manufacturing a three-dimensional shaped object in time series. As shown in FIG. 3A, the metal stereolithography machine includes a modeling table 32 that can freely move up and down inside a modeling frame 33 surrounded by a periphery, and a modeling object is placed on the modeling table 32. A modeling plate 31 for stacking is disposed. As shown in FIG. 3B, the metal stereolithography machine lowers the modeling table 32 by the height B of the first layer at which modeling is started, and a metal paste that is a material on the modeling plate 31 21 is supplied by moving the wiper 42 in the direction of arrow A to form the material layer 22. The operation of lowering the modeling table 32 and supplying the metal paste 21 constitutes a material layer forming process.

  Here, the details of the material layer forming step will be described with reference to FIG. As shown in FIG. 4A, the metal powder 24 and the highly volatile solvent 25 are placed in a mixing container 43 and mixed to prepare the metal paste 21. The creation of the metal paste 21 is preferably performed immediately before the material layer laminating step is started to prevent volatilization of the highly volatile solvent 25. As shown in FIG. 4B, the metal paste 21 in the mixing container 43 is put into the cylindrical container 41. The cylindrical container 41 is adapted to pour out the metal paste 21 from the lower part. As shown in FIG. 4C, the cylindrical container 41 pours the metal paste 21 in the vicinity of the modeling plate 31 while moving in the direction of arrow C. Next, as shown in FIG. 4 (d), the wiper 42 moves in the direction of arrow D, lays the metal paste 21 on the modeling plate 31, and has a thickness of 1 μm to 200 μm, preferably 5 μm to 20 μm. The material layer 22 is formed.

  Returning to FIG. 3 again, the manufacturing method after the material layer 22 is formed will be described. As shown in FIG. 3C, the metal stereolithography machine naturally drys the material layer 22 to generate a fume 23 and volatilize the highly volatile solvent. Next, as shown in FIG. 3D, the metal stereolithography machine irradiates the material layer 22 formed on the modeling plate 31 with the light beam L. Only the irradiated part is joined and modeled on the modeling plate 31 as a first-layer modeled object. The light beam transmitter emits a light beam L, is scanned to an arbitrary position on the material layer 22 by a galvanometer mirror, melts and solidifies the material layer 22, and is a sintered layer 81 integrated with the modeling plate 31. Form. The operation of forming the sintered layer 81 with the light beam L constitutes an irradiation process. The irradiation path of the light beam L is created in advance from three-dimensional CAD data. The contour shape data of each cross section obtained by slicing the STL data generated from the three-dimensional CAD model at an equal pitch is used. Further, the irradiation with the light beam L is desirably performed in an inert atmosphere or a reducing atmosphere. In particular, when a high-density three-dimensional shaped object is manufactured, the inert atmosphere or the reducing atmosphere is used. is necessary.

  When modeling of the first layer is completed, as shown in FIG. 3E, the metal stereolithography machine lowers the modeling table 32 by the height B to be stacked and supplies the metal paste 21 of the next layer. Then, as shown in FIG. 3 (f), the material layer 22 is naturally dried, fume 23 is generated and the highly volatile solvent is volatilized. As shown in FIG. Irradiate the beam L. In this way, by repeating the supply of the metal paste 21 and the irradiation of the light beam L, as shown in FIG. 3 (h), the sintered layer 81 is laminated and the three-dimensional shaped object 82 is manufactured. This operation of laminating the sintered layer 81 constitutes a laminating process.

  In the above-described manufacturing method, the material is the metal paste 21 obtained by kneading the metal powder and the highly volatile solvent. Therefore, even if the metal powder is a fine powder, the fluidity is good, and the material layer 22 is uniformly thinly formed. It is possible to manufacture the three-dimensional shaped object 82 with high accuracy. In addition, the metal powder does not soar and the material is easy to handle. Since the mixing ratio of the metal powder and the highly volatile solvent is set to the above-mentioned mixing ratio, an appropriate fluidity can be obtained, the material layer can be formed uniformly and thinly, and the three-dimensional shaped object 82 with high accuracy can be obtained. Can be manufactured. Since the highly volatile solvent is volatilized before the irradiation with the light beam L and there are few impurities, a three-dimensional shaped article with high density and high strength can be obtained. Moreover, since the average particle diameter of the metal powder is as fine as 1 to 100 μm and the material layer 22 is as thin as 1 to 200 μm, it is possible to manufacture the three-dimensional shaped object 82 with higher accuracy.

  Since the metal powder has the above-described composition, the rising of the sintered layer 81 is reduced, and the next material layer 22 is easily formed. Moreover, generation | occurrence | production of the crack in the external appearance of the three-dimensional shaped molded article 82 manufactured and the micro crack of an internal structure | tissue can be suppressed.

  Since the metal paste 21 is placed in the cylindrical container 41, the highly volatile solvent 25 does not evaporate, and the metal paste 21 can be supplied in a state where the composition is stable. Can be manufactured. Further, since the material supply space can be narrowed, the metal stereolithography machine can be reduced in size, and the inert gas and reducing gas supplied during irradiation with the light beam L can be reduced. .

(Second Embodiment)
A method for manufacturing a three-dimensional shaped object according to the second embodiment of the present invention will be described. FIG. 5 shows the heating operation of the material layer in the manufacturing method of the present embodiment. The metal stereolithography machine in this embodiment may have the same configuration as that of the first embodiment, and each step of the manufacturing method may be the same as that of the first embodiment (the same applies hereinafter). In the present embodiment, the material layer 22 is heated by the heater 71 between the material layer forming step and the irradiation step, and the highly volatile solvent generates fumes 23 and volatilizes. Since the volatilization rate of the highly volatile solvent is faster than that of natural drying, the waiting time for light beam irradiation is shortened, and the manufacturing time can be shortened.

(Third embodiment)
A method for manufacturing a three-dimensional shaped object according to the third embodiment of the present invention will be described. FIG. 6 shows a fume suction operation in the manufacturing method of the present embodiment. In the present embodiment, the suction device 72 sucks the fumes 23 generated from the material layer 22 between the material layer forming step and the irradiation step. By sucking the fume 23, the lens through which the light beam L is transmitted is not soiled by the fume 23, so that the light beam L is stable and a three-dimensional shaped object with high accuracy can be manufactured. Further, by sucking, the volatilization rate of the highly volatile solvent is increased, the waiting time for light beam irradiation is shortened, and the manufacturing time can be shortened. Moreover, environmental pollution can be prevented and the safety of production can be improved.

(Fourth embodiment)
A method for manufacturing a three-dimensional shaped object according to the fourth embodiment of the present invention will be described. FIG. 7 shows a configuration of a wire mesh used in the manufacturing method in the present embodiment. In the present embodiment, the material layer is formed by using the metal paste and the wire net 26 in the material layer stacking step. The metal mesh 26 is configured by metal wires 27 arranged in the vertical direction and the horizontal direction, and the metal wires 27 are joined to each other by electric welding. The wire diameter F of the metal wire 27 is 0.01 to 0.1 mm, and the gap G between the metal wires 27 is 0.01 to 0.1 mm. The component of the metal wire 27 uses the metal contained in the metal powder, and the total composition ratio of the iron wire 27 and the metal powder is 60 to 90 wt% of iron, and the composition ratio of nickel. Is 5 to 35 wt%, and the composition ratio of copper is 5 to 15 wt%.

  FIG. 8 shows the operation of the manufacturing method of the three-dimensional shaped object in time series. As shown in FIG. 8A, the wire net 26 is placed on the modeling plate 31. Next, as shown in FIG. 8B, the metal stereolithography machine lowers the modeling table 32 by the height B of the first layer at which modeling starts, and moves the wiper 42 in the direction of arrow A. Then, the metal paste 21 is supplied onto the modeling plate 31 to form the material layer 22. When the material layer 22 is formed, as shown in FIG. 8C, the metal stereolithography machine naturally drys the material layer 22 to generate fumes 23 to volatilize the highly volatile solvent. Next, as shown in FIG. 8D, the metal stereolithography machine irradiates the material layer 22 with the light beam L. Only the irradiated part is joined and modeled on the modeling plate 31 as a first-layer modeled object. If the sintered layer 81 and the wire net 26 are separated by the light beam L, it is easy to take out the three-dimensional shaped object when the modeling is completed.

  When the formation of the first layer is completed, as shown in FIG. 8E, the modeling table 32 is lowered by the height B to be stacked, the metal mesh 26 of the next layer is placed, and the metal paste 21 is supplied. 8 (f), the material layer 22 is naturally dried to volatilize the highly volatile solvent, and the portion to be shaped is irradiated with the light beam L as shown in FIG. 8 (g). . Thus, by repeating the supply of the wire mesh 26 and the metal paste 21 and the irradiation of the light beam L, the sintered layer 81 is laminated, and as shown in FIG. it can.

  In the present embodiment, since the metal mesh 26 and the metal paste 21 are supplied in combination as the metal material, the metal can be supplied at a higher density compared to the case of the metal paste 21 alone, and the three-dimensional shaped object can be supplied. 82 can be manufactured with high dimensional accuracy, high density and high strength, and segregation of the material hardly occurs. Since the metal wire 27 is thin, the thickness of the material layer 22 can be reduced, and the dimensional accuracy of the three-dimensional shaped object 82 can be improved. Further, since the metal wire 27 is not too thin, the metal wire 27 is unlikely to scatter when irradiated with the light beam L. Since the metal mesh 26 has the above-described composition, the swell of the sintered layer 81 is reduced, the metal mesh 26 to be laminated next can be placed with high accuracy, and cracks in the appearance of the manufactured three-dimensional shaped object 82 can be obtained. In addition, the occurrence of microcracks in the internal structure can be suppressed.

(Fifth embodiment)
A method for manufacturing a three-dimensional shaped object according to the fifth embodiment of the present invention will be described. FIG. 9 shows a cutting process in the manufacturing method according to this embodiment. In the present embodiment, the periphery of the model is cut by the milling head 61. When the thickness of the laminated sintered layer becomes an effective blade length of 1 mm or less of the milling head 61, for example, 0.5 mm, the metal stereolithography machine 1 drives the milling head 61 and the milling head 61 is driven by the XY drive mechanism 62. Is moved in the directions of arrows X and Y (see FIG. 1) to cut the surface of the shaped object. The operation | movement which cuts the surface of this molded article comprises a cutting process. And whenever the thickness of the laminated | stacked sintered layer becomes 0.5 mm, the surface of a molded article is cut repeatedly. The surface roughness of the manufactured three-dimensional shaped object 82 becomes fine, and the dimensional accuracy is improved.

  In addition, this invention is not restricted to the structure of the said various embodiment, A various deformation | transformation is possible in the range which does not change the meaning of invention. For example, the wire mesh may be created by knitting metal wires, or may be created by joining metal wires by pressure bonding. Moreover, in a wire mesh, you may combine a metal wire not in 2 directions but in 3 directions. Moreover, the shape of the metal powder may not be substantially spherical, but may be, for example, a rod shape or a plate shape. The particle size in the case where the metal powder is not substantially spherical refers to the maximum particle passing dimension measured by microscopy.

The perspective view of the metal stereolithography processing machine used for the manufacturing method which concerns on the 1st Embodiment of this invention. The SEM photograph of the metal powder used for the manufacturing method. The figure explaining the manufacturing method in time series. The figure explaining the detail of the material layer formation process of the manufacturing method. The figure explaining the heating operation of the material layer in the manufacturing method which concerns on the 2nd Embodiment of this invention. The figure explaining the suction | inhalation operation | movement of a fume in the manufacturing method which concerns on the 3rd Embodiment of this invention. The block diagram of the wire mesh used for the manufacturing method which concerns on the 4th Embodiment of this invention. The figure explaining the manufacturing method in time series. The figure explaining the cutting process in the manufacturing method which concerns on the 5th Embodiment of this invention.

Explanation of symbols

22 Material layer 24 Metal powder 25 High volatile solvent 26 Wire mesh 27 Metal wire 31 Modeling plate 81 Sintered layer 82 Three-dimensional modeled object L Light beam

Claims (10)

A material layer forming step of supplying a material for three-dimensional shape modeling onto the modeling plate and forming a material layer;
An irradiation step of irradiating the material layer with a light beam to form a sintered layer or a dissolved layer;
In the method for producing a three-dimensional shaped object, comprising a lamination step of laminating the sintered layer or the dissolved layer on the modeling plate by repeating the material layer forming step and the irradiation step.
As the material, a mixture of metal powder and a highly volatile solvent is used,
The method of manufacturing a three-dimensional shaped object, wherein the irradiation with the light beam is performed after the highly volatile solvent in the material layer formed in the material layer forming step is volatilized.   2. The method for producing a three-dimensional shaped article according to claim 1, wherein the material has a metal powder of 50 vol% or more and 70 vol% or less and a highly volatile solvent of 30 vol% or more and 50 vol% or less.   The method for producing a three-dimensional shaped article according to claim 1 or 2, wherein the average particle diameter of the metal powder is 1 µm or more and 100 µm or less.   The metal powder has a composition ratio of the iron-based powder of 60 wt% or more and 90 wt% or less, a composition ratio of either or both of the nickel powder and the nickel-based alloy powder is 5 wt% or more and 35 wt% or less, a copper powder and The method for producing a three-dimensional shaped article according to any one of claims 1 to 3, wherein the composition ratio of both or any one of the copper-based alloy powders is 5 wt% or more and 15 wt% or less. .   The thickness of the said material layer is 1 micrometer or more and 200 micrometers or less, The manufacturing method of the three-dimensional shaped molded article as described in any one of Claim 1 thru | or 4 characterized by the above-mentioned.   The method for producing a three-dimensional shaped structure according to any one of claims 1 to 5, wherein in the material layer forming step, the material layer is heated to volatilize the highly volatile solvent. .   In the said material layer formation process, the said highly volatile solvent volatilized from the said material layer is attracted | sucked and collect | recovered, The three-dimensional shaped molded article as described in any one of Claim 1 thru | or 6 characterized by the above-mentioned. Production method.   The method for manufacturing a three-dimensional shaped object according to any one of claims 1 to 7, wherein the material layer includes a wire mesh formed of a metal wire.   The method further comprises a cutting step of cutting and removing a surface portion and / or an unnecessary portion of the three-dimensionally shaped object obtained by stacking the sintered layer or the melted layer so far. The manufacturing method of the three-dimensional shape molded article as described in any one of Claim 1 thru | or 8. A material for three-dimensional shape modeling, which is used in the method for producing a three-dimensional shape molded product according to any one of claims 1 to 4, and is formed by mixing a metal powder and a highly volatile solvent.