JP2000158545A - Stereo lithographic device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stereo lithographic device, by which the load on the change of a coater is reduced and the easy alteration of the accuracy of a stereo lithography can be possible without the alteration of the resolving power of a light irradiating means. SOLUTION: An upper tank 3, an upper table 13 and a part of an upper unsetting material layer-forming means 70 are freely removably constituted, they can be installed above a lower tank 4 without removing the lower tank 4. In addition, the upper unsetting material layer forming means 70 and a lower unsetting material layer forming means 20 are driven by the same driving means. Further, an upper stage part 50 and a lower stage part 60 are selected in response to the required accuracy of a stereo lithographed matter so as to optically scan with the same scanner 5. Furthermore, when the rotational angle of the movable mirror of the scanner 5 is changed to correct the strain of a liquid level at the irradiation of light, correction data, which for an upper stage are different from ones for a lower stages, are employed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical shaping apparatus, in particular, a method in which a flowable uncured material containing a photocurable resin is accommodated in a molding tank (tank), and the uncured material is selectively irradiated with light. To form a three-dimensional object by forming a hardened layer of a required shape by irradiating the hardened layer and sequentially stacking the hardened layers.

[0002]

2. Description of the Related Art Conventionally, an optical molding apparatus of this type includes an upper irradiation type in which light is irradiated from above on an uncured material accommodated in a tank, and a light transmitting window provided at the bottom of the tank. There is a bottom irradiation type in which the uncured material is irradiated with light from below through the uncured material. As the top irradiation type, for example, there is one described in JP-A-3-227222. In this apparatus, a laser beam is scanned on the liquid surface of the tank containing the uncured material to cure the uncured material liquid in the vicinity of the liquid surface into a required shape on the elevating table, and the cured layer is lowered by the elevating table. , And then the next layer is bonded and laminated thereon. This type of light irradiation means is composed of, for example, a laser light source, an optical system such as a lens, a movable mirror, and the like.

That is, the elevating table is lowered from the liquid level of the uncured material by one layer thickness of the cured layer. Next, coating is performed. In this coating process, the uncured material is supplied on the elevating table by a dipper that is provided above the tank and that can move in the left-right direction,
The uncured material supplied on the elevating table is also smoothed by a knife provided in the left and right direction similarly at the rear of the dipper. After that, the uncured material coated on the upper surface of the elevating table is selectively irradiated with laser light to cure one layer thereof. Further, the steps of lowering the elevating table, coating the uncured material on the upper surface of the elevating table, and forming a hardened layer by irradiating laser light are repeated, and the hardened layers are laminated to form a three-dimensional object, and the three-dimensional object is washed. Then, the stereolithography process is completed. When the stereolithography process is completed in this way, if the same material is used, the above-described steps are repeated to form a three-dimensional object. When other materials are used, the set of coater used this time (tank, lifting table, dipper, and knife) is manually replaced with a set of coater used for the next process. Note that the modeling accuracy of the three-dimensional object is determined by the resolution of the light irradiation means. Also, X
By changing the rotation angles of the two rotatable movable mirrors that scan light in the Y direction, distortion of the light irradiation surface on the lifting table when irradiating laser light is corrected.

[0004]

However, in the conventional stereolithography apparatus, when a series of stereolithography processes are performed, the stereolithography is successively performed using different curing materials (for example, resins having different viscosities). Since the set of coaters was manually replaced, there was a problem that the work load on the user was large and the time required for replacement was long. In particular, the user needs to take out the tank and the elevating table, and attach a new tank and elevating table for which modeling is desired. Further, no consideration is given to easily forming a three-dimensional object having different required accuracy by the same light irradiation means.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an optical shaping apparatus which can solve such a problem and reduce the burden on the user for changing the coater. Still another object of the present invention is to provide an optical shaping apparatus capable of easily changing the accuracy of optical shaping without changing the resolution of the light irradiation means.

[0006]

According to the first aspect of the present invention,
A lower molding tank containing a fluid uncured material containing a photocurable resin, and a lower table which is provided movably up and down in the lower molding tank and forms an uncured material layer of a predetermined thickness on its upper surface side. Supplying the uncured material in the lower molding tank onto the lower table, extending the uncured material to form an uncured material layer having a predetermined thickness, and an upper stage of the lower molding tank. An upper molding tank containing a flowable uncured material including a photocurable resin, and an uncured material layer having a predetermined thickness is formed on the upper surface side so as to be vertically movable in the upper molding tank. An upper uncured material layer forming means for supplying the uncured material in the upper modeling tank onto the upper table, extending the uncured material to form an uncured material layer having a predetermined thickness, and For the uncured material layer formed on the table or lower table Light irradiating means for selectively irradiating light to form a cured layer of a required shape in the uncured material layer, comprising an upper shaping tank, an upper table, and a part of the upper uncured material layer forming means. The upper part including the upper modeling tank, the upper table, and the upper uncured material layer forming means and the lower part including the lower molding tank, the lower table, and the lower uncured material layer forming means are configured to be detachable. The feature is that the selection is made according to the required accuracy in forming the hardened layer.

According to a second aspect of the present invention, in the first aspect, the shaping tank presence / absence detecting means for detecting the presence / absence of the upper shaping tank, and the upper uncured material layer forming means and the lower uncured material layer forming means are driven. A driving unit, and a control unit for controlling the driving unit to drive the upper uncured material layer forming unit when the forming tank presence / absence detecting unit detects the presence of the upper forming tank, and forming the upper uncured material layer. It is characterized in that the means and the lower uncured material layer forming means are driven by the same driving means.

According to a third aspect of the present invention, there is provided a lower molding tank containing a flowable uncured material containing a photocurable resin, a vertically movable tank provided in the lower molding tank, and a predetermined thickness on an upper surface thereof. A lower table for forming an uncured material layer of the same type, and a lower uncured material for supplying the uncured material in the lower modeling tank to the lower table and extending the uncured material to form an uncured material layer having a predetermined thickness. A material layer forming means, a lower driving means for driving the lower uncured material layer forming means, and an upper part which is detachably mounted on an upper stage of the lower shaping tank and contains a fluid uncured material containing a photocurable resin. A modeling tank, an upper table that is provided in the upper modeling tank so as to be detachable and vertically movable, and forms an uncured material layer having a predetermined thickness on the upper surface side, and the uncured material in the upper modeling tank is placed on the upper table. Supply and spread the uncured material to a predetermined thickness of uncured Upper uncured material layer forming means for forming a material layer, upper driving means for driving the upper uncured material layer forming means, and selectively light to the uncured material layer formed on the upper table or the lower table. Light irradiation means for irradiating to form a cured layer of a required shape in the uncured material layer, wherein the upper uncured material layer forming means and the upper driving means are integrally and detachably configured, The upper part including the upper table, the upper uncured material layer forming means and the upper driving means, and the lower molding tank, the lower table, the lower part including the lower uncured material layer forming means and the lower driving means, It is characterized in that the selection is made according to the required accuracy in forming.

According to a fourth aspect of the present invention, in the first to third aspects, the upper shaping tank is formed smaller than the lower shaping tank, and the hardened layer having the required shape is formed using an upper step. It is characterized in that the precision is higher than the precision when forming the hardened layer of the required shape using the lower part. According to a fifth aspect of the present invention, in the first to fourth aspects, the light irradiation means includes a laser light source, an optical lens, and a movable mirror, and is prepared in advance when selectively irradiating light to the uncured material layer. The feature is that the rotation angle of the movable mirror is changed based on the upper-stage correction data or the lower-stage correction data to correct the distortion of the light irradiation surface.

According to a sixth aspect of the present invention, in the first to fifth aspects, a cover for covering an upper surface of the lower modeling tank, a lift-up means for lifting the upper modeling tank on the lower modeling tank covered by the cover, Moving means for moving the upper modeling tank lifted by the lift-up means to a predetermined position on the cover, and installing the upper modeling tank on the upper stage of the lower modeling tank without moving the lower modeling tank. There is a characteristic in that.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be specifically described below with reference to the drawings. First Embodiment FIGS. 1 to 5 are views showing an embodiment of a two-stage stereolithography apparatus according to the present invention. First, the configuration of the apparatus will be described.

FIG. 1 shows a two-stage stereolithography apparatus according to the present embodiment, in which an upper stage 50 such as an upper tank 3, an upper table 13, an upper dipper 28 and an upper knife 29, which are smaller than the lower tank 4, is not mounted. Is shown. The uncured material 1 is a material having fluidity such as a photocurable resin. For example, a liquid photocurable resin having a predetermined viscosity, or a material having a high non-shrinkable fine particle diameter or the like is used for the resin. It is a mixture. The photocurable resin used for the uncured material 1 is a known resin having a property of being cured by, for example, light in the ultraviolet region (or may be light in the ultraviolet region or visible light).

The lower tank 4 is a tank for storing the uncured material 1 and has an upper opening having a predetermined shape (for example, a square or a circle). The lower tank 4 is placed on a roller conveyor (not shown), and replacement of the lower tank 4 is performed manually using the roller conveyor. The lower table 14 is a table provided in the lower tank 4 so as to be able to move up and down. For example, the lower table 14 is moved upward and downward by means of a table raising / lowering motor 48 (shown in FIG. 3) composed of a servomotor or a ball screw mechanism. It is moved relative to the opening in the up and down direction, and at the time of modeling, the amount of movement corresponding to the thickness (layer thickness) of each cured layer constituting the molded article (the laminate 2 of the cured layer 2a) is defined as one movement amount. It is moved a plurality of times downward from the modeling start position (in a direction away from the upper opening), and when the lamination is completed, it is moved once from the position at that time to the modeling start position. That is, when the lower table 14 that moves up and down in the lower tank 4 moves downward, the lower tank 4 on the upper surface side of the lower table 14 moves.
Is formed so that one layer of uncured material having a predetermined thickness is formed in the upper opening. Note that there is a predetermined gap between the peripheral wall of the lower tank 4 and the outer peripheral part of the lower table 14 so that when the lower table 14 moves up and down, the peripheral wall does not contact the lower table 14. The upper table 13 is also driven by the elevation drive means similarly to the lower table 14, and is provided in the upper tank 3 so as to be able to move up and down.

The scanner 5 selectively irradiates light to the uncured material layer 1a to form a cured layer 2a having a required shape in the uncured material layer. The scanner 5 is fixed to an upper portion of the apparatus, and includes a laser light source 56, a mechanical shutter 55, optical lens groups 54 and 52, an optical shutter 53, and a movable mirror 51, as shown in FIG.
Is composed of two rotatable movable mirrors 51a and 51b as shown in FIG. 2B, and is rotated in the XY directions by drive motors M1 and M2 (included in the scanner motor 49 in FIG. 3) which are driven independently. It is configured to be. These components allow the light emitted from the laser light source 56 to be shaped, reflected, deflected and condensed on the liquid surface of the uncured material 1 while scanning the light within a predetermined area. The light emitted from the laser light source 56 is light suitable for the properties of the uncured material 1, for example, light in the ultraviolet region (or light in the infrared region or visible light). The drawing pattern by the light scanning of the scanner 5 corresponds to the shape of each of the plurality of cured layers constituting the modeled object, and the liquid level of the uncured material 1 in the lower tank 4 and the liquid level of the lower table 14 are adjusted. The uncured material layer 1a in between is selectively exposed and cured in accordance with the drawing pattern, thereby forming a cured layer having a required shape.

In the present embodiment, the upper section 50 and the lower section 60 are provided, and the upper and lower sections are selectively used according to the required accuracy of the molding model, so that the same scanner 5 has different focal lengths, required resolutions, and required energy amounts. Optical scanning is performed. At this time, the focal length is changed and set in two steps by moving the optical lens groups 52 and 54 according to the modeling position (height) of the upper and lower stages. Also, the apparent resolution and the energy amount are changed and set in two stages according to the modeling position (height) of the upper and lower stages. Regarding this apparent resolution, since the minimum unit (minimum unit of shake on the liquid surface of the upper and lower stages) when the movable mirror 51 is shaken in the XY directions differs depending on the molding position of the upper and lower stages, the minimum rotation angle of the movable mirror 51 is Despite being the same, the modeling minimum unit in the upper stage is smaller than that in the lower stage, and the upper stage has better apparent resolution. In the present embodiment, by utilizing the apparent difference in resolution between the upper and lower stages, the upper and lower stages are selectively used so as to stereo-model a smaller and more accurate model in the upper stage 50 than in the lower stage 60. Further, a movable mirror 5 is provided at the center and the periphery of the molding surface.
Since the distortion caused by the shake of 1 occurs, it is necessary to appropriately change the position of the movable mirror 51 to correct the distortion. In the present embodiment, data for correcting this distortion is stored in advance in two correction tables corresponding to the upper section 50 and the lower section 60, and the position of the movable mirror 51 is selectively used by using one of the correction tables. Is corrected.

The lower dipper 6 moves along the upper opening of the lower tank 4, scrapes out a predetermined amount of the uncured material 1 from the inside of the lower tank 4, and introduces it onto the lower table 14 in the upper opening. The lower dipper 6 causes the uncured material 1 to overflow onto the lower table 14 from the lower opening end to the rear side in the moving direction from the lower opening end, and the lower dipper 6 lowers according to the degree of fluidity (viscosity or consistency) of the uncured material 1. It moves so as to maintain a predetermined gap between the lower end of the dipper 6 and the lower table 14.

The lower dipper 6 extends in a vertical direction and extends in the front-rear direction of the lower tank 4 (a direction perpendicular to the plane of FIG. 1).
Are supported by a plurality of shafts 8 which are spaced apart from each other.
Are fitted so that they can move up and down. The carriage 9 is guided by a pair of front and rear parallel horizontal guides 10, and is driven in the left-right direction by a feed mechanism such as a feed screw (not shown). Further, the upper end of each shaft 8 is connected to a cam follower member 12 which engages with a lift cam 11, and when the carriage 9 moves from one of the left and right moving ends to the lower tank 4, the lower dipper 6 is moved to the lower tank 4 side.
The shaft 8 is lifted by the lift cam 11 so as to move along the upper opening of the shaft 8.

Further, a pair of right and left knives 7 are mounted on the carriage 9 in parallel so as to be at the same height. These knives 7 are linked to the carriage 9 and the lower dipper 6
When moving right and left, the uncured material 1 scraped from the lower tank 4 is extended near the lower dipper 6 while moving integrally with the carriage 9 and the lower table 14 is moved.
The upper surface of the upper uncured material layer 1a is smoothed. That is, the shaft 8, the carriage 9, the horizontal guide 10, the lift cam 11, the cam follower member 12, and the feed mechanism cooperate with the lower dipper 6 to move the lower dipper 6 and the knife 7 in uncured state. It constitutes a lower uncured material layer forming means 20 for shaping the material layer 1a. In the upper section 50 as well as in the lower section 60, the feed mechanism such as the shaft 36, the carriage 37, the horizontal guide 32, the lift cam 31, the cam follower member 33, and the feed screw moves the upper dipper 28 and the knife 29 in conjunction with each other. The upper dipper 2
8 together with an upper uncured material layer forming means 70 for shaping an uncured material layer (not shown) on the upper table 13. In this embodiment, the upper uncured material layer forming means 70
The lower uncured material layer forming means 20 is driven by the same coater drive motor 47.

Next, the configuration of the control unit shown in FIG. 3 will be described. The controller 41 includes a coater clutch 46, a coater drive motor 47, and a coater clutch 46 based on detection information from the tank presence / absence sensor 43, coater limit detector 44, table limit detector 45, and the like, and necessary data previously stored in the RAM 42 or a ROM (not shown). The drive of the table elevating motor 48, the scanner motor 49, etc. is controlled.

The tank presence / absence sensor 43 is, for example, an optical reflection type sensor, and is disposed in a pair near the installation position of the upper tank 13.
3 is detected. Coater limit detector 44
Is a magnet sensor, for example, which is installed within the movable range of the dipper and knife in the upper uncured material layer forming means 70 and the lower uncured material layer forming means 20, and the upper and lower dippers and knives are installed in each tank. It detects that the limit of the movable range has been reached.

The table limit detectors 45 are, for example, magnet sensors and are installed at three locations near the upper and lower limits of the movable range of the upper table 13 and near the lower limits of the movable range of the lower table 14, and move the lower table. Sometimes the upper limit of the movable range is set as the upper limit of the movable range of the upper table 13. The coater drive motor 47 is
The upper uncured material layer forming means 70 and the lower uncured material layer forming means 20 are driven, and their drive shafts are connected and connected to the upper and lower uncured material layer forming means via a coater clutch 46. The coater clutch 46 is driven based on a signal from the controller 41. When the tank presence / absence sensor 43 is ON, the upper uncured material layer forming means 7
No transmission of the driving force of the coater drive motor 47 to 0
In this case, the driving force of the coater driving motor 47 is controlled not to be transmitted to the lower uncured material layer forming means 20.

The table elevating motor 48 is driven based on a signal from the controller 41, and drives the upper table 13
And the lower table 14 is controlled to move within the range of the vertical movement limit detected by the table limit detector 45. The scan motor 49 is connected to the controller 41
Is driven based on the signal from the
Is ON, the optical lens groups 52 and 54 are moved to a position corresponding to the lower molding position, and the movable mirror 51 is rotated according to the correction table for the lower part to move the light in the X and Y directions to reduce the distortion of the molding surface. It is controlled to correct. Further, the scan motor 49 is configured such that the tank presence sensor 43
In the case of F, the optical lens groups 52 and 54 are moved to a position corresponding to the upper molding position, and the movable mirror 51 is rotated according to the correction table for the upper part to move the light in the XY directions to correct the distortion of the molding surface. Is controlled.

In this embodiment, three-dimensional CAD
A modeling object (three-dimensional object), which is a laminate of a photo-curable resin, is designed by the system, and based on modeling data including each layer shape of the modeling object, the drawing pattern by the scanner 5 and the elevation including the table elevation motor 48 The movement amount of the table by the driving means and the data necessary for the operation of the upper and lower uncured material layer forming means are created, and the data (including the correction table) is stored in the storage unit of the controller 41 which controls the respective means ( (RAM) 42. Further, the controller 41 calculates a scanning amount (including an operation amount of the movable mirror 51) of the scanner 5 in both the main and sub scanning directions from the drawing pattern data, and calculates the scanner 5, the upper and lower tables, the upper and lower The operation timing of the cured material layer forming means is set, and the data is stored in the RAM 42.

Next, the molding operation will be described. Since the molding operation is substantially the same for the upper section 50 and the lower section 60, only the case where the lower section 60 is used will be described. In the present embodiment, prior to the molding operation, the lower table 14 is positioned at a predetermined molding start position based on the detection information of the table limit detector 45, and the uncured material 1 is stored in the lower tank 4. The uncured material 1 is accommodated in the lower tank 4 by providing a cylindrical member slidably fitted to the outer peripheral surface of the lower table 14 at the upper opening side of the lower tank 4. No work is required.

Then, the controller 41 controls the operation of the elevation drive means, the scanner 5, and the lower uncured material layer forming means 20, and starts the molding operation. First, the lower table 14 is lowered with respect to the upper opening by one layer from the modeling start position, and the lower uncured material layer forming means 20 is lowered.
To move the lower dipper 6 and the knife 7 from one side of the lower tank 4 to the other side. At this time, the lower dipper 6 is interlocked with the carriage 9 and the lift cam 11
The uncured material 1 is moved to the lower tank 4 side while being lifted, and overflows the uncured material 1 from one end of the lower table 14 to the rear side in the moving direction.

Next, the lower dipper 6 moves along the upper opening, and the knife 7 (especially on the rear side in the moving direction) that moves integrally with the carriage 9 cooperates with the lower dipper 6 on the lower table 14. While the uncured material 1 is extended, its upper surface is smoothed, and the uncured material layer 1a is shaped in (near) the upper opening so that the upper surface is flush with the upper opening. The surplus uncured material 1 is supplied to the lower dipper 6
And the knife 7 scrapes the lower table 14 toward the other upper opening.

Next, the lower dipper 6 and the knife 7 pass over the upper opening, and the lower dipper 6 moves rightward (or leftward) together with the carriage 9. On the other hand, when the uncured material layer 1a having a predetermined thickness is formed on the lower table 14,
The uncured material layer 1a on the lower table 14 is scanned with light by the scanner 5 and selectively irradiated with light.
A cured layer 2a having a required shape is formed in the uncured material layer.
At this time, the optical lens groups 52 and 54 move so as to correspond to the lower modeling position on the lower table 14, and the movable table 51 is selected so that the correction table for the lower portion is selected and distortion of the modeling surface is corrected. Are swung in the XY directions. This light irradiation may be performed after the lower dipper 6 has passed through the upper opening and before reaching the deepest part.

Next, the lower table 14 is lowered by the thickness of the next uncured material layer, and the storage capacity of the lower tank 4 is increased by a predetermined amount. The uncured material 1 for forming the material layer overflows to the lower table 14 in the same manner as described above, and the uncured material 1 is spread on the cured layer 2 (the lower material layer including the same), and the next uncured material is formed. The material layer is shaped.

Thereafter, the same light irradiation, lowering operation of the lower table 14, and the operation of forming the uncured material layer by the lower uncured material layer forming means 20 are repeated. And
A plurality of cured layers are laminated on the lower table 14, a three-dimensional object as a laminate is formed, and when a series of laminating operations is completed, the lower table 14 returns upward to the modeling start position, and the molded object is removed. It can be taken out from above the lower table 14.

Next, the operation of installing the upper section 50 will be described with reference to FIG. FIG. 4A shows the control by the controller 41, and FIG. 4B shows the procedure of the manual operation. In the present embodiment, for a small-sized model having higher required accuracy than the model formed by the lower section 60, the upper section 50 including the upper table 13 in the upper section of the lower tank 4 without removing the lower table 14 in the following procedure. Is installed, and the molding is performed by the upper portion 50.

First, the coater drive motor 47 is driven to retract the lower dipper 6 and the lower knife 7 to predetermined positions (step 101). In this operation, the user may press a reset button (not shown), and the controller 41 may drive and control the coater driving motor 47 based on the signal. At this time, the tank presence / absence sensor 43 is ON (there is no tank), and the coater drive motor 47 is driven until the coater limit detector 44 detects a predetermined movement limit.

Next, in order to protect the uncured material 1 in the lower tank 4, the upper surface of the lower tank 4 is covered with a cover 17 (FIG. 9).
(Step 111). This operation is manually performed by the user. In FIG. 1, the upper tank 3 is described above the horizontal guide 10 and the lift cam 11 in order to clarify the configuration of the upper section 50.
And at a position close to the lift cam 11 (shown in FIG. 11).

Next, the roller conveyor 18 (shown in FIG. 10) is placed on the cover 17 (step 11).
2). This operation is manually performed by the user. Next, the upper tank 3 is lifted up to the height of the roller conveyor 18 by the hand lift 19 shown in FIG. 5 (step 113). The hand lift 19 is a hydraulic lifter and includes a lift switch valve 19a, a pump handle 19b, front and rear wheels 19c and 19d, and closes the lift switch valve 19a when in use.
The claw 19e is configured to rise by moving b forward and backward. Further, the pawl 19e is configured to be lowered by loosening the lift switching valve 19a.
The operation in step 113 is performed manually by the user. The uncured material stored in the upper tank 3 is supplied by a supply unit (not shown) at the time of tank lift-up or after installing the upper tank 3 on the roller conveyor.

Next, the upper tank 3 is set on the upper stage of the lower tank 4 by the hand lift 19, and the upper table 13 is attached to the lifting drive means (step 1).
14). This operation is manually performed by the user. Next, the upper dipper 28 and the upper knife 29 are attached to the carriage 33 (step 115), and the upper uncured material layer forming means 70 is formed.

On the other hand, when the tank presence / absence sensor 43 detects the upper tank 3 installed in the upper stage of the lower tank 4 (YES in step 102), the controller 41 drives the coater clutch 46 to drive the coater drive motor 47 to the upper uncured state. The operation is switched to the material layer forming means 70 side (step 103), and the upper stage installation operation is completed. [Second Embodiment] FIGS. 6 to 11 are views showing one embodiment of a two-stage stereolithography apparatus according to the present invention. Since the overall configuration is substantially the same as that of the first embodiment, the same components are denoted by the same reference numerals and description thereof is omitted. 9 to 11, the upper part 50 is indicated by a solid line, and the lower part 60 below the upper part 50 is indicated by a dotted line.

First, the configuration of the apparatus will be described. In the present embodiment, the upper coater 15 including the upper uncured material layer forming means 70 and the upper coater driving motor 22 is integrally configured so as to be detachable from the apparatus main body. Further, a lower coater drive motor 23 for driving the lower uncured material layer forming means 20 is fixedly installed on the main body side. These coater drive motors 22, 23 are connected to the controller 41 via connectors 22a, 23a, 41b.
The connection of the connectors 22a and 23a is manually switched by the user. That is, when the lower section 60 is used, the upper coater 1 including the upper uncured material layer forming means 70 and the upper coater drive motor 22 as shown in FIG.
5 is not mounted, and only when the upper section 50 is used, the upper coater 15 is mounted on the apparatus body together with the upper table 13 as shown in FIG. In this embodiment, the upper coater limit detector 24 and the lower coater limit detector 25 are provided, and the connection between the upper and lower parts is switched by the user manually switching the connectors 24a and 25a.

Next, the configuration of the control unit shown in FIG. 7 will be described. The controller 41 controls the upper coater drive motor 22 based on the detection information of the upper coater limit detector 24 or the lower coater limit detector 25 and the detection information of the table limit detector 45 and necessary data previously stored in the RAM 42 or a ROM (not shown). Or lower coater drive motor 2
3. Drive control of the table lifting motor 48, the scanner motor 49, and the like.

The upper coater limit detector 24 is, for example, a magnet sensor and includes the upper uncured material layer forming means 7.
It is installed within the movable range of the upper dipper 28 and the upper knife 29 at 0, and detects that the upper dipper 28 and the upper knife 29 have reached the limit of the movable range. The upper coater limit detector 24 is connected to the connector 24 when used.
a is connected to the controller 41 via the connector 41a.

The lower coater limit detector 25 is, for example, a magnet sensor and is installed within the movable range of the lower dipper 6 and the lower knife 7 in the lower uncured material layer forming means 20. Has reached the limit of the movable range. In use, the lower coater limit detector 25 is connected to the controller 41 via the connector 41a by the connector 25a during use.

The upper coater drive motor 22 operates the upper uncured material layer forming means 70, and is connected to the controller 41 by the connector 22a via the connector 41b when used. The lower coater drive motor 23 is
The lower uncured material layer forming means 20 is operated, and is connected to the controller 41 via the connector 41b by the connector 23a during use.

Next, the operation of installing the upper section 50 will be described with reference to FIGS. In the present embodiment, as in the first embodiment, for a small shaped object with high required accuracy, the upper section 50 is installed on the lower tank 4 without removing the lower table 14, and the upper section 50 Shape it. At this time, the upper part 50 is installed in the following procedure.

First, after the lower dipper 6 and the lower knife 7 are retracted to predetermined positions, the upper surface of the lower tank 4 is covered with the cover 7 as shown in FIG. Cover (step 201). This covering operation is performed manually by the user. Then, FIG.
As shown in (b), the upper coater 15 independent of the apparatus main body is mounted (step 202). At this time, the upper dipper 2
8 and upper knife 29 are not mounted. This is for facilitating mounting of the upper tank 3 and the upper table 13 described later. This mounting operation is manually performed by the user.

Next, the controller 41 is connected to the upper coater limit detector 24 and the upper coater drive motor 22 (step 203). This connection operation is performed by the user using the connector 24a and the connector 41a, and the connector 22a and the connector 4a.
1b is manually switched. Next, as shown in FIG. 10A, the roller conveyor 18 is placed on the cover 17 (step 204). This operation is manually performed by the user.

Next, the upper tank 3 is lifted up to the height of the roller conveyor 18 by the hand lift 19 in the same manner as described above (step 205). This operation is manually performed by the user. Then, as shown in FIG. 11, the upper tank 3 is set on the upper stage of the lower tank 4 by the hand lift 19, and the upper table 13 is attached to the lifting drive means (step 206). This operation is manually performed by the user.

Next, as shown in FIG. 11A, the upper dipper 28 and the upper knife 29 are attached to the carriage 33 of the upper coater 15 (step 207), and the upper uncured material layer forming means 70 is formed to install the upper stage. End the operation.

[0046]

According to the first aspect of the present invention, the upper molding tank, the upper table, and a part of the upper uncured material layer forming means are configured to be detachable, so that the upper part can be moved without moving the lower part. Can be mounted, and the burden on the user regarding the exchange of the coater can be reduced. Further, the upper part including the upper molding tank, the upper table, and the upper uncured material layer forming means and the lower part including the lower molding tank, the lower table, and the lower uncured material layer forming means form the hardened layer of the required shape. Since the selection is made in accordance with the required accuracy at the time of performing, the accuracy of the stereolithography can be easily changed by the same light irradiation means.

According to the second aspect of the present invention, the upper uncured material layer forming means and the lower uncured material layer forming means are driven by the same driving means. It is possible to reduce the burden on the user regarding switching between the layer forming means and the lower uncured material layer forming means). According to the third aspect of the present invention, since the upper uncured material layer forming means and the upper driving means are integrally and detachably configured, the upper part can be mounted without moving the lower part, and the user involved in coater replacement. Can be reduced. Further, the upper part including the upper molding tank, the upper table, the upper uncured material layer forming means and the upper driving means and the lower part including the lower molding tank, the lower table, the lower uncured material layer forming means and the lower driving means are required. Since the selection is made in accordance with the required accuracy in forming the hardened layer having the shape, the accuracy of the optical shaping can be easily changed by the same light irradiation means.

According to the fourth aspect of the present invention, the upper modeling tank is formed smaller than the lower modeling tank, and the accuracy in forming the hardened layer of the required shape using the upper section is lower. It is configured to be higher than the precision when forming the cured layer of the required shape using the same, so that the same light irradiation means, it is possible to easily change the precision of stereolithography between the upper part and the lower part. It is possible.

According to the fifth aspect of the present invention, when the uncured material layer is selectively irradiated with the light from the laser light source, the movable mirror is adjusted based on the upper-stage correction data or the lower-stage correction data prepared in advance. Is changed to correct the distortion of the light irradiation surface, so that the same light irradiation means can easily change the accuracy of the optical shaping in the upper part and the lower part.

According to the sixth aspect of the present invention, a cover for covering the upper surface of the lower modeling tank, lift-up means for lifting the upper modeling tank on the lower modeling tank covered by the cover, and lifting by the lift-up means By using the moving means to move the upper modeling tank to a predetermined position on the cover, without moving the lower modeling tank, the upper modeling tank was installed on the upper stage of the lower modeling tank,
It is possible to reduce the burden on the user regarding the exchange of the coater.

[Brief description of the drawings]

FIG. 1 is a diagram showing a configuration of a two-stage stereolithography apparatus according to a first embodiment of the present invention.

FIG. 2 is a diagram illustrating a configuration of a scanner in FIG. 1;

FIG. 3 is a diagram illustrating a configuration of a control unit of the optical shaping apparatus of FIG. 1;

FIG. 4 is a flowchart showing an installation procedure of an upper portion in the optical shaping apparatus of FIG. 1;

FIG. 5 is a view showing a hand lift used in the upper part installation operation of FIG. 4;

FIG. 6 is a view showing the attachment and detachment of an upper coater of a two-stage stereolithography apparatus according to a second embodiment of the present invention.

FIG. 7 is a diagram illustrating a configuration of a control unit of the optical shaping apparatus of FIG. 6;

8 is a flowchart showing an installation procedure of an upper section in the optical shaping apparatus of FIG. 6;

FIG. 9 is a part of a view showing an installation operation of an upper section in the optical shaping apparatus of FIG. 6;

FIG. 10 is a part of a view showing an installation operation of an upper section in the optical shaping apparatus of FIG. 6;

11 is a part of a view showing an installation operation of an upper section in the optical shaping apparatus of FIG. 6;

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Uncured material 1a Uncured material layer 2 Laminated body 2a Cured layer 3 Upper tank (upper molding tank) 4 Lower tank (lower molding tank) 5 Scanner (light irradiation means) 6 Lower dipper 7 Lower knife 8, 36 Shaft 9, 37 carriage 10,32 horizontal guide 11,31 lift cam 12,33 cam follower member 13 upper table 14 lower table 15 upper coater 17 cover 18 roller conveyor (moving means) 19 hand lift (lift up means) 20 lower uncured material layer forming means 22a, 23a, 24a, 25a, 41a, 41b Connector 22 Upper coater drive motor (upper drive means) 23 Lower coater drive motor (lower drive means) 24 Upper coater limit detector 25 Lower coater limit detector 28 Upper dipper 29 Upper knife 30 Table lifting mode 41 Controller (control means) 42 RAM 43 Tank presence / absence sensor (molding tank presence / absence detection means) 46 Coater clutch (drive means) 47 Coater drive motor (drive means) 50 Upper part 51 Movable mirror 52, 54 Optical lens group 53 Optical shutter 55 Mechanical shutter 56 Laser light source 60 Lower stage 70 Upper uncured material layer forming means

Claims (6)

[Claims] 1. A lower molding tank (4) containing a flowable uncured material containing a photo-curable resin, and a lower molding tank provided movably up and down in the lower molding tank and having a predetermined thickness of uncured material on its upper surface. The lower table (1) for forming the material layer
4) and supplying the uncured material in the lower modeling tank to the lower table,
A lower uncured material layer forming means (20) for extending the uncured material to form an uncured material layer having a predetermined thickness; An upper modeling tank (3) containing a hardened material, and an upper table (1) provided vertically movably in the upper modeling tank and forming an uncured material layer having a predetermined thickness on an upper surface thereof.
3) and supplying the uncured material in the upper modeling tank to the upper table,
An upper uncured material layer forming means (70) for extending the uncured material to form an uncured material layer having a predetermined thickness; and a light selective to the uncured material layer formed on the upper table or the lower table. And a light irradiating means (5) for forming a cured layer of a required shape in the uncured material layer by irradiating the upper molding tank, the upper table, and a part of the upper uncured material layer forming means. Freely configured, upper modeling tank,
The upper part (50) including the upper table and the upper uncured material layer forming means and the lower part (60) including the lower shaping tank, the lower table, and the lower uncured material layer forming means form the hardened layer of the required shape. An optical shaping apparatus characterized in that the selection is made in accordance with the required accuracy when performing. 2. A shaping tank presence / absence detecting means (43) for detecting the presence / absence of said upper shaping tank, and a driving means (46, 47) for driving said upper uncured material layer forming means and lower uncured material layer forming means. And control means (41) for controlling the driving means to drive the upper uncured material layer forming means when the shaping tank presence / absence detecting means detects the presence of the upper shaping tank. 2. An optical molding apparatus according to claim 1, wherein said forming means and said lower uncured material layer forming means are driven by the same driving means. 3. A lower molding tank (4) containing a flowable uncured material containing a photocurable resin, and a vertically-movable lower molding tank is provided in the lower molding tank. The lower table (1) for forming the material layer
4) and supplying the uncured material in the lower modeling tank to the lower table,
A lower uncured material layer forming means (20) for extending the uncured material to form an uncured material layer having a predetermined thickness; a lower driving means (23) for driving the lower uncured material layer forming means; Upper molding tank (3) which is detachably installed on the upper part of the lower molding tank and contains a fluid uncured material including a photocurable resin
An upper table (13) which is provided in the upper modeling tank so as to be attachable, detachable and vertically movable and forms an uncured material layer having a predetermined thickness on an upper surface thereof; and an uncured material in the upper modeling tank is placed on the upper table. Supply to
An upper uncured material layer forming means (70) for extending the uncured material to form an uncured material layer having a predetermined thickness; an upper driving means (22) for driving the upper uncured material layer forming means; Light irradiating means (5) for selectively irradiating light to the uncured material layer formed on the upper table or the lower table to form a cured layer of a required shape in the uncured material layer; The uncured material layer forming means and the upper driving means are integrally and detachably configured, and an upper molding tank, an upper table, an upper step (50) including the upper uncured material layer forming means and the upper driving means, and a lower molding tank, The lower part (6) including the lower table, the lower uncured material layer forming means, and the lower driving means.
0) is selected according to the required accuracy in forming the hardened layer having the required shape. 4. The upper molding tank is formed to be smaller than the lower molding tank, and the accuracy of forming the hardened layer of the required shape by using the upper part is improved by using the lower part. The stereolithography apparatus according to claim 1, wherein the stereolithography apparatus is configured to have higher accuracy than when forming the layer. 5. A laser light source (56) for said light irradiation means,
An optical lens (52, 54) and a movable mirror (51) are provided, and when selectively irradiating light to the uncured material layer, the movable lens is movable based on previously prepared correction data for the upper part or correction data for the lower part. 5. The optical shaping apparatus according to claim 1, wherein the rotation angle of the mirror is changed to correct the distortion of the light irradiation surface. 6. A cover (1) for covering an upper surface of the lower modeling tank.
7), lift-up means (19) for lifting the upper modeling tank on the lower modeling tank covered by the cover, and movement for moving the upper modeling tank lifted by the lift-up means to a predetermined position on the cover. Means (1
8) The stereolithography apparatus according to claim 1, wherein an upper molding tank is provided above the lower molding tank without moving the lower molding tank.