JP2005169878A - Method and apparatus for shaping three-dimensional object - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus for shaping a three-dimensional object which can obtain a uniform, beautiful deposition surface even when the fluidity of a powder material is lowered with the reduction of its particle size. <P>SOLUTION: In the apparatus, a process in which the heat melting powder material B deposited in a prescribed height corresponding to the cross-sectional shape at intervals of the prescribed height in the three-dimensional object is sintered by being irradiated with laser beams is applied to the total height of the object to obtain a product A. The apparatus is composed of a vertically moving plate 5 arranged vertically movably in a shaping space part 2, a moving body 8 set reciprocatably in a prescribed direction at a position above the shaping space part, a powder sprayer 10 which is arranged in the moving body and sprays the powder material into the shaping space part, a powder material supply apparatus 11 for supplying the powder material to the powder sprayer, and a laser beam irradiation device 12 for irradiating the deposition layer of the powder material which is sprayed from the powder sprayer and deposited in the shape of a layer with laser beams corresponding to the cross-sectional shape of the three-dimensional object. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a modeling method and a modeling apparatus for a three-dimensional object.

  Conventionally, for example, when a prototype (prototype) of a three-dimensional object is manufactured (modeled), according to the cross-sectional shape of the three-dimensional object at a predetermined height (every predetermined interval), the predetermined thickness is equal to the predetermined height. There is a technique in which the step of irradiating a laser beam to the heat-meltable powder material thus deposited is sintered over the entire height of the object (see Patent Document 1).

By the way, as shown in FIG. 3, this kind of manufacturing apparatus arranges the raising / lowering table 53 so that raising / lowering is possible in the modeling space part 52 formed of the four vertical wall parts 51, and on this raising / lowering table 53 Next, the heat-meltable powder material B is deposited with a predetermined thickness, and the deposited powder deposition layer is sintered by irradiating a laser beam within a range of a cross-sectional shape at a predetermined height of the three-dimensional object. It is what I did. Of course, the elevating table 53 is configured to be lowered at a predetermined height, and the powder material is supplied into the modeling space 52 by a recoater 54 that is reciprocally movable in a predetermined direction. By feeding the scraper 55 between the pair of front and rear scrapers 55 and moving the scraper 55, a powder accumulation layer having a predetermined thickness is obtained in the gap between the lower surface of the scraper 55 and the lifting table 53.
JP 2003-245981 A

  However, according to the configuration of the manufacturing apparatus described above, the powder material B is deposited at a predetermined height in the modeling space 52 by the scraper 55 that is reciprocated in the horizontal direction. For those with good fluidity, they can be deposited uniformly and cleanly, but depending on the material of the powder material and the powder shape, the fluidity may deteriorate when the particle size is small (for example, 20 μm or less), In this case, there has been a problem that the powder material is caught or adhered to the scraper, and a uniform and clean deposition surface cannot be obtained.

  Therefore, the present invention provides a method and apparatus for modeling a three-dimensional object that can provide a uniform and clean deposition surface even when the powder material is such that the fluidity becomes worse as the particle size becomes smaller. The purpose is to do.

In order to solve the above-described problems, a method for modeling a three-dimensional object according to the present invention includes a laser on a heat-meltable powder material deposited with a predetermined thickness according to a cross-sectional shape at predetermined intervals in a three-dimensional object. When forming a three-dimensional object by performing the process of irradiating and sintering the light beam over the entire height of the object,
In this method, a powder deposit layer having a predetermined thickness is formed by blowing the powder material on the surface on which the powder material is placed.

Further, the three-dimensional object shaping apparatus according to the present invention irradiates a laser beam to a heat-meltable powder material deposited with a predetermined thickness in accordance with the cross-sectional shape of the three-dimensional object at predetermined intervals. An apparatus for modeling a three-dimensional object by performing the process of binding over the entire height of the object,
An elevating body disposed in the modeling space so as to be movable up and down, a moving body provided so as to be reciprocally movable in a predetermined direction at a position above the modeling space, and a powder material disposed on the moving body for the above modeling Cross-sectional shape of a three-dimensional object on a powder spray layer sprayed into the space, a powder material supply device for supplying a powder material to the powder spray tool, and a powder deposition layer sprayed from the powder spray tool and deposited in layers And a laser beam irradiator that irradiates a laser beam according to the above.

  According to the three-dimensional object modeling method and the configuration of the modeling apparatus, the powder material is deposited at every predetermined interval 6 in the three-dimensional object, and the same range as the cross-sectional shape of the three-dimensional object in the powder deposition layer is burned. When the product is manufactured by performing the work to be performed over the entire height of the object, the powder accumulation layer is obtained by spraying the powder material. For example, a scraper is used to obtain a predetermined height equal to the predetermined interval. Unlike the one that smoothes the surface, even if the powder material has poor fluidity, it can be placed uniformly and cleanly on its mounting surface, and therefore the same shape as the three-dimensional object Can be obtained with high accuracy, and a beautiful finished surface can be obtained.

[Embodiment]
Hereinafter, the modeling method and modeling apparatus of the three-dimensional object which concern on embodiment of this invention are demonstrated based on FIG. 1 and FIG.

  In the present embodiment, using CAD data of a three-dimensional object, a case where a three-dimensional object having the same shape [hereinafter also referred to as a product (or may be a prototype)] is manufactured (modeled), At the time of production, the cross-sectional shape (data of the slice portion for each layer of the three-dimensional object) at a predetermined interval, that is, every predetermined height (hereinafter also referred to as a predetermined thickness) in the three-dimensional object is made to coincide. Next, a powder material such as synthetic resin (plastic powder, specifically, nylon powder is used) deposited on a predetermined mounting surface is sintered (melted and solidified) to obtain a slice portion of the three-dimensional object. The product is obtained by stacking the sliced parts (deposited parts) obtained by sintering. The average particle size of the powder material is, for example, about 20 μm, and the predetermined height (layer thickness) is about 40 μm in which two powders are stacked one above the other (of course, more than 40 μm). It can be thick). In addition, it is also called a powder sintering lamination method in the meaning of lamination by sintering.

First, a three-dimensional object modeling apparatus will be described.
As shown in FIG. 1, the modeling apparatus forms a product A having the same shape as a three-dimensional object having a horizontal cross-sectional shape made rectangular by a vertical wall portion 1 arranged in four directions and a predetermined depth. The apparatus main body 3 provided with the modeling space part 2 for performing, and the raising / lowering guide member (for example, it is comprised from the guide rod and the guide cylinder which guides the said guide bar) in the said modeling space part 2 4 is an elevating plate body (which is an example of an elevating body, which is disposed as an elevating body) and is deposited (placed) with a predetermined thickness on the upper surface (mounting surface). 5) and an elevating drive means (for example, using a ball screw mechanism) 6 connected to the lower surface of the elevating plate body 5 and capable of raising the elevating plate body 5 by a predetermined height; Device main body 3 around the space 2 for modeling A roller or the like is provided on a guide member (for example, composed of a pair of left and right guide rails) 7 in a predetermined direction (indicated by arrows a and b and hereinafter also referred to as a front-rear direction) along the surface of the upper wall portion 3a. Via a movable body 8 provided so as to be reciprocally movable (which may use a linear guide mechanism), moving drive means 9 for moving the movable body 8 in the front-rear direction, and powder provided on the movable body 8 A powder spraying tool 10 that blows the material on the lifting plate 5 in the modeling space 2 by a predetermined amount; a powder material supply means 11 that supplies the powder material to the powder spraying tool 10; and the modeling space 2 A laser beam irradiator 12 which is disposed above and irradiates a laser beam on the lifting plate 5 and a powder material which is provided on the apparatus main body 3 side at the front and rear positions of the modeling space 2 and scattered on the upper wall 3a. By a scraper (not shown) Between the collection container 13 for collection, the heater 14 for heat insulation arranged around the vertical wall 1 constituting the modeling space 2, the laser beam irradiator 12 and the powder spraying tool 10 and A heater for heating (for example, a heating wire is used) 15 disposed at four positions corresponding to the peripheral portion of the modeling space portion 2 and the modeling space portion arranged above the modeling space portion 2. 2 and a temperature measuring instrument 16 (for example, an infrared radiation thermometer is used) that measures the temperature of the sintered surface.

  As said powder spraying tool 10, the blowing nozzle which blows off powder material over the predetermined range using air is used. When the blowing range is wide left and right, the powder spraying tool (hereinafter referred to as blowing nozzle) 10 may be provided so as to be able to traverse in the left-right direction orthogonal to the front-rear direction, or may swing its head in the left-right direction. It is configured to be swingable so that it can. Of course, when the blowing nozzle 10 is provided so as to be capable of traversing or swinging, a traversing body and traversing driving motor, or a swinging mechanism and swinging driving motor are provided.

  The powder material supply means 11 includes a storage container 21 for the powder material B, a powder supply pipe 22 for taking out the powder material in the storage container 21 and supplying the powder material to the blowing nozzle 10, and a middle of the powder supply pipe 22. And a compressed air supply machine (not shown) for supplying compressed air into the powder supply pipe 22 and blowing out the powder material from the blowing nozzle 10.

The laser beam irradiator 12 includes a laser oscillator 32 disposed in the irradiator body 31 and a laser beam disposed in the laser irradiation opening of the irradiator body 31 and emitting laser light emitted from the laser oscillator 32. A galvanometer mirror unit 33 for positioning at an arbitrary upper position, and an f-θ lens 34 as an objective lens for focusing the laser beam from the galvanometer mirror unit 33 to a spot so as to reach a high temperature on the sintered surface. And a gas injection nozzle 35 for blowing a gas such as N ₂ gas on the surface of the lens 34 to prevent the lens from being fogged by smoke generated during sintering.

  Further, the driving means 9 for movement is an endless belt (for example, a chain member) 42 wound endlessly between sprockets 41, 41 provided on the front and rear sides of the modeling space 2. And a rotational drive machine (not shown, but using, for example, an electric motor) for rotating either the left or right pair of sprockets 41, and the movable body 8 is connected to the endless belt 42 (connecting material ( (Not shown).

  The f-θ lens 34 described above intentionally produces image distortion so that the ideal image height y of the lens is y = f × θ (where f is the focal length and θ represents the angle of view). This is for converting a constant angular velocity motion into a constant velocity motion (note that the ideal image height y of a normal lens is expressed as y = f × tan θ by the focal length f and the angle of view θ).

Next, an operation for manufacturing a product using the modeling apparatus will be described.
In this production, as described above, a slice portion having a predetermined thickness is obtained using CAD data (cross-sectional shape data of the slice portion) for each predetermined height (corresponding to a predetermined interval and a predetermined thickness) in the three-dimensional object. Sintering is performed sequentially, and products are obtained by stacking them.

  At the start of production, at least the powder material B necessary to form one product is stored in the storage container 21, and the heat retaining heater 14 and the heating heater 15 are operated.

  First, as shown in FIG. 2 (a), the height h between the upper surface (mounting surface) of the elevating plate body 5 in the modeling space 2 and the surface of the upper wall portion 3a of the apparatus main body 3 has been described above. The height is raised to a predetermined height (one slice of the slice portion).

  Next, the moving body 8 is moved in the arrow direction a, and the powder material B is blown from the powder spraying tool 10 onto the surface of the elevating plate body 5 so that the upper surface of the modeling space 2 is filled, that is, a predetermined height. The deposited layer C1 of the powder material is formed so that the thickness (thickness of one slice) is h.

When the deposited layer C1 is formed, the laser beam irradiator 12 irradiates a laser beam to a range of a cross-sectional shape (cross-sectional area) at a predetermined height of the three-dimensional object, and sintering is performed.
When the sintering for one layer is completed, as shown in FIG. 2B, the elevating plate body 5 is further lowered by a predetermined height h by the elevating drive means 6.

  Next, the powder spraying tool 10 is moved in the reverse direction as indicated by the arrow b (of course, as in the first layer, it can be returned to the original position and moved in the arrow direction a) and the powder material is further layered. The second deposition layer C <b> 2 is formed by blowing out by the amount.

  When the second deposition layer C2 is formed, the laser beam irradiator 12 irradiates the laser beam to the range of the cross-sectional shape corresponding to the next predetermined height in the three-dimensional object and performs sintering. .

  Of course, at the time of manufacture, the temperature of the sintered surface is heated to near the melting point of the powder material by the heater 15 and deformation due to the temperature difference between the sintered portion and its surroundings is prevented. ing. The heater 15 is controlled based on the detected temperature from the temperature measuring device 16.

  In addition, the heat retaining heater 14 keeps the lower part of the molded product at a certain high temperature, suppresses the difference in shrinkage from the upper molding part and prevents the heat from the heater 15 from escaping. It is preventing.

  In this way, a product having the same shape as the three-dimensional object is manufactured (modeling) by performing the operation of sintering the powder material in the range corresponding to the cross-sectional shape for each layer of the three-dimensional object over the entire height of the object. can do.

  As described above, the powder material is deposited according to the predetermined height in the three-dimensional object, and the work for sintering the same range as the cross-sectional shape (cross-sectional area) of the three-dimensional object in the powder deposition layer is performed. When the product is manufactured by performing over the entire height of the above, the above-mentioned powder accumulation layer is obtained by spraying the powder material. For example, the surface of the powder is leveled to a predetermined height using a scraper. Unlike the powder material having poor fluidity, it can be arranged uniformly and cleanly on the mounting surface (sintered surface) for sintering, and therefore has the same shape as the three-dimensional object. The product can be obtained with high accuracy and a beautiful finish can be obtained.

It is sectional drawing which shows schematic structure of the modeling apparatus of the three-dimensional object which concerns on embodiment of this invention. It is sectional drawing explaining the procedure of the modeling method of the same three-dimensional object. It is principal part sectional drawing which shows schematic structure of the manufacturing apparatus of the conventional three-dimensional object.

Explanation of symbols

A Product B Powder material 1 Vertical wall part 2 Modeling space part 3 Device body 4 Lifting guide member 5 Lifting plate body 6 Lifting drive means 8 Moving body 9 Moving drive means 10 Powder spraying tool 11 Powder material supply means 12 Laser Light irradiator

Claims (2)

According to the cross-sectional shape at predetermined intervals in the three-dimensional object, the process of irradiating and sintering the heat-meltable powder material deposited with a predetermined thickness over the entire height of the object When modeling 3D objects,
A method for forming a three-dimensional object, wherein a powder deposit layer having a predetermined thickness is formed by blowing out the powder material on a placement surface of the powder material. According to the cross-sectional shape at predetermined intervals in the three-dimensional object, the process of irradiating and sintering the heat-meltable powder material deposited with a predetermined thickness over the entire height of the object An apparatus for modeling a three-dimensional object,
An elevating body disposed in the modeling space so as to be movable up and down, a moving body provided so as to be reciprocally movable in a predetermined direction at a position above the modeling space, and a powder material disposed on the moving body for the above modeling Cross-sectional shape of a three-dimensional object on a powder spray layer sprayed into the space, a powder material supply device for supplying a powder material to the powder spray tool, and a powder deposition layer sprayed from the powder spray tool and deposited in layers A three-dimensional object shaping apparatus comprising a laser beam irradiator that irradiates a laser beam according to the above.

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