JP2015066714A - Laminate forming method and laminate forming apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate forming apparatus capable of forming laminate with a higher speed and higher accuracy.SOLUTION: A laminate forming method (laminate forming apparatus 100) comprises: a particle pattern forming step (discharge heads 10) of applying resin particles 1 to a surface of a transfer medium 20 and forming a particle pattern 2 on the basis of cross-sectional shape data of an object; a melting step (melting section 30) of heating and melting the resin particles 1 forming the particle pattern 2 from one surface of the particle pattern 2; a smoothing step (smoothing section 60) of smoothing the resin particles 1 forming the particle pattern 2 while heating the resin particles 1 from the other surface of the particle pattern 2 and forming a melting pattern 3; and a transferring step (forming section 40) of transferring the melting pattern 3 from the transfer medium 20 and laminating the melting pattern 3.

Description

  The present invention relates to an additive manufacturing method and an additive manufacturing apparatus.

  Conventionally, as a method for layered modeling of a three-dimensional model of a three-dimensional shape, an optical modeling method in which each layer is formed by curing a UV curable resin to a cross-sectional shape of a three-dimensional model, and a powder material is welded and solidified by laser. Powder sintering method to form, melt deposition method to form each layer by heating and extruding the thermoplastic material from the nozzle, and by cutting and stacking the sheet material such as paper into the model cross-sectional shape and bonding A sheet lamination method to be formed has been proposed.

  In Patent Document 1, in a layered modeling apparatus using an electrophotographic method, a chargeable powder is formed in a sheet shape on a photoconductor or an intermediate transfer body by a heat roll, and the sheet-like chargeable powder is stacked to form a stack. A method of modeling is disclosed.

Japanese Patent Laid-Open No. 10-207194

  However, in the technique disclosed in Patent Document 1, there is a problem that when layered modeling is performed at a higher speed while maintaining accuracy, the layered modeling may not be stably performed. Specifically, in order to perform additive manufacturing at a higher speed, the layer thickness per layer is increased or the time required for the formation of one layer (for example, in the technology disclosed in Patent Document 1, It is effective to shorten the heating / pressing time for making the body into a sheet. In contrast, in the technique disclosed in Patent Document 1, the step of forming the sheet-like chargeable powder is a method of heating and pressing the chargeable powder from one direction by a heat roll. When the layer thickness of this layer was increased and processing was performed at high speed, there was a problem that a uniform molten state could not be obtained in the thickness direction. As a result, there arises a problem that the layer thickness varies or delamination occurs after lamination.

  SUMMARY An advantage of some aspects of the invention is to solve at least a part of the problems described above, and the invention can be implemented as the following application examples or forms.

  [Application Example 1] The additive manufacturing method according to this application example includes a particle pattern forming step in which resin particles are applied to the surface of a transfer medium based on cross-sectional shape data of an object to form a particle pattern, and the particle pattern is formed. A melting step for heating and melting resin particles from one surface of the particle pattern, and a smoothing for heating and smoothing the resin particles forming the particle pattern from the other surface of the particle pattern to form a molten pattern And a transfer step of transferring and laminating the melt pattern from the transfer medium.

The additive manufacturing method according to this application example includes a particle pattern forming step of forming a particle pattern by applying resin particles to the surface of a transfer medium based on cross-sectional shape data of an object. Therefore, by using finer resin particles, a higher-definition and high-accuracy latent image can be formed.
In addition, a melting process for heating and melting the resin particles forming the particle pattern from one surface of the particle pattern, and heating and smoothing the resin particles forming the particle pattern from the other surface of the particle pattern to form a molten pattern And a transfer step of transferring and laminating the molten pattern from the transfer medium. In order to perform additive manufacturing at a higher speed, it is effective to increase the layer thickness per layer, and as in this application example, by having a step of heating and melting from both sides of the particle pattern, the layer thickness can be increased. Even with a thick particle pattern, the resin particles can be melted more uniformly in the thickness direction. As a result, delamination caused by insufficiently melted resin particles after lamination is suppressed. In addition, since the layered modeling is performed by smoothing the resin particles melted more uniformly and transferring and layering the smoothed particle pattern, the layered modeling with higher accuracy can be performed.
As described above, according to the layered manufacturing method according to this application example, the layered structure can be formed at higher speed and with higher accuracy.

  Application Example 2 In the additive manufacturing method according to the application example, the particle pattern is configured such that the resin particles overlap each other, and the one surface is in contact with the surface of the transfer medium. Preferably, the other surface is the outermost surface of the resin particles that are stacked in multiple layers.

  According to this application example, it is possible to increase the layer thickness per layer for forming the laminated structure, and it is possible to melt the resin particles more uniformly in the thickness direction. As a result, layered modeling can be performed at a higher speed, and delamination due to insufficiently melted resin particles is suppressed after lamination.

  Application Example 3 In the additive manufacturing method according to the application example described above, the surface of the transfer medium is a curved surface, the stage to which the melt pattern is transferred is a flat surface, and the transfer step includes transferring the transfer medium to the stage. By moving the pressing point between the transfer medium and the stage while pressing in the direction or while pressing the stage in the direction of the transfer medium, the melting pattern is moved to the stage or the stage first. It is characterized in that it is transferred and laminated while being pressed and pressed against the surface layer portion of the melt pattern which has been transferred and laminated and cooled and solidified or has started to solidify.

  According to this application example, the melted pattern formed on the surface of the transfer medium composed of curved surfaces is separated from the surface of the transfer medium by curvature separation, so that the transfer and lamination can be performed more smoothly. Can do.

  Application Example 4 In the additive manufacturing method according to the application example, the particle pattern forming step includes a charging step of charging the resin particles and an electric field acceleration of the charged resin particles to reach the surface of the transfer medium. And an electrostatic discharge step.

  As in this application example, by charging the resin particles and accelerating the charged resin particles to reach the surface of the transfer medium by electric field acceleration, modeling of the laminated structure can be performed more accurately and more easily. become able to. Specifically, by using finer resin particles and controlling the electric field to accelerate the electric field of the resin particles at a higher speed and selectively discharging the resin particles, it is possible to draw directly on the surface of the transfer medium. In addition, it is possible to form a particle pattern with higher definition and higher accuracy. Since the particle pattern formed with higher definition and higher accuracy is stacked more uniformly and with higher accuracy in the thickness direction, a higher definition and higher accuracy stacked structure can be formed.

  Application Example 5 In the additive manufacturing method according to the application example, the particle pattern forming step is based on an electrophotographic method.

  According to this application example, since the particle pattern formed by the electrophotographic method is laminated more uniformly with high accuracy in the thickness direction, a higher-definition and high-precision laminated structure can be formed.

  Application Example 6 In the additive manufacturing method according to the application example, it is preferable that the melting step is performed by heating the transfer medium by electromagnetic heating.

  Since the transfer medium itself generates heat by adopting a method in which the transfer medium is heated by electromagnetic heating as in this application example, the particle pattern formed on the surface of the transfer medium is transferred to one side (the side of the transfer medium). Can be reliably heated and melted. In addition, since the entire transfer medium can generate heat in a concentrated manner at a site where eddy current is generated by electromagnetic waves without generating heat, heating and melting can be performed more effectively.

  Application Example 7 In the additive manufacturing method according to the application example, it is preferable that the resin particles have a color material.

  As in this application example, the resin particle has a color material, so that the layered manufacturing apparatus can model a colored layered structure.

  Application Example 8 In the additive manufacturing method according to the application example, in the particle pattern forming step, the resin particles are formed so that the particle pattern formed on the surface of the transfer medium has a predetermined thickness. It is preferable to apply a plurality of layers.

  As in this application example, in the particle pattern forming step, a plurality of layers of resin particles are applied so that the thickness of the particle pattern formed on the surface of the transfer medium becomes a predetermined thickness. The thickness becomes a predetermined thickness, and the dimension of the laminated structure on which the melt pattern is laminated can be controlled with higher accuracy. That is, according to this application example, it is possible to provide a layered modeling method and a layered modeling method apparatus with higher speed, higher definition, and higher accuracy.

  Application Example 9 In the additive manufacturing method according to the application example, the resin particles have a conductive material.

  According to this application example, since the conductive material of the resin particles also generates heat simultaneously with the heating of the transfer medium, the resin particles can be melted more efficiently.

  Application Example 10 In the additive manufacturing method according to the application example, it is preferable that the particle pattern forming step forms the particle pattern with a plurality of the resin particles having the color material having different colors.

  Like this application example, a colored laminated structure can be modeled by forming a particle pattern with a plurality of resin particles having different color materials.

  [Application Example 11] The additive manufacturing apparatus according to this application example includes a discharge head that selectively discharges resin particles based on cross-sectional shape data of an object, and captures the discharged resin particles so that the surface thereof A transfer medium on which a particle pattern of resin particles is formed; a melting part that heats and melts the resin particles that form the particle pattern from one surface of the particle pattern; and the resin particles that form the particle pattern A smoothing unit that heats and smoothes the other side of the particle pattern to form a molten pattern, and a modeling unit that transfers and stacks the molten pattern from the transfer medium.

The additive manufacturing apparatus according to this application example has a discharge head that selectively discharges resin particles based on cross-sectional shape data of an object, and a particle pattern of resin particles is formed on the surface by capturing the discharged resin particles. A transfer medium. Therefore, a finer and more precise particle pattern can be formed by utilizing finer resin particles.
The additive manufacturing apparatus according to this application example also includes a melting part that heats and melts resin particles forming a particle pattern from one surface of the particle pattern, and heats and smoothes the molten pattern from the other surface of the particle pattern. A smoothing part to be formed and a modeling part for transferring and laminating the molten pattern from the transfer medium are provided. In order to perform additive manufacturing at a higher speed, it is effective to increase the layer thickness per layer.As in this application example, the layer thickness is reduced by heating and melting from both sides of the particle pattern. Even with a thick particle pattern, the resin particles can be melted more uniformly in the thickness direction. As a result, delamination caused by insufficiently melted resin particles after lamination is suppressed. In addition, since the layered modeling is performed by smoothing the resin particles melted more uniformly and transferring and layering the smoothed particle pattern, the layered modeling with higher accuracy can be performed.
As described above, according to the layered manufacturing apparatus according to this application example, it is possible to model the layered structure at higher speed and with higher accuracy.

  Application Example 12 In the additive manufacturing apparatus according to the application example, the melting unit includes a heater unit that heats the transfer medium, and the smoothing unit includes a heat roller.

  As in this application example, the melting unit includes a heater unit that heats the transfer medium, and the smoothing unit includes a heat roller so that the particle pattern can be heated and melted from both sides, Even with a thick particle pattern, the resin particles can be more uniformly melted in the thickness direction. As a result, delamination caused by insufficiently melted resin particles after lamination is suppressed. In addition, since the layered modeling is performed by smoothing the resin particles melted more uniformly and transferring and layering the smoothed particle pattern, the layered modeling with higher accuracy can be performed.

  Application Example 13 In the additive manufacturing apparatus according to the application example, it is preferable that the heater unit heats the transfer medium by an electromagnetic heating method.

  Since the transfer medium itself generates heat by adopting a method in which the transfer medium is heated by electromagnetic heating as in this application example, the particle pattern formed on the surface of the transfer medium is transferred to one side (the side of the transfer medium). Can be reliably heated and melted. In addition, since the entire transfer medium can generate heat in a concentrated manner at a site where eddy current is generated by electromagnetic waves without generating heat, heating and melting can be performed more effectively.

  Application Example 14 In the additive manufacturing apparatus according to the application example, it is preferable that the heat roller includes an electromagnetic heating type heat source.

  As in this application example, both the heat roller and the transfer medium generate heat and the particle pattern is heated from both front and back surfaces by the electromagnetic heating system heat source provided in the heat roller. Can do. Moreover, in this front and back simultaneous heating, it is easy to make the heating energy of the heat roller larger, and the surface (the other surface) of the particle pattern in contact with the heat roller can be more effectively melted. The other surface of the particle pattern is an abutting surface that has been previously transferred and laminated and cooled and solidified, or is laminated on the surface layer portion of the molten pattern that has started to cool and solidify. Transfer and lamination can be performed more effectively, for example, by laminating while redissolving the surface layer portion of the pattern.

  Application Example 15 In the additive manufacturing apparatus according to the application example, the discharge head includes a first electrode, a discharge port, a charging mechanism that charges resin particles, and the charged resin particles on the surface of the first electrode. A charged resin particle layer forming mechanism that forms a charged resin particle layer in a predetermined thickness, a transport mechanism that moves the first electrode and transports the charged resin particle layer to the discharge port, and the discharge port A third electrode provided to the discharge port, and the transfer medium is provided to be opposed to the discharge port so as to be relatively movable, constitute a second electrode, and the first electrode moved to the discharge port; The electric field of the resin particles contained in the charged resin particle layer is accelerated by an electric field formed by the third electrode positioned between the first electrode and the second electrode moved to the discharge port, and the discharge port The third electrode and the second electrode, By an electric field formed, and forming the particles pattern on the surface of the transfer medium by the discharged the resin particles be made to reach the second electrode.

According to this application example, the discharge head includes the first electrode, the discharge port, a charging mechanism for charging the resin particles, and the charged resin particles arranged on the surface of the first electrode so that the charged resin particles have a predetermined thickness. A charging resin particle layer forming mechanism for forming the layer; and a transport mechanism for moving the first electrode to transport the charged resin particle layer to the discharge port.
That is, according to this application example, resin particles formed as a charged resin particle layer having a predetermined thickness are supplied to the discharge port from which the resin particles are discharged.

In addition, the ejection head includes a third electrode provided at the ejection port, and the transfer medium is provided to be opposed to the ejection port so as to be relatively movable, and constitutes a second electrode. The electric field formed by the first electrode moved to the discharge port and the third electrode positioned between the first electrode and the second electrode accelerates the electric field of the resin particles contained in the charged resin particle layer, thereby discharging the discharge port. The particle pattern is formed on the surface of the transfer medium by causing the discharged resin particles to reach the second electrode by the electric field formed by the third electrode and the second electrode.
That is, the resin particles arranged on the surface of the first electrode as a charged resin particle layer having a predetermined thickness are discharged by being accelerated by an electric field formed by the first electrode and the third electrode provided at the discharge port. Since the resin particles in the target area subjected to the electric field acceleration are arranged in a predetermined thickness, variation in the amount of the discharged resin particles (or resin particle groups) is reduced. As a result, the amount of resin particles reaching the second electrode is controlled within a certain range by the electric field formed by the third electrode and the second electrode. That is, the thickness of the particle pattern formed on the second electrode (transfer medium) is controlled within a certain range.

  As described above, according to the additive manufacturing apparatus according to this application example, since the size of the particle pattern forming the molten pattern is controlled with higher accuracy, it is possible to perform additive manufacturing with higher definition and higher accuracy.

  Application Example 16 In the additive manufacturing apparatus according to the application example, the modeling unit includes a stage that is provided so as to be relatively movable facing the transfer medium moved from a position facing the discharge port, and the melt pattern. A laminating mechanism for transferring and laminating from the transfer medium to the stage.

  According to this application example, the modeling unit has a stage that faces the transfer medium moved from a position facing the ejection port and is relatively movable, and a stacking mechanism that transfers and melts the molten pattern from the transfer medium to the stage. And. That is, the modeling unit transfers the molten pattern, whose thickness is controlled within a certain range, from the transfer medium to the stage and stacks it to model the stacked structure. Since the dimension of the laminated structure on which the molten pattern is laminated is controlled with higher accuracy, it is possible to carry out higher-precision and high-precision laminated modeling.

  Application Example 17 In the additive manufacturing apparatus according to the application example, the resin particles included in the charged resin particle layer formed to have a predetermined thickness by the charged resin particle layer forming mechanism are applied to the third electrode. The thickness of the melt pattern formed on the surface of the transfer medium is controlled to a predetermined thickness by selectively discharging and reaching the second electrode by the applied voltage.

  According to this application example, by controlling the voltage (potential) applied to the third electrode, the resin particles contained in the charged resin particle layer are selectively ejected to reach the second electrode. For example, resin particles charged negatively are arranged on the surface of the first electrode, and the resin particles are removed from the first electrode by an electric field generated by setting the third electrode provided in the discharge port to a necessary and sufficient positive potential with respect to the first electrode. It can be exfoliated and accelerated. Further, by setting the transfer medium (second electrode) to a positive potential with respect to the third electrode, the resin particles discharged from the first electrode via the discharge port can reach the transfer medium. In this way, by controlling the voltage applied to the third electrode, it is possible to control the ejection of resin particles (whether ejection is performed, ejection timing, etc.). For example, charged resin particles that are supplied one after another are controlled. An image (particle pattern) made of resin particles can be formed on the surface of the transfer medium by reaching (attaching) the transfer medium that moves relative to the discharge port while controlling the discharge.

  Application Example 18 In the additive manufacturing apparatus according to the application example described above, a plurality of the discharge heads are provided, and each of the resin particles discharged by the plurality of discharge heads has a color material having a different color. Is preferred.

  Like this application example, a colored laminated structure can be modeled by forming a particle pattern with a plurality of resin particles having different color materials.

  Application Example 19 In the additive manufacturing apparatus according to the application example, the resin particles have a conductive material.

  According to this application example, since the conductive material of the resin particles also generates heat simultaneously with the heating of the transfer medium, the resin particles can be melted more efficiently.

  Application Example 20 In the additive manufacturing apparatus according to the application example, the transfer medium is configured to have a cylindrical side surface shape, and the stacking mechanism includes a first movement mechanism that rotates the transfer medium around an axis, and the stage. And a second moving mechanism for moving the transfer medium in a direction tangential to the rotational movement of the transfer medium and a direction intersecting the tangential direction, and the transfer movement of the transfer medium and the movement of the stage are synchronized with each other. While the medium is rotated around the axis, the molten pattern is transferred and laminated by being pressed onto the stage or the surface layer portion of the molten pattern that has been transferred and laminated to the stage and cooled or solidified, or has started to solidify. It is characterized by doing.

According to this application example, the transfer medium is configured to have a cylindrical side surface shape. The stacking mechanism includes a first moving mechanism that rotates the transfer medium about an axis, and a second moving mechanism that moves the stage in a tangential direction of the rotational movement of the transfer medium and a direction intersecting the tangential direction. While the rotational movement of the medium and the movement of the stage are synchronized, the transfer medium is rotated around the axis, and the molten pattern is transferred and laminated on the stage first and then cooled and solidified, or the surface layer of the molten pattern that has started to cool and solidify It is transferred and laminated by pressing the part.
Since the rotational movement of the transfer medium and the movement of the stage are synchronized, it is possible to suppress the positional deviation that occurs in the laminated melt pattern. In addition, the melt pattern formed on the surface of the cylindrical side surface-shaped transfer medium is transferred and laminated by pressing it onto the surface or the surface layer portion of the melt pattern that has been transferred and laminated on the stage and cooled or solidified or has started to solidify. Therefore, the melt pattern can be transferred and laminated more smoothly by separating the curvature of the curvature.

  Application Example 21 In the additive manufacturing apparatus according to the application example, the transfer medium is configured in the shape of an annular belt, and the stacking mechanism includes a first moving mechanism that drives the transfer medium in a belt, and the transfer medium. A roller that presses from the inside of the annular belt; and a second moving mechanism that moves the stage in a tangential direction between the roller and the annular belt of the transfer medium and in a direction crossing the tangential direction, and the transfer medium The belt drive and the movement of the stage are synchronized, and while the transfer medium is driven by the belt, the molten pattern is transferred and laminated on the stage or the stage by the roller and cooled or solidified. It is characterized by transferring and laminating by pressing to the surface layer portion of the molten pattern that has started.

According to this application example, the transfer medium is configured in the shape of an annular belt. Further, the stacking mechanism intersects the tangential direction and the tangential direction of the first moving mechanism for driving the belt of the transfer medium, the roller for pressing the transfer medium from the inside of the annular belt, and the stage. A second moving mechanism that moves in a moving direction, and the belt driving of the transfer medium and the movement of the stage are synchronized, and the transfer pattern is transferred to the stage by the roller while the transfer medium is driven by the belt. Then, it is transferred and laminated by pressing on the surface layer portion of the melt pattern that has been cooled and solidified or has started to solidify.
Since the belt driving of the transfer medium and the movement of the stage are synchronized, it is possible to suppress the positional deviation that occurs in the laminated melt pattern. Also, by pressing the melt pattern formed on the surface of the belt (transfer medium) pressed by the roller onto the stage or the surface layer portion of the melt pattern that has been transferred and laminated on the stage and cooled or solidified, or has started to cool and solidify Due to the structure of transferring and laminating, the melt pattern can be transferred and laminated more smoothly by separating the curvature of curvature.

Side surface conceptual diagram which shows the structure of the additive manufacturing apparatus which concerns on Embodiment 1. FIG. (A) Conceptual sectional view for explaining the ejection head, (b) Plan view showing the ejection port (A) Enlarged view of part A in FIG. 1, (b) Plan view around the discharge port Schematic diagram of melting part (A)-(c) The side surface and top view which show a smoothing part Schematic diagram when using an electromagnetic heating heat source for the smoothing section Conceptual diagram explaining synchronous drive of stage and transfer medium (A)-(d) is a schematic diagram which shows a mode that a fusion pattern is formed. Side surface conceptual diagram which shows the structure of the additive manufacturing apparatus which concerns on the modification 1.

  DESCRIPTION OF EMBODIMENTS Embodiments embodying the present invention will be described below with reference to the drawings. The following is one embodiment of the present invention and does not limit the present invention. In the following drawings, the scale may be different from the actual scale for easy understanding. Also, for convenience of explanation, in the XYZ axes appended to the figure, the X direction is the right direction, the X axis direction (± X direction) is the horizontal direction, the Y direction is the front direction, and the Y axis direction (± Y direction) is the front-back direction. In the following description, the Z direction is the upward direction, and the Z-axis direction (± Z direction) is the vertical direction.

(Embodiment 1)
FIG. 1 is a conceptual side view showing the configuration of the additive manufacturing apparatus 100 according to the first embodiment.
The layered manufacturing apparatus 100 is an apparatus that forms a solid by sequentially stacking layers (cross-sectional layers) constituting a cross section of an object (a three-dimensional solid model).
The additive manufacturing apparatus 100 captures the ejected resin particles 1 by selectively ejecting the resin particles 1 based on the cross-sectional shape data of the object, thereby forming a particle pattern 2 by the resin particles 1 on the surface thereof. The transfer medium 20, the melting part 30 for heating and melting the resin particles 1 forming the particle pattern 2 from one surface of the particle pattern 2, and the resin particles 1 forming the particle pattern 2 from the other surface of the particle pattern 2 A smoothing unit 60 that heats and smoothes to form the melt pattern 3, and a modeling unit 40 that transfers and melts the melt pattern 3 from the transfer medium 20 are provided.
The laminated structure 4 is formed (modeled) by laminating the melt pattern 3 in the modeling unit 40. Further, a cleaning unit 50 having a cleaning blade (not shown) for cleaning the surface of the transfer medium 20 on which the transfer of the melt pattern 3 has been completed is provided.

  The additive manufacturing method using the additive manufacturing apparatus 100 includes a particle pattern forming step for forming the particle pattern 2 by applying the resin particles 1 to the surface of the transfer medium 20 based on the cross-sectional shape data of the object, and a resin particle for forming two particle patterns. A melting process in which 1 is heated from one surface of the particle pattern 2 and melted, and a resin particle 1 forming the particle pattern 2 is heated from the other surface of the particle pattern 2 and smoothed to form a melt pattern 3 And a transfer step of transferring and laminating the melt pattern 3 from the transfer medium 20.

That is, first, in order to form a cross-sectional layer of an object, a resin particle pattern (particle pattern 2) arranged to have a predetermined thickness in accordance with the cross-sectional shape of the object is formed. The particle pattern 2 is formed on the surface of the transfer medium 20 as a desired array pattern that matches the cross-sectional shape of the object by selectively discharging the charged resin particles 1 while accelerating the electric field.
Next, the resin particles 1 arranged on the surface of the transfer medium 20 are heated and melted from one surface and the other surface, thereby fusing and smoothing the resin particles 1 adjacent to the upper, lower, left, and right sides as a cross-sectional layer. The melt pattern 3 is formed. A three-dimensional object is formed by successively transferring and laminating the melt pattern 3.

  Hereinafter, each part which comprises the additive manufacturing apparatus 100 is demonstrated concretely.

<Discharge head>
FIG. 2A is a conceptual cross-sectional view illustrating the ejection head 10, and FIG. 2B is a plan view illustrating ejection ports provided in the ejection head 10.
The discharge head 10 includes a cartridge 11 that stores the resin particles 1, a resin discharge unit 12 that charges and discharges the resin particles 1, and the like.
The cartridge 11 includes a housing 111. The housing 111 accommodates the resin particles 1 inside and supplies the resin particles 1 to the resin discharge unit 12 by being connected to the resin discharge unit 12. The resin particles 1 housed inside the casing 111 move to the resin discharge unit 12 connected to the casing 111 by force F due to gravity (self-weight of the resin particles 1) or a pressing mechanism (not shown). )

  The resin discharge unit 12 includes a transfer roller 121 (the transfer roller 121 constitutes a first electrode 71 described later), a head plate 127 having a plurality of discharge ports 122, a “charging mechanism” that charges the resin particles 1, and a supply A roller 123, a regulating blade 125 for arranging the charged resin particles 1 on the surface of the transport roller 121 and forming the charged resin particle layer 1L to a predetermined thickness, a drive unit (not shown), a seal 128, and the like are provided. These are gathered in a compact form as the resin discharge section 12 by the head casing 126, and the cartridge 11 can be loaded.

The transport roller 121 is formed in a cylindrical side surface shape (drum shape), and constitutes a “transport mechanism” that transports the charged resin particle layer 1 </ b> L to the discharge port 122 by being rotated by a driving unit.
The supply roller 123 is a roller disposed in contact with the circumferential surface of the transport roller 121 so as to be rotatable, and supplies the resin particle 1 to the surface of the transport roller 121 by friction charging while rotating by the driving unit. That is, the supply roller 123 constitutes a “charging mechanism”. The charging of the resin particles is not only due to friction with the supply roller 123 but also due to contact / peeling or friction with a member (for example, the transport roller 121, the casing 111, or the head casing 126) with which the resin particles come into contact. Done. As the material for charging the resin particles 1, it is preferable to use a member made of a material that is located farther on the charging column, including the supply roller 123, so that the resin particles 1 can be charged more efficiently.

The drive unit may be separately provided as a drive unit for rotating the transport roller 121 and the supply roller 123, or each of the drive units may be simultaneously operated in reverse (as indicated by arrows shown in FIG. 2A). It may be configured to rotate (by rotation). Alternatively, a configuration in which the supply roller 123 is rotated and the supply roller 123 rotates on the peripheral surface of the transfer roller 121 may be configured to rotate the transfer roller 121.
When the transport roller 121 and the supply roller 123 are driven separately, the supply roller 123 may be rotated in the direction opposite to the direction of the arrow shown in FIG. Thus, by rotating in the direction opposite to the rotation of the transport roller 121, the fluidity of the resin particles can be improved and the chance of frictional charging can be improved.

  The regulating blade 125 is a plate-like body that presses the peripheral surface of the transport roller 121, and the resin particles 1 supplied so as to overlap the surface of the transport roller 121 by the supply roller 123 have a predetermined thickness (specifically, The “charged resin particle layer forming mechanism” is configured to reduce the thickness of the resin particles 1 to a layer thickness of 1 to 2 layers. The regulating blade 125 is an elastic body having one end fixed to the head casing 126, and may have a configuration in which an elastic body such as a spring is provided in the pressing portion as shown in FIG. The resin particle 1 is thinned so as to be scraped off by the pressing portion of the regulating blade 125, and the charge amount is made more uniform by frictional charging with the regulating blade 125.

The head plate 127 is, for example, an insulating and flexible substrate such as polyimide, and two rows of discharge ports 122 arranged alternately in a direction intersecting the rotation direction of the transport roller 121 are formed at the center. Has been. The width W of the head plate 127 in the direction in which the discharge ports 122 are arranged is substantially equal to the width of the transfer medium 20 described later.
A third electrode 73 for controlling the discharge of the resin particles 1 is provided around each discharge port 122. A drive circuit 130 (driver IC) that drives and controls the third electrode 73 may be provided in the resin discharge unit 12.

  The seal 128 is a seal member disposed on the peripheral surface of the transport roller 121 and is lightly pressed against the peripheral surface of the transport roller 121 to prevent the resin particles 1 from being scattered or leaked to the outside.

As shown in FIG. 1, a plurality of ejection heads 10 are used for each type of resin particle 1 stored in a cartridge 11 to be loaded. The type of the resin particle 1 is classified according to the type of color material included in the resin particle 1 and the presence or absence of the color material. Specifically, as the ejection head 10, an ejection head 10C that ejects cyan resin particles 1, an ejection head 10M that ejects magenta resin particles 1, an ejection head 10Y that ejects yellow resin particles 1, and a transparent Discharge head 10T that discharges colorless resin particles 1; discharge head 10W that discharges white resin particles 1; and support material resin particles 1 that support overhangs and the like of laminated structure 4 during modeling and are removed after modeling. A discharge head 10S for discharging the liquid is disposed.
The particle pattern 2 is constituted by these plural types of resin particles 1. That is, the particle pattern 2, the melt pattern 3, and the laminated structure 4 are made of a resin containing a plurality of color materials.

<Transfer media>
As shown in FIG. 1, the transfer medium 20 is configured in a cylindrical side surface shape (drum shape). In the layered manufacturing apparatus 100 placed on the XY plane, for example, the cylinder axis faces the Y-axis direction. Are arranged as follows. The transfer medium 20 is configured as a second electrode 72 described later. The transfer medium 20 is composed of a nonmagnetic conductive plate (for example, SUS (Steel Use Stainless)).
Above the transfer medium 20 (in the Z direction), a plurality of discharge heads 10 are arranged with a predetermined gap so that the discharge ports 122 (FIG. 2) face the surface of the transfer medium 20. The transfer medium 20 is rotatably installed with the cylindrical axis as a rotation axis while keeping a gap with the ejection head 10 constant, and is rotated around the axis by a “first movement mechanism” described later.
Each of the ejection heads 10 is installed such that the extending direction of the head plate 127 (the direction in which the ejection ports 122 are arranged) intersects the direction in which the surface of the opposing transfer medium 20 rotates. That is, the ejection head 10 is configured as a line head with respect to the transfer medium 20.

FIG. 3A is a conceptual cross-sectional view enlarging the portion A shown in FIG. 1 and shows the periphery of the ejection port 122 and the transfer medium 20 facing the discharge port 122. FIG. 3B is a plan view around the discharge port 122.
A third electrode 73 is disposed around the discharge port 122.
The first electrode 71 located above the discharge port 122 (that is, the transport roller 121 that transports the resin particles 1 to the opening region of the discharge port 122), and the first electrode 71 and the second electrode 72 (transfer medium 20). ) Between the third electrode 73 and the second electrode 72 positioned between the second electrode 72 and the second electrode 72. The charged resin particles 1 are separated from the first electrode 71, accelerated by an electric field, and discharged from the discharge port 122. Electric field reaching the surface (20). Further, by controlling the voltage (potential) applied to the third electrode 73, the resin particles 1 contained in the charged resin particle layer 1 </ b> L are selectively ejected and reach the second electrode 72.

Specifically, for example, as shown in FIG. 3A, the resin particles 1 are negatively charged, the potential of the first electrode 71 is −250 V, the potential of the third electrode 73 is −125 V, and the second electrode 72. Is set to the ground potential (0 V). As a result, an electric field from the second electrode 72 (transfer medium 20) toward the first electrode 71 (conveying roller 121) is generated, and the negatively charged resin particles 1 are released from the first electrode 71 and discharged from the discharge port 122. The ink is discharged and reaches the second electrode 72 (the surface of the transfer medium 20). Further, for example, when the potential of the third electrode 73 is −375 V, the direction of the electric field generated between the first electrode 71 and the third electrode 73 is reversed, and the negatively charged resin particles 1 It stays on one electrode 71 (conveying roller 121).
In this way, by controlling the potential of the third electrode 73, the charged resin particles 1 supplied one after another by the transport roller 121 are discharged and reached the transfer medium 20 that moves relative to the discharge port 122 ( The particle pattern 2 is formed on the surface of the transfer medium 20.

In FIG. 3A, for the gap in the direction in which the resin particles 1 are discharged, for example, when the resin particles 1 are spherical particles of 10 μm, the layer thickness of the charged resin particle layer 1L on the transport roller 121 is approximately two layers. 20 μm. The distance between the transport roller 121 and the head plate 127 is set to, for example, 40 μm because it is advantageous for reducing the wear to be larger than the layer thickness of the charged resin particle layer 1L. The thickness of the head plate 127 is, for example, 60 μm, and the gap between the head plate 127 and the transfer medium 20 is 100 μm.
In order to maintain the gap between the transport roller 121 and the head plate 127 and the gap between the head plate 127 and the transfer medium 20, a spacer (not shown) is provided for each to prevent electric field fluctuations and make the discharge amount uniform. This is preferable.

  Further, the rotational movement of the transfer medium 20 is set to a predetermined speed, and the resin particles 1 contained in the charged resin particle layer 1L formed to a predetermined thickness are selectively ejected by the control of the third electrode 73 and the second electrode. By reaching 72, the layer thickness of the melt pattern 3 formed on the surface of the transfer medium 20 is controlled to a predetermined thickness. That is, the layer thickness of the melt pattern 3 formed on the surface of the transfer medium 20 by the resin particles 1 ejected from the plurality of ejection heads 10 is controlled to a predetermined thickness.

<Melting part>
The melting unit 30 includes a heat source for heating and melting the resin particles 1 forming the particle pattern 2 from one surface of the particle pattern 2, and the discharge head 10 is installed in the transfer medium 20 as shown in FIG. 1. It is installed between the formed upper part and the modeling part 40.
The melting portion 30 is an electromagnetic heating type “heater” for heating the transfer medium 20 on which the particle pattern 2 is formed in order to heat the particle pattern 2 from the back surface (the surface where the resin particles 1 are in contact with the surface of the transfer medium 20). Part ".

FIG. 4 is a schematic diagram of the melting part 30.
The electromagnetic heating type heater unit includes a main yoke 31 disposed outside the transfer medium 20, a back yoke 32 disposed inside the transfer medium 20, an excitation coil 33 provided in the main yoke 31, and the like. . The main yoke 31 and the back yoke 32 are each composed of a soft magnetic material such as iron or ferrite. A high frequency alternating magnetic field is generated between the main yoke 31 and the back yoke 32 by flowing a high frequency alternating current of several tens of kHz through the coil 33 (heat resistant wire), and the transfer medium 20 (non-magnetic conductive plate) is main. By generating an eddy current in a region sandwiched between the yoke 31 and the back yoke 32, heat is generated locally.

<Smoothing part>
5A to 5C are a side view and a plan view showing the smoothing unit 60. FIG.
The smoothing unit 60 includes a heat roller 61 having a heat source 62 therein as a means for melting the resin particles 1 constituting the particle pattern 2. In the outer peripheral portion of the transfer medium 20, the smoothing unit 30 and the modeling unit 40 are provided. It is installed between.
The smoothing unit 60 forms the melt pattern 3 by heating the resin particles 1 forming the particle pattern 2 from the other surface of the particle pattern 2 (the outermost surface of the resin particles 1 that are stacked in layers), and by melting and smoothing. The particle pattern 2 is evacuated by the heat roller 61 and is formed into a sheet with a predetermined layer thickness to form the melt pattern 3.

The heat roller 61 is a hard roller having abutting rollers 63 on both sides as shown in FIG. The heat roller 61 is pressed and fixed to the outer peripheral surface of the transfer medium 20 via the abutment roller 63 by a support portion 64 fixed to the support body 65. The roller portion of the heat roller 61 includes a release layer (PFA (Perfluoroalkoxy polymer resin), PTFE (Polytetrafluoroethylene), etc.) on the surface of a cored bar using a nonmagnetic conductive plate such as SUS (not shown).
The heat source 62 is composed of a halogen lamp or the like, and heats the heat roller 61 to a predetermined temperature by turning on and off, and various heat sources such as nichrome wire can be used.

  The heat roller 61 may be a soft roller whose both ends are supported by a suspension 66 having a spring, as shown in FIG. The roller part has an elastic layer (silicon rubber, fluorine rubber, etc.) formed in a tall shape on the outer periphery of the core metal using a nonmagnetic conductive plate such as SUS in consideration of bending when the roller part is pressed. And a release layer (PFA, PTFE, etc.) is provided on the surface of the elastic layer (not shown).

  Further, as shown in FIG. 5A, the smoothing unit 60 preferably includes a cleaner 67 that cleans the surface of the heat roller 61.

The smoothing unit 60 may use an electromagnetic heating method in the same manner as the melting unit 30 instead of the heat source 62.
FIG. 6 is a schematic diagram when an electromagnetic heating method is used for the smoothing unit 60. When the electromagnetic heating method is used for the smoothing unit 60, it is preferable to use the magnetic circuit of the melting unit 30 described above, and the smoothing unit 60 is provided in the magnetic circuit (the main yoke 31 and the back yoke) that the melting unit 30 configures. 32). The heat roller 61 includes an inner yoke 621 disposed on the inner side. The inner yoke 621 is made of a soft magnetic material such as iron or ferrite.

  In this configuration, a magnetic circuit is constituted by the main yoke 31 to the back yoke 32 to the inner yoke 621 to the main yoke 31 by passing a high-frequency alternating current through the coil 33, and a high-frequency alternating magnetic field at the magnetic force line passing portion of the heat roller 61. The heat roller 61 generates heat locally due to the eddy current accompanying the alternating magnetic field. Thus, since the alternating magnetic field by the coil 33 can be shared with the fusion | melting part 30, not only an apparatus structure can be simplified but the power supply structure and control circuit of a heat source can be simplified. Further, when the angle of the inner yoke 621 is adjusted, the passing magnetic field lines can be changed, so that the temperature of the heat roller 61 can be adjusted.

<Modeling Department>
As shown in FIG. 1, the modeling unit 40 transfers the lamination pattern 3 from the transfer medium 20 to the stage 41 and laminates it with a planar stage 41 that faces the transfer medium 20 and is relatively movable. Mechanism ".
The “stacking mechanism” includes a first moving mechanism (not shown) that rotates and moves the transfer medium 20 around an axis, and a second that moves the stage 41 in a direction tangential to the rotational movement of the transfer medium 20 and a direction intersecting the tangential direction. And a moving mechanism (not shown).
While the transfer medium 20 is rotated about the axis, the molten pattern 3 is transferred by being pressed onto the stage 41 or the surface layer portion of the molten pattern 3 which has been transferred and laminated on the stage 41 and cooled or solidified, or has started to solidify. And laminate. The melt pattern 3 is adhesively transferred on the stage 41 and cooled to form the laminated structure 4.

Here, the stage 41 circulates in the direction of the arrow D shown in FIG. 1 and synchronizes with the rotation of the transfer medium 20, that is, the first moving mechanism and the second moving mechanism are synchronized (that is, in the same cycle). Move on).
Specifically, for example, as shown in FIG. 7, the first moving mechanism and the second moving mechanism are configured by the same drive motor so that the stage 41 moves in one cycle when the transfer medium 20 makes one rotation. It is composed. Further, when the drive motor rotates n (natural number), the transfer medium 20 rotates once, and when the drive motor rotates m (natural number), the stage 41 moves in one cycle. By configuring in this way, fluctuations of the drive motor appear in the same phase, so that stacking misalignment of the melt pattern 3 can be suppressed.

<Resin particles>
The resin particles 1 are irregular or spherical particles having a volume average particle diameter of 5 to 20 μm, and a thermoplastic resin such as polyester is used as the material thereof. In the case of a color, for example, cyan, magenta, yellow, and white pigments are dispersed as a color material, and are prepared by a pulverization method or a polymerization method.
The resin particles 1 are externally added with white or transparent hydrophobic particles. Specifically, inorganic fine particles such as silica and titania having a particle diameter of several nanometers to several tens of nanometers are externally added, and fluidity of 45 degrees or less is given at an angle of repose. Therefore, it is desirable that the inner wall of the cartridge 11 be configured with a wall standing at an angle of repose or more with respect to the direction of gravity so that the resin particles 1 do not stay.

<Layered modeling method>
Next, a series of flows for modeling the laminated structure 4 by the additive manufacturing apparatus 100 having the above-described configuration will be described, and the additive manufacturing method will be described.
8A to 8D show how the melt pattern 3 is formed.
This will be described with reference to FIGS. 1 and 8A to 8D.

<Particle pattern formation process>
First, the cartridge 11 containing the color material corresponding to each discharge head 10 (10S, 10C, 10M, 10Y, 10T, 10W) is loaded, and the additive manufacturing apparatus 100 is operated. To prepare a charged resin particle layer 1L having a predetermined thickness.
Next, the potential of the third electrode 73 of each ejection head 10 is set so that each layer (melting pattern 3) having a predetermined thickness is formed according to the shape and color of the laminated structure 4 to be shaped. The particle pattern 2 is formed on the surface of the transfer medium 20 by controlling and selectively discharging the resin particles 1 supplied to the discharge ports 122 of the discharge head 10.
FIG. 8A shows a case where resin particles 1 having color materials of cyan (C), magenta (M), yellow (Y), and transparent and colorless (T) are selectively ejected in two layers each to a predetermined thickness. It shows a state where six layers are overlapping. The predetermined thickness of the particle pattern 2 is a thickness necessary for the dimensional accuracy of the laminated structure 4 when the particle pattern 2 is melted and laminated to form the laminated structure 4.

<Melting process>
Next, the particle pattern 2 formed on the surface of the transfer medium 20 is moved to the melting part 30 as the transfer medium 20 rotates. In the melting part 30, the transfer medium 20 heated by the heater part is heated from the back surface of the particle pattern 2 (the surface where the resin particles 1 are in contact with the surface of the transfer medium 20), and the particle pattern 2 is melted. At this time, the particle pattern 2 is sufficiently melted in a region closer to the surface of the transfer medium 20.

<Smoothing process>
Next, the melted particle pattern 2 is moved to the smoothing unit 60 as the transfer medium 20 rotates. In the smoothing unit 60, the heat roller 61 heats and melts the resin particles 1 from the surface (the outermost surface of the resin particles 1 in which the particle pattern 2 overlaps six layers) and presses and smoothes to form the melt pattern 3. As shown in FIG. 8B, the particle pattern 2 is air-bleeded by the heat roller 61, and is formed into a sheet with a predetermined layer thickness to form the melt pattern 3. In the smoothing part 60, since the region closer to the heat roller 61 is sufficiently melted, the entire particle pattern 2 is sufficiently melted together with the melting by the melting part 30.
The layer thickness of the melt pattern 3 is approximately one half of the thickness of the particle pattern 2 in which six resin particles 1 are stacked. In addition, as shown in FIG. 8C, an area formed by overlapping cyan (C), magenta (M), and yellow (Y) is blue (B), green (G), and red (R). ) Is expressed.

<Transfer process>
Next, the melt pattern 3 formed on the surface of the transfer medium 20 is moved to the modeling unit 40 as the transfer medium 20 rotates.
In the modeling unit 40, the pressing point between the transfer medium 20 and the stage 41 is moved by rotating the transfer medium 20 around the axis while pressing the stage 41 in the direction of the transfer medium 20, and the melting pattern 3 is The film is transferred and laminated while being pressed onto the surface 41 of the molten pattern 3 that has been transferred and laminated to the stage 41 or the stage 41 and cooled or solidified, or has started to solidify.
As shown in FIG. 8D, the melt pattern 3 is adhesively transferred on the stage 41 while re-dissolving the surface layer portion of the melt pattern 3 that has been previously transferred and laminated and cooled and solidified or has started to cool and solidify. .

After the transfer, the transfer medium 20 is cleaned on the surface by a cleaning blade disposed in the cleaning unit 50 and proceeds to modeling of the next layer.
The laminated structure 4 is formed by synchronizing the formation of the melt pattern 3 by the rotation of the transfer medium 20 and the movement of the stage 41, repeating the above transfer, and laminating the melt pattern 3.

As described above, according to the additive manufacturing method and additive manufacturing apparatus according to the present embodiment, the following effects can be obtained.
The layered modeling apparatus 100 captures the ejected resin particles 1 by selectively ejecting the resin particles 1 based on the cross-sectional shape data of the object, and the particle pattern 2 of the resin particles 1 is formed on the surface thereof. A transfer medium 20 to be formed. Therefore, by using the finer resin particles 1, it is possible to form a particle pattern 2 with higher definition and higher accuracy.

The additive manufacturing apparatus 100 also heats and melts the resin particles 1 forming the particle pattern 2 from one surface of the particle pattern 2 and the other surface of the particle pattern 2 while smoothing and melting. A smoothing unit 60 that forms the pattern 3 and a modeling unit 40 that transfers and melts the molten pattern 3 from the transfer medium 20 are provided. In order to perform layered modeling at a higher speed, it is effective to increase the layer thickness per layer, and the structure in which the particle pattern 2 is heated and melted from both sides as in this embodiment (the melting part 30 is transferred). Even if the particle pattern 2 is formed with a thick layer by providing a heater unit that heats the medium 20 and the smoothing unit 60 includes a heat roller 61, the resin is more uniformly in the thickness direction. The particles 1 can be melted. As a result, it is possible to prevent delamination due to insufficiently melted resin particles 1 after lamination. Moreover, since the layered modeling is performed by smoothing the resin particles 1 melted more uniformly and transferring and layering the smoothed particle pattern 2, the layered modeling with higher accuracy can be performed.
As described above, according to the additive manufacturing apparatus 100 and additive manufacturing method according to the present embodiment, it is possible to model the laminated structure at a higher speed and with higher accuracy.

  In addition, since the transfer medium 20 is heated by electromagnetic heating, the transfer medium 20 itself generates heat. Therefore, the particle pattern 2 formed on the surface of the transfer medium 20 is transferred to one surface (the transfer medium 20 side). Can be reliably heated and melted. In addition, since the entire transfer medium 20 can be heated in a concentrated manner at a site where eddy current is generated by electromagnetic waves without generating heat, heating and melting can be performed more effectively.

  Moreover, since both the heat roller 61 and the transfer medium 20 generate heat by the heat roller 61 and the particle pattern 2 is heated from both the front and back surfaces, heating and melting can be performed more effectively. In addition, the simultaneous heating of the front and back surfaces makes it easy to make the heating energy of the heat roller 61 larger, and the surface (the other surface) of the particle pattern 2 in contact with the heat roller 61 can be more effectively melted. . Since the other surface of the particle pattern 2 is a contact surface that has been previously transferred and laminated and cooled and solidified, or is laminated on the surface layer portion of the molten pattern 3 that has started to be cooled and solidified, this cooling and solidification or cooling and solidification has started. Transfer and lamination can be performed more effectively, for example, by laminating the melt layer 3 while remelting the surface layer portion thereof.

In addition, the discharge head 10 includes a first electrode 71, a discharge port 122, a charging mechanism for charging the resin particles 1, and the charged resin particles 1 arranged on the surface of the first electrode 71, and a charged resin having a predetermined thickness. A charged resin particle layer forming mechanism for forming the particle layer 1L and a transport mechanism for moving the first electrode 71 to transport the charged resin particle layer 1L to the discharge port 122 are provided.
That is, the resin particles 1 formed as the charged resin particle layer 1L having a predetermined thickness are supplied to the discharge port 122 from which the resin particles 1 are discharged.

  In addition, the ejection head 10 includes a third electrode 73 provided in the ejection port 122, and the transfer medium 20 is provided to be opposed to the ejection port 122 so as to be relatively movable, and constitutes a second electrode 72. Resin particles 1 contained in the charged resin particle layer 1L are generated by an electric field formed by the first electrode 71 moved to the discharge port 122 and the third electrode 73 located between the first electrode 71 and the second electrode 72. The electric field is accelerated and discharged from the discharge port 122, and the discharged resin particles 1 reach the second electrode 72 by the electric field formed by the third electrode 73 and the second electrode 72, thereby reaching the surface of the transfer medium 20. A particle pattern 2 is formed.

  That is, the resin particles 1 arranged on the surface of the first electrode 71 as the charged resin particle layer 1L having a predetermined thickness are generated by the electric field formed by the first electrode 71 and the third electrode 73 provided in the discharge port 122. Accelerated and discharged. Since the resin particles 1 in the target region subjected to the electric field acceleration are arranged in a predetermined thickness, variation in the amount of the resin particles 1 to be discharged is reduced. As a result, the amount of the resin particles 1 reaching the second electrode 72 is controlled within a certain range by the electric field formed by the third electrode 73 and the second electrode 72. That is, the thickness of the particle pattern 2 formed on the second electrode 72 (transfer medium 20) is controlled within a certain range.

The modeling unit 40 includes a stage 41 that is opposed to the transfer medium 20 and is capable of relative movement, and a stacking mechanism that transfers and melts the molten pattern 3 from the transfer medium 20 to the stage 41. That is, the modeling unit 40 models the laminated structure 4 by transferring and laminating the melt pattern 3 whose thickness is controlled within a certain range from the transfer medium 20 to the stage 41.
As described above, according to the additive manufacturing apparatus 100 according to the present embodiment, since the dimensions of the stacked structure 4 on which the melt pattern 3 is stacked are controlled with higher accuracy, more precise and highly accurate additive manufacturing can be performed. It can be carried out.

  Further, by controlling the voltage (potential) applied to the third electrode 73, the resin particles 1 contained in the charged resin particle layer 1 </ b> L are selectively ejected to reach the second electrode 72. By controlling the voltage applied to the third electrode 73, it is possible to control the ejection of the resin particles 1 (whether ejection is performed, timing of ejection, etc.), and to control the ejection of the charged charged resin particles 1 one after another. However, an image (particle pattern 2) of the resin particles 1 can be formed on the surface of the transfer medium 20 by reaching (attaching) the transfer medium 20 that moves relative to the ejection port 122.

  Moreover, the colored laminated structure 4 can be modeled by forming the particle pattern 2 with the plurality of resin particles 1 having different color materials.

  Further, while the rotational movement of the transfer medium 20 and the movement of the stage 41 are synchronized, the transfer medium 20 is rotationally moved around the axis, and the melt pattern 3 is first transferred and stacked on the stage 41 or the stage 41 and cooled and solidified. It is transferred and laminated by pressing on the surface layer portion of the melt pattern 3 which is starting to cool and solidify. Since the rotational movement of the transfer medium 20 and the movement of the stage 41 are synchronized, it is possible to suppress the positional deviation that occurs in the melt pattern 3 to be laminated.

  Further, the transfer medium 20 has a cylindrical side surface shape, and the stage 41 to which the melt pattern 3 is transferred is a flat surface. In the modeling unit 40, the pressing point between the transfer medium 20 and the stage 41 is moved by rotating the transfer medium 20 around the axis while pressing the stage 41 in the direction of the transfer medium 20, and the melting pattern 3 is The film is transferred and laminated while being pressed onto the surface 41 of the molten pattern 3 that has been transferred and laminated to the stage 41 or the stage 41 and cooled or solidified, or has started to solidify. The melt pattern 3 can be transferred and laminated more smoothly by separating the curvature.

  Note that the present invention is not limited to the above-described embodiment, and various modifications and improvements can be added to the above-described embodiment. A modification will be described below. Here, the same components as those in the above-described embodiment are denoted by the same reference numerals, and redundant description is omitted.

(Modification 1)
FIG. 9 is a conceptual side view showing the configuration of the additive manufacturing apparatus 101 according to the first modification.
In the first embodiment, as illustrated in FIG. 1, the transfer medium 20 has been described as having a cylindrical side surface shape (drum shape). However, the present invention is not limited to this configuration, and the transfer medium 90 illustrated in FIG. 9 is used. In this way, it may be configured in the shape of an annular belt.

  The transfer medium 90 is configured in the shape of an annular belt, and the “stacking mechanism” includes a first moving mechanism that drives the transfer medium 90 by a belt, a roller 91 that presses the transfer medium 90 from the inside of the annular belt, and a stage 41. A second moving mechanism that moves in a direction tangential to the roller 91 and the annular belt of the transfer medium 90 and a direction that intersects the tangential direction. The belt 91 of the transfer medium 90 and the movement of the stage 41 are synchronized, and while the transfer medium 90 is driven by the belt, the melt pattern 3 is transferred and laminated to the stage 41 or the stage 41 by the roller 91 and cooled and solidified. It is transferred and laminated by pressing on the surface layer portion of the melt pattern 3 which is starting to cool and solidify.

  Further, the smoothing unit 60 is provided with a roller 70 that is disposed between the heat roller 61 and an annular belt of the transfer medium 90. The heat roller 61 presses and heats the particle pattern 2 between the roller 70 and melts / smooths to form the melt pattern 3.

According to the additive manufacturing apparatus 101 according to this modification, in addition to the effects in the above-described embodiment, the following effects can be obtained.
The melt pattern 3 formed on the surface of the belt (transfer medium 90) pressed by the roller 91 is transferred and laminated on the stage 41 or the stage 41 and cooled or solidified, or on the surface layer portion of the melt pattern 3 starting to cool and solidify. Due to the configuration in which the pressing pattern is transferred and laminated, the melt pattern 3 can be transferred and laminated more smoothly by the curvature separation of the melt pattern 3. The transfer medium 20 of the first embodiment has a drum shape, and the curvature for pressing the melt pattern 3 is determined by the diameter of the drum, but the radius of the roller 91 (that is, the curvature) is the length of the transfer medium 90 (belt). Regardless, it can be set arbitrarily within the range of the size within the belt ring. As a result, it is possible to use the roller 91 having a more effective diameter for separating the curvature of the melt pattern 3.

(Modification 2)
In the first embodiment, as shown in FIG. 2, an electrostatic discharge method in which resin particles 1 are charged and discharged by a resin discharge portion 12 of the discharge head 10 to form a particle pattern 2 on the surface of the transfer medium 20 will be described. However, the present invention is not limited to this configuration. For example, the particle pattern 2 may be formed by an electrophotographic method used in a laser printer.
Specifically, a latent image is formed by selectively irradiating a laser beam or LED light or the like onto a photosensitive drum that has been charged uniformly and charged with a surface to form a latent image. This is a method in which resin particles are adhered to the portion by electrostatic force.

  According to this modification, even when the particle pattern 2 is formed by an electrophotographic method, the molten pattern 3 is laminated more uniformly and accurately in the thickness direction, and more smoothly transferred and laminated. Therefore, a laminated structure with higher definition and higher accuracy can be formed.

(Modification 3)
The resin particle 1 may have a conductive material. Since the resin particles 1 have a conductive material, the conductive material of the resin particles 1 also generates heat simultaneously with the heating of the transfer medium 20 by the electromagnetic heater type “heater part” that heats the transfer medium 20. It can be melted more efficiently.

  DESCRIPTION OF SYMBOLS 1 ... Resin particle, 1L ... Charged resin particle layer, 2 ... Particle pattern, 3 ... Melting pattern, 4 ... Laminated structure, 10 ... Discharge head, 11 ... Cartridge, 12 ... Resin discharge part, 20 ... Transfer medium, 30 ... Melting part, 31 ... main yoke, 32 ... back yoke, 33 ... coil, 40 ... modeling part, 41 ... stage, 50 ... cleaning part, 60 ... smoothing part, 61 ... heat roller, 62 ... heat source, 63 ... butting Roller, 64 ... support part, 65 ... support body, 66 ... suspension, 67 ... cleaner, 70 ... roller, 71 ... first electrode, 72 ... second electrode, 73 ... third electrode, 90 ... transfer medium, 91 ... roller DESCRIPTION OF SYMBOLS 100 ... Laminate shaping apparatus, 111 ... Housing | casing, 121 ... Conveyance roller, 122 ... Discharge port, 123 ... Supply roller, 125 ... Restriction blade, 126 ... Head housing, 127 ... Head Rate, 130 ... drive circuit.

Claims (21)

A particle pattern forming step of forming a particle pattern by applying resin particles to the surface of the transfer medium based on the cross-sectional shape data of the object;
A melting step of heating and melting the resin particles forming the particle pattern from one surface of the particle pattern;
A smoothing step of heating the resin particles forming the particle pattern from the other surface of the particle pattern and smoothing to form a molten pattern;
And a transfer step of transferring and laminating the molten pattern from the transfer medium. The particle pattern is configured such that the resin particles overlap each other,
The one surface is a surface where the resin particles are in contact with the surface of the transfer medium,
The additive manufacturing method according to claim 1, wherein the other surface is an outermost surface of the resin particles that are stacked in multiple layers. The surface of the transfer medium is a curved surface, and the stage on which the melt pattern is transferred is a plane,
In the transfer step, the pressing point between the transfer medium and the stage is moved while pressing the transfer medium in the direction of the stage or while pressing the stage in the direction of the transfer medium. The molten pattern is transferred and laminated while being pressed on the surface or a surface layer portion of the molten pattern which has been transferred and laminated to the stage or cooled and solidified or started to be cooled and solidified. Item 3. The additive manufacturing method according to Item 2. The particle pattern forming step includes:
A charging step for charging the resin particles;
4. The additive manufacturing method according to claim 1, further comprising: an electrostatic discharge step of accelerating the electric field of the charged resin particles to reach the surface of the transfer medium. 5.   The additive manufacturing method according to any one of claims 1 to 4, wherein the particle pattern forming step is based on an electrophotographic system.   The additive manufacturing method according to any one of claims 1 to 5, wherein the melting step is performed by heating the transfer medium by electromagnetic heating.   The additive manufacturing method according to any one of claims 1 to 6, wherein the resin particles include a color material.   2. The particle pattern forming step, wherein the resin particles are provided in a plurality of layers so that the particle pattern formed on the surface of the transfer medium has a predetermined thickness. The additive manufacturing method according to claim 7.   The layered manufacturing method according to claim 6, wherein the resin particles have a conductive material.   10. The additive manufacturing method according to claim 7, wherein in the particle pattern forming step, the particle pattern is formed by a plurality of the resin particles having the color material having different colors. . An ejection head that selectively ejects resin particles based on the cross-sectional shape data of the object;
By capturing the discharged resin particles, a transfer medium on which a particle pattern of the resin particles is formed, and
A melting part for heating and melting the resin particles forming the particle pattern from one surface of the particle pattern;
A smoothing part for heating the resin particles forming the particle pattern from the other surface of the particle pattern and smoothing to form a molten pattern;
And a modeling unit that transfers the molten pattern from the transfer medium and stacks it. The melting part includes a heater part for heating the transfer medium,
The layered modeling apparatus according to claim 11, wherein the smoothing unit includes a heat roller.   The additive manufacturing apparatus according to claim 12, wherein the heater unit heats the transfer medium by an electromagnetic heating method.   The additive manufacturing apparatus according to claim 12, wherein the heat roller includes an electromagnetic heating type heat source. The discharge head has a first electrode, a discharge port, a charging mechanism for charging resin particles, and the charged resin particles arranged on the surface of the first electrode to form a charged resin particle layer with a predetermined thickness. A charged resin particle layer forming mechanism, a transport mechanism for moving the first electrode to transport the charged resin particle layer to the discharge port, and a third electrode provided in the discharge port,
The transfer medium is provided so as to be relatively movable facing the discharge port, and constitutes a second electrode,
Due to the electric field formed by the first electrode moved to the discharge port and the third electrode located between the first electrode and the second electrode moved to the discharge port, the charged resin particle layer The resin particles contained are accelerated by an electric field and discharged from the discharge port, and the discharged resin particles reach the second electrode by an electric field formed by the third electrode and the second electrode. The additive manufacturing apparatus according to any one of claims 11 to 14, wherein the particle pattern is formed on a surface of a transfer medium.   The modeling unit includes a stage that is provided so as to face the transfer medium moved from a position facing the discharge port and is relatively movable, and a stacking mechanism that transfers the molten pattern from the transfer medium to the stage and stacks the layers. The additive manufacturing apparatus according to claim 15, comprising:   The resin particles contained in the charged resin particle layer formed to a predetermined thickness by the charged resin particle layer forming mechanism are selectively ejected by the voltage applied to the third electrode and are discharged to the second electrode. The layered manufacturing apparatus according to claim 15 or 16, wherein the layer thickness of the melt pattern formed on the surface of the transfer medium is controlled to be a predetermined thickness by reaching. A plurality of the ejection heads;
18. The additive manufacturing apparatus according to claim 11, wherein each of the resin particles discharged from the plurality of discharge heads includes a color material having a different color. .   The additive manufacturing apparatus according to any one of claims 11 to 18, wherein the resin particles include a conductive material. The transfer medium is configured in a cylindrical side surface shape,
The stacking mechanism is
A first moving mechanism for rotating the transfer medium about an axis;
A second moving mechanism that moves the stage in a tangential direction of the rotational movement of the transfer medium and a direction that intersects the tangential direction;
The rotational movement of the transfer medium and the movement of the stage are synchronized,
While the transfer medium is rotated about the axis, the molten pattern is transferred by being pressed onto the stage or the surface layer portion of the molten pattern which has been transferred and laminated on the stage and cooled or solidified, or has started to solidify. The additive manufacturing apparatus according to any one of claims 11 to 19, wherein the additive manufacturing apparatus is stacked. The transfer medium is configured in the shape of an annular belt,
The stacking mechanism is
A first moving mechanism for driving the transfer medium in a belt;
A roller for pressing from the inside of the annular belt of the transfer medium;
A second moving mechanism that moves the stage in a tangential direction between the roller and the annular belt of the transfer medium and in a direction intersecting the tangential direction;
The belt drive of the transfer medium and the movement of the stage are synchronized,
While the transfer medium is driven by a belt, the roller is transferred by pressing the molten pattern onto the stage or the surface layer portion of the molten pattern which has been transferred and laminated on the stage and cooled or solidified, or has started to cool and solidify. The additive manufacturing apparatus according to any one of claims 11 to 19, wherein the additive manufacturing apparatus is stacked.

Images