JP2017087612A - Manufacturing apparatus for three-dimensional shaped article and manufacturing method for three-dimensional shaped article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a highly accurate three-dimensional shaped article.SOLUTION: A manufacturing apparatus 2000 for a three-dimensional shaped article 500 manufactures the three-dimensional shaped article 500 by laminating layers. The manufacturing apparatus 2000 for the three-dimensional shaped article comprises: a material layer formation section 1230 forming a material layer 310 of the three-dimensional shaped article 500 by using a constituent material containing powder, a solvent and a binder constituting the three-dimensional shaped article 500; a first heating section 810 capable of heating a sintering region or a melting region corresponding to a configuration region of the three-dimensional shaped article 500 out of the material layer 310; and a second heating section 840 capable of heating a peripheral region H2 of a heating region H1 heated by the first heating section 810 at the time of heating by the first heating section 810.SELECTED DRAWING: Figure 9

Description

  The present invention relates to a three-dimensional structure manufacturing apparatus and a three-dimensional structure manufacturing method.

Conventionally, the manufacturing method which manufactures a three-dimensional structure by laminating | stacking a layer is implemented.
Among these, the manufacturing method which manufactures a three-dimensional molded item is disclosed, forming a layer using a fluid composition. For example, Patent Document 1 discloses a manufacturing method in which a layer is formed using a metal paste, and a corresponding region of the three-dimensional structure is irradiated with a laser to produce a three-dimensional structure while being sintered or melted. Yes.
Moreover, as described in Patent Document 2, there are cases where the surface is heated to increase the hardness of the surface by, for example, rolling the laminated three-dimensional structure with a gas burner.

JP 2008-184622 A JP 2003-266548 A

  However, in the conventional manufacturing method of a three-dimensional structure, by locally heating the corresponding region of the three-dimensional structure, the temperature difference between the heating region and its peripheral part increases, and the material forming the layer is scattered. There was a case. When scattering of the formation material of such a layer arises, it will become difficult to manufacture a highly accurate three-dimensional structure.

  Therefore, an object of the present invention is to manufacture a highly accurate three-dimensional structure.

  The apparatus for manufacturing a three-dimensional structure according to the first aspect of the present invention for solving the above-described problem is a three-dimensional structure manufacturing apparatus that manufactures a three-dimensional structure by stacking layers. A material layer forming unit that forms a material layer of a three-dimensional structure using a constituent material including powder, solvent, and binder constituting the three-dimensional object, and a three-dimensional structure of the three-dimensional structure among the material layers A first heating unit capable of heating a sintered region or a melting region corresponding to the first heating unit, and a second heating unit capable of heating a peripheral region of the heating region by the first heating unit during heating by the first heating unit. It is characterized by providing.

  According to this aspect, the 1st heating part which can heat the sintering area | region or fusion | melting area | region corresponding to the structure area | region of the three-dimensional structure in a material layer, and this 1st heating part at the time of the heating by a 1st heating part And a second heating unit capable of heating the peripheral region of the heating region. For this reason, the temperature difference between the heating region by the first heating unit that is the sintering region or the melting region and the peripheral portion thereof can be reduced, and scattering of the constituent materials forming the material layer can be suppressed. . Therefore, a highly accurate three-dimensional structure can be manufactured.

  The three-dimensional structure manufacturing apparatus of the second aspect of the present invention is characterized in that, in the first aspect, the first heating unit is a laser irradiation unit.

  According to this aspect, the first heating unit is a laser irradiation unit. For this reason, the heating area | region by the 1st heating part which is a sintering area | region or a fusion | melting area | region can be sintered or fuse | melted accurately, and especially a highly accurate three-dimensional molded item can be manufactured.

  In the three-dimensional structure manufacturing apparatus of the third aspect of the present invention, in the first or second aspect, the second heating unit is a burner or a heater.

  According to this aspect, the second heating unit is a burner or a heater. For this reason, the range wider than the heating area | region by a 1st heating part can be heated easily.

  In the manufacturing apparatus for a three-dimensional structure according to the fourth aspect of the present invention, in any one of the first to third aspects, the second heating unit is a shape and a range of a heating region by the second heating unit. At least one of the above is variable.

  According to this aspect, the second heating unit can change at least one of the shape and the range of the heating region by the second heating unit. For this reason, the shape and range of the heating region by the second heating unit can be appropriately adjusted according to the shape and size of the three-dimensional structure or the type of the constituent material.

  According to a fifth aspect of the present invention, there is provided the apparatus for manufacturing a three-dimensional structure in the fourth aspect, wherein the second heating unit includes a plurality of heating energy emission ports, and changes the emission port for emitting the heating energy. Thus, at least one of the shape and range of the heating region is variable.

  According to this aspect, the second heating unit includes a plurality of heating energy launch openings, and changes at least one of the shape and range of the heating region by changing the launch openings that emit the heating energy. For this reason, at least one of the shape and range of a heating area | region can be changed with such a simple structure.

  In the manufacturing apparatus for a three-dimensional structure according to the sixth aspect of the present invention, in any one of the first to fifth aspects, the first heating unit moves the heating area to move the sintered area or melt. The region can be heated, and the heating region by the second heating unit is fixed and includes a moving range of the heating region by the first heating unit.

  According to this aspect, the first heating unit can move the heating region to heat the sintering region or the melting region, the heating region by the second heating unit is fixed, and the first heating unit is based on the first heating unit. Includes moving range of heating area. That is, it is possible to manufacture a three-dimensional structure by fixing the second heating unit and moving only the first heating unit. For this reason, since it is not necessary to provide the moving mechanism of a 2nd heating part, an apparatus structure can be simplified.

  The manufacturing apparatus for a three-dimensional structure according to a seventh aspect of the present invention is the manufacturing apparatus according to any one of the first to fifth aspects, wherein the first heating unit moves the heating area to move the sintered area or melt. The region can be heated, and the heating region by the second heating unit moves with the movement of the heating region by the first heating unit.

  According to this aspect, the first heating unit can move the heating region to heat the sintering region or the melting region, and the heating region by the second heating unit moves along with the movement of the heating region by the first heating unit. That is, the three-dimensional structure is manufactured by moving both the first heating unit and the second heating unit. For this reason, since the magnitude | size of the heating area | region of a 2nd heating part can be suppressed to a moderate magnitude | size, the load which enlarges the heating area | region of a 2nd heating part can be suppressed.

  The manufacturing method of the three-dimensional structure according to the eighth aspect of the present invention is a manufacturing method of a three-dimensional structure that manufactures a three-dimensional structure by stacking layers, and a powder that constitutes the three-dimensional structure. A material layer forming step of forming a material layer of the three-dimensional structure using a constituent material including a solvent and a binder, and a sintered region corresponding to the constituent area of the three-dimensional structure among the material layers, or And a heating step of heating the peripheral region of the heating region by the first heating unit with the second heating unit while heating the melting region with the first heating unit.

  According to this aspect, in the heating step, the heating region by the first heating unit is heated while the sintered region or the melting region corresponding to the constituent region of the three-dimensional structure in the material layer is heated by the first heating unit. The peripheral area is heated by the second heating unit. For this reason, the temperature difference between the heating region by the first heating unit that is the sintering region or the melting region and the peripheral portion thereof can be reduced, and scattering of the constituent materials forming the material layer can be suppressed. . Therefore, a highly accurate three-dimensional structure can be manufactured.

FIG. 1A is a schematic configuration diagram illustrating a configuration of a three-dimensional structure manufacturing apparatus according to an embodiment of the present invention, and FIG. 1B is an enlarged view of a portion C illustrated in FIG. 1A. 2A is a schematic configuration diagram showing a configuration of a three-dimensional structure manufacturing apparatus according to an embodiment of the present invention, and FIG. 2B is an enlarged view of a C ′ portion shown in FIG. 2A. The schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention. 1 is a schematic perspective view of a head base according to an embodiment of the present invention. The top view explaining notionally the relationship between arrangement | positioning of the head unit which concerns on one Embodiment of this invention, and the formation form of a three-dimensional structure. Schematic explaining conceptually the formation form of a three-dimensional structure. The schematic diagram which shows the example of other arrangement | positioning of the head unit arrange | positioned at a head base. The schematic perspective view of the heating part which concerns on one Embodiment of this invention. Schematic of the heating part which concerns on one Embodiment of this invention. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. The flowchart of the manufacturing method of the three-dimensional structure based on one Example of this invention.

Embodiments according to the present invention will be described below with reference to the drawings.
1 to 3 are schematic configuration diagrams showing a configuration of a three-dimensional structure manufacturing apparatus according to an embodiment of the present invention.
Here, the three-dimensional structure manufacturing apparatus according to the present embodiment includes two types of material supply units (head bases) and three types of heating units. Among these, FIG. 1 is a diagram showing only one material supply unit (a material supply unit that supplies a constituent material (a material including a powder, a solvent, and a binder constituting a three-dimensional structure)). FIG. 2 also shows one material supply part (a material supply part that supplies a support part forming material that forms a support part that supports the three-dimensional structure when the three-dimensional structure is formed), and one It is a figure showing a heating part (heating part using laser L for sintering a material for forming a support layer). And FIG. 3 shows the 1st heating part (heating part using the laser L) which can heat the sintering area | region or fusion | melting area | region corresponding to the structure area | region of a three-dimensional structure as a heating part, and a 1st heating part. It is the figure showing the 2nd heating part (heating part using a burner) which can heat the peripheral field of the heating field by the 1st heating part at the time of heating by.
In addition, “three-dimensional modeling” in the present specification indicates that a so-called three-dimensional model is formed, and for example, a plate shape, a so-called two-dimensional shape, has a shape having a thickness. Forming is also included. Further, “support” means not only the case of supporting from the lower side, but also the case of supporting from the lateral side and, in some cases, the case of supporting from the upper side.

A three-dimensional structure manufacturing apparatus 2000 (hereinafter referred to as a forming apparatus 2000) shown in FIG. 1 to FIG. 3 includes a base 110 and a driving device 111 as a driving means provided in the base 110. The stage 120 is provided so as to be movable in the Z direction or driven in the rotation direction around the Z axis.
As shown in FIG. 1, a head base 1100 that holds a plurality of head units 1400 having one end portion fixed to the base 110 and having a constituent material discharge portion 1230 that discharges a constituent material to the other end portion. Is provided with a head base support 130.
In addition, as shown in FIG. 2, a support layer forming material discharge unit that discharges a support layer forming material that supports the three-dimensional structure to the other end, with one end fixed to the base 110. A head base support portion 730 on which a head base 1600 that holds a plurality of head units 1900 including 1730 is held and fixed.
Also, as shown in FIG. 3, one end is fixed to the base 110, and the other end includes a laser irradiation unit 810 as a first heating unit and a burner 840 as a second heating unit. A heating unit base support 830 on which a heating unit base 880 that holds the heating unit is held and fixed.
Here, the head base 1100, the head base 1600, and the heating unit base 880 are provided in parallel in the XY plane.
The constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 have the same configuration. However, it is not limited to such a configuration.

On the stage 120, layers 501, 502, and 503 in the process of forming the three-dimensional structure 500 are formed. Since the formation of the three-dimensional structure 500 is irradiated with thermal energy by a laser L or the like, a heat resistant sample plate 121 is used on the sample plate 121 for protection from the heat of the stage 120. A three-dimensional structure 500 may be formed. The sample plate 121 of this embodiment is made of metal that is sturdy and easy to manufacture. However, as the sample plate 121, for example, a ceramic plate can be used to obtain high heat resistance, and also the reactivity with the constituent material of the three-dimensional structure to be melted (or sintered). It is low and the alteration of the three-dimensional structure 500 can be prevented. In FIG. 1A and FIG. 2A, for convenience of explanation, three layers 501, 502, and 503 are illustrated, but the layers are stacked up to the shape of the desired three-dimensional structure 500 (up to the layer 50 n in FIGS. 1A and 2A). Is done.
Here, the layers 501, 502, 503,... 50 n are respectively formed from a support layer forming material discharged from a support layer forming material discharge unit 1730 and a constituent material discharge unit 1230. And a material layer 310 formed of the discharged constituent material.

  FIG. 1B is an enlarged conceptual view of a C portion showing the head base 1100 shown in FIG. 1A. As shown in FIG. 1B, the head base 1100 holds a plurality of head units 1400. As will be described in detail later, one head unit 1400 is configured by holding a constituent material discharge unit 1230 included in the constituent material supply apparatus 1200 by a holding jig 1400a. The constituent material discharge unit 1230 includes a discharge nozzle 1230a and a discharge driving unit 1230b that discharges the constituent material from the discharge nozzle 1230a by the material supply controller 1500.

  FIG. 2B is an enlarged conceptual view of a C ′ portion showing the head base 1600 shown in FIG. 2A. As shown in FIG. 2B, the head base 1600 holds a plurality of head units 1900. The head unit 1900 is configured by holding a support layer forming material discharge unit 1730 included in the support layer forming material supply apparatus 1700 by a holding jig 1900a. The support layer forming material discharge unit 1730 includes a discharge nozzle 1730a and a discharge driving unit 1730b that discharges the support layer forming material from the discharge nozzle 1730a by the material supply controller 1500. Further, a laser irradiation unit 3100 for sintering the support layer forming material and a galvano mirror 3000 for positioning laser light from the laser irradiation unit 3100 are provided above the stage 120.

  The laser irradiation unit 810 of the heating unit base 880 shown in FIG. 3 is controlled by the laser controller 820 in the heating region H1 (see FIG. 9) of the material layer 310 of the three-dimensional structure formed using the constituent materials. It is the structure which can irradiate the laser L toward. In addition, the burner 840 of the heating unit base 880 is configured to be able to heat the peripheral region H2 (see FIG. 9) of the heating region H1 by the laser irradiation unit 810 under the control of the burner controller 850. Details regarding heating of the material layer 310 by the heating unit base 880 will be described later.

  As shown in FIG. 1, the constituent material discharge unit 1230 is connected by a constituent material supply unit 1210 that stores constituent materials corresponding to each of the head units 1400 held by the head base 1100 and a supply tube 1220. . Then, a predetermined constituent material is supplied from the constituent material supply unit 1210 to the constituent material discharge unit 1230. In the constituent material supply unit 1210, the constituent material of the three-dimensional structure 500 that is modeled by the forming apparatus 2000 according to the present embodiment is accommodated in the constituent material accommodating portion 1210a, and each constituent material accommodating portion 1210a is supplied to the supply tube 1220. Are connected to the individual component material discharge sections 1230. In this manner, by providing the individual constituent material accommodating portions 1210a, a plurality of different types of materials can be supplied from the head base 1100.

  As shown in FIG. 2, the support layer forming material discharge unit 1730 has a support layer forming material supply unit 1710 that contains a support layer forming material corresponding to each head unit 1900 held by the head base 1600. And a supply tube 1720. Then, a predetermined support layer forming material is supplied from the support layer forming material supply unit 1710 to the support layer forming material discharge unit 1730. In the support layer forming material supply unit 1710, the support layer forming material constituting the support layer when the three-dimensional structure 500 is formed is accommodated in the support layer forming material accommodating portion 1710a, and each support layer forming material is provided. The material accommodating portion 1710 a is connected to each support layer forming material discharge portion 1730 by a supply tube 1720. As described above, by providing the individual support layer forming material accommodating portions 1710 a, a plurality of different types of support layer forming materials can be supplied from the head base 1600.

For example, magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni) ) Or a mixed powder such as an alloy containing one or more of these metals (maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy) with a solvent. In addition, it can be used as a slurry (or paste) mixed material containing a binder.
In addition, general-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can be used. In addition, engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
Thus, there is no limitation in particular in a constituent material and a support layer formation material, Metals other than the said metal, ceramics, resin, etc. can be used.

Examples of the solvent include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, acetic acid acetates such as iso-propyl, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, acetylacetone Ketones such as ethanol; alcohols such as ethanol, propanol, butanol; tetraalkylammonium acetates; dimethyl sulfoxide, diethyl sulfoxide, etc. One type selected from these, including phosphine solvents; pyridine solvents such as pyridine, γ-picoline, and 2,6-lutidine; and ionic liquids such as tetraalkylammonium acetate (for example, tetrabutylammonium acetate). Alternatively, two or more kinds can be used in combination.
Examples of the binder include acrylic resin, epoxy resin, silicone resin, cellulosic resin, other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), and other thermoplastic resins.

  The forming apparatus 2000 includes a constituent material discharge unit 1230 provided in the above-described stage 120 and constituent material supply apparatus 1200 based on modeling data of a three-dimensional structure that is output from a data output device such as a personal computer (not shown). In addition, a control unit 400 is provided as a control means for controlling the support layer forming material discharge unit 1730 provided in the support layer forming material supply apparatus 1700. Although not shown, the control unit 400 controls the stage 120 and the constituent material discharge unit 1230 to drive and operate in cooperation, and the stage 120 and the support layer forming material discharge unit 1730 operate and operate in cooperation. And a control unit that controls the stage 120, the laser irradiation unit 810, and the burner 840 to drive and operate in cooperation with each other.

The stage 120 movably provided on the base 110 is a signal for controlling the start and stop of movement of the stage 120, the movement direction, the movement amount, the movement speed, and the like in the stage controller 410 based on the control signal from the control unit 400. Is sent to the drive device 111 provided in the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The constituent material discharge unit 1230 provided in the head unit 1400 controls the material discharge amount from the discharge nozzle 1230a in the discharge drive unit 1230b provided in the constituent material discharge unit 1230 in the material supply controller 1500 based on the control signal from the control unit 400. And a predetermined amount of the constituent material is discharged from the discharge nozzle 1230a by the generated signal.
Similarly, in the support layer forming material discharge unit 1730 provided in the head unit 1900, the discharge nozzle in the discharge drive unit 1730 b provided in the support layer forming material discharge unit 1730 in the material supply controller 1500 based on the control signal from the control unit 400. A signal for controlling the material discharge amount and the like from the 1730a is generated, and a predetermined amount of the support layer forming material is discharged from the discharge nozzle 1730a by the generated signal.
In the laser irradiation unit 810 and the burner 840, a signal for controlling the heating timing is generated in the laser controller 820 and the burner controller 850 based on the control signal from the control unit 400, and the laser irradiation unit 810 and the burner are generated by the generated signal. From 840, irradiation of the laser L and injection of the flame F (see FIG. 9) are performed at a predetermined timing.

Next, the head unit 1400 will be described in more detail. The head unit 1900 has the same configuration as the head unit 1400. Therefore, a detailed description of the configuration of the head unit 1900 is omitted.
4 and 5 show an example of a holding form of a plurality of head units 1400 and constituent material discharge units 1230 held by the head base 1100. FIG. 5 shows the head base 1100 from the direction of arrow D shown in FIG. 1B. FIG.

As shown in FIG. 4, a plurality of head units 1400 are held on a head base 1100 by fixing means (not shown). Further, as shown in FIG. 5, in the head base 1100 of the forming apparatus 2000 according to the present embodiment, the first row head unit 1401, the second row head unit 1402, the third row from the lower side of the drawing. The head unit 1403 and the head unit 1404 in the fourth row include four head units 1400 arranged in a staggered manner. Then, as shown in FIG. 5A, the constituent material is discharged from each head unit 1400 while moving the stage 120 in the X direction with respect to the head base 1100, thereby forming the material layer constituent parts 50 (material layer constituent parts 50 a and 50 b). , 50c and 50d) are formed. The formation procedure of the material layer constituting unit 50 will be described later.
Although not shown, the constituent material discharge unit 1230 included in each of the head units 1401 to 1404 is connected to the constituent material supply unit 1210 via a supply tube 1220 via the discharge drive unit 1230b.

  As shown in FIG. 4, the constituent material discharge unit 1230 discharges the material M, which is a constituent material of the three-dimensional structure, from the discharge nozzle 1230 a onto the sample plate 121 placed on the stage 120. The head unit 1401 illustrates a discharge form in which the material M is discharged in the form of droplets, and the head unit 1402 illustrates a discharge form in which the material M is supplied in a continuous form. The discharge form of the material M may be either a droplet form or a continuous form, but in the present embodiment, the material M is described as a form discharged in the form of a droplet.

  The material M discharged in the form of droplets from the discharge nozzle 1230a flies in a substantially gravitational direction and lands on the sample plate 121. The stage 120 moves, and the material layer constituting part 50 is formed by the landed material M. The aggregate of the material layer constituting units 50 is formed as the material layer 310 (see FIG. 1) of the three-dimensional structure 500 formed on the sample plate 121.

Next, the formation procedure of the material layer structure part 50 is demonstrated using FIG.5 and FIG.6.
FIG. 5 is a plan view for conceptually explaining the relationship between the arrangement of the head unit 1400 of the present embodiment and the form of formation of the material layer constituting section 50. FIG. 6 is a side view conceptually showing the formation form of the material layer constituting part 50.

First, when the stage 120 moves in the + X direction, the material M is discharged in droplets from the plurality of discharge nozzles 1230a, the material M is arranged at a predetermined position of the sample plate 121, and the material layer constituting unit 50 is formed. .
More specifically, first, as shown in FIG. 6A, the material M is arranged at a predetermined interval from the plurality of discharge nozzles 1230a to a predetermined position of the sample plate 121 while moving the stage 120 in the + X direction. .

Next, as illustrated in FIG. 6B, the material M is newly arranged so as to fill the space between the materials M arranged at regular intervals while moving the stage 120 in the −X direction illustrated in FIG. 1.
However, a configuration in which the material M overlaps a predetermined position of the sample plate 121 from the plurality of discharge nozzles 1230a while moving the stage 120 in the + X direction (so as not to be spaced apart) (in the X direction of the stage 120). Instead of the structure in which the material layer constituting unit 50 is formed by reciprocating movement, the material layer constituting unit 50 may be formed only by moving one side of the stage 120 in the X direction.

  By forming the material layer constituting part 50 as described above, the head units 1401, 1402, 1403, and 1404 corresponding to one line in the X direction (first line in the Y direction) as shown in FIG. 5A. The material layer constituent part 50 (material layer constituent parts 50a, 50b, 50c and 50d) is formed.

Next, in order to form the material layer constituting part 50 ′ (material layer constituting parts 50a ′, 50b ′, 50c ′ and 50d ′) of the second line in the Y direction of each head unit 1401, 1402, 1403 and 1404, − The head base 1100 is moved in the Y direction. When the pitch between the nozzles is P, the movement amount is moved in the −Y direction by P / n (n is a natural number) pitch. In this embodiment, n is assumed to be 3.
By performing the same operation as described above as shown in FIG. 6A and FIG. 6B, the material layer constituting unit 50 ′ (material layer constituting unit 50a) in the second line in the Y direction as shown in FIG. 5B. ', 50b', 50c 'and 50d') are formed.

Next, the material layer constituting part 50 ″ (material layer constituting parts 50a ″, 50b ″, 50c ″ and 50d ″) of the third line in the Y direction of each head unit 1401, 1402, 1403 and 1404 is moved. In order to form, the head base 1100 is moved in the −Y direction. The movement amount is moved in the −Y direction by P / 3 pitch.
Then, by performing the same operation as described above as shown in FIG. 6A and FIG. 6B, the material layer constituting part 50 ″ (material layer) in the third line in the Y direction as shown in FIG. 5C. The components 50a ″, 50b ″, 50c ″ and 50d ″) are formed, and the material layer 310 can be obtained.

  Further, the material M discharged from the component material discharge unit 1230 can be discharged from one of the head units 1401, 1402, 1403, and 1404, or a component different from the other head units. Therefore, by using the forming apparatus 2000 according to this embodiment, a three-dimensional structure formed from different materials can be obtained.

  Note that, in the first layer 501, before or after the material layer 310 is formed as described above, the support layer forming material is discharged from the support layer forming material discharge portion 1730, and the support is formed in the same manner. Layer 300 can be formed. When the layers 502, 503,... 50n are stacked on the layer 501, the material layer 310 and the support layer 300 can be formed in the same manner. The support layer 300 may not be sintered, but is desirably sintered using the laser irradiation unit 3100 and the galvanometer mirror 3000.

  The number and arrangement of the head units 1400 and 1900 included in the forming apparatus 2000 according to the above-described embodiment are not limited to the above-described number and arrangement. FIG. 7 schematically shows another example of the arrangement of the head unit 1400 arranged on the head base 1100 as an example.

  FIG. 7A shows a form in which a plurality of head units 1400 are arranged in parallel with the head base 1100 in the X-axis direction. FIG. 7B shows a form in which the head units 1400 are arranged in a grid pattern on the head base 1100. Note that the number of head units arranged in each case is not limited to the example shown.

Next, heating of the material layer 310 by the heating unit (heating unit base 880) will be described.
FIG. 8 is a schematic perspective view from the upper side of the burner 840 constituting the heating unit base 880 (viewed from the + Z direction), and FIG. 9 is a schematic view of the heating unit base 880 (viewed from the −Y direction).

  As shown in FIG. 8, the burner 840 according to the present embodiment has a plurality of flame F injection ports 870 (launch ports for emitting heating energy) provided on the lower surface (surface opposite to the laser irradiation unit 810). ing. Then, by controlling the burner controller 850 to turn on and off the injection of the flame F from the plurality of injection ports 870, the injection region of the flame F is variable. For example, by turning on all the injection ports 870 provided in the burner 840, the injection region of the flame F can be set to the region R1 (the entire lower surface of the burner 840) and the injection port 870 provided in the burner 840. By turning on only a part of the flame F, the flame F injection region can be set to a region R2 (a part of the lower surface of the burner 840). With such a configuration, not only the size of the injection region of the flame F but also the shape thereof are variable, that is, the size and shape of the heating region as the peripheral region H2 are variable.

Also, as shown in FIGS. 8 and 9, a hole 860 that extends from the upper surface to the lower surface is formed at the center of the burner 840. For this reason, as shown in FIG. 9, the burner 840 can pass the laser L emitted from the laser irradiation unit 810 through the hole 860. With such a configuration, the heating unit base 880 of the present embodiment can sinter the heating region H1 (sintering region or melting region) by the laser L irradiated from the laser irradiation unit 810 at a desired temperature (sinter the material layer 310). Melting temperature), and the peripheral region H2 can be set to a temperature at which the material can be prevented from scattering.
Here, the heating temperature of the heating region H1 is a temperature at which the material layer 310 is sintered, and the heating temperature of the peripheral region H2 is a temperature at which the material layer 310 is not melted or sintered (a temperature at which at least one of the solvent and the binder is removed). can do.
The heating temperature in the heating region H1 is a temperature at which the material layer 310 is melted, and the heating temperature in the peripheral region H2 is a temperature at which the material layer 310 is not melted (a temperature at which at least one of the solvent and the binder is removed. It may be.
The heating temperature of the heating region H1 is set to a temperature at which the material layer 310 is sintered, and the heating temperature of the peripheral region H2 is sintered at a temperature lower than the heating temperature of the heating region H1 (relative to the sintered state by the heating region H1). (Sintering in which the powder is hardened with an extremely weak bonding force).

  As described above, the forming apparatus 2000 according to the present embodiment is a three-dimensional structure manufacturing apparatus that manufactures a three-dimensional structure by stacking layers. And it is provided with the constituent material discharge part 1230 as a material layer formation part which forms the material layer 310 of a three-dimensional structure using the constituent material containing the powder which comprises a three-dimensional structure, a solvent, and a binder. Yes. In addition, the laser irradiation unit 810 capable of heating the heating region H1 (sintered region or melting region) corresponding to the constituent region of the three-dimensional structure in the material layer 310, and the laser irradiation at the time of heating by the laser irradiation unit 810 And a burner 840 capable of heating the peripheral region H2 of the heating region H1 by the unit 810. For this reason, the temperature difference between the heating region H1 by the first heating unit (laser irradiation unit 810), which is a sintered region or a melting region, and its peripheral portion (peripheral region H2) can be reduced, and the material layer 310 is formed. It is the structure which can suppress that the constituent material to scatter. Therefore, it is the structure which can manufacture a highly accurate three-dimensional structure.

  Further, as described above, since the first heating unit in the present embodiment is the laser irradiation unit 810, the heating region H1 by the first heating unit, which is a sintering region or a melting region, is sintered or melted with high accuracy. In particular, a highly accurate three-dimensional structure can be manufactured.

Further, as described above, since the second heating unit in the present embodiment is a burner, it is possible to easily heat a wider range than the heating region H1 by the first heating unit.
In addition, when the second heating unit is a heater, similarly, a range wider than the heating region H1 by the first heating unit can be easily heated.
However, the burner is particularly advantageous in that it is easy to miniaturize, is low in cost, and has a short standby time.

  In addition, as described above, the burner 840 in the present embodiment turns on and off the flame F from the plurality of injection ports 870, so that the shape and range of the heating region (peripheral region H2) by the burner 840 are increased. At least one of them is variable. For this reason, with such a simple configuration, the shape and range of the heating region by the burner 840 can be appropriately adjusted according to the shape and size of the three-dimensional structure or the type of the constituent material.

  Further, the heating unit base 880 of this embodiment is configured to move in a state where the positions of the laser irradiation unit 810 and the burner 840 are fixed. That is, the forming apparatus 2000 of the present embodiment can heat the sintering region or the melting region by moving the heating region H1 of the laser irradiation unit 810, and the heating region (peripheral region H2) by the burner 840 is the laser irradiation unit 810. It is the structure which moves with the movement of the heating area | region H1 by. Thus, since it becomes the structure which moves both the laser irradiation part 810 and the burner 840 and manufactures a three-dimensional molded item, the magnitude | size of the heating area | region (peripheral area | region H2) by the burner 840 is moderate size. Therefore, the load which enlarges the heating area | region of the burner 840 can be suppressed.

  However, the first heating unit and the second heating unit are provided separately, and the first heating unit can move the heating region H1 to heat the sintering region or the melting region, and the heating region by the second heating unit is It is good also as a structure (for example, the structure which can heat the whole data plate 121) including the movement range of the heating area | region by the 1st heating part while being fixed. By setting it as such a structure, a 2nd heating part can be fixed and only a 1st heating part can be moved, and a three-dimensional molded item can be manufactured. That is, since it is not necessary to provide a moving mechanism for the second heating unit, the apparatus configuration can be simplified.

  Further, both the laser irradiation unit 810 and the burner 840 can be moved together, and the position of the laser irradiation unit 810 can be changed within a predetermined range with respect to the position of the burner 840.

Next, an example of a method for manufacturing a three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 10 is a schematic diagram illustrating an example of a part of a manufacturing process of a three-dimensional structure performed using the forming apparatus 2000, and when the material layer 310 of the first layer 501 is heated (sintered). FIG.

  FIG. 10A shows a state in which the first layer 501 is formed on the sample plate 121 using the constituent material discharge unit 1230 and the support layer forming material discharge unit 1730. Further, the position of the heating unit base 880 with respect to the sample plate 121 becomes the position of the heating region H1 by the laser irradiation unit 810 and the heating region (peripheral region H2) by the burner 840 with respect to the material layer 310 as shown in FIG. 10A. As shown, the stage 120 is moved.

  FIG. 10B shows a state in which the heating region H1 is heated by the laser irradiation unit 810 and the peripheral region H2 is heated by the burner 840 while moving the stage 120 in the −X direction from the position shown in FIG. 10A. FIG. 10B also shows a state in which the heated region H1 of the material layer 310 heated with the movement of the stage 120 is sintered to form the sintered layer 320.

  Thereafter, the stage 120 is moved in the + Y direction, the stage 120 is moved in the + X direction, the heating region H1 is heated by the laser irradiation unit 810, and the peripheral region H2 is heated by the burner 840, as shown in FIG. 10C. Yes.

10D sinters the entire region of the material layer 310 corresponding to the first layer 501 by repeating the operations performed from the state shown in FIG. 10A to the state shown in FIG. 10C. Represents the state.
Furthermore, the manufacturing method of the three-dimensional structure according to the present embodiment repeats the operations performed from the state shown in FIG. 10A to the state shown in FIG. This is sintered while forming the material layer 310 up to the layer 50n, to produce a three-dimensional structure.
In the three-dimensional structure manufacturing method of the present embodiment, the configuration area of the three-dimensional structure matches the formation area of the material layer 310, and the entire area of the material layer 310 is set as the configuration area of the three-dimensional structure. Sintered. However, the forming apparatus 2000 of the present embodiment forms the material layer 310 larger than the constituent area of the three-dimensional structure so that a partial area of the material layer 310 becomes the constituent area of the three-dimensional structure, It is also possible to sinter only a partial region of the material layer 310 corresponding to the constituent region of the three-dimensional structure.

Next, an example of a method for manufacturing a three-dimensional structure performed using the forming apparatus 2000 (an example corresponding to FIG. 10) will be described using a flowchart.
Here, FIG. 11 is a flowchart of the manufacturing method of the three-dimensional structure according to the present embodiment.

  As shown in FIG. 11, in the three-dimensional structure manufacturing method of the present embodiment, first, in step S <b> 110, data of the three-dimensional structure is acquired. Specifically, for example, data representing the shape of the three-dimensional structure is acquired from an application program or the like executed on a personal computer.

Next, in step S120, data for each layer is created. Specifically, in the data representing the shape of the three-dimensional structure, it is sliced according to the modeling resolution in the Z direction, and bitmap data (cross section data) is generated for each section.
At this time, the generated bitmap data is data that is distinguished by the configuration area of the three-dimensional structure (formation area of the material layer 310) and the non-configuration area of the three-dimensional structure (formation area of the support layer 300). It has become.

Next, in step S130, the data of the layer to be formed is data for forming a non-formation region (support layer 300) of the three-dimensional structure or data for forming a formation region (material layer 310) of the three-dimensional structure. Determine whether. Note that. This determination is made by a control unit provided in the control unit 400.
If it is determined in this step that the data forms the support layer 300, the process proceeds to step S140. If it is determined that the data forms the material layer 310, the process proceeds to step S150.

In step S140, the support layer forming material is supplied from the support layer forming material discharge unit 1730 based on the data for forming the support layer 300, thereby supplying the support layer forming material (forming the support layer 300).
Then, when the support layer forming material is discharged in step S140, the support layer 300 is sintered in step S160 by irradiating with laser L (giving energy) using the laser irradiation unit 3100 and the galvanometer mirror 3000. However, this step (step S160) may be omitted.
Furthermore, in the manufacturing method of the three-dimensional structure according to the present embodiment, the support layer 300 is formed in step S140. However, the material layer 310 may be formed without forming the support layer 300, and step S140 is performed. It can be omitted. In other words, the support layer forming material supply device 1700, the laser irradiation unit 3100, and the galvanometer mirror 3000 may be omitted from the configuration of the forming device 2000.

On the other hand, in step S150, the constituent material is supplied from the constituent material discharge unit 1230 to supply the constituent material (form the material layer 310).
When the constituent material is discharged in step S150, in step S170, the heating region H1 (sintered region or molten region) is heated by the laser irradiation unit 810, and the peripheral region H2 is heated by the burner 840. Note that this step is particularly preferably performed under an inert gas or catalyst gas atmosphere.

In step S180, steps S130 to S180 are repeated until the modeling of the three-dimensional structure based on the bitmap data corresponding to each layer generated in step S120 is completed.
And with the completion | finish of step S180, the manufacturing method of the three-dimensional structure of a present Example is complete | finished.

  As described above, the method for manufacturing a three-dimensional structure according to the present embodiment is a method for manufacturing a three-dimensional structure that manufactures a three-dimensional structure by stacking layers. And the material layer formation process (corresponding to step S150) which forms material layer 310 of a three-dimensional structure using the constituent material containing the powder which constitutes a three-dimensional structure, a solvent, and a binder, and a material layer While heating the sintering area | region or fusion | melting area | region corresponding to the structure area | region of the three-dimensional structure among 310 in the laser irradiation part 810, the surrounding area H2 of the heating area | region H1 by this laser irradiation part 810 is heated with the burner 840 Process (corresponding to step S170). For this reason, the temperature difference between the heating region H1 by the laser irradiation unit 810, which is a sintered region or a melting region, and its peripheral portion (peripheral region H2) can be reduced, and the constituent materials forming the material layer 310 are scattered. This can be suppressed. Therefore, a highly accurate three-dimensional structure can be manufactured.

  The present invention is not limited to the above-described embodiments, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features in the embodiments corresponding to the technical features in the embodiments described in the summary section of the invention are intended to solve part or all of the above-described problems, or one of the above-described effects. In order to achieve part or all, replacement or combination can be appropriately performed. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

50, 50a, 50b, 50c, 50d, 50e, 50f, 50g, and 50h ... material layer constituent part,
110 ... Base, 111 ... Drive device, 120 ... Stage, 121 ... Sample plate,
130 ... head base support part, 300 ... support layer, 310 ... material layer, 320 ... sintered layer,
400 ... control unit, 410 ... stage controller, 500 ... three-dimensional structure,
501, 502 and 503 ... layer, 730 ... head base support,
810 ... Laser irradiation part (first heating part), 820 ... Laser controller,
830 ... heating unit base support unit, 840 ... burner (second heating unit),
850 ... burner controller, 860 ... hole, 870 ... injection port (launch port),
880 ... heating unit base, 1100 ... head base, 1200 ... constituent material supply device,
1210 ... Constituent material supply unit, 1210a ... Constituent material container,
1220 ... Supply tube, 1230 ... Constituent material discharge part (material layer forming part),
1230a ... discharge nozzle, 1230b ... discharge drive unit, 1400 ... head unit,
1400a: holding jig,
1401, 1402, 1403 and 1404 ... head unit,
1500 ... Material supply controller, 1600 ... Head base,
1700: Support layer forming material supply device, 1710: Support layer forming material supply unit,
1710a: Support layer forming material container, 1720: Supply tube,
1730: Material discharge part for forming a support layer, 1730a: Discharge nozzle,
1730b ... Discharge drive unit, 1900 ... head unit, 1900a ... holding jig,
2000 ... forming apparatus (manufacturing apparatus for three-dimensional structure), 3000 ... galvanometer mirror,
3100: Laser irradiation unit, F: Flame, H1: Heating region by laser irradiation unit 810,
H2 ... Peripheral region of the heating region H1, L ... Laser, M ... Material (component material),
O ... Completed three-dimensional structure, R1 ... Flame F injection region, R2 ... Flame F injection region

Claims (8)

A three-dimensional structure manufacturing apparatus that manufactures a three-dimensional structure by laminating layers,
A material layer forming unit that forms a material layer of the three-dimensional structure using a constituent material including a powder that constitutes the three-dimensional structure, a solvent, and a binder;
A first heating unit capable of heating a sintered region or a melted region corresponding to a constituent region of the three-dimensional structure in the material layer;
A second heating unit capable of heating a peripheral region of a heating region by the first heating unit at the time of heating by the first heating unit;
An apparatus for producing a three-dimensional structure, comprising: In the manufacturing apparatus of the three-dimensional structure described in claim 1,
The apparatus for manufacturing a three-dimensional structure, wherein the first heating unit is a laser irradiation unit. In the manufacturing apparatus of the three-dimensional structure according to claim 1 or 2,
The apparatus for manufacturing a three-dimensional structure, wherein the second heating unit is a burner or a heater. In the manufacturing apparatus of the three-dimensional structure according to any one of claims 1 to 3,
The apparatus for manufacturing a three-dimensional structure, wherein the second heating unit is variable in at least one of a shape and a range of a heating region by the second heating unit. In the manufacturing apparatus of the three-dimensional structure described in claim 4,
The second heating unit includes a plurality of heating energy launch ports, and is capable of changing at least one of a shape and a range of the heating region by changing a launch port that emits the heating energy. Manufacturing equipment. In the manufacturing apparatus of the three-dimensional structure according to any one of claims 1 to 5,
The first heating unit can move the heating region to heat the sintering region or the melting region,
The heating area by the second heating unit is fixed and includes a moving range of the heating area by the first heating unit. In the manufacturing apparatus of the three-dimensional structure according to any one of claims 1 to 5,
The first heating unit can move the heating region to heat the sintering region or the melting region,
The apparatus for manufacturing a three-dimensional structure, wherein the heating region by the second heating unit moves together with the movement of the heating region by the first heating unit. It is a manufacturing method of a three-dimensional structure that manufactures a three-dimensional structure by laminating layers,
A material layer forming step of forming a material layer of the three-dimensional structure using a constituent material including a powder constituting the three-dimensional structure, a solvent, and a binder;
While heating the sintering area | region or fusion | melting area | region corresponding to the structure area | region of the three-dimensional structure in the said material layer with a 1st heating part, the surrounding area | region of the heating area | region by this 1st heating part is heated with a 2nd heating part. A method of manufacturing a three-dimensional structure.

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