JP2010196099A - Apparatus and method of producing three-dimensional shaped article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and method of producing a three-dimensional shaped article, in which a warping phenomenon occurring in a solidified layer, i.e. three-dimensional shaped article, is prevented as much as possible. <P>SOLUTION: The apparatus of producing the three-dimensional shaped article includes: a powder layer forming means 24 for forming a powder layer; a light beam irradiating means for irradiating the powder layer with a light beam so as to form the solidified layer; and a shaped plate 21 in which a powder layer 22 and/or solidified layer 24 are to be formed. The shaped plate 21 is joinable to the solidified layer 24, and Young's modulus of the shaped plate 21 is approximately 1-15 times Young's modulus of the solidified layer 24. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a manufacturing apparatus and a manufacturing method of a three-dimensional shaped object. More specifically, the present invention manufactures a three-dimensional shaped object in which a plurality of solidified layers are laminated and integrated by repeatedly performing formation of a solidified layer by irradiating a predetermined portion of the powder layer with a light beam. The present invention relates to a method and an apparatus therefor.

  Conventionally, a method of manufacturing a three-dimensional shaped object by irradiating a powder material with a light beam (generally referred to as “powder sintering lamination method”) is known. In such a method, “(i) by irradiating a predetermined portion of the powder layer with a light beam, the powder at the predetermined portion is sintered or melt-solidified to form a solidified layer, and (ii) of the obtained solidified layer A three-dimensional shaped article is manufactured by repeating the process of “laying a new powder layer on the top and irradiating the same with a light beam to form a solidified layer” (see Patent Document 1 or Patent Document 2). When a metal powder is used as the powder material, the obtained three-dimensional shaped object can be used as a mold or the like. When a resin powder is used as the powder material, the obtained three-dimensional shaped object is a plastic. It can be used as a model. According to such a manufacturing technique, it is possible to manufacture a complicated three-dimensional shaped object in a short time.

  In the powder sintering lamination method, a three-dimensional shaped object is manufactured in a chamber maintained in an inert atmosphere from the viewpoint of oxidation prevention and the like. Specifically, the three-dimensional shaped object is manufactured on a “modeling plate arranged on a modeling table” in the chamber. As shown in FIG. 1, when a three-dimensional modeled object is manufactured on a modeling plate 21 arranged on the modeling table 20, first, a powder layer 22 having a predetermined thickness t <b> 1 is first formed on the modeling plate 21. After the formation (see FIG. 1A), the solidified layer 24 is formed on the modeling plate 21 by irradiating a predetermined portion of the powder layer 22 with the light beam L. Then, a new powder layer 22 is laid on the formed solidified layer 24 and irradiated again with a light beam to form a new solidified layer. When the solidified layer is repeatedly formed in this way, a three-dimensional shaped object in which a plurality of solidified layers 24 are laminated and integrated can be obtained (see FIG. 1B). In general, the modeling plate is made of substantially the same material as the powder layer, and the solidified layer corresponding to the lowermost layer can be formed in a state of being adhered to the modeling plate surface. The modeling plate surface is obtained in a state of being bonded to each other (see Patent Document 3).

  Here, since the three-dimensional shaped object is manufactured through the irradiation of the light beam, the three-dimensional shaped object is affected by heat from the light beam. Specifically, the irradiated portion of the powder layer is once melted to be in a molten state and then solidified to form a solidified layer. However, a shrinkage phenomenon may occur when the solidified layer is solidified. In particular, a shrinkage phenomenon occurs when the melted powder is cooled and solidified (see FIG. 2A). On the other hand, the modeling plate that supports the solidified layer (that is, the three-dimensional modeled object) is substantially not easily affected by the heat of the light beam because it is away from the irradiation position of the light beam. As a result, a warping force (moment) is generated in the three-dimensional shaped object 24 on the modeling plate, and if it exceeds a certain limit, it is three-dimensional during manufacturing as shown in FIG. A phenomenon in which the shaped object 24 peels from the modeling plate 21 occurs. If the three-dimensional shaped object is warped or peeled off from the modeling plate, it is not desirable in that the desired three-dimensional shaped object cannot be manufactured. That is, when the three-dimensional shaped object (that is, the solidified layer) is warped, not only the shape accuracy of the obtained three-dimensional shaped object is not obtained, but also the solidified layer is warped, so that the solidified layer is on the solidified layer. It becomes impossible to spread a new powder layer with a predetermined thickness (for example, if the solidified layer warps larger than the thickness of the next powder layer, the powder layer cannot be spread uniformly thereafter).

JP-T-1-502890 JP 2000-73108 A JP 2008-184623 A

  The present invention has been made in view of such circumstances. That is, an object of the present invention is to provide a “three-dimensional shaped article manufacturing apparatus” and a “three-dimensional shaped article manufacturing method” that can suppress a warp phenomenon that may occur in a solidified layer (that is, a three-dimensional shaped article) as much as possible. Is to provide.

In order to solve the above problems, in the present invention,
Powder layer forming means for forming a powder layer,
A light beam irradiation means for irradiating the powder layer with a light beam (eg, a directional energy beam such as a laser beam) and a powder layer and / or a solidified layer are formed so that a solidified layer is formed. Modeling plate,
A three-dimensional shaped article manufacturing apparatus comprising:
There is provided a manufacturing apparatus characterized in that the modeling plate can be joined to the solidified layer, and the Young's modulus of the modeling plate is about 1 to 15 times the Young's modulus of the solidified layer.

  The manufacturing apparatus of the present invention is characterized in that the Young's modulus of the modeling plate that can be joined to the solidified layer is high. More specifically, the Young's modulus of the modeling plate that can be joined to the solidified layer is in the range of about 150 to about 800 GPa, which is about 1 to 15 times the Young's modulus of the solidified layer. In such a case, it is possible to absorb the stress of the three-dimensional shaped object that is going to be warped at the time of manufacture by the modeling plate and to prevent the warping from rising.

  In addition, the “modeling plate” referred to in the present specification substantially means a member that becomes a base of a modeled object to be manufactured. In a particularly preferred aspect, the “modeling plate” refers to a plate-like member disposed on the modeling table.

  In addition, the expression “possible to be joined to the solidified layer” in the present specification substantially refers to an aspect in which the modeling plate and the solidified layer are joined when the solidified layer is formed by irradiating the powder layer with a light beam. In particular, it means a mode in which the “solidified layer formed from the lowermost powder layer provided directly on the modeling plate” and the “molding plate main surface (ie, upper surface)” are joined. Yes.

  In a preferred embodiment, when the powder layer is an iron-based powder and the solidified layer is formed of an iron-based material, the modeling plate is made of a cemented carbide. Since such a cemented carbide has a relatively high Young's modulus, it is possible to effectively prevent warping of the three-dimensional shaped object during manufacture. The “iron-based powder” here is a powder mainly composed of iron-based powder, and in some cases, a group consisting of nickel powder, nickel-based alloy powder, copper powder, copper-based alloy powder, graphite powder, and the like. Substantially means a powder further comprising at least one selected from (for example, the amount of iron-based powder is 60 to 90% by weight, nickel powder and / or nickel-based alloy powder) 5 to 35% by weight, copper powder and / or copper-based alloy powder or 5 to 15% by weight, and graphite powder is 0.2 to 0.8%. Examples thereof include metal powders having a weight%). In order to further improve the bondability with the solidified layer, a nickel coating may be provided on the main surface of the modeling plate.

  In a preferred embodiment, the modeling plate has a two-layer structure composed of an upper layer and a lower layer, and the upper layer is formed of a group consisting of a powder layer component, an iron-based component, a carbon steel component, a nickel component, and a nickel alloy component. It comprises at least one selected component, and the lower layer has a Young's modulus of about 150 to about 800 GPa. In this case, the lower layer of the modeling plate is preferably made of cemented carbide.

  Further, in a preferred aspect, the plate is composed of an upper plate and a lower plate joined to each other, and the upper plate has a powder layer component, an iron-based component, a carbon steel component, a nickel component, and a nickel alloy component. At least one component selected from the group consisting of: The Young's modulus of the lower plate is about 150 to about 800 GPa.

In the present invention, a “manufacturing method of a three-dimensional shaped object” performed using the manufacturing apparatus described above is also provided. Such a production method of the present invention comprises:
(I) a step of irradiating a predetermined portion of the powder layer provided on the modeling plate with a light beam to sinter or melt and solidify the powder at the predetermined portion to form a solidified layer; and (ii) the obtained solidified layer A method for producing a three-dimensional shaped object by repeating a step of forming a new powder layer on the surface and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer,
As the modeling plate, a plate that can be joined to the solidified layer and has a Young's modulus of about 1 to 15 times the Young's modulus of the solidified layer is used. In a preferable aspect of the manufacturing method of the present invention, the modeling plate has a two-layer structure composed of an upper layer and a lower layer, the upper layer can be joined to the solidified layer, and the Young's modulus of the lower layer is about 150. Use a modeling plate of about 800 GPa.

  In the manufacturing apparatus and the manufacturing method of the present invention, stress that can be generated inside the three-dimensional modeled object during manufacturing (particularly stress that can be generated when the three-dimensional modeled object is contracted as a whole) can be received by the modeling plate. . In other words, although not bound by a specific theory, the modeling plate joined to the bottom of the three-dimensional modeled object has a high Young's modulus, so it can effectively absorb the stress in the modeled object, As a result, it is possible to prevent or reduce the warping of the three-dimensional shaped object. Thereby, since the phenomenon that the three-dimensional shaped object (that is, the solidified layer) peels off from the modeling plate surface can be prevented, not only can a new powder layer be laid on the solidified layer with a predetermined thickness, The shape accuracy of the finally obtained three-dimensional shaped object is also improved.

  In addition, in order to obtain the shape accuracy of a three-dimensional shaped object in the prior art, it was necessary to design in advance assuming phenomena such as “warping” and “peeling”, but in the present invention, modeling is performed. The shape accuracy can be substantially obtained only by making the member that becomes the base of the object a material having a high Young's modulus. In other words, the present invention is very useful in that it is possible to omit such a design taking into account such a phenomenon that is difficult to predict by simple means.

Sectional view schematically showing the operation of the stereolithography combined processing machine Cross-sectional view schematically showing a phenomenon that causes warping or peeling of a three-dimensional shaped object The perspective view which showed typically the aspect by which the powder sintering lamination method is performed The perspective view which showed typically the structure of the optical shaping complex processing machine by which a powder sintering lamination method is implemented Flow chart of operation of stereolithography combined processing machine Schematic diagram conceptually showing the features of the present invention Schematic diagram of the modeling plate used in the present invention (the inside of the broken line represents the bottom area of the modeled object to be manufactured) Schematic diagram showing the form of a modeling plate with a nickel coating Schematic diagram showing an aspect of a two-layered modeling plate Schematic diagram showing the form of a modeling plate composed of multiple plates Schematic diagram showing a modified embodiment of the present invention

  Hereinafter, the present invention will be described in more detail with reference to the drawings.

[Powder sintering lamination method]
First, the powder sintering lamination method which is the premise of the present invention will be described. 1, 3, and 4 show the function and configuration of an optical modeling composite processing machine 1 that can perform the powder sintering lamination method. The optical modeling composite processing machine 1 includes “a powder layer forming means 2 for forming a powder layer by spreading a powder such as a metal powder and a resin powder with a predetermined thickness” and “in a modeling tank 29 whose outer periphery is surrounded by a wall 27. In FIG. 2, a modeling table 20 that moves up and down by cylinder drive ”,“ a modeling plate 21 that is arranged on the modeling table 20 and serves as a foundation of the modeling object ”, and“ light beam irradiation means 3 that irradiates the light beam L to an arbitrary position ” "The cutting means 4 which cuts the circumference | surroundings of a molded article" is mainly provided. As shown in FIG. 1, the powder layer forming means 2 includes “a powder table 25 that moves up and down by a cylinder drive in a powder material tank 28 whose outer periphery is surrounded by a wall 26” and “a powder layer 22 on a modeling plate. And a squeezing blade 23 "for forming. As shown in FIGS. 3 and 4, the light beam irradiation means 3 includes a “light beam oscillator 30 that emits a light beam L” and a “galvanomirror 31 that scans (scans) the light beam L onto the powder layer 22 (scanning). Optical system) ”. If necessary, the light beam irradiation means 3 has beam shape correction means (for example, a pair of cylindrical lenses and a rotation drive mechanism for rotating the lenses around the axis of the light beam) for correcting the shape of the light beam spot. And an fθ lens. The cutting means 4 mainly includes “a milling head 40 that cuts the periphery of the modeled object” and “an XY drive mechanism 41 that moves the milling head 40 to a cutting position” (see FIG. 4).

  The operation of the optical modeling complex machine 1 will be described in detail with reference to FIGS. 1 and 5. FIG. 5 shows an operation flow of the stereolithography combined processing machine.

  The operation of the optical modeling composite processing machine includes a powder layer forming step (S1) for forming the powder layer 22, a solidified layer forming step (S2) for forming the solidified layer 24 by irradiating the powder layer 22 with the light beam L, It is mainly composed of a cutting step (S3) for cutting the surface of the modeled object. In the powder layer forming step (S1), the modeling table 20 is first lowered by Δt1 (S11). Next, after raising the powder table 25 by Δt1, as shown in FIG. 1A, the squeezing blade 23 is moved in the direction of arrow A, and the powder (for example, “average particle size”) While “iron powder of about 5 μm to 100 μm” or “powder of nylon, polypropylene, ABS or the like having an average particle size of about 30 μm to 100 μm” is transferred onto the modeling plate 21 (S12), the powder is adjusted to a predetermined thickness Δt1. The layer 22 is formed (S13). Next, the process proceeds to a solidified layer forming step (S2), where a light beam L (for example, a carbon dioxide laser or an ultraviolet ray) is emitted from the light beam oscillator 30 (S21), and the light beam L is arbitrarily selected on the powder layer 22 by the galvanometer mirror 31. (S22), the powder is sintered or melted and solidified to form a solidified layer 24 integrated with the modeling plate 21 (S23).

  The powder layer forming step (S1) and the solidified layer forming step (S2) are repeated until the thickness of the solidified layer 24 reaches a predetermined thickness obtained from the tool length of the milling head 40, and the solidified layer 24 is laminated (FIG. 1). (See (b)). In addition, the solidified layer newly laminated | stacked will be integrated with the solidified layer which comprises the already formed lower layer in the case of sintering or melt-solidification.

  When the thickness of the laminated solidified layer 24 reaches a predetermined thickness, the process proceeds to the cutting step (S3), and the milling head 40 is driven (S31). For example, when the tool (ball end mill) of the milling head 40 has a diameter of 1 mm and an effective blade length of 3 mm, a cutting process with a depth of 3 mm can be performed. Therefore, if Δt1 is 0.05 mm, 60 solidified layers are formed. At that time, the milling head 40 is driven. The milling head 40 is moved in the directions of the arrow X and the arrow Y by the XY drive mechanism 41, and the surface of the modeled object composed of the laminated solidified layer 24 is cut (S32). And when manufacture of a three-dimensional shape molded article has not ended yet, it will return to a powder layer formation step (S1). Thereafter, the solidified layer 24 is further laminated by repeating S1 to S3, thereby manufacturing a three-dimensional shaped object.

  The irradiation path of the light beam L in the solidified layer forming step (S2) and the cutting path in the cutting step (S3) are previously created from three-dimensional CAD data. At this time, a machining path is determined by applying contour line machining. For example, in the solidified layer forming step (S2), contour shape data of each cross section obtained by slicing STL data generated from a three-dimensional CAD model at an equal pitch (for example, 0.05 mm pitch when Δt1 is 0.05 mm) is used. .

[Production apparatus of the present invention]
The manufacturing apparatus of the present invention is obtained by paying attention to “relaxation of internal stress that can occur in a three-dimensional shaped object” in the above-described powder sintering lamination method. In particular, the internal stress that can occur in the three-dimensional shaped object is relaxed by the characteristics of the modeling plate. More specifically, the present invention is characterized in that the phenomenon that the three-dimensional shaped object warps due to the internal stress as shown in FIG. 2B is suppressed by the elastic modulus of the modeling plate. (See FIG. 6).

  In the following description, unless otherwise specified, “metal powder” is used as a powder (that is, a metal powder layer is used as a powder layer), and the solidified layer is a sintered layer on a metal modeling plate. A mode of manufacturing a three-dimensional shaped object will be described as an example.

The production apparatus of the present invention comprises a powder layer forming means 2 for forming a metal powder layer 22, as shown in FIGS.
The light beam irradiation means 3 for irradiating the metal powder layer 22 with a light beam so that the sintered layer 24 is formed, and the “molding table” in which the metal powder layer 24 and / or the sintered layer 22 are formed. 20 modeling plate 21 ″,
It has. In such an apparatus, the modeling plate 21 can be joined to the sintered layer 24, and the Young's modulus of the modeling plate 21 is about 1 to several tens of times the Young's modulus of the sintered layer, preferably about 1 to 15 times (for example, About 1.5 to 10 times).

  Including the operation of the apparatus of the present invention, “powder layer forming means 2”, “light beam irradiating means 3”, “modeling table 20” and the like have already been described above. The description will be focused on the “modeling plate” which is a feature of the present invention.

  For example, as shown in FIG. 7, the modeling plate 21 used in the present invention is a foundation of a manufactured model 24 (that is, a sintered layer), and is directly below the powder layer 22 and the model 24 obtained therefrom. Is to be arranged.

  The Young's modulus of such a shaped plate is preferably 150 to 800 GPa, more preferably 300 to 750 GPa, and even more preferably 500 to 700 GPa. The “Young's modulus” referred to in the present invention substantially means the Young's modulus that can be obtained by carrying out a tensile test (plate temperature at 25 ° C. during the test) in accordance with JIS Z 2241. Yes.

  The shape of the modeling plate may be any shape as long as it provides a base surface (that is, the main surface) to the modeled object, and is not limited to the rectangular parallelepiped shape as shown in FIG. It may be a shape or the like. Regarding the dimensions of the modeling plate, generally, the main surface size is required to be larger than the bottom surface of the modeled object, and may be, for example, about 110 to 200% of the size of the modeled object bottom surface (see FIG. 7). The thickness of the modeling plate (“T” in FIG. 7) may vary depending on the main surface size, the material of the modeling plate, the material of the sintered layer, etc., but may be, for example, about 10 to 70 mm.

  The material of the modeling plate is not particularly limited as long as it provides the Young's modulus. For example, when metal powder (iron-based powder having an average particle size of about 5 μm to 100 μm) is used as the powder, and the solidified layer is a sintered layer (sintered layer made of iron-based material), the material of the modeling plate is carbide The material is preferably at least one material selected from the group consisting of alloys, high-speed tool steels, alloy tool steels, stainless steels, and carbon steels for machine structures.

  The main surface of the modeling plate used in the present invention is required to be able to be joined to the sintered layer (that is, the modeled object). In order to improve the bonding characteristics of the modeling plate, a nickel coating 21 'having a thickness of about 0.5 to 5 mm may be provided on the main surface (see FIG. 8). Such a nickel coating 21 'can be formed using a plating method, or can be formed using various coating forming techniques such as a thermal spraying method or a vapor deposition method (PVD, CVD). Incidentally, the “main surface of the modeling plate” in the present invention substantially means a surface on which a three-dimensional shaped object (or a powder layer or a solidified layer) is provided among the surfaces included in the modeling plate. Yes.

  As the aspect of “the shaped plate that can be bonded to the solidified layer 24 and is about 1 to 15 times the Young's modulus of the solidified layer”, various other aspects are conceivable. This will be described in detail below. In the following description, an example in which metal powder is used as the powder and the solidified layer becomes a sintered layer will be described.

(Modeling plate with a two-layer structure)
As shown in FIG. 9, this mode is a mode in which the modeling plate 21 is composed of an upper layer 21 a and a lower layer 21 b (the upper layer is a “front layer” in direct contact with the modeled object, and the lower layer is a modeling table. Is the “backside layer” that touches directly). The upper layer 21a includes at least one component selected from the group consisting of a powder layer component, an iron-based component, a carbon steel component, a nickel component, and a nickel alloy component, and the lower layer 21b has a Young's modulus sintered. The Young's modulus of the layer is about 1 to several tens of times, preferably about 1 to 15 times. Even in this mode, the modeling plate that can be joined to the sintered layer has a high Young's modulus, so the modeling plate absorbs the stress of the three-dimensional shaped object that tends to warp during manufacturing and prevents its warping. Or it can be made smaller. The “powder layer component” used for the material of the upper layer 21a means a constituent component of various powders constituting the powder layer 22, and the “iron-based component” means a component mainly composed of iron (for example, an iron component). Including 50% by weight or more). The Young's modulus of the lower layer 21b is preferably 150 to 800 GPa, more preferably 300 to 750 GPa, and further preferably 500 to 700 GPa. Further, when the sintered layer is made of, for example, an iron-based material (that is, when the sintered layer is formed from “iron-based powder”), the lower layer 21b of the modeling plate is made of cemented carbide or high-speed tool steel. It is preferably formed of at least one material selected from the group consisting of alloy tool steel, stainless steel and carbon steel for machine structure. The ratio (tb / ta) between the upper layer thickness ta and the lower layer thickness tb is preferably about 1 to 100. In such a modeling plate composed of an upper layer and a lower layer, “joining with a sintered layer” and “high Young's modulus” can be provided in each layer, so that the modeling object to be manufactured, manufacturing cost, etc. are considered. This is advantageous in that a suitable combination of layers can be selected as appropriate. For example, the following combinations can be considered as an example.
Metal powder material: Mixed powder of iron-nickel-copper (Young's modulus of sintered layer: about 130 GPa)
-Upper layer of modeling plate: S50C (Young's modulus: about 200 GPa)
-Lower layer of modeling plate: Cemented carbide (Young's modulus: about 600 GPa)

  “A modeling plate composed of an upper layer and a lower layer” can be produced by, for example, powder sintering, overlay welding, thick plating, or simply, a member corresponding to the upper layer and a lower layer. It can also be produced by preparing the members separately and bonding them together with a metal adhesive (for example, an epoxy resin adhesive or a silicone resin adhesive).

(Modeling plate composed of multiple plates)
As shown in FIG. 10, such an embodiment is an embodiment configured by an upper plate 21 c and a lower plate 21 d that are joined to each other (the upper plate is a “front plate” that is in direct contact with a modeled object. The lower plate is the “back plate” that is in direct contact with the modeling table). The upper plate 21c and the lower plate 21d may be joined by providing nickel 21e or the like between them as shown in the figure. The upper plate 21c includes at least one component selected from the group consisting of a powder layer component, an iron-based component, a carbon steel component, a nickel component, and a nickel alloy component, and the lower plate 21d has a Young's modulus. The Young's modulus of the sintered layer is about 1 to several tens of times, preferably about 1 to 15 times. Even in this mode, the modeling plate that can be joined to the sintered layer has a high Young's modulus, so the modeling plate absorbs the stress of the three-dimensional shaped object that tends to warp during manufacturing and prevents its warping. Or it can be made smaller. The “powder layer component” used for the material of the upper plate 21c means a constituent component of various powders constituting the powder layer 22, and the “iron-based component” is a component containing iron as a main component (for example, an iron component). Containing 50% by weight or more). The Young's modulus of the lower plate 21d is preferably 150 to 800 GPa, more preferably 300 to 750 GPa, and further preferably 500 to 700 GPa. In addition, when the sintered layer is made of, for example, an iron-based material (that is, when the sintered layer is formed of “iron-based powder”), the material of the lower plate is cemented carbide, high-speed tool steel, It is preferable that the material is at least one material selected from the group consisting of alloy tool steel, stainless steel, and carbon steel for machine structure. The ratio (td / tc) between the upper plate thickness tc and the lower plate thickness td is preferably about 1 to 10. In such a “modeling plate composed of an upper plate and a lower plate joined to each other”, “joining with a sintered layer” and “high Young's modulus” can be provided in each plate. This is advantageous in that a suitable combination of plates can be appropriately selected in consideration of a modeled object to be manufactured, manufacturing cost, and the like. For example, the following combinations can be considered as an example.
Metal powder material: Mixed powder of iron-nickel-copper (Young's modulus of sintered layer: about 130 GPa)
-Upper plate: S50C (Young's modulus: about 200 GPa)
-Lower plate: Cemented carbide (Young's modulus: about 600 GPa)

[Production method of the present invention]
Next, the manufacturing method of this invention is demonstrated. The production method of the present invention pays particular attention to the physical properties (elastic modulus) of the modeling plate in the above-described powder sintering lamination method, as in the production apparatus. Taking a metal powder as the powder and taking an example in which the solidified layer becomes a sintered layer, the production method of the present invention is as follows.
(I) a step of irradiating a predetermined portion of the powder layer provided on the modeling plate with a light beam to sinter the powder at the predetermined portion to form a sintered layer; and (ii) of the obtained sintered layer A method for producing a three-dimensional shaped object, wherein a new powder layer is formed thereon, and a step of forming a further sintered layer by irradiating a predetermined portion of the new powder layer with a light beam is repeated,
As a modeling plate, it is a plate that can be joined to a sintered layer, and has a Young's modulus of about 1 to several tens of times the Young's modulus of the sintered layer, preferably about 1 to 15 times Young's modulus (for example, about 1.5 to A plate having a Young's modulus of 10 times) is used. Such a plate may be a “modeling plate having a two-layer structure” or a “modeling plate composed of a plurality of plates” as described above. The Young's modulus, shape / dimension, and material of the modeling plate are the same as those described above in relation to the “manufacturing apparatus of the present invention”, and thus the description thereof is omitted to avoid duplication. Steps (i) and (ii) are also described in the above-described powder sintering lamination method, and thus the description thereof is omitted to avoid duplication.

  The modeling plate 21 is used while being arranged on the modeling table 20. At this time, the modeling plate may be screwed onto the modeling table, or the Young's modulus characteristic of the modeling plate is maximized. It may be attached loosely.

  As mentioned above, although embodiment of this invention has been described, it has only illustrated the typical example of the application scope of this invention. Therefore, those skilled in the art will readily understand that the present invention is not limited thereto and various modifications can be made.

  For example, in the above description, as shown in FIG. 11A, it is assumed that the three-dimensional shaped object 24 is manufactured on the “modeling plate 21 arranged on the modeling table 20”. As shown in b), it is also possible in some cases to manufacture the three-dimensional shaped object 24 directly on the modeling table 20. In such a case, the above-described effects of the present invention can be achieved by providing the modeling table itself with a property capable of being joined to the solidified layer 24 and providing a high Young's modulus that is approximately 1 to 15 times the Young's modulus of the solidified layer. It can be achieved as well.

  Various articles can be manufactured by using the apparatus of the three-dimensional shaped object of the present invention. In particular, since the three-dimensional shaped object obtained by the production apparatus and the production method of the present invention is integrally obtained in a state of being joined to the shaping plate, the “three-dimensional shaped object” and “modeling” integrated as such. It can be used as a product such as a mold without separating the “plate”. For example, in the case of “when the powder layer is a metal powder layer and the solidified layer is a sintered layer”, the resulting three-dimensional shaped article is a plastic injection mold, press mold, die casting mold, casting mold. It can be used as a mold such as a mold or a forged mold. Further, in the case “when the powder layer is a resin powder layer and the solidified layer is a hardened layer”, the obtained three-dimensional shaped article can be used as a resin molded product.

DESCRIPTION OF SYMBOLS 1 Optical modeling combined processing machine 2 Powder layer formation means 3 Light beam irradiation means 4 Cutting means 19 Powder / powder layer (For example, metal powder / metal powder layer or resin powder / resin powder layer)
20 Modeling table 21 Modeling plate 21 'Nickel coating 21a Upper layer 21b of modeling plate Lower layer 21c of modeling plate Upper plate
21d Lower plate 21e Nickel 22 powder layer (for example, metal powder layer or resin powder layer) provided between the upper plate and the lower plate
23 Blade for squeezing 24 Solidified layer (for example, sintered layer or hardened layer) or three-dimensional shaped object 25 obtained therefrom 25 Powder table 26 Wall part 27 of powder material tank 27 Wall part 28 of modeling tank 28 Powder material tank 29 Modeling tank 30 Light beam oscillator 31 Galvano mirror 40 Milling head 41 XY drive mechanism 50 Chamber 52 Light transmission window L Light beam

Claims (9)

Powder layer forming means for forming a powder layer,
A light beam irradiation means for irradiating the powder layer with a light beam so that a solidified layer is formed, and a shaping plate on which the powder layer and / or the solidified layer is to be formed,
Comprising
An apparatus for producing a three-dimensional shaped object, wherein the modeling plate can be joined to the solidified layer, and the Young's modulus of the modeling plate is 1 to 15 times the Young's modulus of the solidified layer.   The Young's modulus of a modeling plate is 150-800 GPa, The manufacturing apparatus of the three-dimensional shape molded article of Claim 1 characterized by the above-mentioned.   The three-dimensional shaped article manufacturing apparatus according to claim 1 or 2, wherein the solidified layer is made of an iron-based material, and the modeling plate is made of a cemented carbide.   The apparatus for producing a three-dimensional shaped article according to any one of claims 1 to 3, wherein a nickel coating is provided on a main surface of the modeling plate. The modeling plate has a two-layer structure consisting of an upper layer and a lower layer,
The upper layer comprises at least one component selected from the group consisting of a powder layer component, an iron-based component, a carbon steel component, a nickel component and a nickel alloy component;
The apparatus for producing a three-dimensional shaped article according to claim 1, wherein the lower layer has a Young's modulus of 150 to 800 GPa.   6. The apparatus for producing a three-dimensional shaped article according to claim 5, wherein the lower layer of the modeling plate is made of cemented carbide. The plate is composed of an upper plate and a lower plate joined together,
The upper plate comprises at least one component selected from the group consisting of a powder layer component, an iron-based component, a carbon steel component, a nickel component and a nickel alloy component;
The Young plate of the lower plate has a Young's modulus of 150 to 800 GPa, and the apparatus for producing a three-dimensional shaped article according to claim 1. (I) a step of irradiating a predetermined portion of the powder layer provided on the modeling plate with a light beam to sinter or melt and solidify the powder at the predetermined portion to form a solidified layer; and (ii) the obtained solidified layer A method for producing a three-dimensional shaped object by repeating a step of forming a new powder layer on the surface and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer,
A method for producing a three-dimensional shaped object, wherein a plate that can be bonded to a solidified layer and has a Young's modulus that is 1 to 15 times the Young's modulus of the solidified layer is used as the modeling plate.   The manufacturing method of the three-dimensional shaped structure according to claim 8, wherein the modeling plate has a two-layer structure composed of an upper layer and a lower layer, the upper layer can be bonded to the solidified layer, and the lower layer has a Young's modulus of 150 to 800 GPa. .

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