JP2017137563A - 三次元形状造形物の製造方法 - Google Patents
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Abstract
【解決手段】(i)粉末層の所定箇所に光ビームを照射して所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および(ii)得られた固化層の上に新たな粉末層を形成し、新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程によって粉末層形成および固化層形成を交互に繰り返して行う三次元形状造形物の製造方法が供される。特に、本発明の製造方法では、三次元形状造形物の製造に先立って、アンダーカット部を予め特定するためのモデル化処理を行う。
【選択図】図2
Description
(i)粉末層の所定箇所に光ビームを照射し、かかる所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程。
(ii)得られた固化層の上に新たな粉末層を形成し、同様に光ビームを照射して更なる固化層を形成する工程。
(i)粉末層の所定箇所に光ビームを照射して該所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および
(ii)得られた固化層の上に新たな粉末層を形成し、該新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程
により粉末層形成および固化層形成を交互に繰り返し行うことによって、アンダーカット部を有して成る三次元形状造形物を製造するための方法であって、
かかる方法の実施に先立って、アンダーカット部を予め特定するためのモデル化処理を行う、三次元形状造形物の製造方法が提供される。
まず、本発明の製造方法の前提となる粉末焼結積層法について説明する。特に粉末焼結積層法において三次元形状造形物の切削処理を付加的に行う光造形複合加工を例として挙げる。図9は、光造形複合加工のプロセス態様を模式的に示しており、図10および図11は、粉末焼結積層法と切削処理とを実施できる光造形複合加工機の主たる構成および動作のフローチャートをそれぞれ示している。
本発明は、上述した粉末焼結積層法において、三次元形状造形物の製造に先立って行う前処理に特徴を有している。
[式1]
突出寸法(OH寸法)=Δt/tanθ
本発明の技術的思想について説明しておく。本発明は『固化層形成時に大きい隆起部が生じると考えられる箇所を予め特定し、より好適な切削加工パスを予め構築しておく』といった技術的思想に基づいている。
まず、三次元形状造形物の製造に先立ってコンピュータを用いて行う前処理について説明する。かかる前処理は、好ましくは以下の(1)および(2)が行われる。
まず、三次元形状造形物を製造する前にCADソフトを用いてモデル化処理を行う。具体的には、例えばいわゆる“STL形式”のCADソフトを用いてモデル化処理を行う。このようなモデル化処理は、アンダーカット部を予め特定するためのコンピュータ処理に相当する。
アンダーカット部10’を特定した後、かかるアンダーカット部10’の所定箇所(固化層の輪郭上面に相当)に対する切削加工パスを決定するコンピュータ処理を行う。かかる処理に際しては、必要に応じて例えばCAD/CAMソフトなどを用いてよい。
次に、三次元形状造形物の製造時における実施態様について説明する。
かかる切削加工により、次なる粉末層を形成するために用いるスキージング・ブレードが隆起部に当たることを回避でき得る。そのため、アンダーカット部における固化層が隆起部に同伴してもぎ取られてしまうことを回避でき得る。その結果、固化層上に所望の新たな粉末層を好適に形成でき得る。従って、最終的に所望の三次元形状造形物を好適に製造することができ得る。
例えば、本発明では、アンダーカット部における傾斜の程度に応じて、アンダーカット部における固化層の輪郭上面の切削加工の要否を予め判断してよい。
本発明では、例えば固化層の積層数に応じて切削加工の要否を予め判断してもよい。
100’ 三次元形状造形物モデル(三次元形状造形物のモデル)
10’ 三次元形状造形物モデルのアンダーカット部
10 三次元形状造形物のアンダーカット部
11’ ピース
12’ 法線ベクトル
13 急峻角度
19 粉末
22 粉末層
24 固化層
24a 固化層の輪郭上面
L 光ビーム
Claims (7)
- (i)粉末層の所定箇所に光ビームを照射して該所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および
(ii)得られた固化層の上に新たな粉末層を形成し、該新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程
により粉末層形成および固化層形成を交互に繰り返し行うことによって、アンダーカット部を有して成る三次元形状造形物を製造するための方法であって、
前記方法の実施に先立って、前記アンダーカット部を予め特定するためのモデル化処理を行う、三次元形状造形物の製造方法。 - 前記モデル化処理において、前記製造される前記三次元形状造形物のモデルの表面を複数のピースに分割し、該複数のピースの各々の法線ベクトルの向きに基づいて、前記三次元形状造形物の前記モデルの前記表面から前記アンダーカット部の表面を抽出する、請求項1に記載の三次元形状造形物の製造方法。
- 前記抽出に際して、前記法線ベクトルの向きが水平よりも下向きとなる前記ピースを前記アンダーカット部の前記表面とみなす、請求項2に記載の三次元形状造形物の製造方法。
- 前記製造される前記三次元形状造形物の前記モデルから複数のスライス面を取り出し、取り出した各スライス面の輪郭のうち前記アンダーカット部に相当する部分の輪郭を特定し、特定した該輪郭から複数のポイントを選択し、選択した各ポイントの座標情報を得る、請求項1〜3のいずれかに記載の三次元形状造形物の製造方法。
- 前記方法の実施時において、前記アンダーカット部における前記固化層の輪郭上面を切削加工に付す、請求項1〜4のいずれかに記載の三次元形状造形物の製造方法。
- 前記座標情報に基づき切削加工パスを形成し、該切削加工パスに従い、前記アンダーカット部における前記固化層の前記輪郭上面を前記切削加工に付す、請求項4に従属する請求項5に記載の三次元形状造形物の製造方法。
- 前記アンダーカット部における急峻角度に応じて、該アンダーカット部における前記固化層の前記輪郭上面の前記切削加工の要否を判断する、請求項5又は6に記載の三次元形状造形物の製造方法。
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