JP2015030199A - Three-dimensional shaping apparatus and three-dimensional shaping method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional shaping apparatus and a three-dimensional shaping method which exhibit high shaping accuracy without increasing the costs.SOLUTION: A three-dimensional shaping apparatus projects an image onto an image projection plane which is a boundary plane facing a liquid-state photocurable resin located on a bottom surface of a tank storing the liquid-state photocurable resin, forms a hardened layer corresponding to a predetermined thickness of liquid layer on an undersurface of shaped object holding means which serves as a bed of a three-dimensionally shaped object to be placed in the tank, and raises the shaped object holding means by the predetermined thickness of liquid layer to repeat in sequence the steps of projecting an image onto the image projection plane and forming a new hardened layer to laminate a hardened layer of the photocurable resin to thereby manufacture a three-dimensionally shaped object. The three-dimensional shaping apparatus has a plurality of image projection means each of which projects an image onto a different region of the image projection plane to thereby project a predetermined image onto the image projection plane.

Description

  The present invention relates to a three-dimensional modeling apparatus and a three-dimensional modeling method, and more particularly to a three-dimensional modeling apparatus and a three-dimensional modeling method for producing a three-dimensional model using a photocurable resin that is cured when irradiated with light. .

  2. Description of the Related Art Conventionally, there is known a three-dimensional modeling apparatus that produces a three-dimensional modeled object using a liquid-state photocurable resin having a property of being cured by irradiation with light such as visible light or ultraviolet light.

  As such a three-dimensional modeling apparatus, for example, a lifting and laminating structure method is used in which a three-dimensional modeling is performed by laminating a photocurable resin cured in a predetermined shape.

  In this suspended laminated structure method, a translucent plate is used on the bottom surface of a container that stores a photocurable resin in a liquid state, and a predetermined image is first irradiated by a projector or the like below the translucent plate. The photocurable resin is cured by a predetermined liquid layer thickness on the lower surface of the modeling object holding plate serving as the foundation of the three-dimensional modeling object disposed on the lower surface of the modeling object holding plate. A cured layer is formed.

  Next, the cured layer cured between the lower surface of the modeling object holding plate and the translucent plate which is the bottom surface of the container is peeled off from the translucent plate while being held by the modeling object holding plate, and the predetermined liquid layer thickness Only raise the model object holding plate.

  After that, a predetermined image is irradiated from the lower side of the translucent plate, and the cured layer held on the lower surface of the modeling object holding plate is further cured by curing the photocurable resin by a predetermined liquid layer thickness. Laminate the layers.

  And by repeating such operation | movement sequentially, the hardened layer of a photocurable resin is laminated | stacked, a three-dimensional modeling is performed, and a three-dimensional molded item will be produced.

According to such a three-dimensional modeling apparatus using the lifting and laminating structure method, by sequentially repeating the above-described operations, cured layers corresponding to a predetermined liquid layer thickness are sequentially laminated. By producing it, a three-dimensional structure having a desired shape can be produced.

  Here, in such a three-dimensional modeling apparatus of the lifted laminated structure system, an image is projected from one projector onto an image projection surface that is an interface between the bottom surface of the container and the photocurable resin stored in the container.

  For this reason, the accuracy of the hardened layer, that is, the modeling accuracy of the three-dimensional model, depends on the resolution of the projector.

Therefore, in such a three-dimensional modeling apparatus, in order to increase modeling accuracy, an expensive high-resolution projector must be used, and the manufacturing cost of the three-dimensional modeling apparatus increases.

In the three-dimensional modeling apparatus, an image is projected onto the image projection surface by a single projector, so that the curing rate of the photocurable resin that increases the curing rate by increasing the amount of irradiated light can be improved. It was not possible, and it was difficult to shorten the manufacturing time of the three-dimensional structure over a certain time.

  For this reason, the proposal of the three-dimensional modeling apparatus and the three-dimensional modeling method which can raise modeling precision without incurring high manufacturing cost was desired.

Moreover, the proposal of the three-dimensional modeling apparatus and the three-dimensional modeling method which can shorten the preparation time of a three-dimensional modeling thing was desired.

  Note that the prior art that the applicant of the present application knows at the time of filing a patent application is not an invention related to a known literature invention, so there is no prior art document information to be described in the present specification.

  The present invention has been made in view of the above-described demands of the prior art, and the object is to provide a three-dimensional modeling apparatus that can achieve high modeling accuracy without incurring high costs. And a three-dimensional modeling method.

  Moreover, the object of the present invention is to provide a three-dimensional modeling apparatus and a three-dimensional modeling method that can shorten the production time of a three-dimensional structure.

  In order to achieve the above object, according to the present invention, the three-dimensional modeling apparatus provides an image with respect to an image projection surface that is an interface with the photocurable resin located on the bottom surface of a container that stores the photocurable resin in a liquid state. Projecting and forming a hardened layer of a predetermined liquid layer thickness on the lower surface of the modeling object holding means serving as a base of the three-dimensional modeled object disposed in the container, and then the predetermined liquid layer thickness By simply repeating the operation of raising the model object holding means and projecting an image onto the image projection surface to form a new cured layer, the cured layer of the photo-curable resin is laminated to form a three-dimensional structure. A three-dimensional modeling apparatus for producing a model has a plurality of image projecting units for projecting a predetermined image onto the image projection surface by projecting an image to the different regions of the image projection surface at the same timing. It is what I did.

  Further, the three-dimensional modeling method according to the present invention projects an image onto an image projection surface that is an interface with the photocurable resin located on the bottom surface of the container that stores the photocurable resin in a liquid state, and the container After forming a hardened layer of a predetermined liquid layer thickness on the lower surface of the modeling object holding means serving as the foundation of the three-dimensional modeling object disposed inside, the modeling object holding means for the predetermined liquid layer thickness is provided. A three-dimensional structure is produced by laminating the cured layer of the photo-curable resin by sequentially repeating the operation of raising and projecting an image onto the image projection surface to form a new cured layer. In the three-dimensional modeling method in the original modeling apparatus, the image projected on the image projection plane is formed by a plurality of images projected on different areas of the image projection plane at the same timing by a plurality of image projection means. I tried to It is.

  Since the present invention is configured as described above, it has an excellent effect that high modeling accuracy can be achieved without incurring high costs.

  Moreover, since this invention is comprised as demonstrated above, there exists the outstanding effect that the preparation time of a three-dimensional molded item can be shortened.

FIG. 1 is a schematic explanatory diagram of a state in which a part of the three-dimensional modeling apparatus according to the present invention is broken. FIG. 2 is an explanatory diagram illustrating a state in which an image is projected from the projector to the image projection plane in the three-dimensional modeling apparatus of FIG. FIG. 3 is an explanatory diagram showing a divided image obtained by dividing the image into four. FIG. 4A is an explanatory diagram showing a state in which an image of a predetermined size is projected onto an image projection plane by a conventional three-dimensional modeling apparatus, and FIG. 4B is a three-dimensional image according to the present invention. It is explanatory drawing which shows the state which projected the image of the predetermined size on the image projection surface with the modeling apparatus, and FIG.4 (c) is an image twice as large as the predetermined size with the three-dimensional modeling apparatus by the prior art. FIG. 4D is an explanatory view showing a state projected onto the image projection plane, and FIG. 4D is an explanation showing a state where an image twice the predetermined size is projected onto the image projection plane by the 3D modeling apparatus according to the present invention. FIG.

Hereinafter, an example of a 3D modeling apparatus and a 3D modeling method according to the present invention will be described in detail with reference to the accompanying drawings.

  First, FIG. 1 shows a schematic configuration explanatory view of a state in which a part of the 3D modeling apparatus according to the present invention is broken, and FIG. 2 shows a projector in the 3D modeling apparatus shown in FIG. An explanatory view showing a state in which an image is projected on the image projection plane is shown.

  The three-dimensional modeling apparatus 10 shown in FIG. 1 includes a container 12 that stores a liquid-state photocurable resin that is cured by irradiation with light such as visible light or ultraviolet light, while a bottom surface 12a is formed of a translucent plate. , A projector 16 that projects an image onto the bottom surface 12a of the container 12, and a model holding unit that holds the photocurable resin cured in the container 12 by moving up and down by driving a drive unit (not shown). 18.

The overall operation of the three-dimensional modeling apparatus 10 is controlled by the microcomputer 20.

  More specifically, the container 12 is disposed on the upper surface 22a of the base member 22, and the upper surface of the translucent plate serving as the bottom surface 12a is transmitted through the bottom surface 12a in order to improve the peelability of the cured photocurable resin. Coating is performed with a coating material (for example, silicon resin) that can transmit light.

Then, the image projected from the projector 16 disposed in the base member 22 is projected onto the image projection surface S that is an interface between the bottom surface 12 a and the photocurable resin stored in the container 12. Yes.

  The projector 16 includes four projectors 16a, 16b, 16b, and 16d. The projectors 16a, 16b, 16c, and 16d are projectors having the same configuration.

  Each of the projectors 16a, 16b, 16c, and 16d is configured to project an image on a different area of the image projection surface S based on the image data output from the microcomputer 20, and is identical to each area from each projector. One large image is projected onto the image projection surface S by the image projected at the timing of (1).

  That is, the projector 16a projects an image onto the area S1 on the image projection plane S, the projector 16b projects an image onto the area S2 on the image projection plane S, the projector 16c projects an image onto the area S3 on the image projection plane S, The projector 16d projects an image on a region S4 on the image projection surface S.

  Note that the region S1 is adjacent to the regions S2 and S3, the region S2 is adjacent to the regions S1 and S4, the region S3 is adjacent to the regions S1 and S4, and the region 4 is adjacent to the regions S2 and S3. And is adjacent. Further, the area S1, the area S2, the area S3, and the area S4 have the same area.

  Thus, one large image (hereinafter referred to as “large image” as appropriate) projected onto the image projection plane S by the projectors 16a, 16b, 16c, and 16d is the shape of the three-dimensional structure to be produced. Is a plurality of images divided horizontally into a plurality of layers.

  In addition, since the large image projected on the image projection plane is formed by the images projected from the four projectors 16a, 16b, 16c, and 16d as described above, the shape of the three-dimensional structure to be produced is set in the horizontal direction. An image of one layer formed by dividing the image into four (this one-layer image is a large image) is divided into four in the same manner as the regions S1 to S4 of the image projection surface S.

  That is, for example, if the large image projected onto the image projection surface S is “A”, the large image “A” is divided into the divided image P1 projected onto the region S1, the divided image P2 projected onto the region S2, and the region S3. Is divided into a divided image P3 projected onto the area S4 and a divided image P4 projected onto the region S4, and the image data of the divided images P1 to P4 is sent to the microcomputer 20 as image data for forming the large image “A”. Remember.

  When the large image “A” is projected onto the image projection surface S, the microcomputer 20 outputs the image data of the divided image P1 to the projector 16a at the same timing, and the image of the divided image P2 to the projector 16b. The data is output, the image data of the divided image P3 is output to the projector 16c, and the image data of the divided image P4 is output to the projector 16d.

In other words, the projectors 16a, 16b, 16c, and 16d project the images of the three-dimensional structure to be produced into a plurality of images that are divided into a plurality of layers in the horizontal direction in order, one layer at a fixed time. It is controlled by the microcomputer 20 so as to project onto the surface S.

  The modeled object holding unit 18 is provided so as to be movable up and down in a vertical direction on a standing member 24 that is erected on the rear end 22aa of the upper surface 22a of the base member 22.

  And the modeling thing holding | maintenance part 18 will move to the upper side and the lower side in the front surface 24a of the standing member 24 by the drive of drive parts (not shown), such as a motor.

In addition, the modeled object holding unit 18 is a base that holds the three-dimensional modeled object in close contact with the photocurable resin that is cured in the container 12 on the lower surface 18a.

  In the above configuration, when a three-dimensional structure is manufactured by the three-dimensional structure forming apparatus 10, when an operator performs an operation to instruct the preparation of the three-dimensional structure, image data stored in advance from the microcomputer 20 is stored. It is output to the projector 16.

  The pre-stored image data is data representing an image of each layer obtained by dividing the shape of the three-dimensional structure to be produced into a plurality of layers in the horizontal direction, and is for one layer every predetermined time. Image data is output from the microcomputer 20 to the projector 16.

  That is, when one layer of image data is output to the projector 16, the image data of the divided images of one layer is output to the projectors 16a, 16b, 16c, and 16d at the same timing. .

  More specifically, the image data of the divided image projected on the area S1 in the image for one layer is output to the projector 16a, and the image data is projected on the area S2 in the image for one layer. The image data of the divided image is output, the image data of the divided image projected onto the region S3 in the image of one layer is output to the projector 16c, and the image of the image of one layer is output to the projector 16d. The image data of the divided image projected on the area S4 is output.

  Note that such image data of the divided image is stored in advance in the microcomputer 20 as image data representing each layer for each layer of the images of the plurality of layers.

  Then, an image for one layer is projected from the projector 16 onto the image projection surface S, and a hardened layer based on the image is formed on the lower surface 18 a of the shaped article holding unit 18.

  Thereafter, the molded object holding unit 18 is raised by the microcomputer 20 by a predetermined liquid layer thickness, and the image data of the next layer of the cured layer is output from the microcomputer 20 to the projector 16, and the cured layer from the projector 16. An image based on the image data of the next layer is projected onto the image projection plane S.

By sequentially repeating these operations, a new cured layer is formed on the lower side of the cured layer to form a three-dimensional structure.

  Here, in the three-dimensional modeling apparatus 10, four projectors 16a, 16b, 16c, and 16d are used as the projector 16 that projects an image for one layer on the image projection surface S, and the four projectors 16a. , 16b, 16c, and 16d, the image data for one layer is projected onto the image projection plane by the images projected onto different regions.

  For this reason, in the three-dimensional modeling apparatus 10, the modeling accuracy can be increased as compared with the three-dimensional modeling apparatus according to the conventional technique in which an image for one layer is projected from one projector onto the image projection surface. it can.

  That is, for example, when an image for one layer is projected onto the image projection plane S by a conventional three-dimensional modeling apparatus, one pixel of the projector is 1 mm on the image projection plane S (FIG. 4A). In the three-dimensional modeling apparatus 10 using the same projector as the conventional three-dimensional modeling apparatus as the projectors 16a, 16b, 16c, and 16d, an image of one layer of the same size on the image projection surface S 1 pixel is 0.5 mm on the image projection plane (see FIG. 4B).

  That is, in the three-dimensional modeling apparatus 10 according to the present invention, it is possible to obtain a modeling accuracy twice as high as that of the conventional three-dimensional modeling apparatus using the same projector as the projector in the conventional three-dimensional modeling apparatus. Become.

Therefore, according to the three-dimensional modeling apparatus 10, it is possible to produce a three-dimensional modeled object with high modeling accuracy using an inexpensive projector without using an expensive high-resolution projector.

  Moreover, in the three-dimensional modeling apparatus 10, the light quantity with respect to the image for one layer projected on the image projection surface increases.

For this reason, according to the three-dimensional modeling apparatus 10, compared with the three-dimensional modeling apparatus by the prior art, a three-dimensional modeling thing can be produced in a shorter time.

  Here, in the three-dimensional modeling apparatus according to the conventional technology, when producing a larger three-dimensional modeled object, an image from the projector must be projected on a wider range of the image projection surface. The size of the image projected on the image projection plane is increased by adjusting the distance to the projection plane.

  Specifically, when producing a three-dimensional structure that is twice the predetermined size, the distance between the projection image plane and the projector is adjusted to produce a three-dimensional structure of a predetermined size. Then, an image twice as large as the image projected on the image projection plane is projected onto the image projection plane.

  For this reason, in an image when a three-dimensional structure having a predetermined size is produced, for example, if one pixel of the projector is 1 mm on the image projection plane (see FIG. 4A), the predetermined size is used. In an image when producing a three-dimensional structure having a size twice as large as 1 mm, one pixel of the projector is 2 mm on the image projection surface (see FIG. 4C).

On the other hand, in the three-dimensional modeling apparatus 10 according to the present invention, an image is projected onto the image projection surface S by the four projectors 16a, 16b, 16c, and 16d. In the image when the original model is produced, one pixel of the projector can remain 1 mm on the image projection surface (see FIG. 4D).

  The embodiment described above may be modified as shown in the following (1) to (4).

  (1) In the above-described embodiment, four projectors 16a, 16b, 16c, and 16d are provided as the projector 16. However, the number of projectors is not limited to this. May use two, three, or five or more projectors depending on the size of the image projected on the image projection surface S and the modeling accuracy of the three-dimensional model.

  Thereby, in the three-dimensional modeling apparatus 10 by this invention, according to the shape of the three-dimensional modeling object to produce, a more accurate three-dimensional modeling thing can be produced.

  (2) In the above-described embodiment, the projector 16 projects an image directly on the image projection surface S which is the interface between the bottom surface 12a of the container 12 and the photocurable resin stored in the container 12, but this Of course, the image is not limited to this, and an image may be projected onto the image projection plane via a mirror.

  (3) Although not specifically described in the above-described embodiment, the projectors 16a, 16b, 16c, and 16d have the operator appropriately set the installation position according to the size of the image projected on the image projection surface S. Alternatively, a mechanism for changing the installation position according to the size of the image from the image data input by the microcomputer 20 may be provided.

  (4) You may make it combine suitably the embodiment shown above and the modification shown in said (1) thru | or (3).

  INDUSTRIAL APPLICABILITY The present invention can be used for a three-dimensional modeling apparatus of a lifted laminated structure method.

  DESCRIPTION OF SYMBOLS 10 3D modeling apparatus, 12 container, 16 projector, 18 modeling object holding part, 20 microcomputer, 22 base member, 24 standing member

Claims (2)

An image is projected onto an image projection surface that is an interface with the photocurable resin located on the bottom surface of a container that stores the photocurable resin in a liquid state, and a base of a three-dimensional structure that is disposed in the container After forming a hardened layer of a predetermined liquid layer thickness on the lower surface of the modeled object holding unit, the modeled model holding unit is raised by the predetermined liquid layer thickness and an image is projected on the image projection surface. In the three-dimensional modeling apparatus for producing a three-dimensional structure by laminating the cured layer of the photocurable resin by sequentially repeating the operation of projecting and forming a new cured layer,
A three-dimensional modeling apparatus, comprising: a plurality of image projecting units that project a predetermined image onto the image projection plane by projecting images onto different areas of the image projection plane at the same timing. An image is projected onto an image projection surface that is an interface with the photocurable resin located on the bottom surface of a container that stores the photocurable resin in a liquid state, and a base of a three-dimensional structure that is disposed in the container After forming a hardened layer of a predetermined liquid layer thickness on the lower surface of the modeled object holding unit, the modeled model holding unit is raised by the predetermined liquid layer thickness and an image is projected on the image projection surface. In the three-dimensional modeling method in the three-dimensional modeling apparatus for producing a three-dimensional structure by laminating the cured layer of the photocurable resin by sequentially repeating the operation of forming a new cured layer by projecting
The image projected on the image projection plane is formed by a plurality of images projected on different areas of the image projection plane at the same timing by a plurality of image projection means. .

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