JP2017159563A - Lamination molding apparatus and lamination molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional lamination molding in which plural materials are molded and laminated in the same layer, and which enables molding with high accuracy, in which warpage, deformation, and deterioration caused by heat is suppressed.SOLUTION: The lamination molding apparatus of the present invention includes: a first material supply section for supplying a first material to a predetermined position in a layer; a second material supply section for supplying a second material of which the melting point is lower than that of the first material to another predetermined position in the same layer; and a third material supply section for supplying a third material into the same layer on a surface of the second material.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a three-dimensional additive manufacturing technique, and more particularly, to an additive manufacturing apparatus and additive manufacturing method for forming an object using a plurality of materials.

  3D CAD (Computer Aided Design) data is divided into layers, and a layer is attached to each divided layer while adding materials so that the layers are stacked on top of each other. In the international standard, it is defined as Additive Manufacturing. 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 facilitate modeling in which a plurality of types of materials are freely arranged in the same layer. This is because a three-dimensional structure having a new function utilizing the characteristics of each material can be realized by modeling using a plurality of materials.

  For example, a three-dimensional structure 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 three-dimensional structure having a function having both strength and flexibility can be realized. These functions can be easily realized without developing new materials.

JP-T-2004-532753

  Patent Document 1 discloses a method of modeling materials having different characteristics in the same layer. According to this method, the first thermosettable material in the molten form is supplied in a predetermined pattern at the first extrusion temperature to define the three-dimensional structure, and at the same time, the second thermosettable material in the molten form. Is distributed at a second extrusion temperature to define a support structure for the three-dimensional structure.

  However, in the method of Patent Document 1, due to the difference in melting point of each material, when a material having a high melting point is melted and solidified to form a shape, an adjacent material having a low melting point is re-dissolved, and the target shape is obtained. Cannot be obtained with high accuracy. That is, in the method of Patent Document 1, when materials are formed adjacent to each other, a material having a low melting point causes warping, deformation, or alteration due to heat. There is a problem that it cannot be applied to modeling of a thin-walled structure that easily deforms.

  The present invention has been made in view of the above problems, and its purpose is to suppress warping, deformation and alteration due to heat in three-dimensional additive manufacturing in which a plurality of materials are formed and stacked in the same layer. This is to enable accurate modeling.

  The additive manufacturing apparatus according to the present invention includes a first material supply unit that supplies a first material to a predetermined position in a layer, and a second material having a melting point lower than that of the first material in the same layer. A second material supply unit that supplies the second material to another predetermined position, and a third material supply unit that supplies a third material into the same layer on the surface of the second material.

  The additive manufacturing method of the present invention supplies a first material to a predetermined position in a layer, and a second material having a melting point lower than that of the first material to another predetermined position in the same layer. And a third material is fed into the same layer on the surface of the second material.

  ADVANTAGE OF THE INVENTION According to this invention, in the three-dimensional additive manufacturing which shape | molds and laminates | stacks a several material in the same layer, the accurate modeling which suppressed the curvature by a heat | fever, a deformation | transformation, and a quality change is attained.

It is a block diagram which shows the structure of the additive manufacturing apparatus of the 1st Embodiment of this invention. It is a block diagram which shows the structure of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the detailed structure of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the process of modeling a three-dimensional structure with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the structure which has a surface treatment part of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the structure which has the cutting mechanism of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the structure which has the cutting mechanism of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the structure which has the discharge mechanism of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the structure which has the discharge mechanism of the additive manufacturing apparatus of the 2nd 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 the configuration of the additive manufacturing apparatus according to the first embodiment of the present invention. The additive manufacturing apparatus 10 according to the present embodiment includes a first material supply unit 11 that supplies a first material to a predetermined position in the layer. Furthermore, it has the 2nd material supply part 12 which supplies the 2nd material whose melting | fusing point is lower than the said 1st material to another predetermined position in the same said layer. Furthermore, it has the 3rd material supply part 13 which supplies a 3rd material in the said said layer on the surface of a said 2nd material.

  According to the additive manufacturing apparatus 10, when the first material having a low melting point and the third material having a high melting point are formed in the same layer, the second material having a melting point lower than that of the first material is the first material. Since the layers of the three materials are connected, a three-dimensional structure can be formed at a temperature equal to or lower than the melting point of the first material. Therefore, warpage, deformation, and alteration due to heat are suppressed in the three-dimensional structure.

As described above, according to the present embodiment, in three-dimensional additive manufacturing in which a plurality of materials are formed and stacked in the same layer, it is possible to perform accurate modeling that suppresses warping, deformation, and alteration due to heat. .
(Second Embodiment)
FIG. 2 is a block diagram showing the configuration of the additive manufacturing apparatus according to the second embodiment of the present invention. The additive manufacturing apparatus 20 of the present embodiment is a additive manufacturing apparatus that laminates layers to form a three-dimensional structure, and includes a first material supply unit 21, a second material supply unit 22, and a third material supply. A unit 23, a heating unit 24, a modeling stage 25, and a control unit 26.

  The first material supply unit 21 supplies the first material to a predetermined position in a layer stacked on the modeling stage 25. The second material supply unit 22 supplies a second material having a lower melting point than the first material to another predetermined position in the same layer as the first material. The third material supply unit 23 supplies the third material into the same layer as the first material on the surface of the second material.

  The third material has a higher melting point than the first material. The second material is assumed to have fluidity. The first material is insulative, and the second material and the third material are conductive.

  When the second material or the third material is supplied to a predetermined position in the layer, the heating unit 24 causes the second material or the third material to be equal to or lower than the melting point of the first material. Heat above the melting point. Thereby, the second material is heated to a temperature equal to or higher than the melting point of the second material. In the case where the third material is heated, the temperature of the interface portion between the second material and the third material can be made higher than the melting point of the second material. As described above, since the entire second material or the surface portion in contact with the third material is melted, adhesion between the second material and the third material can be strengthened.

  At this time, since the temperature of the first material does not exceed the melting point of the first material, warpage, deformation, and alteration of the first material due to heat are suppressed. In addition, since the second material has fluidity, it is possible to ensure adhesion between the second material and the third material without the heating unit 24 being heated.

  The modeling stage 25 is a stage for modeling a predetermined three-dimensional structure by laminating layers having the first material, the second material, and the third material as described above. The modeling stage 25 can include an actuator for performing a necessary operation for modeling a three-dimensional structure, that is, forward / backward, left / right, up / down movement, inclination, and the like. Each layer laminated on the modeling stage 25 does not always need to have the first material, the second material, and the third material. For example, the predetermined layer is formed only by the first material. Alternatively, another layer may be formed of only the third material.

  The control unit 26 controls and cooperates with the first material supply unit 21, the second material supply unit 22, the third material supply unit 23, the heating unit 24, and the modeling stage 25 to model the three-dimensional structure. It has a function to make it. That is, the type, supply amount, supply position, supply timing, heating temperature, position, and time of the material to be supplied to the modeling stage 25, the lifting and lowering amount of the modeling stage 25 corresponding to modeling, the amount of movement to the front and rear, the tilt, etc. Control related to additive manufacturing of a three-dimensional structure is performed.

  The control unit 26 can be realized by operating an information processing apparatus such as a server by a program. The operation by this program is set based on the three-dimensional CAD data of the modeled object. A three-dimensional structure can be formed by laminating layers based on this setting.

  FIG. 3 is a diagram illustrating a detailed configuration of the additive manufacturing apparatus 20 according to the present embodiment. In the following description, it is assumed that a three-dimensional structure having a function of an electronic circuit is manufactured as a three-dimensional structure, and the first material, the second material, and the third material corresponding thereto are taken as an example. However, the present embodiment is not limited to this.

  As shown in FIG. 3, the three-dimensional structure has a portion made of the first material and portions made of the second and third materials. The portion made of the first material has insulation, and the portions made of the second and third materials have conductivity. The second material and the third material are alternately stacked and adhered. The second material has a role as an adhesion layer, and the third material has main conductivity. Therefore, the second material may be thinner than the third material.

  FIG. 3 shows a state in which a modeling layer is newly laminated on the portion made of the first material and the portions made of the second and third materials. The modeling layer has a laminated region of the first material and laminated regions of the second and third materials.

  The first material has an insulating property. This material is typically plastic. Specific examples include, but are not limited to, ABS (Acrylonitrile Butadiene Styrene), polycarbonate, polylactic acid, acrylic, polyetherimide, polyphenylsulfone, nylon, polyethylene, silicone, and epoxy.

  As a method for laminating the first material, a method classified as an additive manufacturing method by ASTM (American Society for Testing and Materials) can be used. For example, there is a material extrusion method in which the first material melted from the first material supply unit 21 is extruded and deposited on the modeling stage 25. Further, as another method, there is a material jetting method (Material jetting) in which droplets of the first material are jetted from the first material supply unit 21 and selectively cured and deposited.

  Regarding the melting and curing of the first material, if it is a thermoplastic resin, a predetermined amount of the melted material can be supplied to a predetermined position and cured by air cooling. In the case of a thermosetting or photocurable resin, the first material is laminated by spraying droplets of the material and heating it if it is a thermosetting resin or irradiating ultraviolet rays or the like if it is a photocurable resin. can do.

  The second material has conductivity. The melting point of the second material can be lower than the melting point of the first material. Examples of this material include silver nano paste and silver nano ink, but are not limited thereto.

  The second material supply unit 22 includes a heating unit 24 and can heat the second material. That is, when the second material supply unit 22 supplies the second material, the fluidity of the second material is increased by heating the second material with the heating unit 24, and the second material is laminated. Can be supplied to the area. By heating, adhesion between the second material and the third material can be strengthened.

  The third material has conductivity. Examples of this material include, but are not limited to, copper, silver, and aluminum. When the third material is a metal, the melting point is usually higher than the melting point of the first material. The third material can be granular. The third material may also be processed into powder, filler, line, plate, or the like.

  The 3rd material supply part 23 is equipped with the function which adsorb | sucks and conveys a 3rd material to the front-end | tip part. As an adsorption method, a method of adsorbing by sucking air or a method of adsorbing by static electricity is possible. In addition, when the third material is a ferromagnetic material, adsorption by magnetic force is possible.

  In addition, as a heating method of the heating unit 24, radiant heat by a heater, laser irradiation, or the like is possible. Moreover, although the heating part 24 is integrated in the 2nd material supply part 22 in FIG. 3, it is not limited to this. The heating unit 24 can be provided not only to heat the second material but also to heat the third material when the third material is supplied.

  Next, the operation of modeling the first material, the second material, and the third material on the modeling layer will be described. 4A to 4F are diagrams illustrating a process of modeling a three-dimensional structure with the additive manufacturing apparatus 20 of the present embodiment.

  In FIG. 4A, in the step of modeling a new modeling layer on the first material portion and the second and third material portions that have already been stacked and modeled, first, the first material supply unit 21 supplies the first material to the stack region of the first material. FIG. 4A shows a state in which the first material is supplied to the stacked region of the first material.

  Subsequently, in FIG. 4B, the second material supply unit 22 is aligned with the stacked region of the second material that supplies the second material.

  Subsequently, in FIG. 4C, the second material supply unit 22 supplies the second material to the stacked region of the second material. At this time, the heating unit 24 can heat the second material below the melting point of the first material and above the melting point of the second material. By heating, the fluidity of the second material is increased, and the adhesion between the second material and the third material can be strengthened.

  FIG. 4D shows a state in which the second material is supplied to the stacked region of the second material.

  Subsequently, in FIG. 4E, the third material supply unit 23 adsorbs the third material and is aligned with the stacked region of the third material that supplies the third material.

  FIG. 4F shows a state in which the third material is supplied to the stacked region of the third material. At this time, the heating unit 24 may heat the third material below the melting point of the first material and above the melting point of the second material. By heating, adhesion between the second material and the third material can be further increased.

  When the third material supply unit 23 supplies the third material to the stacked region of the third material, the third material is supplied by the third material supply unit 23 or a separately provided pressure unit. You may supply, pressing to the lamination | stacking area | region of the 3rd material. By pressurizing, adhesion between the second material and the third material can be further increased.

  In addition, when the third material supply unit 23 supplies the third material to the third material lamination region, the third material supply unit 23 or the vibration unit provided in the modeling stage 25 may The material may be supplied while vibrating. For example, an ultrasonic vibrator is used as the vibration section, and the third material can be vibrated by generating vibration with the ultrasonic vibrator. By vibrating, adhesion between the second material and the third material can be further increased.

  FIG. 5 is a diagram illustrating a configuration in which the additive manufacturing apparatus 20 according to this embodiment includes a surface treatment unit 27. The surface treatment unit 27 can surface-treat the surface of the third material to form irregularities on the surface or make the surface chemically active. As the surface treatment method, anchor treatment, blast treatment, chemical treatment, plasma treatment, and the like are possible, but the method is not limited to these methods. By the surface treatment of the surface of the third material, the adhesion between the second material and the third material further laminated on the surface-treated third material can be further strengthened.

  6A and 6B are diagrams illustrating a configuration in which the additive manufacturing apparatus 20 according to this embodiment includes a cutting mechanism 28. FIG. The cutting mechanism 28 cuts the solid third material such as a rod or filament of the third material supply unit 23 and supplies the third material to the stacked region of the third material. The cutting mechanism 28 includes a blade, and can cut the third material by a predetermined amount. Further, the cutter may have corrugated or rectangular irregularities so that the cut surface of the third material can be cut so as to have corrugated or rectangular irregularities. Thereby, since unevenness | corrugation is formed in the surface of the 3rd material after a cutting | disconnection, adhesion with a 2nd material can be strengthened more.

  The third material supply method of the third material supply unit 23 provided with the cutting mechanism 28 is as follows. That is, the third material supply unit 23 sends out a predetermined amount of a solid third material such as a rod or filament (FIG. 6A). Subsequently, the cutting mechanism 28 cuts the third material by a predetermined amount and supplies it to a predetermined position of the modeling layer (FIG. 6B).

  7A and 7B are diagrams illustrating a configuration in which the additive manufacturing apparatus 20 according to this embodiment includes a discharge mechanism 29. When the third material stack region is sufficiently smaller than the first material stack region, the discharge mechanism 29 is discharged by the discharge when the third material is supplied from the third material supply unit 23. 3 is provided for dissolving and supplying the material. By dissolving the third material, the adhesion between the second material and the third material can be further increased. At this time, the temperature of the third material is equal to or higher than the melting point of the first material, but the region of the third material is sufficiently small so that warpage, deformation, and alteration due to heat in the first material region can be ignored. It can be. As a discharge method, arc discharge or the like is possible.

  The discharge mechanism 29 also heats the third material by discharge to a temperature not higher than the melting point of the first material and not lower than the melting point of the second material when the third material is supplied to the laminated region of the third material. can do. Thereby, adhesion with the 2nd material and the 3rd material can be strengthened.

  The third material supply method of the third material supply unit 23 including the discharge mechanism 29 is as follows. That is, the third material supply unit 23 sends out a predetermined amount of a solid third material such as a rod or filament, and melts the delivered third material by electric discharge (FIG. 7A). Then, the melt | dissolved 3rd material is supplied to the predetermined position of a modeling layer (FIG. 7B).

  According to the additive manufacturing apparatus 20 of the present embodiment, when modeling a first material having a low melting point and a third material having a high melting point in the same layer, the second material having a melting point lower than that of the first material. Since the first material connects the layers of the third material, the three-dimensional structure can be formed at a temperature equal to or lower than the melting point of the first material. Thus, the three-dimensional structure modeled by the layered modeling apparatus 20 is suppressed from warping, deformation, and alteration due to heat.

  As described above, according to the present embodiment, in three-dimensional additive manufacturing in which a plurality of materials are formed and stacked in the same layer, it is possible to perform accurate modeling that suppresses warping, deformation, and alteration due to heat. .

  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 1)
A first material supply for supplying a first material to a predetermined position in the layer;
A second material supply unit for supplying a second material having a melting point lower than that of the first material to another predetermined position in the same layer;
A third material supply for supplying a third material into the same layer on the surface of the second material;
An additive manufacturing apparatus.
(Appendix 2)
The additive manufacturing apparatus according to appendix 1, further comprising a heating unit that heats the second material or the third material to a temperature equal to or lower than a melting point of the first material and equal to or higher than a melting point of the second material.
(Appendix 3)
The additive manufacturing apparatus according to appendix 1 or 2, wherein the second material has fluidity.
(Appendix 4)
4. The additive manufacturing apparatus according to claim 1, wherein the third material has a melting point higher than that of the first material. 5.
(Appendix 5)
5. The additive manufacturing apparatus according to claim 1, wherein the first material has insulating properties, and the second material and the third material have conductivity.
(Appendix 6)
The additive manufacturing apparatus according to any one of appendices 1 to 5, further comprising a surface treatment unit that performs a surface treatment on a surface of the third material.
(Appendix 7)
The additive manufacturing apparatus according to appendix 6, wherein the surface treatment unit forms irregularities on the surface of the third material.
(Appendix 8)
8. The additive manufacturing apparatus according to claim 1, wherein the third material supply unit sucks and conveys the third material.
(Appendix 9)
8. The additive manufacturing apparatus according to claim 1, further comprising: a cutting unit configured to cut the third material, wherein the third material supply unit supplies the third material cut by the cutting unit. .
(Appendix 10)
8. The additive manufacturing apparatus according to claim 1, further comprising: a discharge unit that melts the third material, wherein the third material supply unit supplies the third material melted by the discharge unit. .
(Appendix 11)
Supplying a first material to a predetermined position in the layer;
Supplying a second material having a lower melting point than the first material to another predetermined position in the same layer;
The additive manufacturing method, wherein a third material is supplied into the same layer on the surface of the second material.
(Appendix 12)
The additive manufacturing method according to appendix 11, wherein the second material or the third material is heated below the melting point of the first material and above the melting point of the second material.
(Appendix 13)
The additive manufacturing method according to appendix 11 or 12, wherein the second material has fluidity.
(Appendix 14)
14. The additive manufacturing method according to one of appendices 11 to 13, wherein the third material has a melting point higher than that of the first material.
(Appendix 15)
15. The additive manufacturing method according to one of appendices 11 to 14, wherein the first material has insulating properties, and the second material and the third material have conductivity.
(Appendix 16)
16. The additive manufacturing method according to one of appendices 11 to 15, wherein the surface of the third material is surface-treated.
(Appendix 17)
The additive manufacturing method according to appendix 16, wherein irregularities are formed on the surface of the third material by the surface treatment.
(Appendix 18)
18. The additive manufacturing method according to one of appendices 11 to 17, wherein the third material is adsorbed and conveyed.
(Appendix 19)
18. The additive manufacturing method according to one of appendices 11 to 17, wherein the third material is cut and supplied.
(Appendix 20)
18. The additive manufacturing method according to one of appendices 11 to 17, wherein the third material is melted and supplied.

DESCRIPTION OF SYMBOLS 10, 20 Laminated modeling apparatus 11, 21 1st material supply part 12, 22 2nd material supply part 13, 23 3rd material supply part 24 Heating part 25 Modeling stage 26 Control part 27 Surface treatment part 28 Cutting mechanism 29 Discharge mechanism

Claims (10)

A first material supply for supplying a first material to a predetermined position in the layer;
A second material supply unit for supplying a second material having a melting point lower than that of the first material to another predetermined position in the same layer;
A third material supply for supplying a third material into the same layer on the surface of the second material;
An additive manufacturing apparatus.   The additive manufacturing apparatus according to claim 1, further comprising a heating unit configured to heat the second material or the third material to a temperature equal to or lower than a melting point of the first material and equal to or higher than a melting point of the second material.   The additive manufacturing apparatus according to claim 1, wherein the second material has fluidity.   The additive manufacturing apparatus according to claim 1, wherein the third material has a melting point higher than that of the first material.   5. The additive manufacturing apparatus according to claim 1, wherein the first material has insulating properties, and the second material and the third material have conductivity. 6.   6. The additive manufacturing apparatus according to claim 1, further comprising a surface treatment unit configured to surface-treat the surface of the third material.   The additive manufacturing apparatus according to claim 1, wherein the third material supply unit sucks and conveys the third material.   7. The additive manufacturing method according to claim 1, further comprising: a cutting portion that cuts the third material, wherein the third material supply portion supplies the third material cut by the cutting portion. apparatus.   7. The additive manufacturing according to claim 1, further comprising: a discharge portion that melts the third material, wherein the third material supply portion supplies the third material in which the discharge portion is melted. apparatus. Supplying a first material to a predetermined position in the layer;
Supplying a second material having a lower melting point than the first material to another predetermined position in the same layer;
The additive manufacturing method, wherein a third material is supplied into the same layer on the surface of the second material.

Images