JP2004230692A - Shaping apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a shaping apparatus for rapidly forming a shaped article while a shaping material is discharged from a nozzle. <P>SOLUTION: In the shaping apparatus 1, a plurality of nozzles and a plurality of optical fibers are alternately two-dimensionally arranged on a shaping head 21. A photocurable shaping material is discharged from each nozzle and a light (UV rays) is emitted from the optical fiber. Discharging from each nozzle by a pump 14 is individually controlled by a valve group 22 and a controller 17, and a range of discharging is controlled according to the sectional shape of the shaped article with lowering a stage 11. The light is emitted from the optical fiber in parallel with the discharge of the shaping material, and the shaping material is cured immediately after discharging. Decrease in accuracy of the shape of the shaped article formed on the stage 11 is suppressed thereby. The shaping is rapidly performed by discharging the shaping material from a plurality of the nozzles. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a modeling apparatus for performing three-dimensional modeling, and belongs to the field of so-called high-speed prototyping.
[0002]
[Prior art]
Conventionally, when developing a product, a three-dimensional model of a part or a finished product (hereinafter, also referred to as “three-dimensional modeling”) has been produced in a short time by various methods, and the appearance and handling of the product using the three-dimensional model. Is examined.
[0003]
As the three-dimensional modeling, for example, the surface of a photocurable resin in a container (hereinafter, referred to as a “resin tank”) is scanned and irradiated with laser light while being turned ON / OFF, and the cured portion is put into the resin tank. There are well-known techniques such as a technique of repeating scanning with laser light while sinking (so-called stereolithography), a technique of preparing sheets corresponding to a large number of cross sections of an object, and stacking the sheets to perform modeling. In addition, a method of ejecting droplets of a photocurable resin from a plurality of nozzles by applying a method of ejecting ink at high speed and performing printing as in Patent Document 1 (hereinafter, referred to as an “inkjet method”) is also used. Proposed.
[0004]
In the stereolithography method, a resin tank is required and an optical system for scanning a laser beam is complicated, so that the apparatus is large and expensive. There is also a problem that scanning takes time. Therefore, as disclosed in Patent Document 2, a method of scanning a plurality of LEDs (light emitting diodes) in proximity to the surface of a photocurable resin has been proposed.
[0005]
In addition, in the stereolithography method, since it takes time to remove unnecessary objects attached to the formed object after the formation, as another method, Patent Document 3 discloses a single nozzle that can move freely in a three-dimensional space. And a method of performing modeling by discharging a natural hardening wax or a thermoplastic resin while moving a nozzle.
[0006]
[Patent Document 1]
JP-A-2002-67171
[Patent Document 2]
JP-A-11-254543
[Patent Document 3]
US Patent No. 5,121,329 Abstract
[0007]
[Problems to be solved by the invention]
By the way, in the stereolithography method, it is necessary to store the photocurable resin in the resin tank as described above, and further settle the cured resin into the resin tank. Have. The method of laminating sheets does not require post-processing of a formed article, but requires a high technology of laminating sheets. The ink jet method is suitable for forming a minute object, but is not suitable for forming an object having a certain size.
[0008]
From the above, it can be said that a method of discharging a resin from a nozzle is preferable for manufacturing a model having a certain size. However, since the resin is slowly discharged from the nozzle, high-speed modeling cannot be easily performed. Furthermore, in the case of discharging a natural curable wax, a thermoplastic resin, or the like, since it takes time to cure the resin, when the resin is repeatedly laminated, the molded object is deformed, and it is difficult to increase the shape accuracy. .
[0009]
The present invention has been made in view of the above problems, and has as its object to improve a molding speed and a shape accuracy in a technique of performing a three-dimensional molding by discharging a molding material.
[0010]
[Means for Solving the Problems]
The invention according to claim 1 is a modeling apparatus that performs three-dimensional modeling by curing a modeling material, and includes a discharge unit that discharges a photocurable modeling material from a plurality of discharge ports arranged two-dimensionally. A control unit that individually controls the discharge of the molding material from the plurality of discharge ports, a light emitting unit that emits light toward the modeling material discharged from the plurality of discharge ports, and a light emission unit that is discharged from the discharge unit. And a distance changing mechanism for changing a distance between the stage and the discharge section.
[0011]
The invention according to claim 2 is the molding apparatus according to claim 1, wherein the light emitting unit includes a plurality of light emitting elements two-dimensionally arranged in a region where the plurality of ejection openings are arranged. Have.
[0012]
The invention according to claim 3 is the modeling apparatus according to claim 2, wherein the plurality of light emitting elements are grouped into a plurality of light emitting element groups, and the control unit includes the plurality of light emitting elements. The emission of light from the emission element group is individually controlled.
[0013]
According to a fourth aspect of the present invention, there is provided a molding apparatus for performing a three-dimensional molding by curing a molding material, wherein a photocurable molding material is discharged from a plurality of discharge ports formed in a discharge region that spreads two-dimensionally. A light emitting portion having a plurality of light emitting elements two-dimensionally arranged in the discharging region, and emitting light toward a modeling material discharged from the plurality of discharging ports; and A control unit for individually controlling the emission of light from the light emitting element, a stage on which the modeling material discharged from the discharge unit is accumulated, and a distance changing mechanism for changing a distance between the stage and the discharge unit And
[0014]
The invention according to claim 5 is the molding apparatus according to claim 4, wherein the plurality of discharge ports are two-dimensionally arranged in the discharge area.
[0015]
The invention according to claim 6 is the molding apparatus according to claim 4 or 5, wherein the plurality of discharge ports are grouped into a plurality of discharge port groups, and the control unit controls the plurality of discharge ports. The discharge of the modeling material from the outlet group is individually controlled.
[0016]
According to a seventh aspect of the present invention, there is provided the modeling apparatus according to any one of the second and third aspects and the fifth and sixth aspects, wherein the discharge ports and the light emitting elements are alternately arranged in a predetermined direction.
[0017]
The invention according to claim 8 is the molding apparatus according to any one of claims 2 and 3 and claims 5 and 6, wherein one of the discharge port and the light emitting element surrounds the other.
[0018]
The invention according to claim 9 is the molding apparatus according to claim 7 or 8, wherein a distance between the plurality of discharge ports and the stage is set such that a distance between a tip of the plurality of light emitting elements, the stage, Shorter than the distance between.
[0019]
The invention according to claim 10 is a modeling apparatus that performs three-dimensional modeling by curing a modeling material, and includes a discharge unit that discharges a photocurable modeling material from a plurality of discharge ports arranged in a line. A control unit that individually controls the discharge of the molding material from the plurality of discharge ports, and a light emission unit that emits light from the light emission area along the plurality of discharge ports toward the modeling material after discharge, A stage on which the modeling material discharged from the discharge unit is stacked, and a scanning mechanism that relatively scans the discharge unit and the light emitting unit along the stage in a direction perpendicular to the arrangement direction of the plurality of discharge ports. And a distance changing mechanism for changing a distance between the stage and the discharge unit.
[0020]
According to an eleventh aspect of the present invention, in the modeling apparatus according to the tenth aspect, the light emitting region is located on a rear side of the plurality of discharge ports with respect to a direction in which the discharge unit moves relative to the stage. .
[0021]
The invention according to claim 12 is a modeling apparatus that performs three-dimensional modeling by curing a modeling material, and includes a discharge unit that discharges a photocurable modeling material from a linear discharge region, and A light emitting unit for emitting light from the plurality of light emitting elements arranged along the direction toward the modeling material after ejection; a control unit for individually controlling the emission of light from the plurality of light emitting elements; A stage on which the modeling material discharged from the section is stacked, and a scanning mechanism that relatively scans the discharge section and the light emitting section along the stage in a direction perpendicular to the arrangement direction of the plurality of light emitting elements. And a distance changing mechanism for changing a distance between the stage and the discharge unit.
[0022]
According to a thirteenth aspect of the present invention, in the modeling apparatus according to the twelfth aspect, the plurality of light emitting elements are located on a rear side of the discharge area with respect to a direction in which the discharge unit moves relative to the stage. .
[0023]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is a front view showing a configuration of a modeling apparatus 1 for performing three-dimensional modeling according to a first embodiment of the present invention. The molding apparatus 1 includes a stage 11 on which a molded object is formed, an elevating mechanism 12 for elevating and lowering the stage 11, a molding mechanism 13 disposed above the stage 11, a pump 14 for delivering a paste-like molding material to the molding mechanism 13, It includes a tank 15 for storing the material, a light source unit 16 for supplying light (ultraviolet rays in this embodiment) for curing the molding material to the molding mechanism 13, and a controller 17 for controlling various components.
[0024]
The modeling material has a light (ultraviolet) curable resin as a main component, and contains a solvent and other additives for adjusting fluidity and adhesion. By using a light-curing molding material that is a mixture of a light-curing resin and a low-softening point glass frit that is the main component, it is possible to produce a hard molding by firing as a post-treatment. It is.
[0025]
The elevating mechanism 12 moves the stage 11 up and down by driving a motor 121. During modeling, the stage 11 continuously moves downward. The shaping mechanism 13 has a shaping head 21 in which the lowermost portion has a large number of discharge nozzles arranged two-dimensionally.
[0026]
FIG. 2 is a bottom view showing a part of the modeling head 21. In the modeling head 21, nozzles 31 having discharge ports 311 and optical fibers 32 for emitting light are alternately and two-dimensionally arranged in a lattice pattern. Accordingly, each nozzle 31 is substantially surrounded by the optical fiber 32, and each optical fiber 32 is substantially surrounded by the nozzle 31. In other words, the modeling head 21 includes a group 310 (discharge unit) of a plurality of nozzles that discharges a modeling material from the plurality of discharge ports 311 arranged two-dimensionally, and a two-dimensional group in a region where the plurality of discharge ports 311 are arranged. And a set 320 (light emitting portions) of a plurality of light emitting elements that emit light toward the modeling material after ejection.
[0027]
As shown in FIG. 1, a group of valves 22 for individually controlling the discharge of the molding material from the nozzles 31 is arranged above the modeling head 21, and each valve is connected to one nozzle 31 via a tube. Note that the valve group 22 may be provided in multiple stages up and down in order to arrange the valves at high density. The valve group 22 is attached to a manifold 23, and the pump 14 is connected to the manifold 23. Thus, the molding material is discharged from each nozzle 31 corresponding to the opened valve at the same speed by the action of the pump 14.
[0028]
On the other hand, each optical fiber 32 of the modeling head 21 is connected to the upper light source unit 16 through gaps and sides provided in the bulb group 22 and the manifold 23. The light source unit 16 includes a plurality of light sources 161 that can be individually turned on and off, an optical system 162 that converts light from the light source 161 into light having a uniform intensity distribution, and light (ultraviolet light) to the end face of the optical fiber 32. And a mirror 163 that makes the light incident.
[0029]
FIG. 3 to FIG. 5 are enlarged views showing a state in which a modeled object is being formed on the stage 11. The tip of the optical fiber 32 is located at a position deeper than the discharge port 311 of the nozzle 31, and the distance between the discharge port 311 and the stage 11 is shorter than the distance between the tip of the optical fiber 32 and the stage 11. Has become. This prevents the build material from adhering to the optical fiber 32. Before the modeling is performed, data of a cross-sectional shape (hereinafter, referred to as “cross-sectional data”) obtained by cutting a large number of shapes of the modeled object on a horizontal plane is prepared by a computer provided separately.
[0030]
FIG. 3 shows a state in which a first-stage portion (a portion corresponding to the lowest cross-sectional shape, a portion corresponding to one cross-sectional shape is hereinafter referred to as a “layer”) is formed on the stage 11. FIG. When the operation shown in FIG. 3 is performed, the controller 17 controls the valve group 22 such that the modeling material 91 is discharged only from the nozzles 31 included in the cross section of the lowermost layer in accordance with the cross-sectional data of the lowermost layer. The stage 11 is moved down in synchronization with the ejection. The thickness of one layer is, for example, about 0.5 mm.
[0031]
The lowering speed of the stage 11 is obtained by multiplying the lowering speed by the area on the stage 11 per nozzle 31 (the area obtained by dividing the area occupied by the nozzle group by the number of nozzles) and the lowering speed per one nozzle 31 per unit time. Is controlled to be equal to the volume of the modeling material discharged to Thereby, as shown in FIG. 3, the discharged modeling material 91 is sufficiently applied to a region corresponding to one nozzle 31. As a result, when the modeling material 91 is discharged from the plurality of nozzles 31 adjacent to each other, the modeling material 91 is accumulated upward without any gap.
[0032]
On the other hand, light is emitted from the optical fiber 32 in parallel with the ejection of the molding material 91, and the molding material 91 is gradually cured. The output of the light is adjusted so that the molding material 91 is cured in a semi-cured state immediately after the discharge and spreads to the area corresponding to one nozzle 31 quickly. This prevents the modeling material 91 from unnecessarily spreading (dripping) in the horizontal direction on the stage 11, and as shown in FIG. It is accumulated in.
[0033]
FIG. 4 is a diagram illustrating a state in which a portion corresponding to the cross-sectional shape of the second stage from the bottom of the modeled object is formed. In FIG. 4, the discharge from the leftmost nozzle 31 is stopped, and the second layer is physically formed continuously from the other nozzles 31 on the lowermost modeling material 91. Light continues to be emitted from each optical fiber 32. In addition, since the formation of the upper layer physically continuous with the lower layer due to the accumulation of the modeling material 91 is substantially equivalent to the lamination of the layers, the following description will refer to “lamination” as appropriate. Is used. FIG. 5 is a diagram illustrating a state in which a layer corresponding to the third-level cross-sectional shape from the bottom of the modeled object is formed. In FIG. 5, the ejection from the two nozzles 31 on the left side is stopped, and the third layer is physically and continuously stacked on the second layer from the other nozzles 31. Light is continuously emitted from each optical fiber 32, and the molding material 91 is cured.
[0034]
As described above, in the modeling apparatus 1, ON / OFF of discharge from each nozzle 31 is controlled according to the shape of the modeled object. This realizes rapid modeling using the nozzles 31 arranged two-dimensionally. In addition, since the discharged modeling material 91 is quickly cured by light, a decrease in the shape accuracy of the modeled object is suppressed. Furthermore, since unnecessary materials do not exist in the area outside the modeled object, complicated procedures are not required for post-modeling processing (for example, surface treatment such as polishing), and the material can be efficiently used for modeling. it can.
[0035]
It should be noted that, compared to the optical shaping method, a resin tank for storing the resin is not required, and since it is not necessary to scan with light, the apparatus can be downsized. Also, a procedure for reusing the uncured resin is not required, and the molding operation is simplified.
[0036]
FIG. 6 is a block diagram showing an internal configuration of the controller 17, a configuration connected to the controller 17, and a computer 8 for generating cross-sectional data. In the computer 8, three-dimensional shape data 811 of the modeled object is prepared in advance in the memory 81 using CAD or the like, and as described above, a large number of cross-sectional shapes obtained by cutting the modeled object on a horizontal plane in which a large number of the modeled objects are stacked are described. The section data 812 shown is generated from the shape data 811, and is prepared in the memory 81. Then, the cross-sectional data corresponding to the lowest part (lowest layer) of the modeled object is transmitted to the controller 17, and thereafter, the cross-sectional data corresponding to the one upper part (upper layer) is sequentially transmitted to the controller 17. You.
[0037]
The controller 17 includes a discharge control unit 171 that controls the valve group 22, a light irradiation control unit 172 that controls the emission of light from the optical fiber 32, and a stage drive unit 173 that controls the lowering of the stage 11. It is electrically connected to the bulb group 22, the light source unit 16, and the elevating mechanism 12. Each of the control units 171, 172, and 173 is configured by an arithmetic circuit that processes cross-sectional data, an interface that generates control signals for various components, and the like. The operations illustrated in FIGS. 3 to 5 are realized by the discharge control unit 171 controlling the opening and closing of each valve according to the cross-sectional data while synchronizing with the lowering of the stage by the stage driving unit 173.
[0038]
Here, in the modeling apparatus 1, the light source unit 16 is also controlled according to the cross-sectional data. Specifically, ON / OFF of the plurality of light sources 161 of the light source unit 16 shown in FIG. 1 is controlled. FIG. 7 is a diagram for describing a specific example of control of the light source 161, and illustrates the bottom surface of the modeling head 21 in an abstract manner. In FIG. 7, nine regions 210 arranged three by three in the upper, lower, left, and right directions indicate the range of an optical fiber group in which light emission is controlled by controlling ON / OFF of one light source 161. On the other hand, a region 910 surrounded by a thick solid line indicates a range of a nozzle group in which ejection is performed according to the cross-sectional data.
[0039]
In FIG. 7, only the upper left region 210 and three adjacent regions 210 (a total of four regions 210) overlap with the region 910. In the example shown in FIG. 7, in the modeling apparatus 1, only the light sources 161 corresponding to the four regions 210 overlapping the region 910 are turned on, and the light sources 161 corresponding to the other five regions 210 are turned off. As described above, the light irradiation control unit 172 individually controls the emission of light from the optical fiber group according to the cross-sectional data, so that the molding apparatus 1 omits unnecessary lighting of the light source 161 to reduce power consumption and reduce the light source unit. 16, the frequency of replacing the light source 161 is reduced.
[0040]
FIG. 8 is a front view showing the molding apparatus 1 according to the second embodiment. The molding apparatus 1 according to the second embodiment differs from the first embodiment in the structure of the molding head 21, the bulb group 22 is omitted, and the structure of the light source unit 16 is also different. Other configurations are the same as those of the first embodiment, and are denoted by the same reference numerals.
[0041]
FIG. 9 is a bottom view showing a part of the modeling head 21. In the modeling head 21, the modeling elements 33 are two-dimensionally arranged. FIG. 10 is an enlarged view showing the bottom surface of one modeling element 33. The modeling element 33 has a nozzle 331 that discharges a modeling material from a discharge port 331a at the center, and a plurality of optical fibers 332 are arranged so as to surround the periphery of the nozzle 331. The outside of the optical fiber 332 is further covered with a resin cover 333. As a specific example, the nozzle 331 has an outer diameter of 320 μm and an inner diameter of 140 μm, the diameter of the optical fiber 332 is 70 μm, and the thickness of the resin cover is 90 μm. In this case, the entire outer diameter is 640 μm.
[0042]
Since the modeling elements 33 are arranged, also in the second embodiment, as in the first embodiment, the modeling head 21 discharges a modeling material from a plurality of discharge ports 331a two-dimensionally arranged. And a set of a plurality of light emitting elements (light emitting portions) that emit light toward the discharged modeling material that is two-dimensionally arranged in a region where the plurality of outlets 331a are arranged. ) Are combined. In addition, since the optical fiber 32 surrounds the nozzle 31, the ejection and the light irradiation are accurately associated one-to-one.
[0043]
FIG. 11 is a view showing a vertical section of one modeling element 33, and also shows a state in which the modeling material 91 is discharged. In the shaping element 33, the end face (light emitting surface) of the optical fiber 332 is located on the back side with respect to the discharge port 331 a of the nozzle 331 (that is, the distance between the discharge port 331 a and the stage 11 is the tip of the optical fiber 32). The distance between the resin cover 333 and the stage 11 is shorter than the distance between the light emitting surface and the stage 11). The cross-sectional area (based on the horizontal plane) of the molding material 91 which is discharged from the nozzle 331 and spreads is approximately equal to the molding element 33 by controlling the discharge speed and the descent speed of the stage 11 by the controller 17 as in the first embodiment. Is adjusted to have an area corresponding to Since the light emitting surface of the optical fiber 332 is located at the back, the modeling material 91 discharged from the nozzle 331 is prevented from adhering to the light emitting surface.
[0044]
Further, the outer peripheral surface 341 of the nozzle 331 and the inner peripheral surface 342 of the resin cover 333 below the light emitting surface are mirror-finished by plating or the like. Therefore, as shown by the arrow in FIG. 11 (only the right optical fiber 332 is shown), the light emitted from the optical fiber 332 is reflected by the outer peripheral surface 341 and the inner peripheral surface 342 and is Efficiently enter from inside. As a result, it is possible to accumulate the modeling material 91 in an appropriate cross-sectional shape upward while suppressing deformation of the modeling material 91.
[0045]
The plurality of optical fibers 332 included in one modeling element 33 are bundled (that is, combined) into one optical fiber 32 to the light source unit 16 via a gap or side in the manifold 23 shown in FIG. It is led.
[0046]
As shown in FIG. 8, one light source 161 is provided in the light source unit 16, and the light from the light source 161 is converted by the optical system 162 into a light beam having a uniform intensity in a light beam cross section. In the light source unit 16, instead of the mirror 163 in the first embodiment, a spatial light modulation device 163a having two-dimensionally arranged rotatable minute mirrors is provided. As a result, the spatially modulated light is incident on the end faces of the group of optical fibers 32 on the light source unit 16 side. The end face of one optical fiber 32 is arranged so as to correspond to one micromirror. By controlling the spatial light modulation device 163a, ON / OFF of the light emission from each modeling element 33 can be individually controlled. It is possible. That is, the plurality of optical fibers 332 included in one modeling element 33 are one light emitting element that is a control unit.
[0047]
On the other hand, as described above, since the modeling apparatus 1 according to the second embodiment does not include a valve group for controlling discharge, the modeling material 91 is uniformly discharged from each of the modeling elements 33. As described above, in the modeling apparatus 1, the formation of a modeled object is realized by controlling the emission of light instead of controlling the discharge of the modeling material 91.
[0048]
FIG. 12 to FIG. 14 are diagrams illustrating a state where a modeled object is manufactured by the modeling apparatus 1 according to the second embodiment. In the following description, a portion corresponding to one cross-sectional shape of the modeled object is referred to as a “layer”, as in the first embodiment. In FIGS. 12 to 14, the hardened molding material 91 is indicated by parallel oblique lines.
[0049]
FIG. 12 shows a state where the lowermost layer of the modeled object is formed, FIG. 13 shows a state where the second layer from the bottom is formed, and FIG. 14 shows a state where the third layer from the bottom is formed. In FIG. 12, the molding material 91 is discharged and light is emitted from all the modeling elements 33, and all the molding materials 91 are cured. In FIG. 13, the modeling material 91 is discharged from the leftmost modeling element 33, but the light emission is stopped, and the modeling material 91 is accumulated on the lowermost layer in an uncured state. It is assumed that the uncured molding material 91 has a viscosity that does not cause significant deformation (ie, dripping).
[0050]
FIG. 14 shows a state in which light emission from the two left modeling elements 33 is stopped when the third layer from the bottom is formed. As described above, in the modeling apparatus 1, a part of the molding material 91 to be discharged is cured according to the cross-sectional shape of the molding object, so that the molding material is present inside the block of the molding material 91. Accumulation and curing of 91 are performed to form a model.
[0051]
When the formation of the modeled object on the stage 11 is completed, the modeled object is detached from the stage 11 and the uncured modeling material 91 attached to the surroundings at another place is removed. Thus, only the cured portion is obtained as the modeled object 92 as illustrated in FIG.
[0052]
In the modeling apparatus 1 according to the second embodiment, since the modeling material 91 is discharged from the plurality of modeling elements 33, a modeling object can be manufactured quickly as in the first embodiment. In addition, since the discharged modeling material is quickly cured by light, a decrease in the shape accuracy of the modeled object can be suppressed. In the second embodiment, since the discharge is not controlled unlike the first embodiment, it is not necessary to arrange a large number of valves. Therefore, the device can be easily designed. It should be noted that, compared to the optical shaping method, a resin tank for storing the resin is not required, and there is no need to scan with light, so that the apparatus can be downsized.
[0053]
By the way, in the second embodiment, the ejection may be controlled to some extent. That is, the modeling elements 33 may be divided into a plurality of groups, and a valve may be provided for each group to control the discharge of the modeling material 91 individually. In this case, when it is not necessary to discharge the modeling material 91 from all the modeling elements 33 in the group, the supply of the modeling material 91 to the group is stopped. The valve is provided between the manifold 23 and each group of the shaping element 33 according to the first embodiment.
[0054]
The 16 groups 330 of the shaping elements 33 divided by the thick solid line in FIG. 9 indicate units in which the ejection is controlled. For example, when it is necessary to emit light only from the shaping elements 33 indicated by parallel oblique lines in FIG. 9 according to the cross-sectional data, the shaping material 91 is discharged only from the upper left nine (= 3 × 3) groups 330. , The discharge from the other seven groups 330 is stopped. As a result, unnecessary consumption of the modeling material 91 is prevented, and reduction in the manufacturing cost of the model is realized. When the ejection is also controlled, the internal configuration of the controller 17 is basically the same as that shown in FIG.
[0055]
FIG. 16 is a front view showing the modeling apparatus 1 according to the third embodiment. The shaping apparatus 1 is different from the first embodiment in that the structure of the shaping head 21 and that a sub-stage 111 and a scanning mechanism 112 are provided on the stage 11. Other configurations are the same as those of the first embodiment, and are denoted by the same reference numerals.
[0056]
FIG. 17 is a bottom view showing a part of the modeling head 21. In the modeling head 21, a plurality of nozzles 31 and a plurality of optical fibers 32 each having the same discharge port 311 as in the first embodiment are arranged in parallel in the X direction (left and right direction) shown in FIG. In other words, the modeling head 21 is arranged in a line along the plurality of discharge ports 311 and a set 310 (discharge unit) of a plurality of nozzles that discharges the molding material from the plurality of discharge ports 311 arranged in a line. And a set 320 (light emitting portion) of a plurality of light emitting elements that emit light toward the modeling material after ejection.
[0057]
The substage 111 can be moved in the Y direction (the direction perpendicular to the plane of FIG. 16) in FIG. 16 along a guide rail by a scanning mechanism 112 having a ball screw and a motor. Thus, the modeling head 21 is relatively scanned along the substage 111 in a direction perpendicular to the direction in which the plurality of ejection ports 311 are arranged.
[0058]
FIGS. 18 to 21 are views showing a state where a modeled object is formed on the sub-stage 111 by the modeling apparatus 1 according to the third embodiment. During modeling, the sub-stage 111 is moved in the (-Y) direction by the moving mechanism. Thereby, the modeling head 21 relatively moves on the substage 111 in the (+ Y) direction. FIGS. 18 to 20 show a state in which the lowermost layer corresponding to the lowermost cross-sectional shape of the modeled object is formed. As the modeling head 21 relatively moves in the (+ Y) direction, the modeling material 91 becomes (+ Y). + Y) sequentially on the substage 111. At this time, since the optical fiber 32 is located on the rear side of the nozzle 31 with respect to the relative movement direction of the modeling head 21, the modeling material 91 immediately after ejection is efficiently irradiated with light, and the modeling material 91 is sequentially cured. In FIGS. 18 to 20, the hardened molding material 91 is hatched in parallel.
[0059]
As in the first embodiment, the discharge from each nozzle 31 can be individually controlled by the valve group 22 (see FIG. 16), and each nozzle 31 is placed in an area corresponding to the cross-sectional shape of the modeled object. The molding material 91 is discharged only while is positioned. By selectively performing ejection from the nozzle 31, a layer is formed only in a region corresponding to one cross-sectional shape. When one scan of the modeling head 21 in the relative (+ Y) direction is completed, the formation of one layer is completed.
[0060]
Subsequently, the elevating mechanism 12 lowers the stage 11 by one layer, and the sub-stage 111 returns to the initial position. Then, the relative scanning of the modeling head 21 is performed again. At this time, ejection from each nozzle 31 is selectively performed, and as shown in FIG. 21, the second layer from the bottom is formed on the lowermost layer according to the corresponding cross-sectional shape. The relative scanning and selective ejection of the modeling head 21 are repeated while the stage 11 is intermittently lowered, so that layers are sequentially stacked from the lower side, and finally the modeling is performed as illustrated in FIG. An object 92 is formed on the sub-stage 111.
[0061]
When the light source unit 16 has a plurality of light sources 161 as shown in FIG. 16, the optical fibers 32 are grouped as in the first embodiment, and the lighting of the light sources 161 is controlled by controlling the lighting of the light sources 161. Lighting may be controlled for each fiber group.
[0062]
As described above, in the modeling apparatus 1 according to the third embodiment, since the modeling is performed while the molding material 91 is discharged from the plurality of discharge ports 311 arranged in a line, compared to the first embodiment. The structure of the shaping mechanism 13 is greatly simplified. In addition, by performing discharge from the plurality of discharge ports 311, it is possible to improve the molding speed as compared with the case where discharge is performed using one nozzle. Further, since the molding material 91 is hardened immediately after the discharge, the shape accuracy of the molded object is prevented from being impaired.
[0063]
In addition, compared with the optical molding method, since a resin tank for storing the resin is not required, the apparatus can be downsized, and a procedure for reusing the uncured resin is not required.
[0064]
FIG. 23 is a front view showing the modeling apparatus 1 according to the fourth embodiment. The modeling apparatus 1 is almost the same as the third embodiment, but the structure of the modeling head 21 is different, the bulb group 22 is omitted, and one light source is provided in the light source unit 16 as in the second embodiment. 161 and a spatial light modulation device 163a are provided. Other configurations are the same as those in FIG. 16 and are denoted by the same reference numerals.
[0065]
FIG. 24 is a bottom view showing a part of the modeling head 21 according to the fourth embodiment. In the modeling head 21, a discharge port 312 for discharging the molding material 91 has a slit shape, and a plurality of optical fibers 32 are arranged in parallel with the discharge port 312. In other words, the modeling head 21 includes a nozzle (discharge unit) that discharges a molding material from a linear discharge region and a plurality of nozzles that are arranged in a line along the discharge region and emit light toward the discharged molding material. Of light emitting elements 320 (light emitting portions).
[0066]
Each optical fiber 32 is connected to the upper light source unit 16 as shown in FIG. 23, and the introduction of light into each optical fiber 32 is individually controlled by the spatial light modulation device 163a as in the second embodiment. You. On the other hand, the molding material 91 is uniformly discharged from the slit-shaped discharge port 312. Similarly to the third embodiment, the shaping head 21 is relatively scanned by the scanning mechanism 112 along the sub-stage 111 in a direction perpendicular to the direction in which the optical fibers 32 are arranged. Is located on the rear side of the discharge port 312 with respect to the moving direction relative to the light, and the light is efficiently applied to the modeling material.
[0067]
At the time of shaping, as in the third embodiment, the shaping head 21 is relatively scanned in the (+ Y) direction by moving the sub-stage 111, and when one scan is completed, the stage 11 (and the The stage 111) descends by one layer. In the fourth embodiment, the emission of light from each optical fiber 32 is controlled in synchronization with the scanning of the modeling head 21. Thus, the modeling material 91 discharged from the discharge port 312 in a substantially sheet shape onto the sub-stage 111 is irradiated with light only in a region corresponding to the cross-sectional shape of the modeled object.
[0068]
FIG. 25 is a diagram illustrating a state in which a shaped object is manufactured by the above operation. In FIG. 25, only the portions indicated by parallel oblique lines in the modeling material 91 are hardened. Although only the optical fiber 32 closest to the (+ X) side is shown in FIG. 25, light is selectively emitted from the other optical fibers 32 as well. When the shaping in the shaping apparatus 1 is completed, unnecessary shaping material 91 is removed as in the second embodiment, and a final shaping object is obtained.
[0069]
As described above, in the modeling apparatus 1 according to the fourth embodiment, the molding material 91 is stacked by scanning the discharge port 312 while discharging the molding material 91 from the slit-shaped discharge port 312. Since light is selectively emitted from the optical fiber 32 to manufacture a modeled object, it is possible to quickly manufacture a modeled object with high accuracy. It should be noted that, as compared with the stereolithography method, the size of the apparatus can be reduced because a resin tank for storing the resin is not required.
[0070]
FIG. 26 is a longitudinal sectional view showing another preferred example of the shaping element 33 according to the second embodiment, and FIG. 27 is a bottom view. FIG. 26 corresponds to the cross section at the position of arrow AA shown in FIG. In the modeling element 33 shown in FIGS. 26 and 27, a nozzle 331 having a substantially U-shaped discharge port 331b is provided so as to substantially surround the optical fiber 332 covered with the coating. That is, the inclusion relationship between the nozzle and the optical fiber is opposite to that shown in FIG. Thus, the ejection and the light irradiation can be accurately associated with each other on a one-to-one basis. As shown in FIG. 27, the optical fiber 332 is provided so as to be supported by the nozzle 331. As shown in FIG. 26, the light emitting surface of the optical fiber 332 is located deeper than the discharge port 331b. That is, the distance between the discharge port 331 b and the stage 11 is shorter than the distance between the tip of the optical fiber 332 and the stage 11.
[0071]
When the modeling material 91 is discharged from the modeling element 33, the descending speed of the stage 11 is controlled, and as the modeling material 91 descends, the cross-sectional shape gradually changes from a substantially U-shape to a substantially circular shape. At this time, the light is emitted from the central optical fiber 332 to the molding material 91 at a stage where the cross-sectional shape is substantially U-shaped, and the ejection speed and the stage 11 are adjusted so that the curing is completed when the cross-sectional shape becomes substantially circular. The descending speed is controlled. By making the discharge port 331b substantially U-shaped, air is prevented from staying in the modeling material 91. As described above, when the nozzle and the optical fiber are provided in the molding apparatus 1 as an integral molding element, the optical fiber can be positioned at the center of the molding element.
[0072]
The embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments, and various modifications are possible.
[0073]
The photo-curable molding material may be a resin that is cured by light other than ultraviolet light such as visible light.
[0074]
When the modeling material has a certain degree of viscosity, the stage 11 (or the sub-stage 111) does not need to be horizontal, and in this case, the lifting mechanism 12 that changes the distance between the stage 11 and the modeling head 21 is used. The posture is changed from the state shown in FIG. Alternatively, the stage 11 may be fixed, and the modeling head 21 may move in a direction perpendicular to the stage 11 or along the stage 11.
[0075]
Light emission is not limited to light emission from a light guide member such as an optical fiber, and light may be directly applied to a modeling material from a light emitting element.
[0076]
In the first embodiment, the light may be emitted by another method as long as the light is emitted from a region where the ejection ports 311 are arranged. For example, light may be emitted from a base member to which the nozzle 31 is attached.
[0077]
In the second embodiment, it is not necessary to control the discharge range (or it is not necessary to precisely control the discharge range). Therefore, instead of arranging the discharge ports 331a two-dimensionally, a plurality of slit-shaped discharge ports (discharge ports) (Perpendicular to the direction in which the outlets extend). That is, in the second embodiment, another structure may be adopted as long as discharge is performed from a plurality of discharge ports formed in a discharge region that spreads two-dimensionally on the lower surface of the modeling head 21. , Quick molding is realized.
[0078]
Further, in the second and fourth embodiments, the light emission from each optical fiber 32 is not limited to a device having a rotatable micro mirror group, but a diffraction grating type spatial light modulation device. Or a liquid crystal may be used. Furthermore, spatial light modulation may be performed by arranging minute light sources.
[0079]
The modeling head 21 in the first embodiment can be used in the second embodiment, and the modeling head 21 (the modeling element 33) in the second embodiment can be used in the first embodiment. It is also possible to use it. In the first embodiment, the nozzles 31 and the optical fibers 32 may be alternately arranged in a line. That is, by alternately disposing the nozzles 31 and the optical fibers 32 at least in the predetermined direction on the lower surface of the modeling head 21, the ejection and the curing can be appropriately performed two-dimensionally.
[0080]
In the third embodiment, light may be emitted linearly from a plate-like light guide member, and in the fourth embodiment, a plurality of nozzles may be arranged in a line. When a plurality of nozzles are arranged in the fourth embodiment, the ejection may be controlled for each nozzle group by grouping these nozzles. Also, the modeling element 33 shown in FIGS. 10 and 27 may be used in the third or fourth embodiment, and even in this case, the light is emitted almost along the plurality of linear ejection ports. An area will be formed. Further, light may be separately irradiated after the ejection according to the cross-sectional shape of the modeled object in the third embodiment, and the linear ejection port 312 and the linear light may be emitted in the fourth embodiment. The aggregate of the fibers 32 may move individually.
[0081]
Since the molding material discharged from one nozzle adheres to the side of the molding material discharged from the adjacent nozzle and hardens, a cured layer does not always need to be present on the lower side during discharging. . That is, in the modeling apparatus 1 according to any of the above embodiments, a shape having a slight overhang can be formed.
[0082]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, a molded object can be formed quickly, performing molding by discharge of a molding material, and also the fall of the shape precision of a molded object can be suppressed.
[0083]
Further, in the inventions of claims 1 to 3, claim 6, and claims 10 and 11, the molding material can be efficiently used for molding.
[0084]
According to the third aspect of the present invention, power consumption can be reduced.
[0085]
Further, in the inventions of claims 8, 11 and 13, light can be efficiently applied to the modeling material, and in the invention of claim 9, it is possible to prevent the modeling material from adhering to the light emitting element. it can.
[Brief description of the drawings]
FIG. 1 is a front view showing a configuration of a molding apparatus according to a first embodiment.
FIG. 2 is a bottom view showing a part of the modeling head.
FIG. 3 is an enlarged view showing a state in which a modeled object is formed.
FIG. 4 is an enlarged view showing a state in which a modeled object is formed.
FIG. 5 is an enlarged view showing a state in which a modeled object is formed.
FIG. 6 is a block diagram showing an internal configuration of a controller and a peripheral configuration thereof.
FIG. 7 is a view abstractly showing a bottom surface of a modeling head.
FIG. 8 is a front view illustrating a configuration of a molding apparatus according to a second embodiment.
FIG. 9 is a bottom view showing a part of the modeling head.
FIG. 10 is an enlarged view showing a bottom surface of a shaping element.
FIG. 11 is a longitudinal sectional view of a shaping element.
FIG. 12 is an enlarged view showing a state in which a modeled object is formed.
FIG. 13 is an enlarged view showing a state in which a modeled object is formed.
FIG. 14 is an enlarged view showing a state in which a modeled object is formed.
FIG. 15 is a diagram illustrating a modeled object.
FIG. 16 is a front view illustrating a configuration of a modeling apparatus according to a third embodiment.
FIG. 17 is a bottom view showing a part of the modeling head.
FIG. 18 is an enlarged view showing a state where a modeled object is formed.
FIG. 19 is an enlarged view showing a state in which a modeled object is formed.
FIG. 20 is an enlarged view showing a state in which a modeled object is formed.
FIG. 21 is an enlarged view showing a state in which a modeled object is formed.
FIG. 22 is a diagram illustrating a modeled object.
FIG. 23 is a front view illustrating a configuration of a modeling apparatus according to a fourth embodiment.
FIG. 24 is a bottom view showing a part of the modeling head.
FIG. 25 is an enlarged view showing a state in which a modeled object is formed.
FIG. 26 is a longitudinal sectional view showing another preferred example of the shaping element.
FIG. 27 is a bottom view of the shaping element.
[Explanation of symbols]
1 modeling equipment
11 stages
12 lifting mechanism
17 Controller
22 valve group
32,332 Optical fiber
33 modeling elements
91 Building materials
111 substage
112 Scanning mechanism
163a Spatial light modulation device
171 Discharge control unit
172 Light irradiation controller
Set of 310 nozzles
311, 312, 331 a, 331 b outlet
320 Assembly of optical fiber

Claims (13)

A molding apparatus for performing three-dimensional molding by curing a molding material,
An ejection unit that ejects a photocurable molding material from a plurality of ejection ports arranged two-dimensionally,
A control unit for individually controlling the discharge of the modeling material from the plurality of discharge ports,
A light emitting unit that emits light toward the modeling material discharged from the plurality of discharge ports,
A stage in which the modeling material discharged from the discharge unit is accumulated,
A distance changing mechanism that changes a distance between the stage and the ejection unit,
A shaping device comprising: The modeling apparatus according to claim 1,
The molding apparatus, wherein the light emitting unit has a plurality of light emitting elements two-dimensionally arranged in a region where the plurality of discharge ports are arranged. The modeling device according to claim 2,
The plurality of light emitting elements are grouped into a plurality of light emitting element groups,
The molding apparatus, wherein the control unit individually controls light emission from the plurality of light emitting element groups. A molding apparatus for performing three-dimensional molding by curing a molding material,
A discharge unit that discharges a photocurable molding material from a plurality of discharge ports formed in a discharge region that spreads two-dimensionally;
A light emitting unit that has a plurality of light emitting elements two-dimensionally arranged in the discharge area, and emits light toward a modeling material discharged from the plurality of discharge ports;
A control unit that individually controls light emission from the plurality of light emitting elements,
A stage in which the modeling material discharged from the discharge unit is accumulated,
A distance changing mechanism that changes a distance between the stage and the ejection unit,
A shaping device comprising: The molding apparatus according to claim 4,
The molding apparatus, wherein the plurality of discharge ports are two-dimensionally arranged in the discharge area. It is a modeling device according to claim 4 or 5,
The plurality of outlets are grouped into a plurality of outlet groups.
The molding apparatus, wherein the control unit individually controls ejection of the molding material from the plurality of ejection port groups. The molding apparatus according to any one of claims 2 and 3, and claims 5 and 6,
A molding apparatus wherein discharge ports and light emitting elements are alternately arranged in a predetermined direction. The molding apparatus according to any one of claims 2 and 3, and claims 5 and 6,
A molding apparatus, wherein one of the discharge port and the light emitting element surrounds the periphery of the other. It is a modeling device according to claim 7 or 8,
A molding apparatus, wherein a distance between the plurality of discharge ports and the stage is shorter than a distance between tips of the plurality of light emitting elements and the stage. A molding apparatus for performing three-dimensional molding by curing a molding material,
An ejection unit that ejects a photocurable molding material from a plurality of ejection ports arranged in a line,
A control unit for individually controlling the discharge of the modeling material from the plurality of discharge ports,
A light emitting unit that emits light from the light emitting area along the plurality of ejection ports toward the modeling material after ejection,
A stage on which the modeling material discharged from the discharge unit is stacked,
A scanning mechanism that relatively scans the ejection unit and the light emission unit along the stage in a direction perpendicular to the arrangement direction of the plurality of ejection ports,
A distance changing mechanism that changes a distance between the stage and the ejection unit,
A shaping device comprising: The modeling apparatus according to claim 10,
The molding apparatus according to claim 1, wherein the light emitting region is located behind the plurality of ejection ports with respect to a direction in which the ejection unit moves relative to the stage. A molding apparatus for performing three-dimensional molding by curing a molding material,
An ejection unit that ejects a photocurable molding material from a line-shaped ejection region,
A light emitting unit that emits light from the plurality of light emitting elements arranged along the ejection region toward the modeling material after ejection,
A control unit that individually controls light emission from the plurality of light emitting elements,
A stage on which the modeling material discharged from the discharge unit is stacked,
A scanning mechanism that relatively scans the ejection unit and the light emitting unit along the stage in a direction perpendicular to the arrangement direction of the plurality of light emitting elements;
A distance changing mechanism that changes a distance between the stage and the ejection unit,
A shaping device comprising: The modeling apparatus according to claim 12, wherein
The shaping apparatus according to claim 1, wherein the plurality of light emitting elements are located on a rear side of the discharge area with respect to a direction in which the discharge unit moves relative to the stage.

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