JP2003053846A - Laminate shaping apparatus and laminate shaping method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate shaping apparatus and a laminate shaping method capable of accurately shaping a support part into a necessary shape at a high speed and enabling the shaping of a three-dimensional article having sufficient mechanical strength. SOLUTION: The laminate shaping apparatus is equipped with a data input means for inputting slice image data formed at every preset pitch and support data for forming the support part, an image forming means for forming a thin layer on the basis of the slice image data, a support forming means for forming the support part on the basis of the support data, a lamination means for laminating the thin layer and the support part on a stage and a shaping control means for controlling the operations of the respective means.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention forms a thin layer having a preset layer thickness of a cross-sectional shape of the three-dimensional object on the basis of shape data of the three-dimensional object, and forms the thin layer. The present invention relates to a layered modeling apparatus that stacks on a stage to form a three-dimensional object, and more particularly to a layered modeling apparatus and a layered modeling method that form the thin layer by an electrophotographic method.

[0002]

2. Description of the Related Art Recently, for most manufacturing industries,
How to shorten the time from the start of development to the shipment of products, reduce the cost as much as possible, and quickly deliver the high-quality products that meet the needs of consumers at low cost is a major issue.

Therefore, in design and development work, CAD (Computer Aided) for efficiently creating drawings
Spread of Design system, especially 3D C
With the spread of AD (3D-CAD), a quick prototype that can shorten the product development period by directly forming a three-dimensional model (three-dimensional model) without machining the three-dimensional shape input on CAD Rapid prototyping as a manufacturing method has begun to attract attention.

Rapid prototyping (hereinafter referred to as RP method) is a method of laminating thin layers formed by cross-sectional shape data created by forming a three-dimensional shape at a preset pitch.
It is a generic term for methods of forming a three-dimensional model. For example, an optical molding method, a powder sintering method, a powder bonding method,
There are solid foundation curing methods and the like.

In the stereolithography method, when a photo-curable liquid resin material which is cured by irradiation with light is contained in a container and the liquid surface is irradiated with light of ultraviolet ray or visible light laser, the portion irradiated with light is irradiated. The resin is hardened to form a resin cured layer corresponding to the cross-sectional shape data. After that, a photo-curable liquid resin material is poured onto one surface of the formed resin cured layer so as to have a predetermined thickness, and a laser beam is applied to the liquid surface based on the next cross-sectional shape data. By repeating this, the resin cured layer is laminated, and the article shape as designed can be produced. The liquid resin material that has not solidified is used as a support portion that prevents the solidified portion from losing its shape.

In the powder sintering method, the liquid resin material in the above-mentioned stereolithography method is replaced with a powder resin material to form a powder layer having a predetermined thickness, and laser light is generated based on the cross-sectional shape data of an object to be formed. This is a modeling method in which the sintered powder layers are laminated while the powder is sintered in step. The unsintered powder remains as a support portion that supports the sintered portion, and prevents the sintered portion from being deformed when stacked.

In the powder bonding method, a powder layer having a predetermined thickness is formed as in the above-mentioned powder sintering method, and an adhesive is deposited or sprayed on the powder layer based on the sectional shape data of the object to be formed. This is a molding method of a system in which powder layers are laminated while selectively solidifying the powder by attaching. The powder that has not solidified remains as a support portion, and prevents the solidified portion from collapsing when stacked.

In the solid undercoating method, a master pattern is formed on the basis of the cross-sectional shape data to be formed, and this mask is laid over a resin layer coated with a photocurable resin and irradiated with ultraviolet rays, and after sufficient exposure. Absorb and remove the uncured resin layer. Further, it is a molding method of a system in which the concave portion formed by removing the photocurable resin is filled with wax, the wax is cooled, and the cured resin layer and the wax are cut into a predetermined thickness repeatedly.

However, these RP methods have various problems as described below. Since photo-curing liquid resin is used in the stereolithography method, not only the device or the entire room in which the device is installed needs to have a light-shielding structure that does not allow light to pass through. There is a problem that post-processing such as is complicated. Above all, there is a problem that the formation speed depends on the curing speed of the resin, and it takes a long time to form because the laser beam cannot be irradiated until the liquid surface becomes stable.

In the powder sintering method, in order to sinter the powder,
A high-power carbon dioxide (CO ₂ ) laser is often used, and the carbon dioxide laser device is unavoidably large in size due to its configuration, and not only requires a large installation area of the device itself, but also in the forming process, It is difficult to control the energy density and beam diameter of the carbon dioxide laser, and the sintering characteristics in the depth direction from the powder surface are not stable, so the modeling accuracy in the depth direction is poor, so it is difficult to obtain a strongly bonded model. However, there is a problem in that it takes time to spread the powder with a predetermined thickness in the tank of the modeling apparatus, and the productivity is poor.

Similar to the powder sintering method, the powder bonding method has a problem in that it takes time to spread the powder in a tank of a molding apparatus to a predetermined thickness, resulting in poor productivity. Since the body materials are only bonded by the adhesive, there is a problem that the molding accuracy is poor and it is difficult to obtain sufficient strength.

In the solid base curing method, noise is generated in the process of absorbing the excess photocurable resin, the resin in the fine molding portion is sucked in, or the excess resin is left in the details. Therefore, there is a problem that it is difficult to obtain a model with high modeling accuracy.

For the purpose of solving these problems and modeling a three-dimensional object with high modeling accuracy and high productivity, an electrophotographic process is used to produce a dielectric based on the cross-sectional shape data of the three-dimensional object. A technique related to a layered modeling method and a device for modeling a three-dimensional object by forming an electrostatic latent image on the surface and developing a sheet with a chargeable powder to form a thin layer on a stage is disclosed. 10-20719
No. 4 publication.

The layered manufacturing method and apparatus using this electrophotographic process can certainly form a three-dimensional object with high modeling accuracy and high productivity. The electrostatic latent image on the photoconductor based on the cross-sectional shape data of the three-dimensional object is developed with a chargeable powder made of resin powder as a modeling material instead of the toner of the material, and then heated to form a sheet. In the process of forming a sheet-shaped thin layer and repeatedly heating and laminating the sheet-shaped thin layer, some kind of support was required to prevent the shape from deforming or to support the sheet-shaped thin layer. In this case, since the molding material is only electrostatically charged powder, if the support member is made of electrostatically charged powder, the cross-sectional shape of the support part will be welded and the support member and cross-sectional shape cannot be distinguished. Work to separate the wood has been very difficult. That is, since the support portion cannot be formed by another means different from the means for forming the thin layer or another molding material, it is extremely difficult to form a complicated shape that requires the support portion.

[0015]

SUMMARY OF THE INVENTION In view of the above problems, the present invention provides an additive manufacturing apparatus and an additive manufacturing method using an electrophotographic process, which enables accurate molding at high speed with a shape requiring a support portion. In addition, various materials composed of thermoplastic or thermosetting resin can be applied as the chargeable powder, and the molded three-dimensional object can be colored according to the purpose of use such as development and trial production. An object of the present invention is to provide a layered modeling apparatus and a layered modeling method capable of modeling a three-dimensional object having sufficient mechanical strength.

[0016]

In order to solve the above-mentioned problems, the invention according to claim 1 presets a thin layer of the cross-sectional shape of the three-dimensional object based on the shape data of the three-dimensional object with a modeling material. In a layered manufacturing apparatus that forms a three-dimensional object by laminating the formed thin layer on a stage with a predetermined layer thickness, preset to form the thin layer based on the shape data of the three-dimensional object. Data input means for inputting slice image data created for each of the pitches, and support data for forming a support portion for supporting the thin layers for laminating the thin layers based on the slice image data, An image forming unit that forms the thin layer based on the slice image data, a support forming unit that forms the support unit based on the support data, and the thin layer and the support unit in front of each other. And laminating means to be stacked on the stage,
Modeling control means for controlling the operation of each means for forming a three-dimensional image.

By this, since the support forming means is provided separately from the image forming means for forming the thin layer, the support member adapted to the three-dimensional object to be formed can be promptly provided separately from the thin layer forming.
In addition, because it can be formed at an appropriate location, it can prevent the shape of thin layers from collapsing, efficiently support the lamination of thin layers, and easily form three-dimensional objects with complicated shapes with high mechanical strength and processing dimensional accuracy. Therefore, it is possible to provide a layered modeling apparatus capable of forming a three-dimensional object which is comparable to the product.

According to a second aspect of the present invention, in the first aspect of the invention, the image forming means includes latent image forming means for forming an electrostatic latent image on the surface of the photosensitive member based on the slice image data. And a developing means for developing the electrostatic latent image with a chargeable powder.

Thus, the latent image forming means and the developing means in the electrophotographic process can be used to rapidly and accurately form the thin layer based on the cross-sectional shape data with the chargeable powder.

According to a third aspect of the present invention, in the invention according to the first aspect, the support forming means includes a discharging means for discharging a support material.

Thus, the support material is not limited to the electrostatically-charged powder, but a material that is suitable for the discharging means and is selected according to the purpose of use, so that an appropriate support portion can be provided at an appropriate location. Can be formed in the process. In addition, when you want to evaluate the formed three-dimensional object in terms of design as well, in order to make the appearance similar to that of the product, you should use ejection means to replace the support material with ink and eject it onto the outer shape of the three-dimensional object. You can also color three-dimensional objects.

According to a fourth aspect of the present invention, in the first aspect of the present invention, the laminating means includes a transfer fixing means for transferring and fixing the thin layer onto the stage. .

As a result, the thin layer formed of the chargeable powder can be accurately and firmly laminated on the stage.

According to a fifth aspect of the invention, in the invention according to the fourth aspect, the transfer fixing means includes an image carrying means for conveying the thin layers to a stacking position and a heater means for heating and pressing the thin layers. It is characterized by having.

As a result, the thin layer formed of the chargeable powder is reliably conveyed to the position where it is heated and pressed by the heater means,
Instantly and firmly weld and stack with heater means. Moreover, since the heating is performed only once, the thin layer can be formed not only by the thermoplastic resin but also by the charging powder composed of the thermosetting resin, without limiting the kind of the resin.
It is possible to form a three-dimensional object with the same resin material as the resin used in the product.

According to a sixth aspect of the present invention, in the invention according to any one of the first to fifth aspects, the modeling control means is the shape of the three-dimensional object input to the data input means. Create slice image data sliced at desired pitches to form the thin layer based on the data or the cross-sectional shape data, and support the thin layer to stack the thin layers based on the slice image data. A three-dimensional image is provided by providing data creating means for creating support data for forming a support part, and controlling the image forming means, the support forming means and the laminating means by the slice image data created by the data creating means and the support data. It is characterized in that an object is formed.

Thus, the slice image is not limited to the input cross-sectional shape data, but is selected, for example, by selecting the layer thickness of a thin layer, and the slice image conforming to the forming conditions regarding the characteristics of the additive manufacturing apparatus or the forming material. Since the three-dimensional object can be formed by changing the data, it is possible to easily form a three-dimensional object having a complicated shape with high mechanical strength and processing dimensional accuracy according to the purpose of use.

According to a seventh aspect of the present invention, in the invention according to any one of the first to sixth aspects, the modeling control means includes the shape of the three-dimensional object input to the data input means. In order to stack the thin layer on the stage based on the data or the cross-sectional shape data, an arrangement search means for searching the arrangement direction of the three-dimensional object that minimizes the formation of the support part is provided, and the arrangement search means detects Based on the arranged arrangement, by the data creating means to create slice image data sliced at a desired pitch to form the thin layer, based on the slice image data the thin layer to stack the thin layer Support data for forming a support portion for supporting the image formation is performed by the slice image data and the support data created by the data creating means. Means to control the support-forming means and laminating means is characterized in that so as to form a three-dimensional object.

As a result, the support member for the modeled object to be laminated on the stage can be minimized, and a stable arrangement can be obtained in which the modeled object does not fall down, so that the model can be reliably and firmly laminated on the stage, and the support The time required for forming parts can be shortened, and rapid and efficient three-dimensional modeling can be performed.

According to an eighth aspect of the present invention, a thin layer having a preset layer thickness is formed in a cross-sectional shape of the three-dimensional object on the basis of shape data of the three-dimensional object with a molding material, and the thin layer is formed. In a layered manufacturing method of stacking a plurality of objects on a stage to form a three-dimensional object, slice image data and the slice created at every preset pitch for forming the thin layer based on the shape data of the three-dimensional object. A data input step of inputting support data for forming a support portion for supporting the thin layers for laminating the thin layers based on image data; and an image forming step of forming the thin layers by the slice image data. A support forming step of forming the support part based on the support data, and a stacking step of stacking the thin layer and the support part on the stage. And butterflies.

As a result, an accurate thin layer can be formed by using the electrophotographic process, an appropriate support portion can be formed, and a three-dimensional object having a complicated shape with high mechanical strength and processing dimensional accuracy can be easily formed. It is possible to provide an additive manufacturing method that can be performed.

[0032]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

FIG. 1 is an overall schematic view of the additive manufacturing apparatus of the present invention. FIG. 2 is a block diagram of a circuit configuration of the additive manufacturing apparatus of the present invention. FIG. 3 is a cross-sectional view of a modeled object formed by the layered modeling apparatus of the present invention.

The structure of the layered manufacturing apparatus of the present invention will be described with reference to FIG. In the figure, reference numeral 10 is an image forming means for forming a three-dimensional cross-sectional shape into a thin layer by a charging powder, 20 is an intermediate transfer member as a carrier for carrying the thin layer formed in the cross-sectional shape, and 30 is A stage to which a thin layer is transferred from the intermediate transfer body 20, 40 is a planar heater means as a transfer fixing means for transferring and fixing the thin layer carried by the intermediate transfer body 20 onto the stage 30, and 50 is a supporting means. , For example,
Discharging means for discharging a support material to form a support portion, 6
Reference numeral 0 is a transfer belt cleaner for cleaning the surface of the transfer belt 21 used as the intermediate transfer member 20.

In the present embodiment, the image forming means 10
In order to form the chargeable powder into a three-dimensional cross-sectional shape with a preset thickness by the electrophotographic method.
1, a latent image forming means including a charger 12, an exposure optical member 13 and the like, and a developing means including a developing device 14, a transfer roller 15, a cleaner 16, a separating electrode 17 and the like.

The photoconductor 11 is formed by forming a photoconductive layer of a conductive layer and an organic photosensitive layer (OPC) on the outer circumference of a cylindrical base. The photoconductor 11 is rotated in the counterclockwise direction indicated by the arrow A with the conductive layer grounded by the power from a drive source (not shown) or by following the transfer belt 21 of the intermediate transfer body 20.

The charging device 12 is, for example, a scorotron charging device, and is attached in close proximity to the photoconductor 11 in a direction orthogonal to the moving direction of the photoconductor 11 by corona discharge having the same polarity as the chargeable powder. , A uniform potential is applied to the photoconductor 11.

The exposure optics 13 performs image exposure on the photoconductor 11 uniformly charged by the charger 12 based on the three-dimensional sectional shape data to be formed to form an electrostatic latent image on the photoconductor 11. As the image exposing means, for example, a scanning optical system for scanning with laser light using a laser diode or the like as a light emitting source is provided in parallel with the rotation axis of the photoconductor 11 by a polygon mirror or the like.

The developing device 14 has a magnet body built in a case containing a charging powder, and is regulated to a constant layer thickness by a developing sleeve 14a as a carrier that holds and rotates the charging powder. The electrostatic latent image formed on the photoconductor 11 is developed by being conveyed to the developing area.

The developing sleeve 14a in the developing area
The gap between the photoconductor 11 and the photoconductor 11 is larger than the layer thickness of the charging powder.
However, there is no direct current between the developing sleeve 14a and the photosensitive member 11.
Pressure V _DCAC voltage V_ACAC bias voltage with
Add

The charge of the chargeable powder has the same polarity as the DC voltage V _DC, and the chargeable powder, which is triggered by the AC voltage V _AC to separate from the developing sleeve 14a, has an absolute potential higher than that of the DC voltage V _DC. It does not adhere to the high-value V _H part,
The amount of chargeable powder corresponding to the potential difference adheres to the portion of V _L where the absolute value of the potential is low, and the image is visualized (developed). Further, only the DC voltage V _DC may be applied between the developing sleeve 14a and the photoconductor 11.

The development is preferably non-contact development, but contact development may also be used as long as it does not adversely affect the image formation by the charged powder during development.

Since the chargeable powder is used for development by the electrophotographic method, it has a small particle size (several μm to 20 μm).
Degree), chargeability and fixing performance (melt adhesion performance). Further, it is preferable that the material is strong enough to be used as a prototype of a device component after being fixed, laminated and three-dimensionally molded.

As such a material, a thermoplastic resin powder having a small particle size can be used. ABS resin is mentioned as a preferable thermoplastic resin.

In this embodiment, as the chargeable powder, an ABS resin containing silica and titania as an additive is pulverized to have an average particle size of 10 to 13.67 μm. The ABS resin may be crushed into pellets and used as it is, but it is preferable to melt-knead well-known additives in order to impart charging performance and fixing performance, and then crush.

In the present embodiment, mono-color three-dimensional modeling using one type of charging powder is used, but the present invention is not limited to this, and charging of a plurality of colors such as magenta, cyan, yellow and black is possible. It is also possible to make a full-color layered modeling apparatus by applying the permeable powder and a plurality of image forming means.

Further, since the layered manufacturing apparatus of the present invention heats and presses only once at the time of transfer / fixing described later, it is possible to use not only the thermoplastic resin powder but also the thermosetting resin powder. is there. Further, a powder containing ceramics, a metal, etc., made of a thermoplastic resin is used as a chargeable powder, and then the powder is fired in another step to form a molded product having the same strength as that of the ceramic or the metal. You can also

The transfer roller 15 is provided so as to face the photoconductor 11 with the transfer belt 21 interposed therebetween, and forms a transfer region (no reference numeral) between the transfer belt 21 and the photoconductor 11.

A transfer bias composed of a DC voltage having a polarity opposite to that of the chargeable powder (no reference sign) is applied to the transfer roller 15 to form a transfer electric field in the transfer area, whereby the chargeable powder on the photoreceptor 11 is charged. Is transferred onto the transfer belt 21.

The separation electrode 17 is a charge eliminating means, preferably a corona discharger, for eliminating the charge on the transfer belt 21 charged by the transfer roller 15.

The cleaner 16 is the photosensitive member 1 after transfer.
The chargeable powder remaining on the peripheral surface of No. 1 is scraped off by the blade 16a and cleaned.

As a means for laminating thin layers, the intermediate transfer member 2 is used.
0, stage 30, sheet heater means 40, discharge means 5
It is composed of 0 and the like.

The intermediate transfer member 20 has a function as an image carrier, and conveys to the next step in a state of holding the thin layer developed with the charging powder based on the sectional shape data. The structure is simple and a great degree of freedom can be given to the mechanical layout design of the additive manufacturing apparatus.
Is used.

The transfer belt 21 includes rollers 22a and 22b.
And 22c are circumscribed and circumscribed, and at the time of forming the cross-sectional shape of the charging powder, a thin layer of the charging powder formed on the photoconductor drum 11 by the transfer roller 15 is formed by a drive motor (not shown). Is transferred to the transfer belt 21 while being rotated in the direction indicated by the arrow B in the figure by the driving force of the above, and is conveyed to the next step.

The transfer belt 21 has a volume resistivity of 1
0 ⁸ to 10 ¹² Ω · cm, surface resistivity of 10 ⁸ to 10 ¹² Ω /
□, for example, modified polyimide, thermosetting polyimide,
Conductive material dispersed in engineering plastics such as ethylene tetrafluoroethylene copolymer, polyvinylidene fluoride, nylon alloy, etc., thickness 0.1-1.0 m
A two-layered seamless belt was used, in which a fluorine coating having a thickness of 5 to 50 μm was preferably applied as a toner filming preventing layer on the outside of the semi-conductive film substrate of m. In addition to this, the transfer belt 21 has a thickness of 0.1% obtained by dispersing a conductive material in silicon rubber or urethane rubber.
It is also possible to use a semi-conductive rubber belt of 5 to 2.0 mm.

The sheet heater means 40 is used for the transfer belt 21.
The entire surface of the thin layer (M3) carried on the substrate is uniformly heated via the transfer belt 21, and the fixed thin layer (M1) or the fixed thin layer (M1) is stacked on the stage 30.
There is no particular limitation as long as it can press against the fixed thin layer (M2) laminated thereon. For example, a planar heating element in which a heating element such as a nichrome wire is sandwiched with polyethylene terephthalate resin or the like as a support, A ceramic heating element or the like is used.

A magnetic heating element may be used for the sheet heater means 40. The magnetic heating element generates an alternating magnetic field by the lines of magnetic force generated by the electromagnetic induction element to generate heat.
Examples of the electromagnetic induction element include a combination of a magnetic core and an exciting coil portion wound around the magnetic core. A magnetic field line is generated from the magnetic core by passing a current through the exciting coil section. Then, inside the plate-shaped magnetic heating element,
An AC magnetic field of about 0.5 to 50 kHz is formed, and the magnetic heating element generates heat due to the eddy current in the magnetic heating element generated by the AC magnetic field. The electromagnetic induction element and the magnetic heating element are arranged in contact with each other or slightly apart from each other by about 0.5 to 2 mm.

Needless to say, the heater means is not limited to the planar heater means 40, and a heating roll may be applied from the back side of the sheet member having heat conductivity.

The transfer belt cleaner 60 is for cleaning the charging powder remaining on the transfer belt 21 with the cleaning roller 61, and is preferably equipped.

The discharging means 50 discharges a support material based on the support data in order to support the thin layers or prevent the shape from being deformed in the process of laminating the thin layers developed by the electrostatically charged powder. For example, when the distance between the thin layer stacking surface 30a of the stage 30 and the thin layer to be stacked is large, a base for supporting the thin layer on the stage 30 is necessary. When a support part is formed or a space is created between thin layers, the support part is formed as a filling material that fills the space and is necessary to support the shape so that it does not collapse. A support portion is formed as a bridge for supporting various portions. For example, hot-melt ink, oil-based ink, or ink that ejects water-based ink to print images or characters on paper, etc. Use ejection device known in Ettopurinta is for discharging the support member in place of these inks.

Examples of the support material include a molten resin obtained by melting a thermoplastic resin, wax, or an adhesive,
As the application, for example, the molten resin can be used for the support part as the above-mentioned base, the wax can be removed by melting after molding, so the support part as the above-mentioned filling material, the adhesive can be used for the support part as the above-mentioned bridge, In order to efficiently form the support, it is possible to provide a discharge means for discharging various support materials for each application, or to discharge the same kind of support material by a plurality of discharge means.

Further, by utilizing this discharging means, it is possible to discharge ink as required to color the modeled object. Needless to say, the usage of the support material and the discharging means is not limited to this.

The stage 30 serves as a base body having a thin layer laminating surface 30a for laminating a thin layer made of electrostatically charged powder conveyed by the transfer belt 21 and a support material, and the transfer belt 21 is sandwiched therebetween. The thin layers are stacked on the thin layer stacking surface 30a of the stage 30 by heating and pressing the thin layers by the sheet heater means 40. Then, each time the thin layers are stacked, the stage 3 is formed by the thickness of the thin layers, for example, 20 μm.
By moving the thin layer laminated surface 30a of 0 in the direction away from the planar heater means 40 in FIG. 1, the distance moved by the planar heater means 40 for heating and pressing is always kept constant.

M1 is the thin layer stacking surface 3 of the stage 30.
0a is a thin layer made of a chargeable powder or a support material, M2 is a fixed thin layer stacked on the stage 30 and a fixed thin layer is stacked on M1, and M3 is carried by the transfer belt 21. It is a thin layer in the as-deposited state.

In the three-dimensional modeling by the layered manufacturing apparatus of the present invention, the thin layer M3 made of the chargeable powder is completely released from the transfer belt 21 especially in the transfer / fixing process on the thin layer stacked surface 30a of the stage 30. However, it is necessary to surely melt and adhere to the thin layer M2 which has been fixed without tearing or omission, and in order to carry out the stacking surely and accurately, the surface state adapted to the material characteristics of the electrostatic powder is required. It goes without saying that it is necessary to appropriately set the heating temperature and pressure of the heater means 40, the heating and pressing time, and the like.

The circuit configuration of the layered modeling apparatus of the present invention will be described with reference to FIG. Reference numeral 200 is a 3D-CAD (hereinafter referred to as CAD), which designs a solid object to be created, creates shape data, cross-sectional shape data, support data, etc. of the solid object, and adds them to the additive manufacturing apparatus of the present invention. It is a device that outputs various data.

Reference numeral 100 denotes a modeling control circuit which is a modeling control means of the layered modeling apparatus of the present invention, and includes a CPU 110 which controls the entire layered modeling apparatus, and an image formation control circuit which controls a latent image forming circuit 121 and a developing circuit 122. 120, transfer fixing circuit 131, stage circuit 132, and support circuit 1
A data creation circuit 140 that corrects or changes data based on various data input from the CAD 200, such as the stacking control circuit 130 that controls 33 and the CAD 200, for example, slice data and support data. , Data such as shape data, cross-sectional shape data, or support data input from the CAD 200, control information input from the operation input unit 170, and the like,
An information control circuit 150, which is a data input unit for storing data in the memory 160 or inputting control information to the CPU 110, a memory 160 for storing input data, created data or control information, and a necessary A power supply circuit 190 for supplying power to various circuits and various means,
And an interface (I / F) as a connector for inputting data from the CAD 200 to the modeling control circuit 100
It is composed of 180 and the like.

The I / F 180 is an interface necessary for inputting various data output from the CAD 200 to the modeling control circuit 100. For example, a USB (Uni)
Versal Serial Bus) type and SCS
I (Small Computer System In
interface type, etc., and is appropriately used in consideration of the amount of data, the transfer rate, the data processing performance of the connected device, and the like.

The information control circuit 150 discriminates whether it is the data input from the CAD 200, the data input from the operation input means 170, or the control information, and, for example, the shape data of the three-dimensional object input from the CAD, When it is determined that the data is the cross-sectional shape data or the support data, the data is stored in the memory 160 according to the memory address preset corresponding to the type of the data.

Further, the data inputted from the operation input means 170 is stored at a memory address different from the data inputted from the CAD 200 of the memory 160, so that the data is not confused with each other, and when necessary. It is easy to read.

In the case of control information, the control information controls the operation of the CPU 110 and the like, and is stored in a predetermined address of the memory 160 as a record of the control input from the operation input means 170. , For example, when there is a problem in the operation of the circuit or image formation,
You can browse.

The CPU 110 stores a plurality of types of control programs in consideration of modeling conditions such as the function and performance data of the layered modeling device or the characteristic data of the modeling material in order to control the operation of the layered modeling device, and the memory 160. The type of the data stored in the memory 160 is discriminated from the memory address of the memory 160 and output, and appropriate control is performed according to operation information such as operation start, operation, operation completion or operation state from various circuits. ing.

The CPU 110 first operates the information control circuit 150, which is a data input means, inputs data from the CAD 200, determines the type of the input data, and determines the function and performance data of the layered modeling apparatus or the characteristics of the modeling material. The data creating circuit 140 is created according to the molding conditions based on the data and the like.
Control to create various data required for additive manufacturing.

For example, when the input data is shape data of a three-dimensional object, the data creation circuit 140 first creates slice image data with a layer thickness preset according to the modeling conditions suitable for the additive manufacturing apparatus. After that, support data based on the slice image data is created.

When the input data is the cross-sectional shape data, it is determined whether or not the cross-sectional shape data has a layer thickness according to the molding conditions suitable for the additive manufacturing apparatus. Create the slice image data using the data as it is, and if it is not compatible, create slice image data by changing the cross-sectional shape data with an adapted layer thickness, and generate the support data based on the created slice image data. create.

The data generating circuit 140 of the present invention is
For the purpose of correcting and changing the slice image data when maintaining and controlling the accuracy of the additive manufacturing equipment or using a molding material that is different from the one that is normally used, for example, a layer that is the result of measurement after forming a modeling sample. The thickness data is converted into electrical data by converting the numerical value indicating the layer thickness input by the operation input unit 170 configured by a keyboard or the like, and input into the data creation circuit through the information control circuit 150, thereby obtaining the data. Since the creating circuit 140 is capable of creating slice image data based on the input layer thickness, stable and highly accurate modeling can be performed.

Further, the data generating circuit 140 of the present invention is
Based on the shape data and the cross-sectional shape data input from the CAD 200, the layout that minimizes the support section is calculated to create slice image data so that the formation of an extra support section does not occur and the molding time does not increase. I have to.

Based on the slice image data created by the data creating circuit 140 and the support data, the CP
U110 is the image formation control circuit 120 or the stacking control circuit 130.
A three-dimensional object is formed by controlling the.

The image forming control circuit 120 inputs the slice image data from the data forming circuit 140 and operates the latent image forming circuit 121 and the developing circuit 122 to form a thin layer based on the slice image data.

The latent image forming circuit 121 controls the latent image forming means such as the photosensitive drum 11, the charger 12, the exposure optical member 13 and the like for forming a latent image by the electrophotographic process method based on the slice image data, The developing circuit 122 controls a developing device including a developing device 14, a transfer roller 15, a cleaner 16, a separation electrode 17 and the like for developing a latent image with a chargeable powder to form a thin layer.

The stacking control circuit 130 is the data creation circuit 1
By inputting slice image data or support data from 40, the transfer / fixing circuit 131, the stage circuit 132 and the support circuit 133 are operated, and thin layers are laminated to form a three-dimensional object.

The transfer / fixing circuit 131 has a heating and pressing operation of the sheet heater means 40, that is, the sheet heater means 40.
Temperature control, pressing drive, and heating pressing time are controlled, the stage circuit 132 controls the movement timing and the movement amount of the stage 30, and the support circuit 133 discharges a support material, for example, a support material as a support means. The operation of the ejection means 50 for forming the is controlled.

In FIG. 3, M is an example of a modeled object stacked on the thin layer stacking surface 30a of the stage 30, and S1 and
S2 and S3 are support parts made of a support material discharged by the discharging means 50.

S1 and S3 are support parts formed as a base for laminating thin layers, and S2 is a support part formed as a filling. Then, in selecting the support material, the use and condition of the support portion, for example, S1 and S3
Considering the yield strength when supporting a thin layer as a base and the removability after modeling, or the strength and workability when it needs to be removed as a filling, the support material can be a molten resin, an adhesive, or a wax. It is necessary to select such as. In particular, since S2 needs to be removed after it is completed as a molded article, it is preferable to use wax as a support material.

In this embodiment, since the mass of the modeled object is light and the support part as the filling is required, only the wax is used as the support material and the support material is discharged finely from the discharging means 50. Although the support part was formed by doing so, in order to improve the efficiency of the three-dimensional modeling work, the rougher one can shorten the time for forming the support part and the time for removing the support part, so it is possible to support thin layers to be laminated. Therefore, it is preferable to make it as coarse as possible.

The additive manufacturing method by the additive manufacturing apparatus of the present invention will be described step by step with reference to FIGS. 1 and 2.

In reality, shape data, cross-sectional shape data, support data, reference data such as modeling conditions, etc. are transferred from the CAD 200 according to conditions such as the function and performance of the additive manufacturing apparatus or the form of the modeled object. In the description of this embodiment, it is assumed that at least cross-sectional shape data is transferred. Then, regarding data other than the cross-sectional shape data, description will be added regarding processing and operation different from the processing of the cross-sectional shape data.

In the shape data, the shape of the three-dimensional object is CA.
The cross-sectional shape data is data when converted into three-dimensional data by D, and the cross-sectional shape data is data regarding the shape of the cross section when the shape data is sliced with a preset constant thickness,
It can be easily obtained by using general purpose three-dimensional design drawing (3D-CAD drawing) creation software.

Further, the slice image data is data for forming a thin layer from the chargeable powder by the additive manufacturing apparatus, and when the cross-sectional shape data conforms to the forming conditions by the additive manufacturing apparatus, the slice image data is sliced as it is. Used as image data. The support data is the same as the slice image data, and C
If the support data created on the AD side meets the modeling conditions of the additive manufacturing apparatus, it is used as it is as the support data.

In step 1, the CAD 200 and the modeling control circuit 100 of the layered modeling apparatus of the present invention are electrically connected via the interface (I / F) 180, and the power source operating means (not shown) of the layered modeling apparatus. Then, the power supply circuit 190 of the additive manufacturing apparatus is turned on and activated. Then, the operation input means 170 is operated to start the modeling control circuit 100 in the operating state, and the data can be input from the CAD 200.

In step 2, the operation input means 170 of the additive manufacturing apparatus is operated to start reading data from the CAD 200.

When the cross sectional shape data of the three-dimensional object is transferred from the CAD 200 to the information control circuit 150 via the I / F 180, the information control circuit 150 stores the cross sectional shape data at a predetermined address of the memory 160.

The cross-sectional shape data may include reference data such as pitch data (layer thickness data) obtained by slicing a three-dimensional object, modeling material data, or processing conditions. Reference data is also attached. When it comes, it is stored in a predetermined address of the memory 160 together with the cross-sectional shape data. Similarly, when shape data, support data, etc. are input, they are also stored in a predetermined address of the memory 160.

At step 3, the CPU 110 determines that the sectional shape data is stored in the memory 160,
Instruct to create support data.

In step 4, the data creation circuit 140
The cross-sectional shape data stored in the memory 160 is read out, and the reference data that has been transferred and the additive manufacturing apparatus according to the forming conditions based on the function and performance data of the additive manufacturing apparatus or the characteristic data of the forming material stored in the CPU 110 are used. It is determined whether the cross-sectional shape data is based on the layer thickness according to the modeling conditions that conform to the above, and if the data is compatible, the data is created as slice image data. The slice shape data is created by converting the cross-sectional shape data based on the adapted layer thickness calculated by the above, and the support data is created based on the created slice image data.

Incidentally, when the support data is input together with the cross-sectional shape data, first, the cross-sectional shape data is discriminated in the same manner as described above. In the case of conforming data, the data is created as slice image data and conformed. If not, the slice shape data is created by converting the cross-sectional shape data based on the matched layer thickness calculated by the molding conditions and the like. Then, when the cross-sectional shape data is the above-mentioned conforming data, for example, it is checked whether or not the input support data has a defect, and if there is no defect, the input support data is stored as new support data in the memory. It is stored in 160. If the cross-sectional shape data is not the above-mentioned conforming data, the support data is created based on the slice image data created by converting the cross-sectional shape data as described above.

Of course, it is understood that the input cross-sectional shape data and support data are data created in advance under the modeling conditions and the like adapted to the additive manufacturing apparatus.
In the case of modeling by an additive manufacturing apparatus that is not equipped with the data generation circuit 140, or when it is known that the data can be discriminated by adding an identification symbol or the like to these data and the data is compatible, the input cross section is immediately input. The shape data and the support data may be used as the slice image data and the support data.

When the input data is the shape data of the three-dimensional object, slice image data is created with a layer thickness preset according to the molding conditions and the like, and support data is created based on the created slice image data. .

Further, in the case of maintaining the accuracy of the layered modeling apparatus or using a modeling material different from the normally used modeling material, for example, the operation input means 170 is used for the purpose of correcting or changing the slice image data. The data creating circuit 140 creates slice image data according to the entered layer thickness by inputting the layer thickness input by the keyboard or the like to the data creating circuit via the information control circuit 150, and the created slice image data Create support data based on.

Further, the data creating circuit 140 of the present invention is
Since the slice image data is created by calculating the minimum layout of the support parts, it is possible to prevent an increase in modeling time due to the formation of the extra support parts.

In the present embodiment, the thickness of the thin layer of the charging powder layer after transfer / fixing on the stage 30 is 2 mm.
Since it was designed to perform development, transfer and fixing so that it would be 0 μm, the cross-sectional shape data shows that the solid to be modeled is 20 μm.
Slice image data was obtained by slicing at thicknesses of m.

In step 5, the slice image data and the support data created by the data creating circuit 140 are stored in the memory 1.
When the data is stored at a predetermined address of 60, the CPU 110 receives the data storage completion information from the data creating circuit 140, operates the image forming control circuit 120 and the stacking control circuit 130, and operates the image forming unit 10, the intermediate transfer body 20, and the stage. Three
0, the operation of the laminating means constituted by the sheet heater means 40, the discharging means 50 and the like is started.

In step 6, the image forming control circuit 120
First starts the operation of the latent image forming circuit 121, rotates the photoconductor drum 11 in the direction of arrow A, charges the photoconductor drum 11 by the charger 12, and the first slice stored in the memory 160. The exposure optical system 13 is operated based on the image data to form a latent image on the charged photosensitive drum 11.

In step 7, the image forming control circuit 120 operates the developing circuit 122, and the developing device 14 develops the latent image on the photosensitive drum 11 with the chargeable powder to form a thin layer.

In step 8, the CPU 110 receives the development completion information indicating that the development is completed from the image formation control circuit 120, instructs the stacking control circuit 130 to start driving the transfer belt 21, and the stacking control circuit 130. When the transfer belt 21 rotates in the direction of the arrow B by operating the transfer fixing circuit 131, the thin layer formed on the photoconductor drum 11 is transferred onto the transfer belt 21 by the transfer separation operation of the transfer roller 15 and the separation electrode 17. Transcribe.

In the present embodiment, the charging property is set so that the laminated layer thickness is 20 μm in consideration of the shrinkage due to heating and pressurization by the planar heater means 40 at the time of transfer fixing described later. The thin layer at the time of development and transfer with the thermoplastic ABS resin powder used as the powder was designed to have a layer thickness of about 40 μm.

At step 9, the CPU 110 instructs the stacking control circuit 130 to form the support portion. The stacking control circuit 130 operates the support circuit 133, and interlocks with the moving speed of the transfer belt 21, and on the thin layer or thin layer on the transfer belt 21 based on the support data created by the data creation circuit 140 by the ejection unit 50. The support material is discharged toward a predetermined area around the layer to form the support portion. Of course, when there is no support data, the support circuit 133 does not operate the ejection means 50.

In the present embodiment, wax is used as the support material because it can be melted and removed after shaping, but a molten resin obtained by melting a thermoplastic resin to form the base or the support portion as a bridge is used. It is also possible to selectively use an adhesive or the like according to the purpose. Further, when it is necessary to apply coloring, it is possible to perform coloring by ejecting ink of a desired color as the support material by the ejection means 50.

As described above, in order to properly use the support material, it is easier to control the discharge by providing a plurality of discharge means 50 for each support material to be discharged, which is convenient for the maintenance of the discharge means 50. If the discharge means 50 can be replaced according to the purpose, it can be used for more purposes and is convenient for maintenance.

In step 10, detection means (not shown)
Detects that the thin layer and the support portion formed on the transfer belt 21 have reached a predetermined position facing the stage 30, and outputs the detection information to the stacking control circuit 130,
The stacking control circuit 130 operates the transfer / fixing circuit 131 in response to the input of the detection information of the detection means to transfer the transfer belt 21.
Stop driving.

In the present embodiment, the stop control of the transfer belt 21 is performed by using the detection means. However, for example, a pulse motor is used as the drive means of the transfer belt 21 to start or stop the movement of the transfer belt 21. The control such as the above may be controlled by other control methods such as a sequence control method in which the operation distance is controlled by a preset number of pulses or the like.

In step 11, the stacking control circuit 130 activates the transfer and fixing circuit 131, and the sheet heater means 40 is operated.
The temperature of is raised to a predetermined temperature. Then, when the temperature detecting means (not shown) detects that the heater of the planar heater means 40 reaches a predetermined temperature, the transfer fixing circuit 13
No. 1 is laminated by driving the sheet heater means 40 in the direction of the stage 30 and heating and pressing the thin layer on the transfer belt 21 and the support material on the thin layer laminating surface 30a of the stage 30 for a predetermined time. .

Further, the thin layer and the support material (eg, the thin layer) already stacked on the thin layer stacking surface 30a of the stage 30 (for example,
If there is M1 or M2), the thin layer and the support material on the transfer belt 21 are heated and pressed against the thin layer and the support material, and are instantly melt-bonded and laminated.

In the present embodiment, the transfer / fixing condition of the sheet heater means 40 is preferably set so that the viscosity of the chargeable powder is in the rubber region, and the surface temperature is 220 ° C. Pressing force 50N, pressing time 0.
1 second was set.

In step 12, the stack control circuit 130.
When the heating and pressing operation of the sheet heater 40 for a predetermined time is completed, the sheet heater 40 is moved to the initial position and stopped, and the transfer belt 21 is rotated again so that the transfer belt cleaner 60 moves the transfer belt 21 onto the transfer belt 21. After removing the remaining thin layer and the remaining layer of the support material, the driving of the transfer belt 21 is stopped.

In step 13, the stage circuit 132 is driven to move the stage 30 in the direction away from the planar heater means 40 by an amount (20 μm in the present embodiment) corresponding to the layer thickness of the thin layer on which the stage 30 is laminated. 30 is moved, the amount of movement of the planar heater means 40 is always constant,
In addition, the position of the stage is controlled so that stacking can be performed by a stable heating and pressing operation.

At step 14, the CPU 110 operates the image forming control circuit 120 and the stacking control circuit 130 so as to shift to the second image forming operation based on the second slice image data stored in the memory 160. The operation of the image forming means 10 and the laminating means is started. And CP
U110 causes each means to repeatedly perform the modeling operation of the solid object based on all the slice image data and the support data stored in the memory 160, and the operation based on all the slice image data and the support data stored in the memory 160. When it is determined that the process has ended, the operation of the additive manufacturing apparatus is completed.

In step 15, when the CPU 110 finishes the operation based on all the slice image data and the support data and completes the modeling operation of the three-dimensional object, another sectional shape data and the like is newly read from the CAD 200, and another sectional shape data is read. The system waits for an instruction to execute or terminate the modeling operation of a three-dimensional object. Therefore, if "new" is input by the operation input means 170, the process jumps to step 2, and the modeling operation of the three-dimensional object can be executed based on the new data, and if "end" is input by the operation input means 170, the layered manufacturing apparatus. The operation can be terminated, and the power source operation means (not shown) of the additive manufacturing apparatus can cut off the power supply circuit 190 of the additive manufacturing apparatus.

In the layered manufacturing apparatus according to the embodiment of the present invention, the data forming circuit 140 is provided, and it is possible to input the cross-sectional shape data created by CAD and use it as it is as the slice image data. Correct or change the cross-sectional shape data according to the molding conditions, or input the shape data of the three-dimensional object from CAD, and then slice it to the desired thickness to create slice image data, or put it on the stage. It is also possible to create the necessary data such as the efficient placement of shaped objects.

This is because, when a three-dimensional object is molded as a molded object, in order to ensure that the mechanical strength, accuracy, etc. of the molded object are formed as expected, the functions and performances of the additive manufacturing apparatus to be used, etc. This is because it is possible to respond promptly when it is necessary to correct or change the conditions such as the thickness to be sliced due to the modeling conditions such as the restrictions due to the characteristics of the molding material used, and the like. Similarly, in the support data, in some cases, the modeled object cannot be formed only by the slice image data, and in the process of forming and laminating the thin layer based on the slice image data, the thin layer is used to hold the thin layer so as not to support or collapse. This is because, when it becomes necessary to form the support portion, it is necessary to correct, change, or create the support data for forming the support portion at the place where the support is required.

Further, in an attempt to improve efficiency such as shortening of modeling time, it may be possible to shorten the time for forming the support portion by minimizing the thin layer support portion laminated on the stage. In some cases, it may be necessary to review the layout of the modeled object in consideration of the modeling apparatus used and the method of laminating thin layers on the stage.

As described above, it is desirable that the layered manufacturing apparatus be provided with the ejection means 50 as the support means and also be equipped with the data creation circuit 140 so as to be applicable to all cases.

[0123]

In the layered manufacturing apparatus and the layered manufacturing method using the electrophotographic process, since the support forming means is provided separately from the image forming means for forming the thin layer, it is possible to form the shape requiring the support portion at high speed. Can be shaped with high accuracy,
In addition, various materials composed of thermoplastic or thermosetting resin can be applied as the chargeable powder, and the molded three-dimensional object can be colored enough for the purpose of use such as development and trial production. It is possible to provide a layered modeling apparatus and a layered modeling method capable of modeling a three-dimensional object having mechanical strength.

[Brief description of drawings]

FIG. 1 is an overall schematic view of an additive manufacturing apparatus of the present invention.

FIG. 2 is a block diagram of a circuit configuration of the additive manufacturing apparatus of the present invention.

FIG. 3 is a cross-sectional view of a modeled object formed by the layered modeling apparatus of the present invention.

[Explanation of symbols]

10 Image forming means 20 Intermediate transfer body 30 stages 40 Planar heater means 50 discharging means 60 Transfer belt cleaner 100 modeling control circuit 110 CPU 120 image formation control circuit 130 Stacked control circuit 140 data creation circuit 150 information control circuit 160 memory 170 Operation input means 180 interface (I / F) 190 power supply circuit 200 3D-CAD

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Hiroshi Yamaguchi             Konica Stock Market, 1 Sakura-cho, Hino City, Tokyo             In-house (72) Inventor Hitoshi Morimoto             Konica Stock Market, 1 Sakura-cho, Hino City, Tokyo             In-house F-term (reference) 4F213 AA44 AC03 WA25 WA97 WB01                       WL02 WL27 WL32 WL74 WL85                       WL96

Claims (8)

[Claims] 1. A thin layer having a preset layer thickness of the cross-sectional shape of the three-dimensional object is formed by a molding material based on the shape data of the three-dimensional object, and the formed thin layer is laminated on a stage. In a layered manufacturing apparatus for forming a three-dimensional object, slice image data created at each preset pitch for forming the thin layer based on the shape data of the three-dimensional object, and the thin image based on the slice image data. Data input means for inputting support data for forming a support portion for supporting the thin layer for stacking layers, image forming means for forming the thin layer by the slice image data, and the support data Support forming means for forming the support portion, stacking means for stacking the thin layer and the support portion on the stage, and each means for forming a stereoscopic image A layered modeling apparatus including a modeling control unit that controls the operation of the. 2. The image forming means includes a latent image forming means for forming an electrostatic latent image on the surface of a photoreceptor based on the slice image data, and a developing means for developing the electrostatic latent image with a chargeable powder. The additive manufacturing apparatus according to claim 1, further comprising: 3. The additive manufacturing apparatus according to claim 1, wherein the support forming unit includes a discharging unit that discharges a support material. 4. The additive manufacturing apparatus according to claim 1, wherein the stacking unit includes a transfer fixing unit for transferring and fixing the thin layer onto the stage. 5. The layered manufacturing according to claim 4, wherein the transfer fixing unit includes an image bearing unit that conveys the thin layers to a stacking position and a heater unit that heats and presses the thin layers. apparatus. 6. The slice control unit, based on the shape data or cross-sectional shape data of the three-dimensional object input to the data input unit, slice images sliced at desired pitches to form the thin layer. Data is created by the data creating means, which creates data and creates support data for forming a support portion that supports the thin layers for laminating the thin layers based on the slice image data. 6. The three-dimensional object is formed by controlling the image forming means, the support forming means, and the laminating means based on the slice image data and the support data. The additive manufacturing apparatus described. 7. The modeling control means, in order to stack the thin layer on the stage, based on the shape data or the cross-sectional shape data of the three-dimensional object inputted to the data input means, A layout search means for searching the layout direction of the three-dimensional object that minimizes the formation is provided, and based on the layout detected by the layout search means, the data creation means slices each desired pitch to form the thin layer. Created slice image data, to create support data for forming a support portion for supporting the thin layer for laminating the thin layer based on the slice image data, the created by the data creating means The image forming means, the support forming means, and the laminating means are controlled by the slice image data and the support data to form a three-dimensional object. The additive manufacturing apparatus according to any one of claims 1 to 6. 8. A thin layer having a preset layer thickness of the cross-sectional shape of the three-dimensional object is formed by a molding material based on the shape data of the three-dimensional object, and the formed thin layer is laminated on a stage. In a layered manufacturing method for forming a three-dimensional object, slice image data created at every preset pitch for forming the thin layer based on the shape data of the three-dimensional object and the thin layer based on the slice image data. A data input step of inputting support data for forming a support portion for supporting the thin layer for stacking, an image forming step of forming the thin layer by the slice image data, and the support by the support data. A layered manufacturing method comprising: a support forming step of forming a portion; and a laminating step of laminating the thin layer and the support portion on the stage.