JP2006248039A - Three-dimensional shaping method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To surely manufacture a three-dimensionally shaped article by preventing the dissociation between a part formed from an auxiliary material and a part formed from a shaping material in cutting. <P>SOLUTION: In a three-dimensional shaping method for manufacturing the three-dimensionally shaped article comprising a shaping material layer, an auxiliary material layer is removed after a process for cutting the auxiliary material layer formed from the auxiliary material and a process for cutting the shaping material layer formed from the shaping material are repeated. A part or the whole of an area formed from one of the auxiliary material and the shaping material is supported by supplying the other different from the material forming the area to cut part of the area. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a three-dimensional modeling method, and more specifically, a three-dimensional modeling method for producing a three-dimensional modeled object while laminating an auxiliary material layer formed of an auxiliary material and a modeling material layer formed of a modeling material. About.

  Conventionally, after a predetermined portion of the auxiliary material layer formed of the auxiliary material is removed by cutting with a cutting tool such as an end mill, a modeling material layer is formed on the removed portion with a modeling material, and these are removed. A three-dimensional modeling apparatus is known in which a desired three-dimensional modeled object can be obtained by repeatedly performing a two-dimensional cross-sectional shape by laminating (for example, Patent Document 1).

  In the 3D modeling apparatus as described above, since the second layer is laminated on the already formed first layer (see FIG. 1A), the second auxiliary layer is the first layer. They are fixed with mutual adhesive strength to the modeling material layer (see FIG. 1B). Then, the auxiliary material layer of the second layer is cut and formed by an end mill as a cutting tool (see FIG. 1C).

However, depending on the shape and size of the three-dimensional structure to be produced, the type of modeling material and auxiliary material, etc., the mutual adhesive force is lost to the cutting resistance of the cutting by the cutting tool, and the auxiliary layer laminated on the modeling material layer. In the process of cutting and molding the material layer, the first modeling material layer and the second auxiliary material layer are dissociated (see the broken line shown in FIG. 1 (d)), and as a result, a three-dimensional structure is formed. There was a fear of not being able to.
JP-A-8-318573

  The present invention has been made in view of the various problems of the conventional techniques as described above. The object of the present invention is to form a part formed by an auxiliary material and a modeling material at the time of cutting. It is an object of the present invention to provide a three-dimensional modeling method that prevents a dissociated portion from being dissociated and enables a three-dimensional model to be reliably produced.

  In order to achieve the above object, the invention according to claim 1 of the present invention includes a step of cutting an auxiliary material layer formed of an auxiliary material and a step of cutting a modeling material layer formed of a modeling material. After repeatedly performing, in the three-dimensional modeling method of removing the auxiliary material layer and producing a three-dimensional modeled object composed of the modeling material layer, the region formed by one of the auxiliary material and the modeling material A part or the whole is supplied and supported by another material different from the material forming the region, and a part of the region is cut.

  According to a second aspect of the present invention, the second material different from the first material is supplied onto the first region formed of the first material, and the second region The first material is formed so as to be in contact with and connected to a part or all of the surface of the second region formed in the first step. A second stage of supply and a third stage of cutting a part of the second region are provided.

  Moreover, invention of Claim 3 among this invention WHEREIN: The invention of Claim 2 WHEREIN: The said 1st material is either one of an auxiliary material and a modeling material, The said 2nd material is the above-mentioned. The first material is different from the other.

  According to a fourth aspect of the present invention, in the first or third aspect of the present invention, at least one of the auxiliary material and the modeling material is substantially a dot. It is made to supply in the form.

  The present invention has an excellent effect that a part formed by an auxiliary material and a part formed by a modeling material can be prevented from dissociating at the time of cutting, and a three-dimensional structure can be reliably manufactured.

  Hereinafter, an example of an embodiment of a three-dimensional modeling method according to the present invention will be described in detail with reference to the accompanying drawings.

  First, a three-dimensional modeling method according to the first embodiment of the present invention will be described with reference to FIGS.

  FIG. 2 shows a schematic configuration explanatory diagram of an example of an embodiment of a three-dimensional modeling apparatus that realizes a three-dimensional modeling method according to the present invention. The three-dimensional modeling apparatus 10 shown in FIG. 2 is formed in a U-shape formed by a pair of substantially quadrangular columnar support portions 12L and 12R extending in the vertical direction and a bottom portion 12B connecting the support portions 12L and 12R. The gate-type arm portion 12 is provided. Furthermore, the rail part 14 supported by the upper ends of each of the pair of support parts 12L and 12R, and the rail part 14 are within a predetermined range in the X-axis direction in the XYZ orthogonal coordinate system (see the reference diagram showing the coordinate system in FIG. 2). The carriage 16 is disposed so as to be freely movable.

  Further, a spindle 28, a dispenser 24 for discharging an auxiliary material, and a modeling material are discharged to a head (see FIGS. 2 and 3) provided movably within a predetermined range in the Z-axis direction with respect to the carriage 16. A dispenser 26 is also provided.

  Further, on the frame portion 18, a table 22 having a flat upper surface that is movable within a predetermined range in the Y-axis direction is disposed. On the upper surface 22a, an auxiliary material layer formed by an auxiliary material and a modeling process are provided. A modeling material layer formed of the material is laminated to form a three-dimensional modeled object.

  Note that the entire operation of the three-dimensional modeling apparatus 10 is controlled by a microcomputer. The dispenser 24, the dispenser 26, and the spindle 28 are moved in the Z-axis direction along with the movement of the head and X along with the movement of the carriage 16. The table 22 is moved in the axial direction and in the Y-axis direction.

  Accordingly, the relative positional relationship between the end mill 30 supported by the dispenser 24, the dispenser 26 and the spindle 28 and the three-dimensional structure formed on the table upper surface 22a moves in any direction in the X, Y, and Z axis directions. It is possible.

  Next, FIG. 3 shows a schematic configuration explanatory view (perspective view) in which the carriage 16 portion of the three-dimensional modeling apparatus 10 shown in FIG. 2 is enlarged, and detailed description will be given below.

  The dispenser 24 is designed so that auxiliary material accommodated in a tank (not shown) is supplied to the syringe 24b with a built-in heater, and can heat the auxiliary material stored in the syringe to a predetermined temperature.

  In this embodiment, a metal, particularly a low melting point alloy is used as an auxiliary material. For example, solder.

  The low melting point alloy heated to a predetermined temperature is melted in the syringe 24b, connected to the syringe 24b and discharged from the discharge port 24a located at the tip of the dispenser 24, and drops into a predetermined droplet. It is controlled so that a predetermined amount is applied to the position.

  The dispenser 26 is designed so that the modeling material accommodated in a tank (not shown) is supplied to the syringe 26b. One drop of the modeling material is connected to the syringe 26b from the discharge port 26a located at the tip of the dispenser 26. It is controlled so that a single droplet is ejected and applied to a predetermined position as a flying droplet.

  In this embodiment, an ultraviolet curable resin that cures when irradiated with ultraviolet rays is used as the modeling material.

  Further, a light guide member 42 is disposed so as to be positioned on the outer peripheral side of the discharge port 26a of the dispenser 26. The light guide member 42 is designed such that the optical fiber 50 for irradiating the ultraviolet rays drawn from the introduction tube portion 42c is positioned on the inclined surface 42s through the connecting portion 42b. For this reason, the ultraviolet rays irradiated from the front end portion of the optical fiber 50 are irradiated in a 360 ° ring shape, and are condensed in a spot shape directly below the through-hole 42h drilled in a substantially central portion of the main body portion 42a (see FIG. 6 (b)).

  Therefore, as described above, the ultraviolet curable resin applied at a predetermined position from the discharge port 26a of the dispenser 26 is controlled so as to be cured by the ultraviolet rays irradiated from the light guide member 42.

  The end mill 30 is connected to a rotating spindle 28 and cuts an auxiliary material layer and a modeling material layer by a cutting portion 30a.

  In the above configuration, a three-dimensional structure having a substantially hemispherical shape shown in FIG. 4H is obtained by the three-dimensional modeling method of the present invention using the three-dimensional modeling apparatus 10 described above with reference to FIGS. The process of manufacturing 100 will be described in detail. Note that in FIGS. 4 to 6, the portion formed of the auxiliary material is appropriately shown with light ink.

  First, under the control of the microcomputer, the droplets of the low-melting-point alloy, which is an auxiliary material, are ejected from the discharge port 24a of the dispenser 24 located at a predetermined distance from the upper surface 22a of the table 22 to a predetermined position on the table upper surface 22a. The three-dimensional shape is supplied in the form of dots and the amount of cutting by the end mill 30 is minimized (see FIG. 5A), and is naturally cooled and solidified to form the auxiliary material layer 102 (FIG. 4A). reference).

  The auxiliary material layer 102 (see FIG. 4A) formed of the low melting point alloy as the auxiliary material is cut by the end mill 30 to obtain a desired shape 102 '(see FIG. 4B).

  Next, under the control of the microcomputer, the droplets of UV curable resin, which is a modeling material, are ejected from the discharge port 26a of the dispenser 26 located at a predetermined distance from the upper surface 102'a of the auxiliary material layer 102 '. A three-dimensional shape in which the amount of cutting by the end mill 30 is minimized is supplied to a predetermined position on the layer 102 ′ in a substantially dot shape (see FIG. 6A).

  At this time, as described above, the light guide portion 42 irradiates the ultraviolet rays and simultaneously cures the ultraviolet curable resin (see FIG. 6B).

  When the modeling material layer 104 is thus laminated on the auxiliary material layer 102 ′ as shown in FIG. 4C, the auxiliary material layer 102 is formed prior to the cutting of the modeling material layer 104. By this method, the auxiliary material region 202 is formed so as to support the modeling material layer 104 in a bridge shape (see FIG. 4D-1 and FIG. 5B). FIG. 4 (d-2) shows a view taken along arrow A in FIG. 4 (d-1).

  More specifically, the auxiliary material region 202 has a band shape having a predetermined width, and passes through the modeling material layer 104 from the upper surface 102′a of the auxiliary material layer 102 ′ positioned below the modeling material layer 104. It is formed in an arch shape reaching the upper surface 102'a of the auxiliary material layer 102 'again. That is, in the auxiliary material region 202, the inner surface 202a is bonded to the surface 104a of the modeling material layer 104, and both end portions 202b and 202c thereof are the same material located in the lower layer of the modeling material layer 104. Since the auxiliary material layer 102 ′ is connected to the auxiliary material layer 102 ′ and has a predetermined mutual adhesive force, the modeling material layer 104 laminated on the auxiliary material layer 102 ′ is stably formed on the upper surface of the auxiliary material layer by the auxiliary material region 202. It is integrated with the auxiliary material layer 102 'while being fixed to 102'a.

  Next, a portion of the modeling material layer 104 that is not covered by the auxiliary material region 202 is cut by the end mill 30 so that the modeling material layer 104 ′ after cutting has an outer surface 104 ′ b having a desired shape. (See FIG. 4E).

  At this time, as described above, the modeling material layer 104 is stably fixed to the auxiliary material layer upper surface 102'a, that is, the modeling material layer 104 can be accurately cut.

  When the modeling material layer 104 ′ is thus formed, the auxiliary material regions 204 and 206 are similarly formed so as to cover the outer surface 104 b ′ (see FIG. 4F).

  More specifically, the auxiliary material regions 204 and 206 have their inner surfaces bonded to the outer surface 104′b of the modeling material layer 104 ′ and their lower end portions 204a and 206a under the modeling material layer 104 ′. Since the auxiliary material layer 102 ′ made of a low melting point alloy which is the same material is connected and has a predetermined mutual adhesive force, the modeling material layer 104 on the auxiliary material layer 102 ′ is formed by the auxiliary material regions 204 and 206. 'Is integrated with the auxiliary material layer 102' while being stably fixed to the upper surface 102'a of the auxiliary material layer.

  Next, a portion that has not been cut in the previous cutting, that is, a portion covered with the auxiliary material region 202 of the modeling material layer 104 ′ is cut and formed into an outer peripheral surface 104 ′ c having a desired shape by the end mill 30. (See FIG. 4G).

  In addition, the modeling material layer 104 ′ can be accurately cut and formed by stable fixation as in the previous case.

  Next, the above-described three-dimensional structure 100 ′ (see FIG. 4G) is heated to a predetermined temperature, for example, by removing it from the upper surface 22 a of the table 22. Then, the low-melting-point alloy that is the auxiliary material forming the auxiliary material layer 102 ′ and the auxiliary material regions 204 and 206 is removed by heat dissolution, and the three-dimensional structure 100 constituted by the modeling material layer 104 ′ (FIG. 4H). Reference) is obtained.

  As described above, in the three-dimensional modeling method according to the first embodiment of the present invention, when the modeling material layer 104 laminated on the auxiliary material layer 102 ′ is cut, a part of the modeling material layers 104 and 104 ′. Auxiliary material is supplied to form auxiliary material regions 202, 204, and 206 so that the modeling material layers 104 and 104 ′ made of the modeling material are stably fixed to the cutting resistance of the end mill 30 by the auxiliary material. Therefore, an accurate three-dimensional structure can be produced.

  Therefore, even if it is a case where the mutual adhesive force is poor depending on the shape and size of the three-dimensional structure to be manufactured, or the type and combination of the modeling material and auxiliary material, the tertiary according to the present invention. According to the original modeling method, it is possible to prevent the part formed by the auxiliary material and the part formed by the modeling material from being dissociated in the middle of the production of the three-dimensional modeled object by losing the cutting resistance of the cutting by the cutting tool. Can do. In other words, the present invention has high versatility, and according to the present invention, the width and shape of usable materials are greatly expanded, and various three-dimensional structures can be produced.

  Next, a three-dimensional modeling method according to the second embodiment of the present invention will be described with reference to FIG.

  FIG. 7 is an explanatory view sequentially showing steps for producing the three-dimensional structure shown in FIG. 7H by the three-dimensional modeling method according to the second embodiment of the present invention. In FIG. 7, the portion formed of the auxiliary material is appropriately shown with light ink.

  The three-dimensional structure shown in FIG. 7 (h) is the same as the three-dimensional structure 100 (see FIG. 4 (h)) of the first embodiment described above, and is shown in FIGS. The same components as those shown are denoted by the same reference numerals for easy understanding.

  In the first embodiment, the auxiliary material region 202 and then 204 and 206 are formed so as to support the modeling material layer 104 in a bridge shape. However, in the second embodiment, the modeling material layer 104 is formed. The auxiliary material region 302 and then 304 are formed so as to cover approximately half of the material layer. In the second embodiment, the modeling material layers 104 and 104 ′ are formed of the auxiliary material in the second embodiment as in the first embodiment. Since the layer is stably fixed, an accurate three-dimensional structure can be produced.

  The embodiment described above may be modified as described in the following (1) to (7).

  (1) The first and second embodiments described above may be combined as appropriate according to the type of three-dimensional structure to be produced. Furthermore, in order to produce a single three-dimensional structure, a step of supporting the modeling material layer with the auxiliary material and a step of supporting the auxiliary material layer with the modeling material may be performed.

  (2) In the above-described embodiment, the low melting point alloy is used as the auxiliary material and the ultraviolet curable resin is used as the modeling material. However, the present invention is not limited to this, and various materials are supported. It may be used as a material or as a modeling material.

  For example, as an auxiliary material, a thermoplastic resin such as wax may be used, and as a modeling material, a photo-curing resin that is cured by visible light, electron beam, or other light of radiation different from ultraviolet rays, Similarly to the auxiliary material, a thermoplastic resin such as wax may be used.

  According to the three-dimensional modeling method according to the present invention, the degree of freedom of the material is widened. For example, a combination of a wax having a low mutual adhesive force and a low melting point alloy can be used.

  (3) The auxiliary material regions 202, 204, 206 (see FIG. 4) of the first embodiment and the auxiliary material regions 302, 304 (see FIG. 7) of the second embodiment are respectively described above. The shape, position, size, etc. of the auxiliary material (or modeling material) that supports the part formed by the modeling material (or auxiliary material) are not limited to the shape of the form of the three-dimensional model to be manufactured. The shape and size, the area where the modeling material layer and the auxiliary material layer are in contact with each other in the process of production, the order of cutting and lamination, and the like can be changed as appropriate.

  For example, the width of the band-shaped auxiliary material region 202 shown in FIG. 4D-1 can be about 2 to 3 mm, but is not limited to this size. Further, depending on the three-dimensional structure to be produced, an auxiliary material is applied so as to form a hill on the outer peripheral edge of the modeling material layer (see symbols 502 and 504 shown in FIG. 8A), or a modeling material layer An auxiliary material may be applied so as to cover the entire surface, or the modeling material layer may be supported in a series of chains by an auxiliary material supplied in a dot shape prior to cutting of the modeling material layer (FIG. 8B). Reference numeral 506 shown in FIG.

  Further, depending on the shape of the three-dimensional structure to be produced, the modeling material (or auxiliary material) is applied so as to support the auxiliary material layer (or modeling material layer) that is first formed on the upper surface 22a of the table 22. You may do it.

  (4) In the above-described embodiment, the auxiliary material regions 202, 204, 206, 302, and 304 (see FIGS. 4 and 7) are immediately supported by the auxiliary material region and the modeling material region. Of course, the modeling material layer and the auxiliary material layer are cut. However, the present invention is not limited to this.

  Depending on the position and shape of the formed auxiliary material region and modeling material region, or the shape and size of the three-dimensional structure to be manufactured, and the cutting and laminating processes, for example, to support the modeling material layer The auxiliary material may be applied to the substrate, and then the auxiliary material layer or the modeling material layer may be laminated on the modeling material layer, and then the modeling material layer supported by the applied auxiliary material may be cut. The three-dimensional modeling method according to the present invention can be changed as appropriate in a three-dimensional model manufacturing process that combines application, lamination, and cutting of materials.

  (5) In the above-described embodiment, the auxiliary material and the modeling material are both supplied in a substantially dot shape. However, the present invention is not limited to this, and only the auxiliary material or Even if only the modeling material is supplied in a substantially dot shape, the material can be applied with high accuracy. Also, depending on the type of auxiliary material and modeling material, the range to be applied, etc., a method different from a substantially dot shape, for example, a linear shape or a predetermined amount may be applied.

  (6) In the above-described embodiment, the 3D modeling apparatus 10 shown in FIGS. 2 and 3 is used. However, the present invention is not limited to this, and various types of 3D modeling apparatus 10 may be used. You may make it add a structure or use another modeling apparatus.

  Therefore, various configurations such as using other cutting tools such as a cutter different from the end mill 30 or changing the relative positional relationship between the three-dimensional structure to be produced and the dispensers 24 and 26 in the three-dimensional direction can be employed. Is. Moreover, the process of removing the part formed with the auxiliary material to obtain a three-dimensional structure may be performed in a system in the modeling apparatus.

  (7) You may make it combine the above-mentioned embodiment and the modification shown in said (1) thru | or (6) suitably.

  The present invention can be used in a three-dimensional processing apparatus such as a modeling machine, a two-dimensional engraving apparatus that performs cutting with a tool, or the like when producing parts or design models in trial production or mass production.

(A) (b) (c) is explanatory drawing which shows the method in the conventional three-dimensional modeling apparatus sequentially, (d) is a perspective explanatory drawing of (c). It is schematic structure explanatory drawing which shows an example of embodiment of the three-dimensional modeling apparatus which implement | achieves the three-dimensional modeling method by this invention. FIG. 3 is a schematic configuration explanatory diagram (perspective view) illustrating an enlarged carriage portion of the three-dimensional modeling apparatus illustrated in FIG. 2. (A) (b) (c) (d-1) (e) (f) (g) is a three-dimensional structure shown in (h) by the three-dimensional structure forming method according to the first embodiment of the present invention. FIG. 6 is an explanatory view sequentially showing the steps for manufacturing the film, and (d-2) is a view taken in the direction of arrow A in (d-1). (A) (b) is explanatory drawing which showed application | coating of auxiliary material typically. (A) (b) is explanatory drawing which showed typically application | coating of modeling material. (A), (b), (c), (d), (e), (f), and (g) produce the three-dimensional structure shown in (h) by the three-dimensional structure forming method according to the second embodiment of the present invention. It is explanatory drawing which shows the process to perform one by one. (A) (b) is explanatory drawing which shows the other example of the three-dimensional modeling method by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 3D modeling apparatus 12 Portal arm part 14 Rail part 16 Carriage 18 Frame part 22 Table 24 Dispenser 26 Dispenser 28 Spindle 30 End mill 42 Light guide member 50 Optical fiber 100 Three-dimensional modeling thing

Claims (4)

After repeatedly performing the process of cutting the auxiliary material layer formed of the auxiliary material and the process of cutting the modeling material layer formed of the modeling material, the auxiliary material layer is removed to form a three-dimensional structure composed of the modeling material layer In the three-dimensional modeling method for producing a modeled object,
A part or the whole of the region formed by one of the auxiliary material and the modeling material is supported by supplying the other material different from the material forming the region, and a part of the region is cut. A three-dimensional modeling method characterized by: Supplying a second material different from the first material on the first region formed by the first material to form the second region; and
A second step of supplying the first material in contact with a part or all of the surface of the second region formed in the first step and being connected to the first region;
And a third step of cutting a part of the second region. In the three-dimensional modeling method according to claim 2,
The three-dimensional modeling method, wherein the first material is one of an auxiliary material and a modeling material, and the second material is one of the other materials different from the first material. In the three-dimensional modeling method according to any one of claims 1 and 3,
A three-dimensional modeling method, comprising supplying at least one of the auxiliary material and the modeling material in a substantially dot shape.