JP2002115004A - Method and equipment for manufacturing article with three-dimensional shape - Google Patents

Method and equipment for manufacturing article with three-dimensional shape

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Publication number
JP2002115004A
JP2002115004A JP2000306546A JP2000306546A JP2002115004A JP 2002115004 A JP2002115004 A JP 2002115004A JP 2000306546 A JP2000306546 A JP 2000306546A JP 2000306546 A JP2000306546 A JP 2000306546A JP 2002115004 A JP2002115004 A JP 2002115004A
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Prior art keywords
powder
layer
shaped object
removal
sintered
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JP3446733B2 (en
Inventor
Satoshi Abe
Yoshikazu Azuma
Isao Fuwa
Shuji Kaminaga
Hirohiko Tougeyama
Tokuo Yoshida
修士 上永
勲 不破
徳雄 吉田
裕彦 峠山
喜万 東
諭 阿部
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Matsushita Electric Works Ltd
松下電工株式会社
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Priority to JP2000306546A priority Critical patent/JP3446733B2/en
Priority claimed from TW090123973A external-priority patent/TW506868B/en
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/105Sintering only by using electric current other than for infra-red radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F3/1055Selective sintering, i.e. stereolithography
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/153Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/105Sintering only by using electric current other than for infra-red radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F3/1055Selective sintering, i.e. stereolithography
    • B22F2003/1056Apparatus components, details or accessories
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24After-treatment of workpieces or articles
    • B22F2003/247Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Process efficiency
    • Y02P10/25Process efficiency by increasing the energy efficiency of the process
    • Y02P10/29Additive manufacturing
    • Y02P10/295Additive manufacturing of metals

Abstract

PROBLEM TO BE SOLVED: To smoothly finish the surface of an article regardless of its shape at a low cost.
SOLUTION: Powder metallurgical sintered parts in which a plurality of sintered layers 11 are integrally laminated are manufactured by repeating a procedure consisting of steps of; forming a sintered layer 11 by irradiating the prescribed part of a layer 10 of inorganic or organic powders with a light beam L to sinter the powders in the corresponding part, and forming a new sintered layer 11 integrated with the previously-formed sintered layer 11 as a lower layer by covering the previously-formed sintered layer 11 with a new layer 10 of the powder material and irradiating the prescribed part with the light beam L to sinter the powder in the corresponding part. In this method, a step where the surface part and/or unnecessary part of the formed part obtained theretofore is removed after the formation of the sintered layer 11 is inserted between a plurality of manufacturing steps of the sintered layer 11.
COPYRIGHT: (C)2002,JPO

Description

【発明の詳細な説明】 DETAILED DESCRIPTION OF THE INVENTION

【0001】 [0001]

【発明の属する技術分野】本発明は粉末材料を光ビームで焼結硬化させることで三次元形状造形物を製造する三次元形状造形物の製造方法及びその装置に関するものである。 The present invention relates to relates to a manufacturing method and apparatus for three-dimensionally shaped object to produce a three-dimensionally shaped object by causing sintering curing the powder material with a light beam.

【0002】 [0002]

【従来の技術】光造形法として知られている三次元形状造形物の製造方法がある。 There are provided methods for producing the Related Art A three-dimensionally shaped object known as stereolithography. 特許第2620353号などに示された該製造方法は、図18(a)に示すように、無機質あるいは有機質の粉末材料の層の所定箇所に光ビームLを照射して該当個所の粉末を焼結することで焼結層11を形成し、この焼結層11の上に粉末材料の新たな層10を被覆して該粉末層10の所定箇所に光ビームL Patent The method shown in the like No. 2,620,353, as shown in FIG. 18 (a), sintering the powder of relevant sections by irradiating a light beam L at a predetermined position of the layer of powder material of inorganic or organic the sintered layer 11 is formed by the light beam to a predetermined portion of the powder layer 10 a new layer 10 of powder material was coated L over the sintered layer 11
を照射して該当個所の粉末を焼結することで下層の焼結層11と一体になった新たな焼結層11を形成することを繰り返すことによって、複数の焼結層が積層一体化された粉末焼結部品(三次元形状造形物)を作成するものであり、三次元形状造形物の設計データ(CADデータ)であるモデルを所望の層厚みにスライスして生成する各層の断面形状データをもとに光ビームLを照射することから、いわゆるCAM装置が無くとも任意形状の三次元形状造形物を製造することができるほか、切削加工などによる製造方法に比して、迅速に所望の形状の造形物を得ることができる。 By repeating the formation of a new sintered layer 11 became a powder relevant sections together and the underlying sintered layer 11 by sintering is irradiated with a plurality of sintered layers are stacked integrally powder sintered components (three-dimensionally shaped object) is intended to create a three-dimensionally shaped object of the design data (CAD data) a is the model of each layer to produce sliced ​​to the desired layer thickness cross-sectional shape data since the irradiation based on the light beam L a, well capable of producing three-dimensional shaped object having an arbitrary shape even called CAM device without compared to the manufacturing method such as by cutting, rapidly desired it can be obtained a molded article shape.

【0003】 [0003]

【発明が解決しようとする課題】ところで、図20に示すように、光ビームLを照射して焼結硬化させた部分の周囲には伝達された熱が原因となって不要な粉末15が付着するものであり、該付着粉末は密度の低い表面層1 Meanwhile [0007] As shown in FIG. 20, the light beam unnecessary powder 15 caused is transmitted heat L by irradiating the periphery of the portion obtained by sintering cured adhesion is intended to, said adhesion powder low surface layer density 1
6を造形物に形成してしまう。 6 will be formed on the modeling was.

【0004】特開2000−73108号公報には、焼結層11を積層することで生じる外表面の段差(図18 [0004] JP-A 2000-73108 discloses, the outer surface caused by laminating the sintered layers 11 step (FIG. 18
(b)参照)を除去することが示されているが、この段差を除去するだけでは図18(c)に示すように、低密度表面層16が残ってしまい、滑らかな表面を得ることができない。 (B) see) has been shown to remove, but as only removes the step is shown in FIG. 18 (c), it will remain a low density surface layer 16, to obtain a smooth surface Can not.

【0005】また焼結工程において十分な密度(低気孔率)の焼結体を形成しておかないと、段差を除去しても除去後の表面に気孔が現れて滑らかな表面は得られない。 [0005] Failure to form a sintered body having a sufficient density in the sintering process (low porosity), not smooth surface obtained appears pores on the surface after removal be removed step .

【0006】さらに造形物を完成させた後に上記低密度表面層を除去する仕上げを行う場合は、造形物形状に対して、加工工具による限界が生じる。 [0006] Further, in the case of conducting the finish of removing the low-density surface layer after completing a molded article, relative to molded product shape, limit due to the machining tool is caused. たとえば深いリブ等を切削する場合、小径工具では工具長さに制限があるために加工不可能となることがあるために、別途放電加工等の工程が必要となり、時間及びコストの点で問題が多い。 For example when cutting deep ribs or the like, for it may become impossible processing because there is a limit to the tool length in small diameter tools, a separate process of electrical discharge machining or the like is required, a problem in terms of time and cost many.

【0007】本発明はこのような点に鑑みなされたものであって、その目的とするところは造形物表面をその形状にかかわらず低コストで滑らかに仕上げることができる三次元形状造形物の製造方法及びその装置を提供するにある。 [0007] The present invention has been made in view of the above problems, production of three-dimensional shaped object has as its object that can be finished smoothly at low cost regardless of the shaped object surface to the shape to provide a method and apparatus.

【0008】 [0008]

【課題を解決するための手段】しかして本発明に係る三次元形状造形物の製造方法は、無機質あるいは有機質の粉末材料の層の所定箇所に光ビームを照射して該当個所の粉末を焼結することで焼結層を形成し、この焼結層の上に粉末材料の新たな層を被覆して所定箇所に光ビームを照射して該当個所の粉末を焼結することで下層の焼結層と一体になった新たな焼結層を形成することを繰り返して、複数の焼結層が積層一体化された粉末焼結部品を作成するにあたり、焼結層の形成後にそれまでに作成した造形物の表面部及びまたは不要部分の除去を行う工程を複数回の焼結層の作成工程中に挿入することに特徴を有している。 Method of manufacturing SUMMARY OF THE INVENTION Thus three-dimensionally shaped object according to the present invention, sintering the powder of relevant sections by irradiating a light beam to a predetermined portion of the layer of powder material of inorganic or organic a sintered layer formed by sintering a new layer coated by irradiating light beam at a predetermined position of the lower layer by sintering a powder of the corresponding point of the powder material on the sintered layer Repeat to form a new sintered layer integral with the layer, were prepared Upon plurality of sintered layers to create a laminated integrated powder sintered components, so far after the formation of the sintered layer It is characterized in inserting a step of removing the surface portions and or unnecessary portion of the shaped article during the creation process of the plurality of sintered layers.

【0009】この時、除去工程に際しての造形物の表面部の除去深さを焼結部の周囲に付着した粉末による低密度表面層の深さより大とすることが好ましく、また、三次元形状造形物である粉末焼結部品の表面を高密度に焼結させておくとともに、除去工程により上記高密度部を露出させることが好ましい。 [0009] At this time, it is preferable to larger than the depth of the low-density surface layer by powder adhered to the surface portion removal depth of the molded article during removal step around the sintered part, also, three-dimensionally shaped with advance by sintering a powder sintered component surface is ones at high density, to expose the high density portion is preferably the removal process.

【0010】除去工程は切削やレーザーによって行うことができる。 [0010] removal step can be done by cutting or laser.

【0011】除去工程の直前に除去対象部に光ビームを照射して除去対象部を軟化させたり、除去工程の直後に除去対象部を除去した部分に溶融硬化もしくは熱処理用の光ビームを照射するようにしてもよい。 [0011] irradiation or softens the removal target portion by irradiating a light beam to the removal target part immediately before the removing step, a light beam for melting and setting or heat treatment portion removed removal target portion immediately after the removing step it may be so.

【0012】また、除去工程における除去作業と同時に三次元形状造形物である粉末焼結部品の周囲の未焼結粉末や除去作業で発生する屑の排除作業を行うことも好ましく、未焼結粉末の排除は除去工程の直前に行ってもよい。 [0012] It is also preferable to perform the elimination work debris generated by unsintered powder or removal work around the powder sintered parts at the same time three-dimensionally shaped object removal operation in the removal step, unsintered powder of exclusion may be carried out immediately before the removal process.

【0013】上記排除を行う場合は、除去工程の直後に除去部及び排除部に対して樹脂またはろう材を流し込み、次いで次の粉末材料の層の形成及び焼結を行うようにしてもよい。 [0013] When performing the exclusion pouring resin or braze to removal portion and the exclusion section immediately after the removing step, then it may perform the formation and sintering of the layer of the following powdered materials.

【0014】焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行い、該計測結果に基づき、次の焼結層の形成のための光ビームの照射経路データ及び次の除去工程での被除去部の除去加工経路データの修正を行うことも好ましい。 [0014] Perform the measurement of the shape and the position of the shaped article formed so far just after just after or removal step of forming the sintered layer, on the basis of the measurement result, the light beam for the formation of subsequent sintering layer it is also preferable to correct the removal processing path data of the removed portion of the irradiation path data and subsequent removal step. .

【0015】除去工程の前に未焼結粉末を固化させておくようにしてもよく、この場合の固化は、未焼結粉末を冷凍したり、樹脂またはろう材を用いるとよい。 [0015] may also be allowed to solidify the unsintered powder prior to removal process, solidification of the case, or frozen unsintered powder, it may be used a resin or wax material.

【0016】そして本発明に係る三次元形状造形物の製造装置は、無機質あるいは有機質の粉末材料の層を形成する粉末層形成手段と、上記粉末層の所定箇所に光ビームを照射して該当個所の粉末を焼結して焼結層を形成する焼結層形成手段と、焼結層形成手段と焼結層との相対距離を調整する調整手段とを備えるとともに、造形物の表面部及びまたは不要部分の除去を行う除去手段を備えていることに特徴を有している。 [0016] The apparatus for producing a three-dimensionally shaped object according to the present invention comprises a powder layer forming means for forming a layer of powder material of inorganic or organic, relevant sections by irradiating a light beam to a predetermined portion of the powder layer by sintering of powder and sintered layer forming means for forming a sintered layer, with and an adjusting means for adjusting the relative distance between the sintered layer forming means and the sintered layer, the surface portion of the shaped object and or It is characterized in that it comprises a removal means for removing the unnecessary portion.

【0017】未焼結粉末や除去手段による除去工程で発生する屑を排除する排除手段を備えたものとしてもよく、この排除手段は、粉末層形成手段に付設したものや、XY駆動機構を有して造形物の断面輪郭形状に沿って排除作業を行うものを好適に用いることができる。 [0017] may be those with an exclusion means for excluding debris generated in removing step by unsintered powder and removing means, the removing means are those attached to the powder layer forming means and, have a XY drive mechanism can be suitably used to perform elimination operations along section contour shape of the shaped object was.

【0018】また、焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行う計測手段と、計測手段による計測結果に基づいて焼結層形成手段の動作を補正する補正手段とを備えたものとするのも好ましく、この場合の計測手段には、X Further, measuring means to measure the shape and position of the shaped article formed so far just after just after or removal step of forming the sintered layer, the sintered layer forming means on the basis of the measurement result by the measurement means also preferably be one having a correction means for correcting the operation, the measuring means in this case, X
Y駆動機構を有して造形物の断面輪郭形状に沿って計測を行うものを好適に用いることができる。 Those performing measurement along the cross-sectional profile shape of the shaped object has a Y drive mechanism can be preferably used.

【0019】 [0019]

【発明の実施の形態】以下本発明を実施の形態の一例に基づいて詳述すると、図3は本発明に係る三次元形状造形物の製造装置を示しており、シリンダーで外周が囲まれた空間内を上下に昇降する昇降テーブル20上に供給した無機質あるいは有機質の粉末材料をスキージング用ブレード21でならすことで所定厚みΔt1の粉末層1 More specifically, based DETAILED DESCRIPTION OF THE INVENTION The present invention follows an example of an embodiment, FIG. 3 shows an apparatus for manufacturing a three-dimensionally shaped object according to the present invention, the outer periphery in the cylinder is surrounded powder layer 1 having a predetermined thickness Δt1 by sounding a powdered inorganic material or an organic which is supplied onto the lifting table 20 which moves up and down in the space up and down squeegee blade 21
0を形成する粉末層形成手段2と、レーザー発振器30 A powder layer forming means 2 for forming a 0, the laser oscillator 30
から出力されたレーザーをガルバノミラー31等のスキャン光学系を介して上記粉末層10に照射することで粉末を焼結して焼結層11を形成する焼結層形成手段3 Sintered layer forming means the outputted laser through the scan optical system such as a galvanometer mirror 31 to form a sintered layer 11 by sintering the powder by irradiating the powder layer 10 from 3
と、上記粉末層形成手段2のベース部にXY駆動機構(高速化の点で直動リニアモータ駆動のものが好ましい)40を介してミーリングヘッド41を設けて、除去手段4を形成してある。 When, by providing a milling head 41 through the powder layer forming means (preferably those of the linear motion linear motor driven in terms of speed) XY driving mechanism to the base portion of 2 40, there is formed a removal means 4 .

【0020】このものにおける三次元形状造形物の製造は、図1に示すように、焼結層形成手段と焼結層との相対距離を調整する調整手段であるところの昇降テーブル20上面の造形用ベース22表面に無機質または有機質の粉末材料を供給してブレード21でならすことで第1 The production of three-dimensional shaped object in this compound, as shown in FIG. 1, the shaped of the lifting table 20 the upper surface where an adjustment means for adjusting the relative distance between the sintered layer forming means and the sintered layer the in use base 22 surface powder material inorganic or organic by leveling blade 21 by supplying 1
層目の粉末層10を形成し、この粉末層10の硬化させたい箇所に光ビーム(レーザー)Lを照射して粉末を焼結させてベース22と一体化した焼結層11を形成する。 To form a powder layer 10 of the layer first, to form a sintered layer 11 by sintering the by irradiating a light beam (laser) L powders integrated with the base 22 with the portion to be cured of the powder layer 10.

【0021】この後、昇降テーブル20を少し下げて再度無機質または有機質の粉末材料を供給してブレード2 [0021] Then, by supplying the powder material of the lifting table 20 slightly lowered again inorganic or organic blade 2
1でならすことで第2層目の粉末層10を形成し、この粉末層10の硬化させたい箇所に光ビーム(レーザー) The powder layer 10 of the second layer formed by leveling at 1, the light beam with the portion to be cured of the powder layer 10 (laser)
Lを照射して粉末を焼結させて下層の焼結層11と一体化した焼結層11を形成する。 By irradiating L by sintering powder to form a sintered layer 11 integrated with the underlying sintered layer 11.

【0022】昇降テーブル20を下降させて新たな粉末層10を形成し、光ビームを照射して所要箇所を焼結層11とする工程を繰り返すことで、目的とする三次元形状造形物を製造するものであり、たとえば、粉末材料として平均粒径約20μmの球形の鉄粉、光ビームとしては炭酸ガスレーザー、粉末層10の厚みΔt1としては0.05mmが好適である。 [0022] lowers the elevating table 20 to form a new powder layer 10, by repeating the steps of the sintered layer 11 the required locations by irradiating a light beam, producing a three-dimensionally shaped object of interest is intended to, for example, iron powder spherical average particle size of about 20μm as a powder material, a carbon dioxide gas laser as a light beam, as the thickness Δt1 of the powder layer 10 is 0.05mm is preferred.

【0023】光ビームの照射経路は、予め三次元CAD [0023] The irradiation path of the light beam, in advance three-dimensional CAD
データから作成しておく。 It has been created from the data. すなわち、従来のものと同様に、三次元CADモデルから生成したSTLデータを等ピッチ(ここでは0.05mm)でスライスした各断面の輪郭形状データを用いる。 That is, as is conventional, using contour data of each section sliced ​​at equal pitch STL data generated from three-dimensional CAD model (where 0.05mm is). この時、三次元形状造形物の少なくとも最表面が高密度(気孔率5%以下)となるように焼結させることができるように光ビームの照射を行うのが好ましい。 In this case, it is preferable to carry out the irradiation of the light beam so that it can be sintered such that at least the outermost surface of the three-dimensionally shaped object is a high-density (porosity 5%). 除去手段によって後述する表面除去を行っても、露出した部分がポーラスであれば、除去加工後の表面もポーラスな状態となるためであり、このために予め形状モデルデータを図4に示すように、表層部Sと内部Nとに分割しておき、内部Nについてはポーラスとなるような焼結条件、表層部Sはほぼ粉末が溶融して高密度となる条件で光ビームを照射する。 Be subjected to surface removal to be described later by the removal means, if the exposed portion porous, surface after removal processing is also because a porous state, a pre-geometric model for this, as shown in FIG. 4 , previously divided into a surface layer portion S and the inner N, sintering conditions such that porous for internal N, the surface portion S substantially powder is irradiated with a light beam under conditions where the high density melt. 図5(a)の図中12が高密度部を示しており、図中16は前述の付着粉末によるところの低密度表面層である。 Figure 5 shows a drawing 12 is a high-density portion of (a), reference numeral 16 is a low density surface layer where by the above-described attachment powder.

【0024】そして、上記粉末層10を形成しては光ビームを照射して焼結層11を形成することを繰り返していくのであるが、焼結層11の全厚みがたとえばミーリングヘッド41の工具長さなどから求めた所要の値になれば、いったん除去手段4を作動させてそれまでに造形した造形物の表面を切削する。 [0024] Then, although to form the powder layer 10 is going to repeat the formation of a sintered layer 11 by irradiating a light beam, the total thickness eg of the milling head 41 tool sintered layer 11 once the required values ​​obtained from such length, once cutting the surface of the shaped article according to shaped so far by operating the removal means 4. たとえば、ミーリングヘッド41の工具(ボールエンドミル)が直径1mm、有効刃長3mmで深さ3mmの切削加工が可能であり、粉末層10の厚みΔt1が0.05mmであるならば、6 For example, the tool (ball end mill) diameter 1mm milling head 41, is capable of cutting depth 3mm in effective blade length 3mm, if the thickness of the powder layer 10 .DELTA.t1 is 0.05 mm, 6
0層の焼結層11を形成した時点で、除去手段4を作動させる。 At the time of forming the sintered layer 11 of layer 0, activating the removal means 4.

【0025】この除去手段4による切削加工により、図5に示すように、造形物表面に付着した粉末による低密度表面層16を除去すると同時に、高密度部12まで削り込むことで、造形物表面に高密度部12を全面的に露出させる。 [0025] By cutting using the removing means 4, As shown in FIG. 5, at the same time to remove the low-density surface layer 16 by powder adhering to the shaped object surface, in a way to push cutting to high density portion 12, shaped object surface fully expose the high density portion 12 to. このために、所望の形状Mよりも焼結層11 For this, the sintered layer than desired shape M 11
が少し大きくなるようにしておく。 But keep that is slightly greater.

【0026】この除去手段4による切削加工経路は、光ビームの照射経路と同様に予め三次元CADデータから作成しておく。 The machining path by the removing means 4 is previously created for the same in advance three-dimensional CAD data and irradiation path of the light beam. この時、等高線加工を適用して加工経路を決定するが、Z方向ピッチは焼結時の積層ピッチにこだわる必要はなく、緩い傾斜の場合はZ方向ピッチをより細かくして補間することで、滑らかな表面を得られるようにしておく。 At this time, by applying a contouring determining a machining path, the Z-direction pitch need not to stick to stacking pitch during sintering, in the case of gentle slope to interpolate with finer Z-direction pitch, keep to obtain a smooth surface. 切削加工を直径1mmのボールエンドミルで行う場合は、切り込み量を0.1〜0.5mm、 When performing cutting ball end mill having a diameter of 1mm is the depth of cut 0.1 to 0.5 mm,
送り速度を5m/min〜50m/min、工具回転数を20,000rpm〜100,000rpmとするのが好ましい。 The feed speed 5m / min~50m / min, preferably in the 20,000rpm~100,000rpm the tool rotation speed.

【0027】なお、切削による除去に際しては、図6に示すように、切削加工の直前の部分にエネルギー密度を小さくした光ビーム(レーザー)Lを照射して加熱することで軟化させておき、この軟化した状態の部分を工具44が切削していくようにすると、切削抵抗が小さくなるために切削加工時間を短くできるとともに工具44の寿命を延ばすことができる。 [0027] Note that when the removal by cutting, as shown in FIG. 6, allowed to soften by heating by irradiating a light beam (laser) L having a reduced energy density in the portion immediately before the cutting, the When a portion of the softened state the tool 44 so as gradually to cut, it is possible to extend the life of the tool 44 with a shorter machining time because the cutting resistance is reduced.

【0028】また、図7に示すように、切削除去直後の部分に再度光ビームLを照射して溶融硬化させたり熱処理することで、密度を高めるようにすることも好ましい。 Further, as shown in FIG. 7, by irradiating again the light beam L on the portion immediately cutting removal by thermal treatment or melted hardened, it is also preferable to increase the density.

【0029】図8に示すものは、焼結層形成手段3であるレーザー発振器30からのレーザーを光ファイバー3 The one shown in Figure 8, the laser from the laser oscillator 30 is a sintered layer forming means 3 optical fiber 3
6を通じて受けて出力する照射ヘッド35を除去手段4 Removing means irradiation head 35 to be output by receiving through 6 4
におけるXY駆動機構40に取り付けている。 It is attached to the XY drive mechanism 40 in. 共用部品が増えるために部品点数を少なくすることができる。 It is possible to reduce the number of components to a shared component is increased.

【0030】ところで、除去手段4による造形物表面及び不要部分の除去に際して、未焼結粉末や除去手段4による切削屑が除去作業の邪魔になる上に、次の粉末層1 By the way, when the removal of the shaped article surface and unnecessary portions by removing means 4, on which the cutting chips from the unsintered powder and removing means 4 is in the way of work removed, the next powder layer 1
0の形成に際して、ブレード21に切削屑が引っかかって平坦な粉末層10を形成することができなかったり、 In forming the 0, or not possible to form a flat powder layer 10 caught cutting debris blade 21,
ブレード21と造形物との間に切削屑が挟まってブレード21が停止してしまうことがある。 Blade 21 caught cutting debris between the blade 21 and the shaped object is sometimes stopped. このために、図9 To this end, as shown in FIG. 9
及び図10(a)あるいは図10(b)に示すように、たとえばエアポンプ50に接続した吸引ノズル51を工具44 And as shown in FIG. 10 (a) or FIG. 10 (b), the tool 44 a suction nozzle 51 connected to, for example, the air pump 50
に隣接させて配置して、切削と同時に未焼結粉末及び切削屑を吸引排除してしまうとよい。 To be placed adjacent, it may cut the thus sucked eliminate unsintered powder and swarf simultaneously. 吸引ノズル51で工具44を囲んでいる図10(b)に示すものでは、工具4 It intended shown in FIG. 10 (b) surrounding the tool 44 with the suction nozzle 51, the tool 4
4としてスピンドルヘッドを好適に用いることができる。 It can be suitably used spindle head as 4.

【0031】図11に示すように、切削加工前に未焼結粉末のみを吸引除去し、切削加工と同時に切削屑を吸引除去するようにしてもよく、この場合、未焼結粉末に切削屑が混入することがないために、未焼結粉末の再利用が容易となる。 As shown in FIG. 11, the cutting before processing unsintered powder only was aspirated, may be removed by suction cutting simultaneously with cutting chips. In this case, cutting debris unsintered powder There for never mixed, it is easy to reuse the unsintered powder.

【0032】ところで、未焼結粉末を吸引排除してしまった場合、除去工程後にさらに粉末層10を積層する時、多量の粉末が必要となり、除去工程を複数回繰り返す場合、その都度、未焼結粉末を排除した全空間に粉末を埋めなくてはならず、時間的なロスが大きくなる。 [0032] Incidentally, if you've suction-discharge unsintered powder, when further stacking powder layer 10 after the removal process, a large amount of powder is required, if repeated a plurality of times removing step, each time, unsintered without filling the powder into the entire space which eliminated the binding powder must not, time loss is large.

【0033】このために、未焼結粉末を排除した空間には、図12に示すように、樹脂あるいはろう材を流し込んで固化させることで固化部18を形成し、次の粉末層10は最上層の焼結層11と上記固化部18の上面に形成するとよい。 [0033] For this, in a space which eliminated the unsintered powder, as shown in FIG. 12, the coated portion 18 is formed by solidifying by pouring resin or brazing material, the following powder layer 10 is the outermost the upper layer of the may be formed on the upper surface of the sintered layer 11 and the solidified portion 18. 使用する粉末量を削減することができる。 It is possible to reduce the amount of powder to be used.

【0034】なお、上記エアポンプ50及び吸引ノズル51からなる排除手段における吸引ノズル51は、除去工程に先だって未焼結粉末を排除するものについては、 [0034] Incidentally, the suction nozzle 51 in the removing means consisting of said air pump 50 and the suction nozzle 51, the exclude unsintered powder prior to removal step,
図13に示すように、粉末層形成手段2におけるブレード21の駆動部に取り付けておくと、全域の未焼結粉末の排除を行うことができるとともに吸引ノズル51のための専用の駆動機構を必要としなくなるために、装置構成を簡単にすることができる。 As shown in FIG. 13, requires the previously attached to the drive of the blade 21 in the powder layer forming means 2, a dedicated drive mechanism for the suction nozzle 51 it is possible to carry out the elimination of unsintered powder of whole for longer and, thereby simplifying the device configuration.

【0035】また、図14に示すように、吸引ノズル5 Further, as shown in FIG. 14, the suction nozzle 5
1を専用のXY駆動機構55、もしくは除去手段4におけるXY駆動機構40に取り付けた場合には、造形物の断面輪郭線形状に沿って吸引ノズル51を移動させることができる。 1 when mounted to the XY drive mechanism 40 is in the dedicated XY driving mechanism 55 or removal means 4, and can move the suction nozzle 51 along section contour shape of the shaped object.

【0036】未焼結粉末については、除去工程の直前に吸引排除してしまうのではなく、例えば液体窒素などを吹き付ける(必要とあれば湿気を含んだガスを同時に吹き付ける)ことで未焼結粉末を固化させたり、樹脂やろう材などを流し込んで固化させておき、この状態で除去手段4を動作させるようにしてもよい。 [0036] Not For sintered powder, rather than resulting in suction-discharge immediately prior to the removal step, such as liquid nitrogen blowing, etc. (blowing moist gas at the same time if necessary) be in a non-sintered powder the or solidified, allowed to solidify by pouring resin or wax material, it may be to operate the removing means 4 in this state. 切削屑が未焼結粉末内に入り込んでしまうことがないために、切削屑の排除を容易に行うことができる。 For cutting debris never intrudes into unsintered the powder, it is possible to easily eliminate cutting chips.

【0037】図15に示すものは、焼結直後もしくは除去加工直後の造形物の形状及び位置を測定するための計測手段6を設けたものを示している。 The one shown in FIG. 15 shows the one provided with measuring means 6 for measuring the shape and position immediately or removal machining a molded article after sintered. 光ビームの照射精度や除去加工の加工精度をオンマシンで計測することができるものであり、計測結果をフィードバックして、測定データ(位置座標データ)とCADデータを比較することで、造形精度を算出することができるとともに、比較結果に基づいて次の光ビーム照射経路データを修正したり、次の除去加工経路データを修正したりすることで、より高精度な造形が可能となる。 Are those capable of measuring the machining accuracy of the irradiation accuracy and removal processing of the light beam on-machine, by feeding back the measurement results, the measurement data (positional coordinate data) and by comparing the CAD data, the molding accuracy it is possible to calculate, or modify the next light beam irradiation path data based on the comparison result, it or modify the following removal machining path data, thereby enabling more accurate modeling.

【0038】上記計測手段6がたとえば圧電型接触センサである場合には、除去手段4におけるXY駆動機構4 [0038] When the measuring means 6 is a piezoelectric-type contact sensor for example, XY driving mechanism in the removal means 4 4
0に計測手段6を設けると、計測手段6のための専用駆動機構を必要とすることなく、計測を行うことができる。 When 0 to providing the measuring means 6, without the need for a dedicated drive mechanism for measuring means 6, the measurement can be performed.

【0039】また、計測手段6としてはCCDカメラのような撮像手段を用いてもよい。 [0039] It is also possible to use an imaging device such as a CCD camera as the measuring unit 6. 測定しようとする点が画像の中心となるように撮像手段を移動させて、画像中心と造形物中の測定しようとしている点とのずれた画素数からずれ量を計測するのである。 Points to be measured by moving the imaging means so that the center of the image, is to measure the amount of deviation from the deviation number of pixels of the point to be measured of the shaped object in the image center.

【0040】以上の各例では、除去手段4として切削で除去を行うものを示したが、このほか、高出力レーザーで除去を行うようにしてもよい。 [0040] In each of the above examples, although the performs cutting by removing the removing means 4, the addition may be performed to remove a high-output laser. たとえばピーク出力が10kW以上のQスイッチYAGレーザーを使用すれば、造形物表面の低密度表面層16を瞬時に蒸発させて除去することができる。 For example, if using a Q-switched YAG laser peak power above 10 kW, it evaporated low density surface layer 16 of the molded product surface instantaneously can be removed. また、除去部分は造形物の表面部に限るものではなく、造形の都合上、本来ならば不要である部分も造形しなくてはならない場合、この不要部分の除去も行うことができる。 Further, the removed portion is not limited to the surface portion of the shaped object, if the convenience of a shaped, must not be shaped portion is not necessary if the original can be carried out the removal of the unnecessary portion.

【0041】 [0041]

【発明の効果】以上のように本発明の三次元形状造形物の製造方法は、無機質あるいは有機質の粉末材料の層の所定箇所に光ビームを照射して該当個所の粉末を焼結することで焼結層を形成し、この焼結層の上に粉末材料の新たな層を被覆して所定箇所に光ビームを照射して該当個所の粉末を焼結することで下層の焼結層と一体になった新たな焼結層を形成することを繰り返して、複数の焼結層が積層一体化された粉末焼結部品を作成するにあたり、焼結層の形成後にそれまでに作成した造形物の表面部及びまたは不要部分の除去を行う工程を複数回の焼結層の作成工程中に挿入することから、つまりは焼結層の作成と造形物の表面部及びまたは不要部分の除去を繰り返し行うために、仕上げにドリル長などの制約を受けることなく表面を仕 Method for producing a three-dimensionally shaped object of the present invention as described above, according to the present invention, by sintering a powder of relevant sections by irradiating a light beam to a predetermined portion of the layer of powder material of inorganic or organic to form a sintered layer, the lower layer of the sintered layer integrally by sintering a powder of relevant sections by irradiating a light beam at a predetermined position to cover the new layer of powder material over the sintered layer Repeat to form a new sintered layer becomes, when a plurality of sintered layers to create a laminated integrated powder sintered component, the shaped object that was created so far after the formation of the sintered layer since inserting a step of performing surface portion and or removal of unwanted portions in a plurality of times of generation step of sintering layer, repeating the removal of the surface portion and or unnecessary portion of the shaped object that is, the creation of the sintered layer in order, specification the surface without being subjected to constraints such as drill length to finish げることができる。 It can gel.

【0042】この時、除去工程に際しての造形物の表面部の除去深さを焼結部の周囲に付着した粉末による低密度表面層の深さより大とすることで、造形物表面を確実に滑らかにすることができる。 [0042] At this time, by a larger than the depth of the low-density surface layer by powder adhering the removal depth of the surface portion of the molded article during removal step around the sintered portion, reliably smooth shaped object surface it can be.

【0043】また、三次元形状造形物である粉末焼結部品の表面を高密度に焼結させておくとともに、除去工程により上記高密度部を露出させることで、表面の面粗度を高くすることができる。 [0043] Further, the surface of the powder sintered component is three-dimensionally shaped object with allowed to densely sintered, by exposing the dense portion by removal step, to increase the surface roughness of the surface be able to.

【0044】除去工程の直前に除去対象部に光ビームを照射して除去対象部を軟化させるならば、除去を切削で行う場合、切削抵抗を下げることができるために、切削時間の短縮及び切削工具寿命の向上を図ることができる。 [0044] If softening the removal target portion by irradiating a light beam to the removal target part immediately before the removal step, if for removing the cutting, in order to be able to reduce the cutting resistance, reducing the cutting time and cutting it is possible to improve the tool life.

【0045】また、除去工程の直後に除去対象部を除去した部分に溶融硬化もしくは熱処理用の光ビームを照射するならば、表面密度を向上させることができる。 Further, if a light beam for melting and setting or heat treatment portion removed removal target portion immediately after the removal step, it is possible to improve the surface density.

【0046】そして、除去工程における除去作業と同時に三次元形状造形物である粉末焼結部品の周囲の未焼結粉末や除去作業で発生する屑の排除作業を行うと、切削屑の処理が可能であって、次の粉末層の形成に際して切削屑が悪影響を及ぼしてしまうことを避けることができる。 [0046] Then, when the elimination work debris generated by unsintered powder or removal work around the powder sintered parts at the same time three-dimensionally shaped object removal operation in the removal step, can be processed swarf a is, the cutting chips in the formation of the next layer of powder can be avoided adversely affected. 未焼結粉末の排除は除去工程の直前に行ってもよく、この場合、未焼結粉末と切削屑とを分離して処理することができるために未焼結粉末の再利用が容易となる。 Elimination of unsintered powder may be carried out immediately prior to the removal step, in this case, it is easy to reuse the unsintered powder in order to be able to separate and treat the unsintered powder and swarf .

【0047】上記排除を行う場合は、除去工程の直後に除去部及び排除部に対して樹脂またはろう材を流し込み、次いで次の粉末材料の層の形成及び焼結を行うと、 [0047] When performing the exclusion pouring resin or braze to removal portion and the exclusion section immediately after the removing step, then performed the formation and sintering of the layer of the next powder material,
粉末の使用量を削減することができる。 It is possible to reduce the amount of powder.

【0048】焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行い、該計測結果に基づき、次の焼結層の形成のための光ビームの照射経路データ及び次の除去工程での被除去部の除去加工経路データの修正を行うことで、より高精度な造形が可能となる。 [0048] Perform the measurement of the shape and the position of the shaped article formed so far just after just after or removal step of forming the sintered layer, on the basis of the measurement result, the light beam for the formation of subsequent sintering layer by correcting the removal processing path data of the removed portion of the irradiation path data and subsequent removal process, thereby enabling more accurate modeling.

【0049】除去工程の前に未焼結粉末を固化させておくようにしてもよく、この場合の固化は、未焼結粉末を冷凍したり、樹脂またはろう材を用いるとよい。 [0049] may also be allowed to solidify the unsintered powder prior to removal process, solidification of the case, or frozen unsintered powder, it may be used a resin or wax material. このように固化させた場合、粉末の再充填などを必要とすることなく、切削屑のみを容易に除去することができる。 If solidified Thus, without the need for such re-filling of the powder, only the cutting chips can be easily removed.

【0050】そして本発明に係る三次元形状造形物の製造装置は、無機質あるいは有機質の粉末材料の層を形成する粉末層形成手段と、上記粉末層の所定箇所に光ビームを照射して該当個所の粉末を焼結して焼結層を形成する焼結層形成手段と、焼結層形成手段と焼結層との相対距離を調整する調整手段とを備えるとともに、造形物の表面部及びまたは不要部分の除去を行う除去手段を備えていることから、造形加工後の表面粗度の向上を図ることができるものであり、また上記製造方法を簡便に実施することができる。 [0050] The apparatus for producing a three-dimensionally shaped object according to the present invention comprises a powder layer forming means for forming a layer of powder material of inorganic or organic, relevant sections by irradiating a light beam to a predetermined portion of the powder layer by sintering of powder and sintered layer forming means for forming a sintered layer, with and an adjusting means for adjusting the relative distance between the sintered layer forming means and the sintered layer, the surface portion of the shaped object and or since it is provided with a removal means for removing unnecessary portions are those can be improved surface roughness after molding processing and can be conveniently carried out the production method.

【0051】未焼結粉末や除去手段による除去工程で発生する屑を排除する排除手段を備えたものとすることで、屑の影響を避けることができるものとなる。 [0051] With those with an exclusion means for excluding debris generated in removing step by unsintered powder and removing means, and which can avoid the influence of dust.

【0052】また、焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行う計測手段と、XY駆動機構を有して造形物の断面輪郭形状に沿って計測を行う上記計測手段による計測結果に基づいて焼結層形成手段の動作を補正する補正手段とを備えたものとすることで、高精度な造形物を容易に得ることができるものとなる。 [0052] In addition, measuring means to measure the shape and position of the shaped article formed so far just after just after or removal step of forming the sintered layer, the cross-sectional contour of the shaped object has an XY drive mechanism along with that a correcting means for correcting the operation of the sintered layer forming means on the basis of the measurement result by the measuring means to measure, and that can be easily obtained with high precision shaped object Become.

【図面の簡単な説明】 BRIEF DESCRIPTION OF THE DRAWINGS

【図1】本発明の実施の形態の一例に係る動作説明図である。 [1] is an operation explanatory diagram according to an exemplary embodiment of the present invention.

【図2】同上のブロック図である。 FIG. 2 is a block diagram of the same.

【図3】同上の概略斜視図である。 Figure 3 is a schematic perspective view of the same.

【図4】同上の表面高密度部に関する説明図である。 4 is an explanatory diagram relating to the surface density of the same as above.

【図5】(a)(b)は同上の除去工程を示す断面図である。 [5] (a) (b) is a sectional view showing a removal step of the same.

【図6】同上の他例の動作を示す斜視図である。 6 is a perspective view showing the operation of another example of the same.

【図7】同上の更に他例の動作を示す斜視図である。 7 is a perspective view showing the operation of still another example of the same.

【図8】別の例の概略斜視図である。 8 is a schematic perspective view of another example.

【図9】さらに他例の概略斜視図である。 9 is a schematic perspective view of yet another embodiment.

【図10】(a)(b)は夫々排除手段の一例を示している概略断面図である。 [10] (a) (b) is a schematic sectional view showing an example of each elimination means.

【図11】(a)(b)は排除手段の他例の動作を示す概略断面図である。 11 (a) (b) is a schematic sectional view showing the operation of another example of the removing means.

【図12】(a)(b)は排除加工後の処理を示す概略断面図である。 [12] (a) (b) is a schematic sectional view showing the process after exclusion processing.

【図13】排除手段のさらに他例を示す概略断面図である。 13 is a schematic sectional view showing still another example of the removing means.

【図14】排除手段の別の例を示す概略斜視図である。 14 is a schematic perspective view showing another example of the removing means.

【図15】計測手段を備えた例の概略斜視図である。 15 is a schematic perspective view of an example provided with a measuring means.

【図16】(a)(b)は同上の動作を示す断面図である。 [16] (a) (b) is a sectional view showing the operation of the same.

【図17】計測手段の他例を示す概略斜視図である。 17 is a schematic perspective view showing another example of the measuring means.

【図18】(a)は焼結層の形成に際しての粉末の付着を説明する断面図、(b)は低密度表面層を示す断面図、(c) [18] (a) is a sectional view illustrating the deposition of the powder in the formation of the sintered layer, (b) is a sectional view showing a low-density surface layer, (c)
は段差のみを除去した場合の断面図である。 Is a cross-sectional view of a case of removing only step.

【符号の説明】 DESCRIPTION OF SYMBOLS

L 光ビーム 4 除去手段 10 粉末層 11 焼結層 L light beam 4 removal means 10 the powder layer 11 sintered layer

───────────────────────────────────────────────────── フロントページの続き (72)発明者 東 喜万 大阪府門真市大字門真1048番地松下電工株 式会社内 (72)発明者 峠山 裕彦 大阪府門真市大字門真1048番地松下電工株 式会社内 (72)発明者 不破 勲 大阪府門真市大字門真1048番地松下電工株 式会社内 (72)発明者 上永 修士 大阪府門真市大字門真1048番地松下電工株 式会社内 Fターム(参考) 4F213 AC04 AP06 AR07 WA22 WA25 WA43 WA53 WA67 WA83 WB01 WL03 WL04 WL13 WL21 WL32 WL52 WL85 WL96 4K018 CA44 CA50 EA51 EA60 FA01 JA05 ────────────────────────────────────────────────── ─── of the front page continued (72) inventor east Hee ten thousand Osaka Prefecture Kadoma Oaza Kadoma 1048 address Matsushita Electric Works Co., within the company (72) inventor Togeyama Yasuhiko Osaka Prefecture Kadoma Oaza Kadoma 1048 address Matsushita Electric Works Co., the company (72) inventor Isao Fuwa Osaka Prefecture Kadoma Oaza Kadoma 1048 address Matsushita Electric Works Co., within the company (72) inventor UeHisashi Master's Osaka Prefecture Kadoma Oaza Kadoma 1048 address Matsushita Electric Works Co., Ltd. in the F-term (reference) 4F213 AC04 AP06 AR07 WA22 WA25 WA43 WA53 WA67 WA83 WB01 WL03 WL04 WL13 WL21 WL32 WL52 WL85 WL96 4K018 CA44 CA50 EA51 EA60 FA01 JA05

Claims (18)

    【特許請求の範囲】 [The claims]
  1. 【請求項1】 無機質あるいは有機質の粉末材料の層の所定箇所に光ビームを照射して該当個所の粉末を焼結することで焼結層を形成し、この焼結層の上に粉末材料の新たな層を被覆して所定箇所に光ビームを照射して該当個所の粉末を焼結することで下層の焼結層と一体になった新たな焼結層を形成することを繰り返して、複数の焼結層が積層一体化された粉末焼結部品を作成するにあたり、焼結層の形成後にそれまでに作成した造形物の表面部及びまたは不要部分の除去を行う工程を複数回の焼結層の作成工程中に挿入することを特徴とする三次元形状造形物の製造方法。 1. A powder of relevant sections by irradiating a light beam to a predetermined portion of the layer of powder material of inorganic or organic form a sintered layer by sintering, powder material over the sintered layer Repeat to form a new sintered layer became a powder of the corresponding points by irradiating a light beam together with the underlying sintered layer by sintering at a predetermined position to cover the new layer, a plurality Upon sintering layer to create a layered integrated powder sintered component, the step of removing the surface portions and or unnecessary portion of the shaped object that was created so far after the formation of the sintered layer of the multiple sintering method for producing a three-dimensionally shaped object, characterized in that inserted in the layer of the creation process.
  2. 【請求項2】 除去工程に際しての造形物の表面部の除去深さを焼結部の周囲に付着した粉末による低密度表面層の深さより大とすることを特徴とする請求項1記載の三次元形状造形物の製造方法。 2. A tertiary according to claim 1, characterized in that a larger than the depth of the low-density surface layer by powder adhering the removal depth of the surface portion of the molded article during removal step around the sintered portion manufacturing method of the original shaped object.
  3. 【請求項3】 三次元形状造形物である粉末焼結部品の表面を高密度に焼結させておくとともに、除去工程により上記高密度部を露出させることを特徴とする請求項1 3. A process according to claim together with in advance by sintering at a high density surface of the powder sintered component is three-dimensionally shaped object by removal step and wherein the exposing the dense portion 1
    または2記載の三次元形状造形物の製造方法。 Method for producing or 2 three-dimensionally shaped object according.
  4. 【請求項4】 除去工程を切削によって行うことを特徴とする請求項1〜3のいずれかの項に記載の三次元形状造形物の製造方法。 4. The process for producing three-dimensionally shaped object according to any one of claims 1 to 3, characterized in that the cutting removal process.
  5. 【請求項5】 除去工程をレーザーによって行うことを特徴とする請求項1〜3のいずれかの項に記載の三次元形状造形物の製造方法。 5. The process for producing a three-dimensionally shaped object according to any one of claims 1 to 3, characterized in that the laser removal process.
  6. 【請求項6】 除去工程の直前に除去対象部に光ビームを照射して除去対象部を軟化させることを特徴とする請求項1〜5のいずれかの項に記載の三次元形状造形物の製造方法。 Of 6. The three-dimensional shaped object according to any one of claims 1 to 5, characterized in that softening the removal target portion by irradiating a light beam to the removal target part immediately before the removal process Production method.
  7. 【請求項7】 除去工程の直後に除去対象部を除去した部分に溶融硬化もしくは熱処理用の光ビームを照射することを特徴とする請求項1〜6のいずれかの項に記載の三次元形状造形物の製造方法。 7. A three-dimensional shape according to any one of claims 1 to 6, wherein the irradiating light beam for melting and setting or heat treatment portion removed removal target portion immediately after the removing step method of producing a molded article.
  8. 【請求項8】 除去工程における除去作業と同時に三次元形状造形物である粉末焼結部品の周囲の未焼結粉末や除去作業で発生する屑の排除作業を行うことを特徴とする請求項1〜7のいずれかの項に記載の三次元形状造形物の製造方法。 8. claim 1, characterized in that the elimination work debris generated by unsintered powder or removal work around the powder sintered parts at the same time three-dimensionally shaped object removal operation in the removing step method for producing a three-dimensionally shaped object according to any one of the paragraphs to 7.
  9. 【請求項9】 除去工程の直前に未焼結粉末の排除を行うことを特徴とする請求項1〜7のいずれかの項に記載の三次元形状造形物の製造方法。 9. The method of any one of three-dimensionally shaped object according to claim of claims 1 to 7, characterized in that the elimination of unsintered powder immediately before the removing step.
  10. 【請求項10】 除去工程の直後に除去部及び排除部に対して樹脂またはろう材を流し込み、次いで次の粉末材料の層の形成及び焼結を行うことを特徴とする請求項1 10. poured resin or braze to removal portion and the exclusion section immediately after the removing step, then claim 1, characterized in that the formation and sintering of the layer of the following powdered materials
    〜9のいずれかの項に記載の三次元形状造形物の製造方法。 Method for producing a three-dimensionally shaped object according to any one of the paragraphs to 9.
  11. 【請求項11】 焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行い、該計測結果に基づき、次の焼結層の形成のための光ビームの照射経路データ及び次の除去工程での被除去部の除去加工経路データの修正を行うことを特徴とする請求項1〜10のいずれかの項に記載の三次元形状造形物の製造方法。 11. Perform the measurement of the shape and the position of the shaped article formed so far just after just after or removal step of forming the sintered layer, on the basis of the measurement result, light for the formation of subsequent sintering layer method for producing a three-dimensionally shaped object according to any one of claims 1 to 10, characterized in that to correct the removal processing path data of the removed portion of the irradiation path data and subsequent removal steps of the beam .
  12. 【請求項12】 除去工程の前に未焼結粉末を固化させることを特徴とする請求項1〜11のいずれかの項に記載の三次元形状造形物の製造方法。 12. The method of manufacturing a three-dimensionally shaped object according to any one of claims 1 to 11, characterized in that solidifying the unsintered powder prior to removal process.
  13. 【請求項13】 未焼結粉末を冷凍にて固化させることを特徴とする請求項12記載の三次元形状造形物の製造方法。 13. The method of claim 12 three-dimensionally shaped object of wherein the solidifying in frozen unsintered powder.
  14. 【請求項14】 未焼結粉末を樹脂またはろう材にて固化させることを特徴とする請求項12記載の三次元形状造形物の製造方法。 14. The method of claim 12 three-dimensionally shaped object of wherein the solidified at unsintered powder resin or wax material.
  15. 【請求項15】 無機質あるいは有機質の粉末材料の層を形成する粉末層形成手段と、上記粉末層の所定箇所に光ビームを照射して該当個所の粉末を焼結して焼結層を形成する焼結層形成手段と、焼結層形成手段と焼結層との相対距離を調整する調整手段とを備えるとともに、造形物の表面部及びまたは不要部分の除去を行う除去手段を備えていることを特徴とする三次元形状造形物の製造装置。 15. A powder layer forming means for forming a layer of powder material of inorganic or organic, by sintering the powder of the relevant sections by irradiating a light beam to a predetermined portion of the powder layer to form a sintered layer a sintered layer forming means, with and an adjusting means for adjusting the relative distance between the sintered layer forming means and the sintered layer, that is provided with a removal means for removing the surface portion and or unnecessary portion of the shaped article apparatus for producing a three-dimensionally shaped object according to claim.
  16. 【請求項16】 未焼結粉末や除去手段による除去工程で発生する屑を排除する排除手段を粉末層形成手段に付設していることを特徴とする請求項15記載の三次元形状造形物の製造装置。 16. of claim 15 three-dimensionally shaped object according to the elimination means for eliminating the debris generated by the removal process by unsintered powder and removing means characterized in that it is attached to the powder layer forming means manufacturing device.
  17. 【請求項17】 未焼結粉末や除去手段による除去工程で発生する屑を排除する排除手段を備えるとともに該排除手段はXY駆動機構を有して造形物の断面輪郭形状に沿って排除作業を行うものであることを特徴とする請求項15記載の三次元形状造形物の製造装置。 17. The elimination work along section contour shape of the exhaust removal means shaped object has a XY drive mechanism provided with a removing means for eliminating the debris generated by the removal process by unsintered powder and removing means manufacturing apparatus according to claim 15 three-dimensionally shaped object of wherein a is performed.
  18. 【請求項18】 焼結層の形成直後もしくは除去工程の直後にそれまでに形成した造形物の形状及び位置の計測を行う計測手段と、計測手段による計測結果に基づいて焼結層形成手段の動作を補正する補正手段とを備えるとともに、上記計測手段は、XY駆動機構を有して造形物の断面輪郭形状に沿って計測を行うものであることを特徴とする請求項15〜17のいずれかの項に記載の三次元形状造形物の製造装置。 18. measuring means to measure the shape and position of the shaped article formed so far just after just after or removal step of forming the sintered layer, the sintered layer forming means on the basis of the measurement result by the measurement means together and a correcting means for correcting operation, the measuring means, any claim 15 to 17, characterized in that for performing the measurement along the cross-sectional profile shape of the shaped object has an XY drive mechanism apparatus for producing a three-dimensionally shaped object according to Kano section.
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