JP2000153556A - Optical method for shaping object three-dimensionally - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply shape an object three-dimensionally with high dimensional precision and high productivity by bringing the lower face of a light-transmitting film into contact with the liquid face of a photocurable resin liquid and pressing the resin liquid to be flattened, and then forming a cured resin layer with a specified pattern and a specified thickness through the emission of light from above and further, peeling the film to again form a photocurable resin liquid layer with a specified thickness on the curable resin layer. SOLUTION: The entire curable resin layer L1 on the liquid level 2' of a photocurable resin liquid 2 in a shaping bath 1 is covered with a continuous long light-transmitting film 4 using supply rollers 5a, 5b and take-up rollers 6a, 6b. The lower face of the film 4 is brought into contact with the liquid level 2', which is, in turn, pressed using a light-transmitting pressing plate 8 to be flattened. Further, light is emitted to the resin liquid 2 from a light source 9 above so that the resin liquid 2 is photocured to the specified pattern and thickness and a cured resin layer L2 is formed on the lower face of the film 4. In addition, a pressing plate 8 is sidetracked to gradually peel the film 4 from the cured resin layer L2 and a table 3 on which the cured resin laminates L2/L1 are placed is lowered to repeat the process. Thus it is possible to manufacture an optical three-dimensionally shaped object with a flat surface and a high dimensional precision rapidly, efficiently and smoothly.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical three-dimensional molding method and an optical three-dimensional molding apparatus using a photocurable resin. More specifically, the present invention uses a photocurable resin liquid,
The present invention relates to an optical three-dimensional modeling method and an optical three-dimensional modeling apparatus for manufacturing a three-dimensional molded object having a flat surface and excellent dimensional accuracy at a good energy efficiency and a high optical molding speed.

[0002]

2. Description of the Related Art In recent years, an optical molding method and an apparatus for manufacturing a three-dimensional object by curing a photocurable resin based on data input to a three-dimensional CAD have been put to practical use. This stereolithography technology includes models for verifying the external design during design, models for checking the functionality of parts, resin molds for producing molds, and base models for producing molds. It attracts attention because it can easily form such complex three-dimensional objects.

[0003] Generally adopted optical three-dimensional molding method and apparatus include: (1) A liquid photocurable resin is put in a molding bath, and ultraviolet light controlled by a computer so that a desired pattern is obtained on the liquid surface. Selectively irradiate light such as laser to light-cur to a predetermined thickness to form a cured resin layer, and move the cured resin layer downward in the molding bath to remove the photocurable resin liquid in the molding bath. The photocurable resin liquid layer is formed by flowing on the cured resin layer, and the photocurable resin liquid layer is irradiated with light to form a cured resin layer. A so-called free liquid surface method and an apparatus therefor, which are repeatedly performed until a three-dimensional object is obtained; (2) a predetermined thickness (generally 50 to 200 μm) on a table (substrate) using a blade or other coating means; About one layer) After forming the layer of the photocurable resin liquid, the photocurable resin liquid layer is irradiated with light to form a cured resin layer having a predetermined pattern and thickness, and then the table on which the cured resin layer is placed is lowered. To further apply one layer of a photo-curable resin liquid on the cured resin layer, and photo-curing it in a predetermined pattern to form a second cured resin layer,
A method and an apparatus for repeatedly performing the above steps until a three-dimensional structure having a predetermined shape and dimensions is obtained.

However, in the case of the free liquid level method and the apparatus of the above (1), the liquid surface of the photocurable resin liquid stored in the molding bath rises due to the surface tension of the photocurable resin liquid, or In many cases, the surface of the layer of the photocurable resin liquid that has been flowed and laminated on the cured resin layer formed in the previous stage rises, and the liquid surface of the photocurable resin liquid to be photocured is not flat. As a result, the upper part of the obtained three-dimensional structure is rounded as shown in, for example, FIGS. 1A and 1B, is not flat, and tends to have poor dimensional accuracy. . In order to avoid the problem of a decrease in dimensional accuracy due to this surface tension, it is conceivable to select a photocurable resin having a low surface tension, but the type of photocurable resin to be used is limited. However, there is a drawback that an optical three-dimensional object having characteristics (mechanical characteristics, physical characteristics, chemical characteristics, and the like) matching the intended use and intended use cannot be obtained. Moreover, in the free liquid level method (1), since the liquid level of the photocurable resin liquid in the molding bath changes depending on the resin temperature, it is difficult to keep the liquid level constant, and the liquid level changes. The dimensional accuracy of the obtained three-dimensional structure is reduced. As a method of keeping the liquid level of the photocurable resin liquid in the molding bath constant, the liquid level is always detected by a sensor,
A method of raising and lowering a counter volume arranged in a modeling bath according to the detection result is known, but it is expensive in terms of equipment and disadvantageous in cost.

In the case of the optical three-dimensional molding method and apparatus (2), the liquid surface of the photocurable resin liquid layer applied on the table or the cured resin layer becomes completely flat immediately after the application. In many cases, it is wavy, and this is one of the causes of a decrease in the dimensional accuracy of the obtained three-dimensional structure. As a solution to the problem due to the waving of the liquid surface of the photocurable resin liquid layer, take a waiting time of several tens of seconds after applying the photocurable resin liquid, and perform the light irradiation after the waving of the liquid surface is eliminated. Although the method is generally employed, since a waiting time of several tens of seconds is required, the optical molding speed is reduced, which causes a decrease in productivity.

Further, in optical three-dimensional molding, acrylate-based photocurable resins are often used as photocurable resins. However, acrylate-based photocurable resins may cause curing inhibition due to atmospheric oxygen. In order to sufficiently cure the acrylate-based photocurable resin, it is necessary to increase the irradiation energy, which tends to lower the energy efficiency. The problem of such curing inhibition is described above in which light irradiation is performed while the photocurable resin liquid layer is exposed to the atmosphere (1).
This occurs in any of the methods (2) and (2).

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to provide an optical three-dimensional modeling method and an optical three-dimensional modeling apparatus which do not have the drawbacks as in the above-mentioned prior art.
More specifically, an object of the present invention is to eliminate the problem of a decrease in dimensional accuracy (non-flat state) on the surface of an optical three-dimensional object due to the surface tension of a photocurable resin liquid stored in a molding bath,
There is no need to select and use a photocurable resin with a low surface tension, and it is possible to freely select and use a photocurable resin that matches each application and purpose. Based on the detection results, there is no need to use an expensive device that moves the counter volume up and down in the modeling bath to keep the liquid level constant, and it is not necessary to use a photocurable resin liquid layer coated on a table or cured resin layer. It is not necessary to take a waiting time until the ripples disappear, and furthermore, without causing a problem of inhibition of curing of the acrylate-based photocurable resin due to oxygen in the atmosphere, a three-dimensional molded article having a predetermined shape and size can be formed to a high size. An object of the present invention is to provide an optical three-dimensional modeling method and an optical three-dimensional modeling apparatus that can be manufactured with high accuracy, high optical modeling speed, and good energy efficiency.

[0008]

The present inventors have made intensive studies to achieve the above object. As a result, in the manufacturing technology of an optical three-dimensional molded object, in which the process of irradiating the liquid photocurable resin stored in the molding bath with light to form a cured resin layer is repeated, the photocuring resin stored in the molding bath is used. When a light-transmitting film is placed on the liquid surface of the curable resin liquid, and the light-curable resin liquid in contact with the lower surface of the light-transmitting film is pressed to make it flat, and then irradiated with light in that state, the light enters the molding bath. The liquid surface of the photocurable resin liquid is prevented from bulging round due to surface tension, and a cured resin layer that is photocured in a flat state is formed, so that a three-dimensional structure obtained therefrom has a flat surface, It was found that the dimensional accuracy was excellent. In addition, the present inventors have proposed that when performing the above-described optical three-dimensional modeling, since the liquid surface of the photocurable resin liquid is covered with the light transmitting film during light irradiation, the photocurable resin liquid and oxygen It has been found that the contact with the resin is interrupted, the curing inhibition by oxygen is prevented, the photocurable resin liquid can be rapidly photocured, and the molding speed and energy efficiency are improved.

Further, in performing the above-mentioned optical three-dimensional modeling, the present inventors press the light-curable resin liquid that is in contact with the lower surface of the light-transmitting film, and tension the light-transmitting film itself. Although a flattening method can be adopted, it has been found that when a light-transmitting pressing plate is arranged on the upper surface of the light-transmitting film and pressed by the pressing plate, flattening can be performed more smoothly. In addition, the present inventors, the peeling of the light-transmitting film from the cured resin layer formed by light curing is gradually performed from the end of the cured resin layer, the light-transmitting film is smoothly and smoothly peeled off. I found that I got it.

In addition, in the above-mentioned optical three-dimensional modeling, the present inventors have used a supply roller and a take-up roller in which a long continuous film is used as the light-transmitting film and the films are arranged at intervals in the horizontal direction. By transferring to the light irradiation area and taking it out from the light irradiation area by using, and irradiating light in the area between the supply roller and the take-off roller, the three-dimensional object with excellent dimensional accuracy can be easily manufactured. The present inventors have found that they can be manufactured with high productivity and high productivity, and have completed the present invention based on those various findings.

That is, the present invention provides: (1) (i) a step of arranging the lower surface of a light-transmitting film in contact with the surface of a photocurable resin liquid stored in a molding bath; Pressing the liquid surface of the photocurable resin liquid in contact with the lower surface of the transparent film to flatten it; (iii) keeping the liquid surface of the photocurable resin liquid flat,
Irradiating light from above the light-transmitting film, light-curing the photocurable resin liquid in a predetermined pattern and thickness designed in advance, and forming a cured resin layer on the lower surface of the light-transmitting film; (Iv) a step of peeling the light-transmitting film from the cured resin layer; and (v) a step of moving the cured resin layer downward in the molding bath to form a photocurable resin in the molding bath on the cured resin layer. Flowing the resin liquid to form a liquid layer having a predetermined thickness of the photocurable resin liquid;
After that, until a three-dimensional structure having a predetermined shape and dimensions is formed, the above-described steps (i) to (v) are repeated to perform lamination and modeling to manufacture a three-dimensional structure. This is an optical three-dimensional modeling method.

Further, the present invention provides: (2) the step (ii) of flattening the liquid surface of the photo-curable resin liquid in contact with the lower surface of the light-transmitting film; This is performed by arranging a transparent pressing plate and pressing the liquid surfaces of the light transmitting film and the photocurable resin liquid with the light transmitting pressing plate to form a light transmitting layer after the step (iii) of forming the cured resin layer. (3) the optical three-dimensional modeling method of (1), comprising performing the step (iv) of retracting the flexible pressing plate and then peeling the light-transmitting film from the cured resin layer; The optical three-dimensional modeling method according to (1) or (2), wherein the step (iv) of peeling the film is performed by gradually peeling the light-transmitting film from one end of the cured resin layer; (4) Light-transmitting property The film is a continuous long film, The step (i) of arranging the lower surface of the permeable film in contact with the surface of the photo-curable resin liquid in the molding bath is performed using a supply roller and a take-off roller that are arranged at intervals in the lateral direction, and the photo-curing is performed. The step (ii) of flattening the liquid surface of the conductive resin liquid
And the step (iii) of irradiating with light is performed in a stationary state in which the transfer of the light-transmitting film is stopped, and the step (iv) of peeling the light-transmitting film from the cured resin layer is performed by connecting the take-up roller to the supply roller side. (1) to (2) by taking the light-transmitting film with a take-off roller while moving
(3) Any one of the optical three-dimensional modeling methods as a preferred embodiment.

Further, the present invention provides: (5) a shaping bath (A) for storing a photocurable resin liquid; a means (B) for disposing a light-transmitting film on the liquid surface of the shaping bath; Means (C) for flattening the liquid surface of the photocurable resin liquid in contact with the lower surface of the resin; light irradiating means (D) disposed above the light transmissive film; means for peeling the light transmissive film from the cured resin layer ( E) means for placing the cured resin layer formed in the molding bath and moving it up and down (F); and control means for sequentially operating the means (B) to (F). An optical three-dimensional printing apparatus characterized by the following.

(6) The flattening means (C) is a light-transmitting pressing plate disposed on an upper part of the light-transmitting film, and the light-transmitting pressing plate is disposed on an upper surface of the light-transmitting film. (3) The optical three-dimensional modeling apparatus according to (5) above, further comprising: means for disposing the pressing plate, and means for retracting the light transmitting pressing plate from the upper surface of the light transmitting film; (7) means for disposing the light transmitting film (B) Are a supply roller and a take-off roller for a light-transmissive film designed to have a variable distance, and a means for increasing the distance between the supply roller and the take-off roller when the light-transmissive pressing plate presses the light-transmissive film from above. Means for arranging and pressing the light-transmitting pressing plate on the upper surface of the light-transmitting film between the roller and the take-off roller, keeping the light-transmitting film stationary when pressed by the light-transmitting pressing plate and during light irradiation Means for hard The optical three-dimensional modeling apparatus according to the above (6), which has means for moving the take-up roller to the supply roller side when the light-transmitting film is peeled off from the functionalized resin layer and for taking out the light-transmitting film;

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail. In the optical three-dimensional modeling method and apparatus of the present invention, a photocurable resin liquid stored in the stereolithography is used. As the photocurable resin liquid, any of a liquid photocurable resin and a photocurable resin composition that can be used for optical three-dimensional modeling can be used, and the type of the photocurable resin liquid is not particularly limited. A table (substrate) that can move up and down is arranged in the modeling bath, and the table is a cured resin layer formed into a predetermined pattern by photo-curing (a molded article in the middle of molding, a finally obtained three-dimensional molding). The object is placed on the object and supported from below to perform stereolithography.

First, the light-transmitting film is disposed on the liquid surface of the photocurable resin liquid such that the lower surface thereof is in contact with the liquid surface of the photocurable resin liquid stored in the molding bath [Step (i)]. . In arranging the light-transmitting film on the liquid surface of the light-curable resin liquid, the light-transmitting film is held at both ends or the entire circumference by holding means, and the light-curing film which is in contact with the lower surface of the light-transmitting film is held. The pressing force is applied to the liquid surface of the resin liquid. Specific arrangements that can be adopted include: (1) a continuous long film is used as the light-transmitting film, and the lower surface of the light-transmitting film can be kept horizontal; The light-transmitting film is transported to the light irradiation area by using the supply roller and the take-up roller which are arranged, arranged and taken out from the light irradiation area after the light irradiation. (2) The light-transmitting film cut into a predetermined size is irradiated with the light. In the area, a method of gripping (fixing) at both ends or the entire periphery and arranging the same can be cited. Among them, the method (1) using the supply roller and the take-off roller can continuously and easily supply the light-transmitting film to the light irradiation area and carry out the light-transmitting film from the light irradiation area, It is preferably employed because the optical molding speed can be increased.

As the light-transmitting film, any film can be used as long as it is light-transmitting and easily peelable from the cured resin layer.
Polypropylene film, polyvinyl chloride film, polystyrene film, polyvinyl alcohol film,
Examples include transparent plastic films such as polyester films, polycarbonate films, and acetate films such as triacetate.Especially, polyethylene films and acetate films such as triacetate are easily peeled from the cured resin layer, durability, cost, etc. It is preferably used from the point of view. The dimensions of the light-transmitting film can be determined according to the plane dimensions of the three-dimensional object to be manufactured, the size of the molding bath, and the like, and are not particularly limited. ) Needs to be dimensioned so that the entire cured resin layer formed by stereolithography can be planarly covered. The thickness of the light-transmitting film is not particularly limited as long as the film has a strength that does not cause breakage during optical shaping or peeling from the cured resin layer.

Next, the surface of the photocurable resin liquid in contact with the lower surface of the light transmitting film is pressed to be flattened [step (ii)]. At this time, the method of pressing and flattening the liquid surface of the photo-curable resin liquid includes (1) disposing a light-transmitting pressing plate on the upper surface of the light-transmitting film, and applying light-transmitting pressure by the light-transmitting pressing plate. (2) tension is applied from both ends or the entire circumference of the light-transmitting film to flatten the light-transmitting film and flatten the light-transmitting film. A method of pressing the liquid surface of the photocurable resin in contact with the lower surface of the film by the light transmitting film itself to flatten the liquid surface, or the like can be adopted.
Among them, the method (1) using the light-transmitting pressing plate can easily and reliably press and flatten the liquid surface of the light-curable resin liquid in contact with the light-transmitting film and the lower surface thereof. It is preferred. The light-transmitting pressing plate may be any plate-like body that is light-transmitting and can apply a uniform pressing force to the liquid surface of the light-curable resin liquid that is in contact with the light-transmitting film and the lower surface thereof. Examples thereof include a glass plate, an acrylic resin plate, a polycarbonate resin plate, a polystyrene plate, a polyvinyl chloride plate, a polyvinyl alcohol plate, and a polyester resin plate.

In the pressing and flattening step (ii),
If the pressing force is too strong, the light-transmitting film is immersed in the light-curable resin liquid, and the light-curable resin liquid penetrates toward the upper surface of the light-transmitting film, and it is difficult to form the cured resin layer with high dimensional accuracy. In addition, the cured resin layer is also formed on the upper surface of the light transmissive film, so that the light transmissive film is not easily separated from the cured resin layer. Therefore, it is necessary to adjust the pressing force so that only the lower surface of the light transmissive film is in contact with the liquid surface of the photocurable resin liquid and the liquid surface is flattened.

A continuous long film is used as the light-transmitting film, and a supply roller and a take-off roller are used in which the light-transmitting film is in contact with the liquid surface of the photocurable resin liquid at a lateral interval. In this case, during the flattening step of the liquid surface of the photo-curable resin liquid, the transfer of the light-transmitting film is stopped and the light-transmitting film is stopped, and the light-transmitting film portion is located between the supply roller and the take-off roller. It is necessary to press and flatten the liquid surface of the photocurable resin liquid in order to make the liquid surface flat. At this time, both sides (both ends in the width direction) of the long film are bent (lifted) upward by appropriate means, and the film is supplied by a supply roller and a take-off roller while air is not mixed between the film and the liquid surface. The lower surface of the liquid is brought into contact with the liquid surface of the photo-curable resin liquid, and then, at a predetermined position, a light-transmitting pressing plate having a width slightly smaller than the entire width of the film is placed on the film, and When the pressing and flattening are performed, the pressing and flattening of the liquid surface of the photocurable resin liquid can be performed smoothly.

Next, light is irradiated from above the light-transmitting film while the liquid surface of the photocurable resin liquid in contact with the lower surface of the light-transmitting film is kept flat and the light-transmitting film is stationary. Then, the photocurable resin liquid is photocured in a predetermined shape (pattern) and thickness designed in advance to form a cured resin layer on the lower surface of the light transmissive film [step (iii)]. The method of light irradiation at this time is not particularly limited. For example, even if a spot-shaped light beam is irradiated on the photo-curable resin liquid surface to form a cured resin layer by a drawing method, a linear light beam is irradiated. Alternatively, the cured resin layer may be formed by irradiating light in a plane using a mask or the like. In addition, the type of light to be applied is not particularly limited, and any light used in optical three-dimensional printing can be used.
r-laser, He-Cd laser, LD laser (semiconductor-excited solid-state laser), xenon lamp, metal halide lamp, mercury lamp, fluorescent lamp and other active energy rays can be used. It is preferably adopted from the viewpoint of high molding accuracy due to the above. The intensity of the irradiated light, the distance between the liquid surface of the photocurable resin liquid and the light source, and the like can also be appropriately set according to each situation. When a continuous long film is used as the light-transmitting film, and the contact arrangement of the light-transmitting film on the liquid surface of the photo-curable resin liquid is performed in the lateral direction using the supply roller and the take-off roller, the light transmission In a stationary state in which the transfer of the conductive film is stopped, light is irradiated on the light transmitting film portion between the supply roller and the take-off roller to form a cured resin layer having a predetermined pattern and a predetermined thickness.

Then, the light-transmitting film is peeled from the cured resin layer formed as described above [Step (iv)]. Step (ii) above (pressing and flattening the liquid surface of the photocurable resin liquid)
Is performed by disposing a light-transmitting pressing plate on the upper surface of the light-transmitting film, the light-transmitting pressing plate is retracted to a position where the light-transmitting pressing plate does not hinder the peeling operation, and then the peeling step is performed. As a method of peeling the light-transmitting film, any method may be adopted as long as the light-transmitting film is smoothly peeled off from the surface of the cured resin layer. , The light-transmitting film is gradually peeled off from one end of the light-curing resin, so that the light-transmitting film can be smoothly and smoothly transmitted without causing any damage to the cured resin layer or adhesion of the cured resin layer to the light-transmitting film. It is preferable because the conductive film can be peeled off.

In order to facilitate peeling of the light transmitting film from the cured resin layer, it is conceivable to apply a release agent on the lower surface of the light transmitting film. The release agent remains on the surface of the cured resin layer, and when the next cured resin layer is further laminated on the cured resin layer, the cured resin is easily separated from the cured resin layer. Care must be taken because the adhesion of the layers is weakened and delamination is likely to occur in the resulting three-dimensionally shaped object, which may reduce the strength of the shaped object.

A continuous long film is used as the light-transmitting film, and the supply roller and the take-up roller are arranged with the light-transmitting film disposed on the liquid surface of the photo-curable resin liquid at intervals in the horizontal direction. If the light-transmitting film is pulled by the pulling roller while moving (pulling) the pulling roller toward the supply roller side, the light-transmitting film is gradually and smoothly spread from one end of the cured resin layer. Can be peeled off.

Then, the series of steps (i) to (i)
After one hardened resin layer is formed at the liquid level position of the molding bath according to v), the table on which the hardened resin layer is placed and supported is moved downward by a distance corresponding to the next one layer in the shaping bath. To form a liquid layer (one liquid layer) of a predetermined thickness of the photo-curable resin liquid by flowing the photo-curable resin liquid in the molding bath on the cured resin layer [step ( v)]. Note that, in this step (v), when the light transmitting film is disposed on the liquid surface of the photocurable resin liquid [step (i)], the cured resin layer formed in the step (iii) has a light transmitting property. As long as it is at a position where it does not come into contact with the film, it may be performed before or after the above step (i) of disposing the light-transmitting film on the liquid surface of the photocurable resin liquid.

The above-described series of steps (i) to (v) is repeatedly performed on the liquid layer of the photocurable resin liquid formed on the cured resin layer in step (v). By repeating the steps (i) to (v) until a three-dimensional object having a predetermined shape and dimensions is formed, the three-dimensional object having a flat surface and excellent dimensional accuracy is obtained. Can be manufactured smoothly with good energy efficiency and high stereolithography speed. In the present invention, when the above-described series of steps (i) to (v) are performed by an automatic control method, an optical three-dimensional object having excellent dimensional accuracy can be manufactured at a higher optical forming speed.

[0027]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to FIGS. However, the invention is not limited in any way to those of FIGS. As shown in FIG. 2A, a photo-curable resin liquid 2 is stored in a molding bath 1. The in shaping bath 1 to place the vertically movable table 3 for placing a molded article (cured resin layer) L _1. A continuous long light-transmitting film 4 (made of polyethylene or other light-transmitting plastic) is formed by using a pair of supply rollers 5a and 5b and a pair of take-off rollers 6a and 6b that can adjust a horizontal interval. Liquid level 2 ′ of photocurable resin liquid 2
Contact and position. If necessary, a means 7 (for example, a rotating roller or the like) for keeping the liquid level 2 'of the photocurable resin liquid 2 constant may be provided.

Next, as shown in FIG. 2 (b), the distance between the supply rollers 5a, 5b and the take-off rollers 6a, 6b is widened by a variable distance means (not shown), and so that the whole (cured resin layer) L ₁ is at least covered by the light transmissive film 4. At that time,
As shown in FIG. 3 (a cross-sectional view of the light-transmitting film 4 as viewed from the width direction), both sides 4a and 4b of the light-transmitting film 4
Is bent (lifted) upward by appropriate means such as film straightening rollers 10a, 10b, etc., so that air does not enter between the light transmitting film 4 and the liquid surface 2 ', and the supply roller 5b and the take-up roller 6b, the lower surface of the light transmitting film 4 is brought into contact with the liquid surface 2 'of the photocurable resin liquid 2, and thereafter the supply rollers 5a, 5b and the take-up roller 6
With the a and 6b stationary, as shown in FIG. 2 (c), a light-transmitting pressing plate 8 (a glass plate or other material) having a width slightly smaller than the width of the light-transmitting film 4 is provided at a predetermined position. Of the liquid surface 2 ′ by appropriately pressing the liquid surface 2 ′ of the light transmitting film 4 and the photocurable resin liquid 2 by the light transmitting pressing plate 8. At the same time, the liquid level 2 'is shielded from oxygen in the atmosphere while flattening. The arrangement of the light transmitting pressing plate 8 on the upper surface of the light transmitting film 4 and the retreat from the upper surface of the light transmitting film 4 are automatically performed by means not shown.

Next, as shown in FIG. 2D, while the liquid surface 2 ′ of the photocurable resin liquid 2 is kept flat, light ( For example, as shown in FIG. 2 (e), the photocurable resin liquid 2 is photocured in a predetermined pattern and thickness designed in advance, and the lower surface to form a cured resin layer L _2. Thereafter, as shown in FIG. 2 (f), the light-transmitting pressing plate 8 is retracted, and then the take-up rollers 6a, 6b are gradually moved to the supply rollers 5a, 5b as shown in FIG. 2 (g). It is allowed while a light transmissive film 4 a take-up roller 6a, by taking up in 6b, gradually peeled off the light transmissive film 4 from the one end of the cured resin layer L _2.

Then, as shown in FIG. 2H, the table 3 on which the molded article (cured resin laminate) L ₂ / L ₁ is placed is moved to the next position as shown in FIG. Then, a three-dimensional structure having a desired shape and size is manufactured by lowering the cured resin layer downward by the thickness of the cured resin layer and repeating the series of steps described above. This makes it possible to manufacture a three-dimensional object having excellent dimensional accuracy at a high optical molding speed and with good light energy efficiency.

[0031]

According to the optical stereolithography method and the optical stereolithography apparatus of the present invention, (1) dimensions on the surface of the optical stereolithography object caused by the surface tension of the photocurable resin liquid stored in the modeling bath; It is possible to manufacture a three-dimensional molded article having a flat surface and excellent dimensional accuracy by eliminating the problem of a decrease in accuracy (non-flat state); (2) A photocurable resin having a low surface tension is particularly selected and used. There is no need to do this, and it is possible to perform optical three-dimensional molding by freely selecting a photocurable resin that matches each application or purpose; (3) The liquid level is detected by a sensor and the molding is performed based on the detection result An expensive device that keeps the liquid level constant by moving the counter volume up and down in the bath becomes unnecessary. (4) The coating process of the photocurable composition becomes unnecessary, and accompanying the coating, Rip of photocurable resin liquid layer There is no problem and there is no need for a waiting time for eliminating foaming; and (5) oxygen irradiation in the atmosphere is performed because light irradiation is performed while the liquid surface of the photocurable resin liquid is covered with a light transmitting film. This eliminates the problem of the inhibition of the curing of the acrylate-based photocurable resin.
Therefore, in the case of the present invention, an optical three-dimensional object having a flat surface and excellent dimensional accuracy, a high optical molding speed,
And it can be manufactured smoothly with good energy efficiency.

[Brief description of the drawings]

FIG. 1 is a view schematically showing the surface shape of an optical three-dimensional structure obtained by a conventional free liquid surface method.

FIG. 2 is a schematic view showing an example of an optical three-dimensional printing method and apparatus according to the present invention.

FIG. 3 is a diagram illustrating an example when a liquid surface of a photocurable resin liquid is pressed and flattened using a light transmitting film and a light transmitting pressing plate.

[Explanation of symbols]

L ₁ cured resin layer L ₂ cured resin layer 1 molding bath 2 light curable resin liquid 2 ′ liquid surface of light curable resin liquid 3 table 4 light transmitting film 4 a one side of light transmitting film 4 b light transmitting film 5a supply roller 5b supply roller 6a take-off roller 6b take-up roller 7 liquid level holding means 8 light-transmitting pressing plate 9 light source 10a light-transmitting film straightening roller 10b light-transmitting film straightening roller

Claims (7)

[Claims] (I) contacting the lower surface of the light-transmitting film with the liquid surface of the photocurable resin liquid stored in the molding bath; and (ii) contacting the lower surface of the light-transmitting film. Pressing the liquid surface of the photocurable resin liquid to be flattened; (iii) maintaining the liquid surface of the photocurable resin liquid flat,
Irradiating light from above the light-transmitting film, light-curing the photocurable resin liquid in a predetermined pattern and thickness designed in advance, and forming a cured resin layer on the lower surface of the light-transmitting film; (Iv) a step of peeling the light-transmitting film from the cured resin layer; and (v) a step of moving the cured resin layer downward in the molding bath to form a photocurable resin in the molding bath on the cured resin layer. Flowing the resin liquid to form a liquid layer having a predetermined thickness of the photocurable resin liquid;
After that, until a three-dimensional structure having a predetermined shape and dimensions is formed, the above-described steps (i) to (v) are repeated to perform lamination and modeling to manufacture a three-dimensional structure. Optical three-dimensional modeling method. 2. The step (ii) of flattening the liquid surface of the photocurable resin liquid in contact with the lower surface of the light transmitting film,
This is performed by arranging a light-transmitting pressing plate on the upper surface of the light-transmitting film and pressing the liquid surfaces of the light-transmitting film and the photocurable resin liquid with the light-transmitting pressing plate to form a cured resin layer. The optical three-dimensional modeling method according to claim 1, comprising performing the step (iv) of retracting the light-transmitting pressing plate after the step (iii), and then separating the light-transmitting film from the cured resin layer. 3. The optical device according to claim 1, wherein the step (iv) of peeling the light transmitting film from the cured resin layer is performed by gradually peeling the light transmitting film from one end of the cured resin layer. 3D modeling method. 4. The step (i) in which the light-transmitting film is a continuous long film and the lower surface of the light-transmitting film is arranged in contact with the surface of the photocurable resin liquid in the molding bath in the lateral direction. The step (ii) of flattening the liquid surface of the photo-curable resin liquid and the step (iii) of irradiating light are performed using a supply roller and a take-off roller which are arranged at intervals. The step (iv), which is performed in a stationary state in which the transfer is stopped, and which peels the light-transmitting film from the cured resin layer,
The optical three-dimensional modeling method according to any one of claims 1 to 3, wherein the method is performed by moving the take-up roller to the supply roller side and taking up the light-transmitting film with the take-up roller. 5. A shaping bath (A) for storing a photo-curable resin liquid; a means (B) for arranging a light-transmitting film on a liquid surface of the shaping bath; Means for flattening the liquid surface of the permeable resin liquid (C); irradiating means (D) disposed above the permeable film; means for removing the permeable film from the cured resin layer (E); An optical system comprising: means (F) for placing and moving the cured resin layer up and down; and control means for sequentially operating the means (B) to (F). 3D modeling equipment. 6. The flattening means (C) is a light-transmitting pressing plate disposed on an upper part of a light-transmitting film, and means for arranging the light-transmitting pressing plate on an upper surface of the light-transmitting film; The optical three-dimensional modeling apparatus according to claim 5, further comprising a retracting unit for retracting the light-transmitting pressing plate from an upper surface of the light-transmitting film. 7. A method for arranging a light-transmitting film (B),
A supply roller and a take-off roller for a light-transmissive film designed to have a variable interval, and a means for expanding the distance between the supply roller and the take-off roller when the light-transmitting pressing plate is pressed from the upper surface of the light-transmissive film; Means for arranging and pressing the light-transmitting pressing plate on the upper surface of the light-transmitting film between the take-up roller and the light-transmitting pressing plate, for keeping the light-transmitting film stationary at the time of pressing by the light-transmitting pressing plate and light irradiation. 7. The optical three-dimensional modeling apparatus according to claim 6, further comprising: means for pulling the light-transmitting film while moving the pulling roller toward the supply roller when the light-transmitting film is separated from the cured resin layer.