JP2015189085A - Lamination shaping method and lamination shaping apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lamination shaping method which suppresses deterioration of a resin material in shaping a three-dimentional structure containing a metal material and the resin material.SOLUTION: A lamination shaping method is used to shape a three-dimensional structure 30 containing a metal material 31 and a resin material 32 and includes a step of forming a metal layer, a step of immersing the shaped metal layer in a photocurable resin liquid 11 to cool the shaped metal layer and a step of hardening the photocurable resin liquid 11 by irradiating the photocurable resin liquid 11 with a laser beam in a state where the shaped metal layer is immersed in the photocurable resin liquid 11 so as to form a resin layer.

Description

  The present invention relates to an additive manufacturing method and an additive manufacturing apparatus, and more particularly, to an additive manufacturing method and an additive manufacturing apparatus capable of forming a three-dimensional structure including a metal material and a resin material.

  In recent years, attention has been paid to 3D printer technology that forms a three-dimensional structure by laminating each layer constituting the three-dimensional structure in the stacking direction. Techniques for modeling such a three-dimensional structure include stereolithography (SL), hot melt lamination (FDM), inkjet method, and powder sintering (SLS). Etc. are known.

  Patent Document 1 discloses a technique for forming a three-dimensional structure by melting granular metal materials and bonding them together to form a metal layer and laminating the metal layer. Patent Document 1 discloses a technique for modeling a three-dimensional structure using two or more kinds of metal materials and a technique for modeling a three-dimensional structure using a metal material and a resin material.

JP-A-10-226803

  As described in the background art, Patent Document 1 discloses a technique for modeling a three-dimensional structure using a metal material and a resin material. However, since the melting point of the metal material is higher than the melting point of the resin material, when the three-dimensional structure is formed using the metal material and the resin material, the resin material around the metal material by the heat of the molten metal material There is a problem that will deteriorate.

  In view of the above problems, an object of the present invention is to provide an additive manufacturing method and additive manufacturing apparatus capable of suppressing deterioration of a resin material when forming a three-dimensional structure including a metal material and a resin material. Is to provide.

  The layered manufacturing method according to the present invention is a layered manufacturing method for forming a three-dimensional structure including a metal material and a resin material, the step of forming a metal layer, and the formed metal layer being a photocurable resin. Immersing the photocurable resin liquid in a state of immersing in the liquid and cooling the formed metal layer; and immersing the formed metal layer in the photocurable resin liquid; Curing the photocurable resin liquid to form a resin layer.

  The additive manufacturing apparatus according to the present invention is an additive manufacturing apparatus for forming a three-dimensional structure including a metal material and a resin material, and is capable of being displaced in a vertical direction with a storage tank in which a photocurable resin liquid is stored. A stage, a metal layer forming part for forming a metal layer, a resin layer forming part for forming a resin layer by irradiating the photocurable resin liquid with a laser beam, the stage and the metal layer forming part, A control unit that controls the resin layer forming unit, the control unit forming the metal layer using the metal layer forming unit, lowering the stage, and In the state where the formed metal layer is immersed in the photocurable resin liquid, the laser light is irradiated to the photocurable resin liquid using the resin layer forming unit, The photocurable resin liquid is cured to form a resin layer.

  In the present invention, after the metal layer is formed, the formed metal layer is immersed in a photocurable resin liquid and cooled. And in the state which the formed metal layer was immersed in the photocurable resin liquid, a laser beam is irradiated to a photocurable resin liquid, the said photocurable resin liquid is hardened, and the resin layer is formed. Thus, in this invention, since the resin layer is formed after cooling the formed metal layer using a photocurable resin liquid, it can suppress that the heat of a metal layer is transmitted to the surrounding resin layer. it can. Therefore, when modeling a three-dimensional structure including a metal material and a resin material, the resin material can be prevented from deteriorating.

  According to the present invention, it is possible to provide an additive manufacturing method and an additive manufacturing apparatus capable of suppressing deterioration of a resin material when forming a three-dimensional structure including a metal material and a resin material.

1 is a cross-sectional view illustrating an additive manufacturing apparatus according to a first embodiment. 3 is a top view showing an example of a three-dimensional structure formed using the layered manufacturing method according to Embodiment 1. FIG. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. FIG. 3 is a diagram for explaining an additive manufacturing method according to the first embodiment. It is sectional drawing for demonstrating the case where a metal layer is formed on a resin layer. FIG. 6 is a cross-sectional view for explaining a three-dimensional structure formed using the layered manufacturing method according to the second embodiment. It is sectional drawing which shows an example of the three-dimensional structure formed using the layered manufacturing method concerning Embodiment 2. FIG. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. FIG. 6 is a diagram for explaining an additive manufacturing method according to a second embodiment. 6 is a flowchart for explaining an additive manufacturing method according to a second embodiment; It is sectional drawing which shows the other example of the heat conductive resin layer formed using the layered manufacturing method concerning Embodiment 2. FIG.

<Embodiment 1>
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view illustrating an additive manufacturing apparatus 1 according to the first embodiment. As shown in FIG. 1, the additive manufacturing apparatus 1 according to the present embodiment includes a storage tank 10 in which a photocurable resin liquid 11 is stored, a stage 12, a metal layer forming unit 14, a curing laser light source (resin layer formation). Part) 17, the control part 20, the filter 21, and the cooling part 22.

  The storage tank 10 is a box-shaped tank whose upper part is opened. A photocurable resin liquid 11 such as an ultraviolet curable resin liquid is accommodated in the storage tank 10.

  The stage 12 is a pedestal for supporting the formed three-dimensional structure 30. The stage 12 is supported by the support portion 13 so as to be displaceable in the vertical direction (vertical direction). The position of the stage 12 is controlled by the control unit 20. For example, when the three-dimensional structure 30 is formed, the metal layer 31 and the resin layer 32 constituting the three-dimensional structure 30 are stacked while the stage 12 is gradually moved downward. Further, when the formed three-dimensional structure 30 is taken out, the stage 12 is moved upward, and the three-dimensional structure 30 is taken out of the photocurable resin liquid 11 to thereby remove the three-dimensional structure 30. Easy to take out.

The metal layer forming unit 14 forms the metal layer 31 constituting the three-dimensional structure 30. The metal layer forming unit 14 includes a metal particle supplying unit 15 that supplies metal particles to a portion where the metal layer 31 is formed, and a melting laser light source that forms the metal layer 31 by melting and solidifying the supplied metal particles. 16. For example, the metal layer forming unit 14 can be configured using a laser cladding apparatus. The metal layer forming unit 14 is configured to be movable using a moving device such as a six-axis robot. In addition, the metal layer forming unit 14 may be configured to be able to supply an antioxidant gas (Ar gas, N ₂ gas, etc.) to the part where the metal layer 31 is formed.

  The type of metal particles supplied from the metal particle supply unit 15 may be one type or a plurality of types. When there are a plurality of types of metal particles supplied from the metal particle supply unit 15, these metal particles may be selectively supplied. In the present embodiment, a plurality of metal layer forming portions 14 may be provided. For example, iron, aluminum, copper, and alloys thereof can be used for the metal particles. Moreover, you may use apparatuses other than a laser clad apparatus as the metal layer formation part 14. FIG. For example, a molten metal lamination molding method in which a metal layer is formed by melting a wire metal may be used.

  The curing laser light source (resin layer forming unit) 17 irradiates a laser beam for curing the photocurable resin liquid 11. When the photocurable resin is an ultraviolet curable resin, an ultraviolet laser can be used as the laser light. The curing laser light source 17 is configured to irradiate a predetermined position on the stage 12 with laser light. In other words, the curing laser light source 17 is configured to be able to irradiate laser light to a predetermined position in the horizontal plane of the three-dimensional structure 30 to be formed. For example, the irradiation position of the laser beam can be controlled using a galvano scanner, a MEMS mirror, a liquid crystal filter, or the like. A galvano scanner, a MEMS mirror, a liquid crystal filter, or the like may be built in the curing laser light source 17 or may be provided separately from the curing laser light source 17. In the present embodiment, a plurality of curing laser light sources 17 may be provided.

  The control unit 20 controls the stage 12, the metal layer forming unit 14, and the curing laser light source 17. For example, the control unit 20 can control the stage 12 to be displaced in the vertical direction. Further, the control unit 20 can control the amount of metal particles supplied from the metal particle supply unit 15, the presence / absence of supply of metal particles, the position of supplying metal particles, and the like. Further, the control unit 20 can control the power of the laser light emitted from the melting laser light source 16, the presence / absence of laser light irradiation, the irradiation position of the laser light, and the like. Further, the control unit 20 can control the power of the laser light emitted from the curing laser light source 17, the presence / absence of laser light irradiation, the irradiation position of the laser light, and the like.

  The additive manufacturing apparatus 1 according to the present embodiment creates, for example, a plurality of cross-sectional data obtained by slicing a three-dimensional structure at a predetermined pitch from design data based on three-dimensional CAD (Computer Aided Design), and metal based on each cross-sectional data A layer and a resin layer are formed. That is, the control unit 20 controls the stage 12, the metal layer forming unit 14, and the curing laser light source 17 based on each cross-sectional data to form a three-dimensional structure. At this time, the control unit 20 may recognize the material of each part of the three-dimensional structure and automatically calculate the optimal order for forming the metal layer and the resin layer.

  The filter 21 removes impurities contained in the photocurable resin liquid 11 stored in the storage tank 10. Here, the impurities contained in the photocurable resin liquid 11 are, for example, metal particles supplied from the metal layer forming unit 14 (metal particles mixed in the photocurable resin liquid 11 without being fixed to the metal layer), resin Photocurable resin that has not been fixed to the layer, photocured resin that has been carbonized or deteriorated, and the like. For example, the photocurable resin liquid 11 stored in the storage tank 10 is configured to circulate using a pump (not shown), and the circulating photocurable resin liquid 11 is passed through the filter 21. Thus, impurities contained in the photocurable resin liquid 11 can be removed. The filter 21 is not limited to such a configuration. For example, the filter 21 may be configured to precipitate and remove impurities using a specific gravity difference between the photocurable resin liquid 11 and the impurities. .

  The cooling unit 22 cools the photocurable resin liquid 11 stored in the storage tank 10. For example, the photocurable resin liquid 11 accommodated in the accommodating tank 10 is configured to circulate using a pump (not shown), and the circulating photocurable resin liquid 11 is cooled using the cooling unit 22. The photocurable resin liquid 11 accommodated in the storage tank 10 can be cooled by cooling. The cooling unit 22 is not limited to such a configuration. For example, the cooling unit 22 may be configured to directly cool the storage tank 10 to cool the photocurable resin liquid 11.

  Next, the additive manufacturing method (that is, the operation of the additive manufacturing apparatus 1) according to the present embodiment will be described. FIG. 2 is a top view showing an example of a three-dimensional structure formed using the layered manufacturing method according to the present embodiment. In the three-dimensional structure 40 shown in FIG. 2, a metal material 41 is disposed at the center portion, and resin materials 42_1 and 42_2 are disposed on both sides of the metal material 41. In the three-dimensional structure 50, the resin material 51 is disposed at the center, and the metal materials 52_1 and 52_2 are disposed on both sides of the resin material 51. That is, the three-dimensional structures 40 and 50 have a structure in which the metal material and the resin material are in contact with each other in the horizontal plane. In addition, the shape of each horizontal cross section of the three-dimensional structures 40 and 50 is the same in each layer (that is, the same as the top view shown in FIG. 2).

Hereinafter, a method of forming the three-dimensional structures 40 and 50 shown in FIG. 2 will be described with reference to FIGS. 3A to 3F (note that the description of the control unit 20 is omitted in FIGS. 3A to 3F). First, as shown in FIG. 3A, a metal layer 43 constituting the three-dimensional structure 40 and a metal layer 53 constituting the three-dimensional structure 50 are formed on the stage 12.
When the metal layers 43 and 53 are formed, the metal particles 25 are melted and solidified by the laser beam 26 while supplying the metal particles 25 to the surface of the stage 12. At this time, the surface of the stage 12 may be slightly higher than the liquid level of the photocurable resin liquid 11 so that the photocurable resin liquid 11 does not flow into the surface of the stage 12.

  Next, as shown in FIG. 3B, the stage 12 is moved downward, and the formed metal layers 43 and 53 are immersed in the photocurable resin liquid 11. Thus, by immersing the metal layers 43 and 53 in the photocurable resin liquid 11, the heat of the metal layers 43 and 53 can be transferred to the photocurable resin liquid 11, and the metal layers 43 and 53 are cooled. can do.

  In the case shown in FIG. 3B, the stage 12 is moved downward by the thickness of one layer of the three-dimensional structures 40 and 50. However, in the present embodiment, for example, after moving the stage 12 to a deeper position, the stage 12 may be moved upward again to return to the position of FIG. 3B. You may make it reciprocate several times in the up-down direction. By moving the stage 12 in this way, the heat of the metal layers 43 and 53 can be efficiently moved to the photocurable resin liquid 11. Further, by moving the stage 12 in this way, the photocurable resin liquid 11 can be infiltrated into a portion of the three-dimensional structure that is difficult for the photocurable resin liquid 11 to enter.

  Next, as shown in FIG. 3C, in a state where the metal layers 43 and 53 are immersed in the photocurable resin liquid 11, the photocurable resin liquid 11 is irradiated with the laser beam 28, and the photocurable resin liquid 11 is applied. The resin layers 44 and 54 are formed by curing.

  Next, as shown in FIG. 3D, metal layers 45 and 55 are formed on the metal layers 43 and 53, respectively. When the metal layers 45 and 55 are formed, the metal particles 25 are melted and solidified by the laser beam 26 while supplying the metal particles 25 to the formation surfaces on which the metal layers 45 and 55 are to be formed. At this time, the surfaces of the metal layers 43 and 53 may be slightly higher than the liquid surface of the photocurable resin liquid 11 so that the photocurable resin liquid 11 does not flow into the surfaces of the metal layers 43 and 53. .

  Next, as shown in FIG. 3E, the stage 12 is moved downward, and the formed metal layers 45 and 55 are immersed in the photocurable resin liquid 11. Thus, by immersing the metal layers 45 and 55 in the photocurable resin liquid 11, the heat of the metal layers 45 and 55 can be transferred to the photocurable resin liquid 11, and the metal layers 45 and 55 are cooled. can do.

  In the case shown in FIG. 3E, the stage 12 is moved downward by the thickness of one layer of the three-dimensional structure. However, in the present embodiment, for example, after moving the stage 12 to a deeper position, the stage 12 may be moved upward again to return to the position of FIG. 3E. You may make it reciprocate several times in the up-down direction. Thus, by moving the stage 12, the heat of the metal layers 45 and 55 can be efficiently moved to the photocurable resin liquid 11.

  Next, as shown in FIG. 3F, in a state where the metal layers 45 and 55 are immersed in the photocurable resin liquid 11, the photocurable resin liquid 11 is irradiated with the laser beam 28, and the photocurable resin liquid 11 is applied. The resin layers 46 and 56 are formed by curing.

  By repeating such an operation, the three-dimensional structures 40 and 50 including the metal material and the resin material as shown in FIG. 2 can be formed. In the steps shown in FIGS. 3A to 3F, the photocurable resin liquid 11 stored in the storage tank 10 is cooled using the cooling unit 22. Thus, by cooling the photocurable resin liquid 11, the metal layers 43, 45, 53, and 55 formed in FIGS. 3A and 3D can be quickly cooled.

  3A to 3F, impurities contained in the photocurable resin liquid 11 stored in the storage tank 10 are removed using the filter 21. For example, when the metal layers 43, 45, 53, and 55 are formed in FIGS. 3A and 3D, metal particles that are not fixed to the metal layers 43, 45, 53, and 55 are mixed into the photocurable resin liquid 11. The metal particles (impurities) mixed in this way are removed by the filter 21. Moreover, in FIG. 3B and FIG. 3E, a part of photocurable resin liquid 11 may solidify with the heat | fever of the metal layers 43, 45, 53, and 55. FIG. The photocurable resin thus solidified is removed by the filter 21.

  As described in the background art, Patent Document 1 discloses a technique for modeling a three-dimensional structure using a metal material and a resin material. However, since the melting point of the metal material is higher than the melting point of the resin material, when the three-dimensional structure is formed using the metal material and the resin material, the resin material around the metal material is affected by the heat of the molten metal material. There was a problem of deterioration. Here, by using a low melting point metal for the metal material, the melting point of the metal material can be brought close to the melting point of the resin material and deterioration of the resin material can be suppressed to some extent, but the low melting point metal is expensive. Also, the choice of materials is limited.

  Therefore, in the invention according to the present embodiment, after the metal layer is formed, the formed metal layer is immersed in a photocurable resin liquid and cooled (see FIGS. 3B and 3E). And in the state which the formed metal layer was immersed in the photocurable resin liquid, a laser beam is irradiated to the photocurable resin liquid, the said photocurable resin liquid is hardened, and the resin layer is formed ( 3C and FIG. 3F). As described above, in the invention according to the present embodiment, since the resin layer is formed after the formed metal layer is cooled using the photocurable resin liquid, the heat of the metal layer is transmitted to the surrounding resin layers. Can be suppressed. Therefore, when modeling a three-dimensional structure including a metal material and a resin material, the resin material can be prevented from deteriorating.

  In the example described with reference to FIGS. 3A to 3F, the case where the metal layers 45 and 55 are formed on the metal layers 43 and 53 has been described. However, in the additive manufacturing method according to the present embodiment, the resin layer Alternatively, a metal layer may be formed. In this case, the resin layer is sufficiently cooled with a photo-curable resin liquid, and then the metal layer is formed on the resin layer so that the resin layer below the metal layer becomes the heat of the metal layer. It can suppress that it deteriorates by.

  Further, the additive manufacturing method and additive manufacturing apparatus according to the present embodiment are not limited to the above configuration, and can be appropriately changed without departing from the spirit of the additive manufacturing method. For example, the stage 12 may be configured to be inclined with respect to the liquid level (that is, a horizontal plane) of the photocurable resin liquid 11. In other words, when the three-dimensional structure is formed, the three-dimensional structure having various shapes can be formed by tilting the stage 12 with respect to the horizontal plane.

  Further, the other structure is positioned and fixed on the stage 12, and the three-dimensional structure is formed using the layered manufacturing method described above, so that the three-dimensional structure is formed on a part of the other structure. Can be formed. Further, a mechanism that keeps the distance between the three-dimensional structure on the stage 12 and the liquid surface of the photocurable resin liquid 11 constant may be provided.

  In the present embodiment, the stage 12 may be configured to be movable in the horizontal direction in addition to the vertical direction. In this case, the metal layer forming part 14 and the curing laser light source (resin layer forming part) 17 may be fixed.

  In the present embodiment, impurities removed by the filter 21 (metal particles, carbonized / deteriorated photocurable resin, etc.) may be collected and reused.

  In the present embodiment, the temperature of the three-dimensional structure is monitored using temperature detection means such as thermography, and the three-dimensional structure is manufactured when the temperature of the three-dimensional structure exceeds a predetermined threshold. You may make it stop and immerse a three-dimensional structure in the photocurable resin liquid 11, and you may make it cool.

  In the present embodiment, the shape of the three-dimensional structure is monitored using a three-dimensional shape recognition unit such as a laser scanner. If the accuracy of the shape of the three-dimensional structure exceeds a predetermined specified value, 3 The production of the three-dimensional structure may be stopped, and the shape of the three-dimensional structure may be corrected (that is, corrected by laser ablation processing) using a processing laser.

  By the invention according to the present embodiment described above, a layered manufacturing method capable of suppressing deterioration of the resin material when forming a three-dimensional structure including a metal material and a resin material, and a layered method A modeling apparatus can be provided.

<Embodiment 2>
Next, a second embodiment of the present invention will be described.
As shown in the cross-sectional view of FIG. 4, when the metal layer 61 is formed on the resin layer 60 by melting the metal particles 25 with the laser beam 26, the position 62 of the resin layer 60 (on the lower side of the metal layer 61). Position) is locally heated by the heat of the metal layer 61, and there is a problem that the resin layer 60 is carbonized, disappears, or deteriorates. Such a problem is a problem that may occur even when the resin layer 60 is cooled in advance using the photocurable resin liquid 11. That is, the heat transferred from the metal layer 61 to the resin layer 60 when the metal layer 61 is formed on the resin layer 60 is difficult to transfer in the resin layer 60 because the resin layer 60 has low thermal conductivity. For this reason, the lower position 62 of the metal layer 61 is locally heated by the heat of the metal layer 61. That is, since heat hardly diffuses from the position 62 of the resin layer 60 to the surroundings, the position 62 of the resin layer 60 may be locally heated and carbonized and lost.

  In order to solve such a problem, in this embodiment, as shown in the cross-sectional view of FIG. 5, a heat conductive resin layer 62 having a higher heat conductivity than the resin layer 60 is formed on the resin layer 60. The metal layer 61 is formed on the heat conductive resin layer 62. Thus, by providing the heat conductive resin layer 62 between the resin layer 60 and the metal layer 61, the heat transferred from the metal layer 61 to the heat conductive resin layer 62 is transferred in the heat conductive resin layer 62. Can be dispersed. Therefore, since it can suppress that the resin layer 60 and the heat conductive resin layer 62 are heated locally with the heat of the metal layer 61, the resin layer 60 and the heat conductive resin layer 62 are carbonized and disappeared. It is possible to suppress deterioration.

  Hereinafter, the additive manufacturing method according to the present embodiment will be described in detail. Note that the additive manufacturing apparatus 2 used in the present embodiment is basically the same as the additive manufacturing apparatus 1 described in the first embodiment, and therefore, the same components are denoted by the same reference numerals and duplicated description. Is omitted.

  FIG. 6 is a cross-sectional view showing an example of a three-dimensional structure formed using the layered manufacturing method according to the present embodiment. A three-dimensional structure 70 shown in FIG. 6 has a structure in which a metal material 72 is embedded in a resin material 71 having a U-shaped cross section. A heat conductive resin layer 73 is provided between the resin material 71 and the metal material 72.

  Hereinafter, a method of forming the three-dimensional structure 70 shown in FIG. 6 will be described with reference to FIGS. 7A to 7F (note that the description of the control unit 20 is omitted in FIGS. 7A to 7F). First, as shown in FIG. 7A, a resin layer 75 constituting the three-dimensional structure 70 is formed on the stage 12. That is, the photocurable resin liquid 11 is irradiated with the laser light 28 to cure the photocurable resin liquid 11 to form the resin layer 75.

  Next, as shown in FIG. 7B, after moving the stage 12 downward, the photocurable resin liquid 11 is irradiated with the laser light 28 to cure the photocurable resin liquid 11 to be on the resin layer 75. A resin layer 76 is formed.

  Next, as shown in FIG. 7C, a heat conductive resin layer 77 is formed on the resin layer 75. The thermally conductive resin layer 77 can be formed by irradiating the photocurable resin liquid 11 with the laser beam 28 after supplying the metal particles (filler) 25 to the photocurable resin liquid 11. At this time, the laser beam is not irradiated from the melting laser light source 16 of the metal layer forming unit 14. In other words, the metal layer forming unit 14 supplies only the metal particles 25 to the photocurable resin liquid 11.

  Thus, the heat conductivity of the heat conductive resin layer 77 can be improved by mixing the metal particles 25 into the photocurable resin liquid 11. At this time, the thermal conductivity of the heat conductive resin layer 77 can be adjusted by adjusting the amount of the metal particles 25 mixed in the heat conductive resin layer 77. That is, as the amount of the metal particles 25 mixed in the heat conductive resin layer 77 is increased, the heat conductivity of the heat conductive resin layer 77 can be increased.

  In FIG. 7C, the case where the metal particles 25 are supplied using the metal layer forming unit 14 is shown as an example. However, in the present embodiment, the metal particle supplying means (not provided) provided separately from the metal layer forming unit 14 is used. You may make it supply metal particle (filler) to the photocurable resin liquid 11 using illustration. Further, the heat conductive resin layer 77 may be formed by irradiating the photocurable resin liquid 11 with the laser beam 28 while supplying the metal particles 25 to the photocurable resin liquid 11. That is, the supply of the metal particles 25 and the irradiation with the laser beam 28 may be performed simultaneously. As a material of the metal particles (filler) mixed in the photocurable resin liquid 11, for example, iron, aluminum, copper, and alloys thereof can be used.

  Next, as shown in FIG. 7D, a metal layer 78 is formed on the heat conductive resin layer 77. When the metal layer 78 is formed, the metal particles 25 are melted and solidified by the laser beam 26 while supplying the metal particles 25 to the surface of the heat conductive resin layer 77. At this time, the surface of the heat conductive resin layer 77 may be slightly higher than the surface of the photocurable resin liquid 11 so that the photocurable resin liquid 11 does not flow into the surface of the metal layer 78. The heat of the formed metal layer 78 is transmitted to the photocurable resin liquid 11 through the heat conductive resin layer 77, and the metal layer 78 is indirectly cooled.

  Next, as shown in FIG. 7E, the stage 12 is moved downward to immerse the formed metal layer 78 in the photocurable resin liquid 11. Thus, by immersing the metal layer 78 in the photocurable resin liquid 11, the heat of the metal layer 78 can be transferred to the photocurable resin liquid 11, and the metal layer 78 can be directly cooled.

  In the case shown in FIG. 7E, the stage 12 is moved downward by the thickness of one layer of the three-dimensional structure. However, in the present embodiment, for example, after moving the stage 12 to a deeper position, the stage 12 may be moved upward again to return to the position of FIG. 7E. You may make it reciprocate several times in the up-down direction. Thus, by moving the stage 12, the heat of the metal layer 78 can be efficiently moved to the photocurable resin liquid 11.

  Next, as shown in FIG. 7F, in a state where the metal layer 78 is immersed in the photocurable resin liquid 11, the photocurable resin liquid 11 is irradiated with laser light 28 to cure the photocurable resin liquid 11. Thus, the resin layer 79 is formed.

  By repeating such an operation, a three-dimensional structure 70 including a metal material and a resin material as shown in FIG. 6 can be formed. In the steps shown in FIGS. 7A to 7F, the photocurable resin liquid 11 stored in the storage tank 10 is cooled using the cooling unit 22. Thus, by cooling the photocurable resin liquid 11, the metal layer 78 formed in FIG. 7D can be rapidly cooled.

  7A to 7F, impurities contained in the photocurable resin liquid 11 stored in the storage tank 10 are removed using the filter 21. For example, in FIG. 7C, among the metal particles 25 supplied when forming the heat conductive resin layer 77, the metal particles not taken into the heat conductive resin layer 77 are mixed into the photocurable resin liquid 11. To do. In addition, when the metal layer 78 is formed in FIG. 7D, the metal particles that are not fixed to the metal layer 78 are mixed into the photocurable resin liquid 11. The metal particles (impurities) mixed in this way are removed by the filter 21. Moreover, in FIG. 7F, a part of the photocurable resin liquid 11 may be solidified by the heat of the metal layer 78. The photocurable resin thus solidified is removed by the filter 21.

  The additive manufacturing apparatus 2 according to the present embodiment creates, for example, a plurality of cross-sectional data obtained by slicing a three-dimensional structure at a predetermined pitch from design data by three-dimensional CAD, and a metal layer and a resin layer are formed based on each cross-sectional data. Form. At this time, it is possible to determine whether or not to form a thermally conductive resin layer by performing the processing shown in the flowchart of FIG. 8 based on each cross-sectional data.

  That is, as shown in FIG. 8, first, it is determined whether or not the N layer (N is an integer of 1 or more) is a resin layer (step S1). When the N layer is a resin layer (step S1: Yes), it is determined whether or not the N + 2 layer is a metal layer (step S2). If the N + 2 layer is a metal layer (step S2: Yes), a thermally conductive resin layer is formed on the N + 1 layer (step S3). If it is determined in step S1 that the N layer is not a resin layer (step S1: No), and if it is determined in step S2 that the N + 2 layer is not a metal layer (step S2: No), the value of N In step S1, it is determined whether or not the next N + 1 layer is a resin layer. By repeating such processing, it is possible to determine whether or not to form a thermally conductive resin layer.

  In the present embodiment, since the heat conductive resin layer is provided between the resin layer and the metal layer as described above, the heat transferred from the metal layer to the heat conductive resin layer is transferred in the heat conductive resin layer. Can be dispersed. Therefore, since it can suppress that a resin layer and a heat conductive resin layer are locally heated with the heat | fever of a metal layer, a resin layer and a heat conductive resin layer are carbonized, lose | disappeared, or deteriorated. This can be suppressed.

  Moreover, in this Embodiment, you may form the heat conductive resin layer which consists of a several layer between a resin layer and a metal layer. At this time, as shown in the cross-sectional view of FIG. 9, the thermal conductivity of the plurality of thermally conductive resin layers 81_1 to 81_4 may be gradually increased from the resin layer 80 side toward the metal layer 82 side. For example, the thermal conductivity of each of the heat conductive resin layers 81_1 to 81_4 can be adjusted by adjusting the amount of the metal particles (filler) mixed in each of the heat conductive resin layers 81_1 to 81_4. In this case, the amount of metal particles contained in each of the heat conductive resin layers 81_1 to 81_4 is gradually increased from the resin layer 80 side toward the metal layer 82 side.

  In this way, by making the thermal conductivity of the plurality of thermally conductive resin layers 81_1 to 81_4 gradually increase from the resin layer 80 side toward the metal layer 82 side, the heat transferred from the metal layer 82 is increased. It can be more reliably dispersed in the heat conductive resin layers 81_1 to 81_4.

  As the addition amount (% by weight) of the metal particles, for example, the amount of the metal particles contained in the heat conductive resin layer 81_1 is 30%, the amount of the metal particles contained in the heat conductive resin layer 81_2 is 50%, and the heat conduction. The amount of metal particles contained in the conductive resin layer 81_3 can be 75%, and the amount of metal particles contained in the thermally conductive resin layer 81_4 can be 90%.

  Although the present invention has been described with reference to the above embodiment, the present invention is not limited only to the configuration of the above embodiment, and within the scope of the invention of the claims of the present application. It goes without saying that various modifications, corrections, and combinations that can be made by those skilled in the art are included.

1, 2, 3 additive manufacturing apparatus 10 container 11 photocurable resin liquid 12 stage 13 support part 14 metal layer forming part 15 metal particle supplying part 16 melting laser light source 17 curing laser light source (resin layer forming part)
DESCRIPTION OF SYMBOLS 20 Control part 21 Filter 22 Cooling part 25 Metal particle 26 Laser beam 28 Laser beam 60 Resin layer 61 Metal layer 62 Thermally conductive resin layer 80 Resin layer 81_1-81_4 Thermally conductive resin layer 82 Metal layer

Claims (9)

An additive manufacturing method for forming a three-dimensional structure including a metal material and a resin material,
Forming a metal layer;
Immersing the formed metal layer in a photocurable resin liquid, and cooling the formed metal layer;
Irradiating the photocurable resin liquid with laser light in a state where the formed metal layer is immersed in the photocurable resin liquid, and curing the photocurable resin liquid to form a resin layer; Comprising
Additive manufacturing method. When forming the metal layer on the resin layer,
On the resin layer, a heat conductive resin layer having a higher thermal conductivity than the resin layer is formed,
Forming the metal layer on the thermally conductive resin layer;
The additive manufacturing method according to claim 1.   The additive manufacturing method according to claim 2, wherein the thermally conductive resin layer is formed by irradiating the photocurable resin liquid with the laser light after supplying metal particles to the photocurable resin liquid.   When a plurality of thermally conductive resin layers are formed between the resin layer and the metal layer, the thermal conductivity of the plurality of thermally conductive resin layers gradually increases from the resin layer side toward the metal layer side. The additive manufacturing method according to claim 3, wherein the plurality of thermally conductive resin layers are formed to be higher.   The additive manufacturing method according to claim 1, wherein the photocurable resin liquid is cooled while the three-dimensional structure is formed. An additive manufacturing apparatus for modeling a three-dimensional structure including a metal material and a resin material,
A storage tank containing a photocurable resin liquid;
A vertically displaceable stage;
A metal layer forming portion for forming the metal layer;
A resin layer forming part for forming a resin layer by irradiating the photocurable resin liquid with a laser beam;
A control unit for controlling the stage, the metal layer forming unit, and the resin layer forming unit,
The controller is
Forming the metal layer using the metal layer forming portion;
Lowering the stage, immersing the formed metal layer in the photocurable resin liquid,
In the state where the formed metal layer is immersed in the photocurable resin liquid, the resin layer forming unit is used to irradiate the photocurable resin liquid with laser light to cure the photocurable resin liquid. To form a resin layer,
Additive manufacturing equipment. The controller is
When forming the metal layer on the resin layer,
On the resin layer, a thermally conductive resin layer having a higher thermal conductivity than the resin layer is formed,
Forming the metal layer on the thermally conductive resin layer;
The additive manufacturing apparatus according to claim 6.   The additive manufacturing apparatus according to any one of claims 6 and 7, further comprising a cooling unit that cools the photocurable resin liquid stored in the storage tank.   The additive manufacturing apparatus according to any one of claims 6 to 8, further comprising a filter that removes impurities contained in the photocurable resin liquid stored in the storage tank.

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