JP2017166050A - Method for producing three-dimensional molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a three-dimensional molding producing a three-dimensional molding of high precision.SOLUTION: Provided is a method for producing a three-dimensional molding 500 comprising: a contour layer formation step where a first material including a first powder, a first solvent and a binder and a second material including a second powder, a second solvent and a binder are discharged from discharge means so as to be integrated into flight, and, by the integrated first material and second material, a contour layer 320 equivalent to the contour of the three-dimensional molding 500 is formed; a constituting layer formation step where the first material is discharged from the discharge means to the side of the first powder of the contour layer 320 to form a constituting layer 310; a supporting layer formation step where the second material is discharged from the discharge means to the side of the second powder of the contour layer 320 to form a supporting layer 300; and solidification step where energy is applied to the first powder and the second powder, and solidification is performed.SELECTED DRAWING: Figure 4B

Description

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

  Conventionally, the manufacturing method which manufactures a three-dimensional structure by laminating | stacking a layer is implemented. For example, in Patent Document 1, a layer made of a powder material is formed on a support, and a cross-sectional shape of a shaped object is formed by discharging a binder to a predetermined region of the layer to bond the powder material. A technique for manufacturing a three-dimensional structure by repeating is known.

JP-A-2005-007572

  However, in the conventional method for manufacturing a three-dimensional structure, the penetrability of the discharged binding material and the anti-bleeding liquid in the powder material layer has affected the contour accuracy of the structure. The binding material that has landed at a specific position and the anti-bleeding solution penetrate while interacting with each other in the layer of the powder material, and the interface formed when it penetrates becomes the contour of the modeled object. When the time difference occurs, unevenness occurs and it is difficult to express a smooth surface.

  In view of the above, an object of the present invention is to provide a method for manufacturing a three-dimensional structure that can eliminate the time difference when landing and can form a highly accurate contour shape.

  Application Example 1 A manufacturing method of a three-dimensional structure according to this application example is a manufacturing method of manufacturing a three-dimensional structure by forming a layer and laminating the first powder and the first solvent. And the first material containing the binder and the second powder, the second material containing the second solvent and the binder are discharged from the discharge means and integrated during the flight, and the first material is integrated. A contour layer forming step of forming a contour layer corresponding to a contour of the three-dimensional structure with the material and the second material, and the first material from the discharge means to the first powder side of the contour layer And forming a support layer by forming the support layer by discharging the second material from the discharge means to the second powder side of the contour layer. And solidifying the first powder and the second powder by applying energy to the first powder and the second powder. And having a step.

  According to this application example, in the contour layer forming step, the first material and the second material are integrated during the flight, and the interface between the first material and the second material is formed before landing. Since the interface formed during flight is maintained even after landing, it is possible to eliminate the dimensional error at the time of contour formation due to the wetting spread speed and the time difference when landing, and the contour of the molded object can be formed with high accuracy . As a result, a highly accurate three-dimensional structure can be obtained. In addition, a configuration layer having a contour layer forming step, a constituent layer forming step, a support layer forming step, and a solidifying step, the contour layer being formed in advance by the contour layer forming step, and delimited by the contour layer The first material and the second material can be disposed in the region and the region of the support layer, respectively. Accordingly, interference with the material arrangement position due to wetting and spreading to the contour layer due to the material discharged when forming the constituent layer and the support layer can be prevented, so that the modeling accuracy can be improved. Furthermore, a solidification process can also be implemented immediately after a contour layer formation process. As a result, the contour layer formed earlier is fixed to prevent the interference of the contour position in the constituent layer forming step and the support layer forming step, thereby improving the modeling accuracy.

  Application Example 2 In the method for manufacturing a three-dimensional structure according to the application example, the first solvent and the second solvent include at least one solvent having the same composition, and the first material and the second solvent The second material preferably has a viscosity range of 10 Pa · s or more and 20 Pa · s or less, and the difference in viscosity range between the first material and the second material is preferably 2 Pa · s or less.

  According to this application example, since the first solvent and the second solvent include at least one solvent having the same composition, they have affinity at the interface and can be integrated during the flight. Moreover, if the viscosity range of the material is 10 Pa · s or more and 20 Pa · s or less, the first powder and the second powder are mixed in the time from the integration of the first material and the second material to the solidification step. Can be prevented from being dispersed and mixed. Therefore, when the second material is removed after the solidification step, a smooth contour surface by the solidified first material can be obtained, and the modeling accuracy can be improved. Further, by setting the difference in viscosity range to 2 Pa · s or less, the difference between the height of the first material and the height of the second material after landing can be suppressed. Therefore, the dimensional error in the thickness direction of the layer can be reduced, and the modeling accuracy can be improved.

  Application Example 3 In the method for manufacturing a three-dimensional structure according to the application example described above, the sintering temperature or melting point of the first powder is preferably lower than the sintering temperature or melting point of the second powder. .

  According to this application example, the sintering temperature or melting point of the first powder is lower than the sintering temperature or melting point of the second powder. The second material can be separated. As a result, a three-dimensional structure can be easily obtained.

  Application Example 4 In the method for manufacturing a three-dimensional structure according to the application example, the first powder is a material constituting the three-dimensional structure, and includes aluminum, titanium, iron, copper, magnesium, and stainless steel. A powder containing at least one component of steel and maraging steel, and the second powder is a material that supports the three-dimensional structure, and is at least one of silica, alumina, titanium oxide, and zircon oxide. A powder containing one component is preferred.

  According to this application example, due to the difference in sintering temperature or melting point of the first powder that is a material constituting the three-dimensional structure and the second powder that is a material that supports the three-dimensional structure, in the solidification step, Since it is easy to selectively solidify only the first powder and keep the second powder in a powder state or a sintered state that is easy to remove, while ensuring the strength of the three-dimensional structure, It can suppress that load, such as a separation operation at the time of removing a three-dimensional structure, and a forming operation after removing, becomes large.

  Application Example 5 In the method of manufacturing a three-dimensional structure according to the application example, the contour layer forming step rotates the discharge unit around the flight direction, and the first material is the three-dimensional material. It is preferable to discharge so that it may be located in the area | region corresponded to a molded article.

  According to this application example, the interface between the first material and the second material can be controlled in an arbitrary direction by rotating the discharge means around the flight direction, so that the direction along the contour of the modeled object An interface between the first material and the second material can be formed. Thereby, modeling accuracy can be improved.

  Application Example 6 In the method for manufacturing a three-dimensional structure according to the application example, the solidification step is preferably performed for each layer.

  According to this application example, when the solidification step is performed for each layer, energy application can be adjusted for each layer, and solidification can be performed efficiently.

  Application Example 7 In the method for manufacturing a three-dimensional structure according to the application example described above, it is preferable that the solidification step is performed after all the layer formation steps are completed.

  According to this application example, when the three-dimensional structure of all layers is performed as a solidification target, changes in the dimensions of the three-dimensional structure can be alleviated as a whole. In particular, this embodiment is suitable when a solidification means by sintering is employed.

The schematic block diagram which shows the structure of the manufacturing apparatus used for the manufacturing method of the three-dimensional structure based on embodiment of this invention. The enlarged view of the C section shown in FIG. The flowchart of the manufacturing method of the three-dimensional structure based on embodiment of this invention. The figure explaining the method of discharging a constituent material and a support material in a continuous body form. The figure explaining the method of discharging a constituent material and a support material in droplet shape. The top view explaining notionally the relationship between arrangement | positioning of the discharge part which concerns on embodiment of this invention, and the formation form of a three-dimensional structure. The top view explaining notionally the relationship between arrangement | positioning of the discharge part which concerns on embodiment of this invention, and the formation form of a three-dimensional structure. The top view explaining notionally the relationship between arrangement | positioning of the discharge part which concerns on embodiment of this invention, and the formation form of a three-dimensional structure. The enlarged view of the A section shown to FIG. 5A. The enlarged view of the A section shown in Drawing 5A (after discharge part rotation). The figure explaining the method of discharging only a constituent material from a discharge part.

  Embodiments according to the present invention will be described below with reference to the drawings. In the following drawings, the scale of each layer and each member is made different from the actual scale so that each layer and each member can be recognized. In each figure, for convenience of explanation, the X axis, the Y axis, and the Z axis are illustrated as three axes orthogonal to each other. In the following description, a direction parallel to the X axis is referred to as an “X axis direction”. A direction parallel to the Y axis is referred to as a “Y axis direction”, and a direction parallel to the Z axis is referred to as a “Z axis direction”.

<Manufacturing device for three-dimensional structure>
First, the structure of the manufacturing apparatus 2000 used for the manufacturing method of the three-dimensional structure 500 according to the embodiment of the present invention will be described with reference to FIG.
FIG. 1 is a schematic configuration diagram showing a configuration of a manufacturing apparatus used in a method for manufacturing a three-dimensional structure according to an embodiment of the present invention.
The manufacturing apparatus 2000 for the three-dimensional structure 500 according to this embodiment includes a discharge unit 1830 that is a discharge unit that supplies a material, and a laser irradiation unit 3100 that solidifies the material. What is supplied from the discharge unit 1830 is a constituent material as a first material and a support material as a second material. The constituent material includes a powder constituting the three-dimensional structure 500 that is the first powder, a first solvent, and a binder. Further, the support material includes a powder that forms a support portion that supports the three-dimensional structure 500 that is the second powder, a second solvent, and a binder.
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.

  The manufacturing apparatus 2000 for the three-dimensional structure 500 shown in FIG. 1 moves in the X, Y, and Z directions shown in the figure or in a rotational direction around the Z axis by the base 110 and the driving means provided in the base 110. The stage 120 provided so as to be drivable, the control unit 400 that controls the discharge unit 1830 and the stage 120, the constituent material supply unit 1210 that supplies the constituent material to the discharge unit 1830, and the support that supplies the support material to the discharge unit 1830 A material supply unit 1710. The discharge unit 1830 is held at the end of the head base 840 that is fixed to the base 110 and facing the stage 120. Further, a laser irradiation unit 3100 for sintering or melting the constituent material and the support material, and a galvano mirror 3000 for positioning the laser beam from the laser irradiation unit 3100 are provided above the stage 120. 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 performed by irradiating heat energy with a laser or the like, the sample plate 121 having heat resistance is used for the third order on the sample plate 121 in order to protect the stage 120 from heat. The original model 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 the reactivity with the constituent material of the three-dimensional structure 500 to be melted (or sintered). And the alteration of the three-dimensional structure 500 can be prevented. In FIG. 1, 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 FIG. 1). Here, each of the layers 501, 502, 503,..., 50n is a contour layer 320 that is discharged from the discharge portion 1830 and forms a boundary surface of two kinds of materials by the support material and the constituent material, and only the support material. The support layer 300 is formed of the component layer 310, and the component layer 310 is formed of only the component material.

Next, the discharge part 1830 which discharges a constituent material and a support material is demonstrated with reference to FIG.
FIG. 2 is an enlarged view of a portion C shown in FIG.
As shown in FIG. 2, the discharge unit 1830 includes a component material discharge nozzle 1830c and a component material discharge drive unit 1830d for discharging a component material, and a support material discharge nozzle 1830a and a support material discharge drive for discharging a support material. Part 1830b. The constituent material discharge drive unit 1830d is connected to the constituent material supply unit 1210 via a supply tube, and supplies the constituent material of the constituent material supply unit 1210 to the constituent material discharge nozzle 1830c and discharges it. The support material discharge driving unit 1830b is connected to the support material supply unit 1710 via a supply tube, and supplies the support material of the support material supply unit 1710 to the support material discharge nozzle 1830a and discharges it.

  The distance between the outlet hole of the constituent material discharge nozzle 1830c provided in the discharge unit 1830 and the outlet hole of the support material discharge nozzle 1830a is preferably about 1 mm. Further, the distance between the discharge unit 1830 and the sample plate 121 is about 5 mm, and the angle θ formed by the central axes of the constituent material discharge nozzle 1830c and the support material discharge nozzle 1830a is preferably about 19 degrees.

  When the constituent material and the support material are simultaneously ejected from the constituent material discharge nozzle 1830c and the support material discharge nozzle 1830a, the constituent material and the support material are integrated at a position where it has jumped about 3 mm from the discharge portion 1830. The integrated component material and the support material cancel the velocity components in the X and Y axis directions, fly in a substantially Z direction, and land on the sample plate 121. At this time, the discharge amounts of the constituent material and the support material are preferably about 3 nL, and the discharge speed is preferably about 10 m / s. Such discharge conditions can prevent scattering when the constituent material and the support material are integrated.

  The discharge unit 1830 is connected to a constituent material supply unit 1210 that contains a constituent material and a support material supply unit 1710 that contains a support material. Then, the constituent material is supplied from the constituent material supply unit 1210 to the discharge unit 1830. Further, the support material is supplied from the support material supply unit 1710 to the discharge unit 1830. By selecting a material having a melting point higher than that of the constituent material as the support material, it is possible to suppress an increase in loads such as separation work when removing the three-dimensional structure 500 and molding work after removal.

  Returning to FIG. 1 again, the control unit 400 controls the stage 120 and the discharge unit 1830 based on modeling data of the three-dimensional model 500 output from a data output device such as a personal computer (not shown). Yes. The control unit 400 controls the stage 120 and the discharge unit 1830 so as to drive and operate in cooperation.

  The stage 120 movably provided on the base 110 receives signals from the control unit 400 that control the start and stop of movement of the stage 120, the movement direction, the movement amount, the movement speed, and the like, in the X, Y, and Z directions. Move to. The material supply controller 1500 generates a signal for controlling a support material discharge amount from the support material discharge nozzle 1830a in the support material discharge drive unit 1830b based on a control signal from the control unit 400, and the support material discharge nozzle is generated based on the signal. A predetermined amount of the support material is discharged from 1830a. In addition, the material supply controller 1500 generates a signal for controlling the component material discharge amount from the component material discharge nozzle 1830c in the component material discharge drive unit 1830d based on the control signal from the control unit 400, and the component material is generated based on the signal. A predetermined amount of the constituent material is discharged from the discharge nozzle 1830c. By simultaneously discharging the supporting material and the constituent material, the two materials can be integrated during flight to form a boundary, which can land and form the contour layer 320.

Next, the constituent materials of the constituent material and the support material will be described.
As the first powder that is a powder constituting the three-dimensional structure 500, for example, magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), Copper (Cu), nickel (Ni) simple powder, or 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) It is possible to use mixed powders such as. 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.

  Examples of the second powder that is a powder that supports the three-dimensional structure 500 include various metal oxides such as silica, alumina, titanium oxide, zinc oxide, zircon oxide, tin oxide, magnesium oxide, and potassium titanate. Various metal hydroxides such as magnesium hydroxide, aluminum hydroxide and calcium hydroxide, various metal nitrides such as silicon nitride, titanium nitride and aluminum nitride; various metal carbides such as silicon carbide and titanium carbide, various types such as zinc sulfide Various metal carbonates such as metal sulfides, calcium carbonate and magnesium carbonate, sulfates of various metals such as calcium sulfate and magnesium sulfate, various silicates such as calcium silicate and magnesium silicate, calcium phosphate Various metal borates such as metal phosphate, aluminum borate, magnesium borate, etc. Products such as, (each hydrates of calcium sulfate, anhydrous calcium sulfate) gypsum it is possible to use a mixed powder of such.

  As described above, the first powder and the second powder are not particularly limited, and metals other than the above metals, ceramics, resins, and the like can be used. However, it is preferable to select a material having a higher melting point than the first powder for the second powder. When a metal is used for the first powder, it is preferable to use a ceramic powder having a higher melting point as the second powder. This is because when the first powder is solidified by applying energy, only the first powder is solidified by selecting a material that is solidified at a higher temperature, and the second powder is in a powder state. Or it is because the load of the isolation | separation operation | work at the time of removing the three-dimensional structure 500 and the shaping | molding operation | work after removing by suppressing the sintered state of the grade which is easy to remove is suppressed.

  Examples of the first solvent contained in the constituent material include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetic acid Acetic acid esters such as ethyl, n-propyl acetate, iso-propyl acetate, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl Ketones such as n-butyl ketone, diisopropyl ketone, and acetylacetone; Alcohols such as ethanol, propanol, and butanol; Tetraalkylammonium acetates; Dimethyl sulfoxide, Di Examples include sulfoxide solvents such as til sulfoxide; pyridine solvents such as pyridine, γ-picoline, and 2,6-lutidine; and ionic liquids such as tetraalkylammonium acetate (for example, tetrabutylammonium acetate). These can be used alone or in combination of two or more.

  Moreover, as a 2nd solvent contained in a support material, the solvent quoted in the example of said 1st solvent can be used, and it can be used combining 1 type (s) or 2 or more types selected from these. However, it contains at least one solvent having the same composition with respect to the first solvent.

  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 viscosity ranges of the first material and the second material are each in the range of 10 Pa · s to 20 Pa · s, and the difference in the viscosity range between the first material and the second material is 2 Pa · s or less. Preferably there is. By setting the viscosity ranges of the first material and the second material within the range of 10 Pa · s to 20 Pa · s, respectively, after the first material and the second material are integrated in the contour layer forming step. It is possible to prevent the first powder and the second powder from being dispersed and mixed during the time until the solidification step. Further, by setting the difference in viscosity range to 2 Pa · s or less, the difference between the height of the first material and the height of the second material after landing can be suppressed.

  The constituent material and the support material preferably have the same solid content concentration, and the ratio is preferably about 90 wt%. Thereby, the thickness of the layer can be made uniform during the solidification step.

<Method for manufacturing three-dimensional structure>
Next, an example of a method for manufacturing the three-dimensional structure 500 using the manufacturing apparatus 2000 will be described with reference to FIG. FIG. 3 is a flowchart of the method for manufacturing a three-dimensional structure according to the embodiment of the present invention.

  In the manufacturing method of the three-dimensional structure 500 according to the present embodiment, as shown in FIG. 3, first, in step S <b> 110, data of the three-dimensional structure 500 is acquired by the control unit 400. Specifically, for example, data representing the shape of the three-dimensional structure 500 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 500, the data is sliced according to the modeling resolution in the Z direction, and bitmap data (cross section data) is generated for each section by the control unit 400.
At this time, the generated bitmap data includes a non-configuration area of the three-dimensional structure 500 (formation area of the support layer 300), a configuration area of the three-dimensional structure 500 (formation area of the configuration layer 310), and its contour. The data is classified into a region (region where the contour layer 320 is formed).

Next, in step S130, the data of the layer to be formed is the data for forming the non-configuration area (support layer 300) of the three-dimensional structure 500, or the configuration area (configuration layer 310) of the three-dimensional structure 500. It is determined whether the data to be formed is data to form a contour region (contour layer 320). This determination is made by the control unit 400.
If it is determined in this step that the data forms the support layer 300, the process proceeds to step S 140. If it is determined that the data forms the constituent layer 310, the process proceeds to step S 150, and the data is determined to form the contour layer 320. If yes, the process proceeds to step S190.
Hereinafter, a method of manufacturing the contour layer 320, the constituent layer 310, and the support layer 300 in this order will be described as an example.

(Contour layer forming process)
In the contour layer forming step of step S190, the constituent material including the first powder, the first solvent, and the binder, and the support material including the second powder, the second solvent, and the binder are discharged from the discharge unit 1830. In this process, the contour layer 320 corresponding to the contour of the three-dimensional structure 500 is formed by the integrated constituent material and support material. Since there are two methods for discharging the constituent material and the support material, description will be made with reference to FIGS. 4A and 4B. FIG. 4A is a diagram illustrating a method of discharging a constituent material and a support material in a continuous form. FIG. 4B is a diagram for explaining a method of discharging the constituent material and the support material into droplets. The first discharge method of the discharge unit 1830 shown in FIG. 2 is a form in which the contour layer 320 is formed in a state where the constituent material and the support material are discharged in a continuous form as shown in FIG. 4A. The second ejection method is a mode in which the contour layer 320 is formed in a state where the constituent material and the support material are supplied in the form of droplets, as shown in FIG. 4B. The ejection form of the constituent material and the support material may be either a droplet form or a continuous form, but in the present embodiment, the explanation will be given by the form in which the constituent material and the support material are ejected in the form of droplets To do.

  Hereinafter, a procedure for forming the contour layer 320 will be described with reference to FIGS. 5A to 5C and FIGS. 6A to 6B. 5A to 5C are plan views conceptually illustrating the relationship between the arrangement of the discharge unit 1830 and the formation form of the three-dimensional structure 500. 6A to 6B are enlarged views of a portion A shown in FIG. 5A. In the contour layer forming step, an example in which the head base 840 is provided with four ejection units 1830 will be described.

  In the head base 840, as shown in FIG. 5A, four ejection units 1831 to 1834 are arranged in a staggered arrangement along the Y-axis direction. First, when the stage 120 moves in the X-axis direction, the constituent material and the support material are ejected from the plurality of ejection units 1831 to 1834 in a droplet state at substantially the same volume and at the same timing, The constituent material and the support material that are integrated at the position (the region that should be the contour of the three-dimensional structure 500) are arranged, and the contour layer 320 is formed. Since the thickness of the contour layer 320 (the height of the constituent material and the support material) is required to be uniform, the solid content concentration of the powder contained in the constituent material and the support material is adjusted to be approximately equal. Specifically, as shown in FIG. 5A, while moving the stage 120 in the X-axis direction, the constituent material and the supporting material are discharged from the discharge units 1831 to 1834 and integrated during the flight, and the integrated constituent material is integrated. And the composite material by support material is arrange | positioned in the predetermined position of the sample plate 121, and the outline layer structure parts 320a, 320b, 320c, and 320d are formed. In addition, when forming the outline of the three-dimensional structure 500 in a direction crossing the X-axis direction, as shown in FIGS. 6A and 6B, the support material is discharged by a predetermined angle around the Z-axis that is the flight direction. The nozzle 1830a and the constituent material discharge nozzle 1830c are rotated and discharged. Next, the stage 120 is moved in the Y-axis direction in order to form the contour layer constituting portions (320a ′, 320b ′, 320c ′, 320d ′) on the second line in the Y-axis direction of the ejection units 1831 to 1834. When the pitch between the nozzles is P, the movement amount is moved in the Y-axis direction by P / n (n is a natural number) pitch. In this embodiment, n is assumed to be 3.

  By forming the contour layer constituting portion as described above, as shown in FIG. 5A, the contour layer constituting portion (320a) corresponding to one line in the X axis direction (first line in the Y axis direction) of the discharge portions 1831 to 1834 is formed. , 320b, 320c, 320d), and the second layer outline layer constituent parts (320a ′, 320b ′, 320c ′, 320d ′) in the Y-axis direction are formed as shown in FIG. 5B.

  Next, in order to form the contour layer constituting portions (320a ″, 320b ″, 320c ″, 320d ″) on the third line in the Y-axis direction of the discharge portions 1831 to 1834, the stage 120 is moved in the Y-axis direction. Move. The amount of movement is moved in the Y-axis direction by P / 3 pitch. Then, by performing the same operation as described above, as shown in FIG. 5C, the contour layer constituting portions (320a ″, 320b ″, 320c ″, 320d ″) of the third line in the Y-axis direction are formed. Thus, the contour layer 320 can be obtained.

(Contour layer solidification process)
Next, it progresses to the outline layer solidification process of step S200. In this embodiment, after forming the contour layer 320 composed of the contour layer constituent portion, the contour layer 320 is sintered or melted and solidified using the laser irradiation unit 3100 and the galvanometer mirror 3000. Each time the contour layer constituent portion is formed, the contour layer constituent portion may be sintered or melted and solidified. At this time, organic components such as a solvent and a binder contained in the constituent material and the support material are vaporized or thermally decomposed and removed. Note that this step is particularly preferably performed under an inert gas or catalyst gas atmosphere.

(Structural layer forming process)
Next, the process proceeds to the constituent layer forming process of step S150, which is a process of forming the constituent layer 310. The constituent layer forming step in step S150 is a step of forming the constituent layer 310 by discharging only constituent materials from the discharge portion 1830. Next, a procedure for forming the constituent layer 310 will be described. In the constituent layer forming step, the constituent layer 310 is formed by ejecting only the constituent material from the ejection unit 1830 in the form of droplets. The constituent material is discharged so as to be in contact with the constituent material surface including the first powder of the contour layer. At this time, the amount of droplets ejected when forming the constituent layer 310 in the constituent layer forming step is larger than the amount of constituent droplets ejected when the contour layer 320 is formed in the contour layer forming step. large. That is, the contour layer 320 is formed with droplets smaller than the droplets used when forming the constituent layer 310. That is, the contour layer 320 that determines the shape of the contour of the three-dimensional structure 500 is formed with relatively small droplets, and the constituent layer 310 that forms the inside of the three-dimensional structure 500 is formed with relatively large droplets. To do. Therefore, the contour layer 320 for determining the shape of the contour that needs to be formed with high accuracy in the three-dimensional structure 500 can be formed with high accuracy, and it is necessary to form the contour layer 320 with high precision in the three-dimensional structure 500. It is possible to quickly form the constituent layer 310 that constitutes the interior not present. Specifically, the discharge amount when forming the constituent layer 310 is preferably 6 nL, compared with the discharge amount 3 nL when forming the contour layer 320. Note that the constituent layer 310 may be formed in a continuous form as described above.

  Here, a method of discharging only the constituent material from the discharge unit 1830 will be described with reference to FIG. FIG. 7 is a diagram for explaining a method of discharging only the constituent material from the discharge unit. When only the constituent material is ejected from the ejection unit 1830, as shown in FIG. 7, the constituent material ejection nozzle 1830c has an inclination of about 9.5 degrees with respect to the Z axis, so the flight direction follows the constituent material ejection nozzle 1830c. Lean. At this time, the landing position is deviated by the offset amount O from the position when the contour layer 320 is formed. The offset amount O is about 0.33 mm, and the relative position between the ejection unit 1830 and the stage 120 is corrected by this amount, and the constituent material is supplied to an arbitrary position.

(Structure layer solidification process)
After forming the constituent layer 310, the process proceeds to the constituent layer solidifying step of step S170. In the constituent layer solidifying step of step S170, the constituent layer 310 is sintered or melted and solidified using the laser irradiation unit 3100 and the galvanometer mirror 3000. At this time, flatness can be improved by sintering or melting and solidifying including the constituent material surface of the contour layer. At this time, the organic components such as the first solvent and binder contained in the constituent materials are vaporized or thermally decomposed and gradually vaporized. It is particularly preferable to carry out in an inert gas or catalyst gas atmosphere.

(Support layer forming step)
Next, the process proceeds to the support layer forming process of step S140, which is a process of forming the support layer 300. The support layer forming step in step S140 is a step of forming the support layer 300 by discharging only the support material from the discharge unit 1830. Next, a procedure for forming the support layer 300 will be described. In the support layer formation step, the support layer 300 is formed by discharging only the support material from the discharge unit 1830 in the form of droplets. The support material is discharged so as to contact the surface of the support material including the second powder of the contour layer. At this time, the amount of droplets ejected when forming the support layer 300 in the support layer forming step is more than the amount of droplets of the support material ejected when forming the contour layer 320 in the contour layer forming step. large. That is, the contour layer 320 is formed with droplets smaller than the droplets used when forming the support layer 300. That is, the contour layer 320 that determines the shape of the contour of the three-dimensional structure 500 is formed with relatively small droplets, and the support layer 300 that supports the three-dimensional structure 500 is formed with relatively large droplets. Therefore, the contour layer 320 for determining the shape of the contour that needs to be formed with high accuracy in the three-dimensional structure 500 can be formed with high accuracy, and it is necessary to form the contour layer 320 with high precision in the three-dimensional structure 500. The support layer 300 that is not present can be formed quickly. Specifically, the discharge amount when forming the support layer 300 is preferably 6 nL, compared to the discharge amount 3 nL when forming the contour layer 320. In addition, you may form the support layer 300 by the continuous form mentioned above.

  Similarly to the above-described constituent materials, when only the support material is discharged from the discharge unit 1830, the support material discharge nozzle 1830a has an inclination of about 9.5 degrees with respect to the Z axis, so the flight direction is the support material discharge nozzle 1830a. Tilt along. At this time, the landing position is deviated by the offset amount O from the position when the contour layer 320 is formed. The offset amount O is about 0.33 mm, and the relative position between the discharge unit 1830 and the stage 120 is corrected by this amount, and the support material is supplied to an arbitrary position.

(Support layer solidification process)
After the formation of the support layer 300, the process proceeds to the support layer solidifying step in step S160. In the support layer solidifying step in step S160, the support layer 300 is sintered using the laser irradiation unit 3100 and the galvanometer mirror 3000. Flatness can be improved by sintering including the support material surface of the contour layer 320. At this time, the organic components such as the second solvent and binder contained in the support material are vaporized or thermally decomposed to be vaporized and gradually removed. However, this step (step S160) may be omitted.

  As described above, the layer 501 including the contour layer 320, the constituent layer 310, and the support layer 300 is formed. In step S180, steps S130 to S180 are repeated until the formation of the three-dimensional structure 500 based on the bitmap data corresponding to each layer generated in step S120 is completed.

That is, the solidification process is performed for each of the contour layer 320, the constituent layer 310, and the support layer 300 to form the three-dimensional structure 500 as a laminate. And with completion | finish of step S180, the manufacturing method of the three-dimensional structure 500 of a present Example is complete | finished.
In addition, when a solidification process is performed for every layer, energy provision can be adjusted for every layer and it becomes possible to perform solidification efficiently.
The order of forming the support layer 300 in step S140, forming the constituent layer 310 in step S150, and forming the contour layer 320 in step S190 is not particularly limited.

  Next, another example of the method for manufacturing the three-dimensional structure 500 according to the above-described embodiment will be described. In embodiment mentioned above, it had the solidification process for every process of an outline layer formation process, a structure layer formation process, and a support layer formation process. In this embodiment, the solidification step is performed in a lump after forming the three-dimensional structure 500 as a laminate. Specifically, the component layer 310 is heated in a constant temperature bath (heating unit) provided separately from the manufacturing apparatus 2000 so that the sintering temperature of the first powder becomes lower than the sintering temperature of the second powder. Is sintered and solidified. In the solidification step, organic components such as a solvent and a binder contained in the constituent material and the supporting material are thermally decomposed and vaporized, so that the unsintered supporting layer 300 is in a powder state and can be easily removed from the sintered constituent layer 310. It is possible to remove.

  In the above-described embodiment, the constituent material and the support material are used. However, the constituent layer 310 and the support layer 300 may be formed by discharging a material different from the constituent material and the support material from a dischargeable head unit. good. As a result, a three-dimensional structure 500 made of different materials can be obtained.

As described above, according to the method for manufacturing the three-dimensional structure 500 according to this embodiment, the following effects can be obtained.
In the contour layer forming step, the first material and the second material are integrated during the flight, and the interface between the first material and the second material is formed before landing. Since the interface formed during flight is maintained even after landing, it is possible to eliminate the dimensional error at the time of contour formation due to the wetting spread speed and the time difference when landing, and the contour of the molded object can be formed with high accuracy . As a result, a highly accurate three-dimensional structure 500 can be obtained. The contour layer forming step, the constituent layer forming step, the support layer forming step, and the solidifying step are included. The contour layer 320 is formed in advance by the contour layer forming step, and is delimited by the contour layer 320. A first material and a second material can be disposed in the region of the constituent layer 310 and the region of the support layer 300, respectively. Thereby, interference with the material arrangement position due to wetting and spreading to the contour layer 320 due to the material discharged during the formation of the constituent layer 310 and the support layer 300 can be prevented, so that the modeling accuracy can be improved. Furthermore, a solidification process can also be implemented immediately after a contour layer formation process. As a result, the contour layer 320 formed earlier is fixed and interference of the contour position by the constituent layer forming step and the support layer forming step can be prevented, thereby improving the modeling accuracy.

  Further, since the first solvent and the second solvent contain at least one solvent having the same composition, they have affinity at the interface and can be integrated during the flight. Further, if the viscosity range of the material is 10 Pa · s or more and 20 Pa · s or less, the constituent powder and the supporting powder are dispersed and mixed in the time from the integration of the constituent material and the supporting material to the solidification step. Can be prevented. Therefore, when the supporting material is removed after the solidification step, a smooth contour surface by the solidified constituent material can be obtained, and the modeling accuracy can be improved. Further, by setting the difference in viscosity range to 2 Pa · s or less, the difference between the height of the constituent material and the height of the support material after landing can be suppressed. Therefore, the dimensional error in the thickness direction of the layer can be reduced, and the modeling accuracy can be improved.

  In addition, since the sintering temperature or melting point of the first powder is lower than the sintering temperature or melting point of the second powder, the constituent material and the support material are easily separated after the solidification step by utilizing the difference. be able to. Thereby, the three-dimensional structure 500 can be easily obtained.

  The first powder is a material constituting the three-dimensional structure 500, and is a powder containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel, The second powder is a material that supports the three-dimensional structure 500 and includes at least one component of silica, alumina, titanium oxide, and zircon oxide. Therefore, due to the difference in sintering temperature or melting point between the first powder and the second powder, only the first powder is selectively solidified in the solidification step, and the second powder is sintered in a powder state or easily removed. It is easy to keep it in a knotted state. Therefore, it is possible to suppress an increase in loads such as separation work when removing the three-dimensional structure 500 and molding work after removal while securing the strength of the three-dimensional structure 500.

  Further, in the contour layer forming step, the interface between the first material and the second material can be controlled in an arbitrary direction by rotating the discharge unit 1830 around the flight direction. An interface between the constituent material and the support material can be formed in the direction. Thereby, modeling accuracy can be improved.

  Further, by performing the solidification step for each layer formation, energy application can be adjusted for each layer, and solidification can be performed efficiently.

  Further, when the solidification step is performed after all the layer formation steps are completed, the three-dimensional structure 500 of all layers is performed as a solidification target, and the change in the dimensions of the three-dimensional structure 500 can be alleviated as a whole. In particular, it is suitable when a solidification means by sintering is employed.

  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.

  DESCRIPTION OF SYMBOLS 110 ... Base, 120 ... Stage, 121 ... Sample plate, 300 ... Support layer, 310 ... Constituent layer, 320 ... Contour layer, 320a, 320b, 320c, 320d ... Contour layer constituent part, 400 ... Control unit, 500 ... Tertiary Original shaped object, 501, 502, 503, 50n ... layer, 840 ... head base, 1210 ... constituent material supply unit, 1500 ... material supply controller, 1710 ... support material supply unit, 1830 ... discharge part, 1830a ... support material discharge nozzle , 1830b ... support material discharge drive unit, 1830c ... constituent material discharge nozzle, 1830d ... constituent material discharge drive unit, 1831, 1832, 1833, 1834 ... discharge unit, 2000 ... manufacturing apparatus, 3000 ... galvanomirror, 3100 ... laser irradiation unit , O ... Landing position offset amount.

Claims (7)

A manufacturing method for manufacturing a three-dimensional structure by forming a layer and laminating,
The first material containing the first powder, the first solvent and the binder and the second material containing the second powder, the second solvent and the binder are discharged from the discharge means and integrated during the flight. A contour layer forming step of forming a contour layer corresponding to the contour of the three-dimensional structure with the integrated first material and the second material;
A constituent layer forming step of forming the constituent layer by discharging the first material from the discharge means to the first powder side of the contour layer;
A support layer forming step of forming the support layer by discharging the second material from the discharge means to the second powder side of the contour layer;
And a solidifying step of applying energy to the first powder and the second powder to solidify the three-dimensional structure. The first solvent and the second solvent include at least one solvent having the same composition,
The viscosity ranges of the first material and the second material are each in the range of 10 Pa · s to 20 Pa · s, and the difference in viscosity range between the first material and the second material is 2 Pa · s or less. The method for producing a three-dimensional structure according to claim 1, wherein:   The method for producing a three-dimensional structure according to claim 1 or 2, wherein the sintering temperature or melting point of the first powder is lower than the sintering temperature or melting point of the second powder. The first powder is a material constituting the three-dimensional structure, and is a powder containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, maraging steel,
The second powder is a material that supports the three-dimensional structure, and is a powder containing at least one component of silica, alumina, titanium oxide, and zircon oxide. The manufacturing method of the three-dimensional structure as described in any one of these. The contour layer forming step rotates the discharge means around the flight direction,
The method for producing a three-dimensional structure according to claim 1, wherein the first material is discharged so as to be positioned in a region corresponding to the three-dimensional structure.   The said solidification process is performed for every said layer, The manufacturing method of the three-dimensional molded item as described in any one of Claim 1 thru | or 5 characterized by the above-mentioned.   The method for producing a three-dimensional structure according to any one of claims 1 to 5, wherein the solidifying step is performed after all the layer forming steps are completed.

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