JP2017052097A - Molding apparatus and molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase productivity of manufacturing a molded object requiring a plurality of different processes in a molding apparatus for molding a three-dimensional molded object by stacking layers.SOLUTION: A molding apparatus of the present invention includes: a first molding area having first molding means for performing first molding; a second molding area having second molding means for performing second molding; a first stage and a second stage respectively forming molded objects based on the first molding and the second molding; and exchanging means to alternately exchange the first stage and the second stage into the first molding area and the second molding area. The first molding means and the second molding means simultaneously perform the first molding and second molding in parallel.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a modeling technique for forming a three-dimensional structure by stacking layers.

  A method of manufacturing a three-dimensional structure by dividing a layer of three-dimensional CAD (Computer Aided Design) data and adding a material so that the divided layers are stacked on each layer is defined as an additive manufacturing in the international standard. Has been. This manufacturing method invented in the 1980's is generally called a 3D printer (3D printer). In recent years, 3D printers are attracting attention as a new manufacturing method because they can easily manufacture complex shapes without using a mold if there is 3D CAD data.

  In 3D printers, shapes that were once difficult to manufacture, such as mesh shapes and porous shapes, can be easily and accurately manufactured, unlike removal processing by cutting and molding processing in which a material is poured into a mold and hardened. Furthermore, it is also expected to enable modeling in which a plurality of types of materials are freely arranged in the same layer. This is because modeling using a plurality of materials can realize a model with a new function utilizing the characteristics of each material.

  For example, a composite having a function of an electronic circuit is realized by combining a conductive material and an insulating material. In addition, by combining a hard material and a flexible material, a shaped article having a function having both strength and flexibility can be realized. These functions can be realized without developing new materials.

  By the way, when modeling a three-dimensional structure by stacking layers, modeling processes by different methods such as stacking different layers of different materials or excising part of the layers are performed within the same layer. You may need to do it. Patent Document 1 and Patent Document 2 disclose a method of modeling a three-dimensional structure by using a plurality of different methods.

  In Patent Document 1, an end mill operation unit that drives an end mill tool is provided at the stacking side end of a stack forming unit that stacks powder materials by laser irradiation, thereby sequentially stacking by laser light irradiation. An apparatus for cutting and removing is disclosed.

  In Patent Document 2, a laser beam is applied to a powder material to form a sintered layer, and a work area in which the operation of removing the unsintered powder material adhering to the sintered layer is collectively performed on the surface of the sintered layer. By arranging the work area for surface modification by irradiating the electron beam and the work area for cutting and grinding on the surface of the sintered layer, and laying the guide rail over each work area, An apparatus is disclosed in which a sintered body placed on a moving device can move between work areas.

JP 2007-204828 A Japanese Patent Laid-Open No. 2015-30872

  By the way, according to the methods disclosed in Patent Document 1 and Patent Document 2, when performing a process using different methods such as a lamination process, a surface modification process, and a cutting grinding process, contamination, warpage, deformation, and alteration of the material are prevented. Therefore, each process is performed serially. For this reason, the timing, speed, and processing conditions for processing each process are limited, and as a result, the productivity is lowered in modeling.

  The present invention has been made in view of the above problems, and its purpose is to increase the productivity of a shaped object that requires a plurality of different construction methods in a modeling apparatus that laminates layers to form a three-dimensional shaped object. It is in.

  The modeling apparatus according to the present invention includes a first modeling area having a first modeling means for performing a first modeling, a second modeling area having a second modeling means for performing a second modeling, and the first modeling area. The first stage and the second stage, the first stage and the second stage, respectively, which form a modeled object based on the modeling and the second modeling, respectively, and the first modeling area and the second stage. Replacement means for alternately switching to the second modeling area, wherein the first modeling means and the second modeling means simultaneously perform the first modeling and the second modeling. carry out.

  In the modeling method according to the present invention, the first modeling is performed on the first stage in the first modeling area, and simultaneously, the second modeling is performed on the second stage in the second modeling area. The first stage and the second stage are switched between the first modeling area and the second modeling area, and the second modeling is performed on the first stage in the second modeling area. In parallel, the first modeling is performed on the second stage in the first modeling area.

  ADVANTAGE OF THE INVENTION According to this invention, in the modeling apparatus which laminates | stacks a layer and models a three-dimensional molded item, productivity of the molded item which requires a several different construction method can be improved.

It is a block diagram which shows the structure of the modeling apparatus of the 1st Embodiment of this invention. It is a block diagram which shows the structure of the modeling apparatus of the 2nd Embodiment of this invention. It is a figure which shows the structure of the replacement means of the modeling apparatus of the 2nd Embodiment of this invention. It is a figure which shows the structure of the replacement means of the modeling apparatus of the 2nd Embodiment of this invention. It is a figure for demonstrating operation | movement of the modeling apparatus of the 2nd Embodiment of this invention. It is a block diagram which shows the structure of the modeling apparatus of the 3rd Embodiment of this invention. It is a figure for demonstrating operation | movement of the modeling apparatus of the 3rd Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the preferred embodiments described below are technically preferable for carrying out the present invention, but the scope of the invention is not limited to the following.
(First embodiment)
FIG. 1 is a block diagram showing a configuration of a modeling apparatus according to the first embodiment of the present invention. The modeling apparatus 10 of the present embodiment includes a first modeling region 11 having a first modeling unit 111 that performs first modeling and a second modeling region having a second modeling unit 121 that performs second modeling. 12, the first stage 14 and the second stage 15, and the first stage 14 and the second stage 15, each of which forms a modeled object based on the first modeling and the second modeling, respectively. The first modeling unit 111 and the second modeling unit 121 include a first modeling unit and a second modeling unit. The replacement unit 13 alternately replaces the modeling region 11 and the second modeling region 12. Are performed concurrently.

According to the present embodiment, in a modeling apparatus that models layers by stacking layers, the productivity of a modeled object that requires a plurality of different construction methods can be increased.
(Second Embodiment)
FIG. 2 is a block diagram illustrating a configuration of a modeling apparatus according to the second embodiment of the present invention. The modeling apparatus 20 of the present embodiment includes a first modeling unit 211 that performs a first modeling and a first material supply unit 212 that supplies a first material for the first modeling. The modeling area 21 is included. Furthermore, it has the 2nd modeling area | region 22 which has the 2nd modeling means 221 which performs 2nd modeling, and the 2nd material supply means 222 which supplies the 2nd material for 2nd modeling. Each modeling region can be provided by surrounding a set of modeling means and material supply means with a chamber or the like for each set.

  The modeling apparatus 20 further includes a first stage 24 and a second stage 25 that respectively form a three-dimensional modeled object based on the first modeling and the second modeling. The second stage 25 has rails 23 for alternately switching the first modeling area 21 and the second modeling area 22.

  Further, the modeling apparatus 20 includes a first modeling unit 211, a first material supply unit 212, a second modeling unit 221, a second material supply unit 222, a first stage 24, a second stage 25, and a rail. Control means 26 connected to The control means 26 performs control related to the layered modeling of the modeled object, such as the supply amount of each material, the supply position, the supply timing, the layered modeling speed, the layered modeling timing, the stage moving speed, and the stage position. Further, the control unit 26 controls the first modeling unit 211 and the second modeling unit 221 to perform the first modeling and the second modeling in parallel.

  The control means 26 can be realized by operating an information processing apparatus such as a server by a program. The operation of the program is set based on the three-dimensional CAD data of the three-dimensional structure.

  The first modeling means 211 and the second modeling means 221 can perform different modeling processes. The first modeling means 211 and the second modeling means 221 can have different construction methods.

  As the construction method of the first shaping means 211 and the second shaping means 221, a method classified as an additive manufacturing method by ASTM (American Society for Testing and Materials) can be used. Specifically, there is a material extrusion method in which a molten material is selectively extruded from an opening such as a nozzle and deposited. In addition, a material jetting method in which droplets of material are jetted and selectively cured and deposited with ultraviolet rays, or powder bed melting in which powdery materials are layered one after another and laser-irradiated for each layer for sintering. A combination method (Powder bed fusion) etc. are mentioned. Further, as another construction method, a layered modeling may be performed by repeating a process of having a pressurizing unit and a vibrating unit and joining the layers by pressurizing and vibrating. The construction methods of the first modeling means 211 and the second modeling means 221 are not limited to the above construction methods.

  The material to be laminated can be selected according to the construction method. For example, in the case of the material extrusion method, thermoplastic resins such as ABS, polycarbonate, and polylactic acid are exemplified. In the case of the powder bed fusion bonding method, gold, copper, silver, aluminum and the like can be mentioned. In addition, in the case of layered modeling by bonding layers by pressurization or vibration, gold, copper, silver, aluminum or the like having performance as a conductor can be used. Each material according to the construction method is not limited to the above materials.

  In the modeling apparatus 20 of the present embodiment, since the modeling area is different for each construction method, it is possible to prevent material contamination, and it is possible to optimally adjust conditions such as the type and supply amount of materials related to additive manufacturing in each modeling area. , Improve productivity and quality. Furthermore, since modeling can be performed simultaneously in the first modeling area 21 and the second modeling area 22, productivity is further improved.

  3A and 3B are diagrams illustrating a configuration of a rail as a stage replacement unit of the modeling apparatus 20. In FIG. 3A, the first stage 24 and the second stage 25 are alternately switched to the first modeling area 21 and the second modeling area 22 along the circumferential rail 23. At this time, the first stage 24 and the second stage 25 may move on the rail 23 as indicated by arrows, for example, and the first stage 24 and the second stage 25 are fixed to the rail 23. The rail 23 may rotate as indicated by an arrow, for example. The shape of the rail 23 may be an ellipse or a polygon such as a rectangle in addition to a circle.

  In FIG. 3B, the first stage 24 and the second stage 25 are alternately switched to the first modeling area 21 and the second modeling area 22 along the radial rail 27. At this time, the first stage 24 and the second stage 25 may move on the rail 27 as indicated by an arrow, for example, and the first stage 24 and the second stage 25 are fixed to the rail 27 and the rail. 27 may rotate. The shape of the rail 27 is not limited to a cross shape.

  In the modeling apparatus 20 described above, the case where the modeling area and the stage are each set to two sets has been described, but the number is not limited to two sets, and a plurality of sets of two or more can be set.

  FIG. 4 is a diagram for explaining the operation of the modeling apparatus 20 of the present embodiment. In FIG. 4, in order to briefly explain the operation, the first and second modeling means 211 and 221 and the first and second material supply means 212 and 222 are provided in a portion for directly supplying the material to the stage. A simplified first head 213 and second head 223 are shown.

  First, in (a), the first stage 24 is set in the first modeling area 21, and the second stage 25 is set in the second modeling area 22. In the first stage 24, the first modeling unit is modeled at a predetermined position by the first head 213. In the second stage 25, the second modeling unit is modeled at a predetermined position by the second head 223. The modeling of the first modeling unit and the modeling of the second modeling unit can be performed in parallel. The term “simultaneous” refers to, for example, matching the timing for starting modeling. For example, when modeling of the 1st modeling part is completed earlier than modeling of the 2nd modeling part, it waits until the end of modeling of the 2nd modeling part.

  Next, in (b), when the modeling of the first modeling unit and the modeling of the second modeling unit are finished, the first stage 24 is in the second modeling region 22 and the second stage 25 is in the first format. Move to the modeling area 21.

  Further, in (c), the first stage 24 is set in the second modeling area 22, and the second stage 25 is set in the first modeling area 21. In the first stage 24, the second modeling unit is modeled at a predetermined position by the second head 223. In the second stage 25, the first modeling unit is modeled at a predetermined position by the first head 213. The modeling of the first modeling unit and the modeling of the second modeling unit can be performed in parallel.

  By repeating the above operation for each layer, a three-dimensional structure is layered and formed on each of the first stage 24 and the second stage 25. The first stage 24 and the second stage 25 can exchange the modeling area for each layer, or can exchange the modeling area after processing a plurality of layers together. By performing different processes simultaneously in each of the first modeling region 21 and the second modeling region 22, the productivity of the modeled object can be increased.

As described above, according to the present embodiment, in a modeling apparatus that stacks layers to model a three-dimensional modeled object, the productivity of a modeled object that requires a plurality of different construction methods can be increased.
(Third embodiment)
FIG. 5 is a block diagram showing a configuration of a modeling apparatus according to the third embodiment of the present invention. The modeling apparatus 30 of the present embodiment includes a first modeling area 31, a second modeling area 32, a rail 33, a first stage 34, a second stage 35, and a control means 36. The first modeling region 31 includes a first modeling unit 311 that performs the first modeling, and a first material supply unit 312 that supplies a first material for the first modeling. The second modeling area 32 includes second modeling means 321 that performs the second modeling.

  Functions and operations of the first modeling region 31, the rail 33, the first stage 34, the second stage 35, and the control unit 36 of the modeling apparatus 30 are elements corresponding to those of the modeling apparatus 20 of the second embodiment. It is the same. Furthermore, the construction method of the first modeling means 311 and the material handled by the first material supply means 312 are the same as the construction method and materials of the modeling apparatus 20 of the second embodiment.

  The 2nd modeling means 321 of the 2nd modeling area | region 32 has a function which cuts a modeling part, for example, is provided with the cutter. The second modeling unit 321 is controlled by the control unit 36.

  FIG. 6 is a diagram for explaining the operation of the modeling apparatus 30 of the present embodiment. In FIG. 6, in order to briefly explain the operation, the first modeling unit 311 and the first material supply unit 312 are connected to the first head 313 which is a part for directly supplying the material to the stage. The modeling means 321 is represented in a simplified manner on a blade 323 that cuts the modeling part of the stage.

  First, in (a), the first stage 34 is set in the first modeling area 31, and the second stage 35 is set in the second modeling area 32. In the first stage 34, the modeling part is modeled at a predetermined position by the head 313. In the second stage 35, nothing is done.

  Next, in (b), when the modeling of the first modeling unit is completed, the first stage 34 moves to the second modeling area 32, and the second stage 35 moves to the first modeling area 31.

  Further, in (c), the first stage 34 is set in the second modeling area 32, and the second stage 35 is set in the first modeling area 31. In the first stage 34, the modeling part is cut by the blade 323. In the second stage 35, the modeling part is modeled at a predetermined position by the head 313. The modeling of the modeling part and the cutting of the modeling part can be performed in parallel. The term “simultaneous” refers to, for example, matching the timing for starting modeling. For example, when modeling of a modeling part is completed earlier than cutting of a modeling part, it waits until completion of cutting of a modeling part.

  By repeating the above operation for each layer, a three-dimensional structure is layered and formed on each of the first stage 34 and the second stage 35. The first stage 34 and the second stage 35 can exchange the modeling area for each layer, or can exchange the modeling area after processing a plurality of layers together. By performing different processes simultaneously in the first modeling area 31 and the second modeling area 32, the productivity of the modeled object can be increased.

  As described above, according to the present embodiment, in a modeling apparatus that stacks layers to model a three-dimensional modeled object, the productivity of a modeled object that requires a plurality of different construction methods can be increased.

  The present invention is not limited to the above embodiment, and various modifications are possible within the scope of the invention described in the claims, and these are also included in the scope of the present invention.

  Moreover, although a part or all of said embodiment may be described also as the following additional remarks, it is not restricted to the following.

Appendix (Appendix 1)
A first modeling region having a first modeling means for performing first modeling;
A second modeling region having a second modeling means for performing second modeling;
A first stage and a second stage, each of which forms a model based on the first modeling and the second modeling;
A replacement means for alternately switching the first stage and the second stage to the first modeling area and the second modeling area;
The first modeling unit and the second modeling unit are modeling apparatuses that perform the first modeling and the second modeling in parallel.
(Appendix 2)
The modeling apparatus according to appendix 1, wherein the first modeling unit and the second modeling unit have different construction methods.
(Appendix 3)
The modeling apparatus according to appendix 1 or 2, wherein the replacement means includes a rail that connects the first modeling area and the second modeling area circumferentially or radially.
(Appendix 4)
The modeling apparatus according to any one of appendices 1 to 3, wherein the first modeling unit and the second modeling unit include a stacking unit that stacks layers or a cutting unit that cuts a layer.
(Appendix 5)
The modeling apparatus according to appendix 4, wherein the laminating means has a material extrusion method, a material injection method, or a powder bed fusion method.
(Appendix 6)
The modeling apparatus according to appendix 4, wherein the laminating means includes a pressurizing means and a vibrating means for joining the layers.
(Appendix 7)
The modeling apparatus according to appendix 4, wherein the cutting means has a blade.
(Appendix 8)
First modeling is performed in the first modeling area on the first stage, and simultaneously, second modeling is performed in the second modeling area on the second stage,
Replacing the first stage and the second stage with the first modeling area and the second modeling area,
The modeling method, wherein the second modeling is performed on the first stage in the second modeling area, and the first modeling is performed on the second stage in the first modeling area simultaneously.
(Appendix 9)
The modeling method according to appendix 8, wherein the first modeling and the second modeling are different from each other.
(Appendix 10)
The modeling method according to appendix 8 or 9, wherein the replacement is by a rail that connects the first modeling area and the second modeling area circumferentially or radially.
(Appendix 11)
11. The modeling method according to any one of appendices 8 to 10, wherein the first modeling and the second modeling include layer lamination or layer cutting.
(Appendix 12)
The layering method according to claim 11, wherein the layers are stacked by a material extrusion method, a material injection method, or a powder bed fusion method.
(Appendix 13)
The layering method according to appendix 11, wherein the layer is laminated by heating or vibration.
(Appendix 14)
The modeling method according to appendix 11, wherein the cutting of the layer includes cutting with a blade.

10, 20, 30 Modeling apparatus 11, 21, 31 First modeling area 12, 22, 32 Second modeling area 111, 211, 311 First modeling means 121, 221, 321 Second modeling means 212, 312 First material supply means 222 Second material supply means 13 Replacement means 14, 24, 34 First stage 15, 25, 35 Second stage 23, 27, 33 Rail 26, 36 Control means 213 First head 223 Second head 313 Head 323 Blade

Claims (10)

A first modeling region having a first modeling means for performing first modeling;
A second modeling region having a second modeling means for performing second modeling;
A first stage and a second stage, each of which forms a model based on the first modeling and the second modeling;
A replacement means for alternately switching the first stage and the second stage to the first modeling area and the second modeling area;
The first modeling unit and the second modeling unit are modeling apparatuses that perform the first modeling and the second modeling in parallel. The modeling apparatus according to claim 1, wherein the first modeling unit and the second modeling unit have different construction methods. The modeling apparatus according to claim 1, wherein the replacement unit includes a rail that connects the first modeling region and the second modeling region circumferentially or radially. The modeling apparatus according to claim 1, wherein the first modeling unit and the second modeling unit include a stacking unit that stacks layers or a cutting unit that cuts layers. The modeling apparatus according to claim 4, wherein the laminating unit has a material extrusion method, a material injection method, or a powder bed fusion method. The modeling apparatus according to claim 4, wherein the stacking unit includes a pressurizing unit and a vibrating unit that join the layers. The modeling apparatus according to claim 4, wherein the cutting means has a blade. First modeling is performed in the first modeling area on the first stage, and simultaneously, second modeling is performed in the second modeling area on the second stage,
Replacing the first stage and the second stage with the first modeling area and the second modeling area,
The modeling method, wherein the second modeling is performed on the first stage in the second modeling area, and the first modeling is performed on the second stage in the first modeling area simultaneously. The modeling method according to claim 8, wherein the first modeling and the second modeling are based on different construction methods. The modeling method according to claim 8 or 9, wherein the replacement is performed by a rail that connects the first modeling area and the second modeling area circumferentially or radially.

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