JP2018030323A - Three-dimensional molding apparatus and method for manufacturing three-dimensional molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase a filling rate for a space for the subsequent layer with an uncured photocurable resin and thereby to increase a molding rate in a configuration of manufacturing a three-dimensional molded object by repeating irradiating a photocurable resin accommodated in a vessel with light and moving a molding stage.SOLUTION: One surface of a vessel 5 accommodating a photocurable resin 1 is constituted by a gas permeable sheet 7 that opposes the photocurable resin 1 and transmits irradiation light from a light irradiation device (8 to 10), and a light-transmitting plate 6 disposed outside the vessel over the gas permeable member. A pressure chamber 11 in which pressure can be controlled by a pressure controller 12 is segmented between the gas permeable sheet 7 and the light-transmitting plate 6. Upon moving a molding stage 3, the pressure in the pressure chamber 11 is reduced to deform the gas permeable sheet 7 into a concave shape, and upon irradiating the resin with light, gas in the pressure chamber 11 is permeated into the photocurable resin 1 by pressurizing.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a three-dimensional modeling apparatus for manufacturing a three-dimensional structure by irradiating a photocurable resin accommodated in a container with light, and a method for manufacturing the three-dimensional structure.

  In recent years, development of a three-dimensional modeling technique for forming a modeled object by repeating a process of exposing and solidifying (curing) an uncured photocurable resin has been advanced. In this type of three-dimensional modeling apparatus, a configuration is known in which a photocurable resin of a material is applied to a modeling stage or a solidified modeled object (work) one by one with an application roller or the like, and light irradiation is repeated. In addition, a modeling stage (or a modeled part of a modeled object) is immersed in a photocurable resin contained in a container, and light irradiation is performed from below or above to perform layer modeling, and a modeling stage for modeling the next layer There is also known a configuration for moving the upper or lower side.

  The latter configuration does not use a coating mechanism like the former configuration, so there is an advantage that, for example, the mechanical configuration and control of the modeling apparatus is simple, but the modeling speed in the stacking direction is a problem. (Patent Document 1). One of the factors that reduce the modeling speed is a problem that the photocurable resin is fixed (or increased in viscosity) in a resin container, for example, a portion of a light transmitting member that transmits cured light, depending on modeling conditions. In this case, for example, when one stage is formed and then the stage is moved up and down for the next layer, it is necessary to forcibly peel off the part where sticking or viscosity increase has occurred. Decreases. There is also a problem that a large driving force is required for the moving device of the modeling stage. Another factor that reduces the modeling speed is that when the modeling stage is moved after modeling one layer, the photocurable resin is supplied to the space that forms the next modeling layer, depending on the modeling conditions. Is a problem that does not happen quickly.

  Therefore, a method has been proposed in which a state that inhibits the curing (polymerization) of the photocurable resin is formed in a specific portion of the container, for example, a spatial region in the vicinity of the light transmitting member that transmits the curing light (Patent Document 2). . In this configuration, for example, a light transmissive member facing the photocurable resin in the container is formed of a gas permeable member, and a gas (for example, oxygen) that inhibits the curing (polymerization) of the photocurable resin into the photocurable resin from the outside. Permeate those containing atoms). According to this configuration, curing (polymerization) of the photocurable resin is prevented in the space near the light transmitting member by the gas that has passed through the gas transmitting member. Therefore, the fixing to the light transmission member and the stage moving speed are reduced, and the decrease in the supply speed of the molten resin for the next layer is suppressed. With such a configuration, there is a possibility that continuous and high-speed layered modeling operation can be performed by, for example, irradiating curing light as a moving image and performing continuous stage movement.

US Patent Application Publication No. 2015/54198 U.S. Patent No. 9216546

  Here, in the modeling technique which repeats the photocuring of the photocurable resin and the movement of the modeling stage, the relationship between various modeling conditions and the modeling speed will be considered.

  For example, when a solidified layer is continuously laminated by continuously irradiating an exposure image by a technique such as moving image irradiation, the thickness of the solidified layer is as thin as about 0.02 mm to 0.2 mm. Then, the stage is moved by an amount corresponding to the thickness of the solidified layer for each irradiation of one frame (for example, one modeling layer). By moving the stage, for example, resin is supplied to a space where the density between the vicinity of the transmission window of the container has decreased, but for supplying such uncured photocurable resin to such a narrow (thin) space. take time.

  Therefore, in order to increase the supply speed of the photo-curing resin, a technique for reducing the cross-sectional area in each layer of the modeled object or dividing the modeled object into a plurality of blocks is performed. In addition, measures to use a low viscosity material for the photocurable resin may be taken. In order to reduce the cross-sectional area in each layer of the modeled object, for example, if the modeled layer is made small or divided like a lattice structure, there arises a problem that the strength of the modeled product is lowered. In the first place, a structure such as a lattice shape may not necessarily match the structure of an intended model to be manufactured.

  In addition, when using a material with low viscosity for the photocurable resin, there is a problem that the shrinkage at the time of solidification increases and deformation of the molded article, or the degree of polymerization at the time of photocuring does not increase, resulting in a decrease in strength, There is a possibility that problems such as low heat resistance may occur.

  Therefore, in order to speed up the material supply to the solidified layer using a material with low viscosity, there is also a method of rapidly executing the modeling phase that performs photocuring by moving image projection etc. and performing the post cure method as a post-processing step after the modeling phase It is considered. In this post-cure method, in order to increase the strength of the resin, a step of curing the uncured portion by applying light or heat is performed. However, when secondary curing is performed by post-cure, problems such as dimensional changes and deformation during curing may occur.

  As described above, taking into consideration the supply rate of the photocurable resin, it is not an essential solution to subdivide the shaped article (solidified layer) or reduce the viscosity of the photocurable resin. In addition, there are problems that various other undesirable side effects occur. For this reason, when performing solid modeling with a small amount of lightening parts without reducing the viscosity of the photo-curing resin, it has conventionally been in a narrow space for the next layer after moving the stage. The time for filling the uncured material with high accuracy tends to increase.

  Even in the case of a method of permeating a curing-inhibiting gas as in Patent Document 2 described above, in the case of a resin having a high viscosity or a shaped object having a large irradiation (curing) area of one layer, for example, a next layer having a thickness of 25 to 35 μm. It is not so easy to shorten the time for filling the space for the material.

  In view of the above-described problems, an object of the present invention is a speed at which a space for a next layer is filled with an uncured photocurable resin in three-dimensional modeling that repeats photocuring of a photocurable resin and movement of a modeling stage. Is to improve. Another object of the present invention is to suppress the solidification, fixation, and viscosity reduction of the photocurable resin in the vicinity of the transmission window of the curing light (modeling light), for example, by using a gas having curing inhibition.

  In order to solve the above problems, in the present invention, a container for storing a photocurable resin, a light irradiation device for irradiating light to the photocurable resin stored in the container, and the light inside the container. A gas permeable member that faces the curable resin and transmits the irradiation light of the light irradiation device, a light transmission member that is disposed outside the container with respect to the gas transmission member, and is cured by light irradiation of the light irradiation device A pressure chamber defined by a moving device that moves the shaped part that is made to move away from the gas permeable member, the gas permeable member, and the light transmissive member; and a gas inside the pressure chamber. The structure provided with the pressure control apparatus which controls a pressure, the said light irradiation apparatus, the said moving apparatus, and the control part which controls the said pressure control apparatus was employ | adopted.

  Alternatively, a container that stores a photocurable resin, a light irradiation device that performs light irradiation on the photocurable resin stored in the container, and the light irradiation that faces the photocurable resin inside the container. A gas permeable member that transmits the irradiation light of the apparatus; a light transmissive member that is disposed outside the container with respect to the gas permeable member; and a molded part that is cured by light irradiation of the light irradiation apparatus. A pressure device defined by a moving device, a gas permeable member, and a light transmissive member, a pressure control device that controls a pressure of a gas inside the pressure chamber, and In the manufacturing method of the three-dimensional structure manufactured by the manufacturing apparatus including the light irradiation device, the moving device, and the control unit that controls the pressure control device, the control unit includes the light irradiation device. For light irradiation After the light irradiation step of curing the photocurable resin, and after the light irradiation step, the control unit moves the shaped part in a direction away from the gas permeable member by the moving device. The pressure control device reduces the gas inside the pressure chamber and deforms the gas permeable member in a direction away from the shaped part, and the control unit is configured to remove the shaped part by the moving device. After the movement is completed, the pressure control device pressurizes the gas inside the pressure chamber and allows the gas inside the pressure chamber to permeate the photocurable resin through the gas permeable member. And the structure including was adopted.

  According to the above configuration, when the modeling stage is moved after light irradiation, for example, by depressurizing the pressure chamber, the gas permeable member is deformed in a direction away from the modeled site, and the volume of the modeling region is increased. Thereby, the speed | rate which fills the space for next layers with uncured photocurable resin can be improved. Further, for example, when the movement of the shaped part is completed and light irradiation is performed, the photocurable resin is allowed to permeate through the gas permeable member by pressurizing the gas having curing inhibition inside the pressure chamber. As a result, for example, the photocuring resin can be prevented from solidifying, adhering or lowering in viscosity in the vicinity of the light transmitting member, etc., which can also be expected to improve the filling speed of the photocurable resin after irradiation, thereby smoothly performing the modeling stage. be able to. As described above, the three-dimensional modeling speed can be greatly improved.

It is explanatory drawing which showed the structure of the three-dimensional modeling apparatus which concerns on Embodiment 1 of this invention. It is explanatory drawing which expanded and showed the principal part of the apparatus of FIG. It is explanatory drawing which showed the structure of the three-dimensional modeling apparatus which concerns on Embodiment 2 of this invention. It is the flowchart figure which showed the three-dimensional modeling control procedure which concerns on this invention. It is the block diagram which showed the structural example of the control system of the three-dimensional modeling apparatus which concerns on this invention.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described with reference to embodiments shown in the accompanying drawings. The following embodiment is merely an example, and for example, a detailed configuration can be appropriately changed by those skilled in the art without departing from the gist of the present invention. Moreover, the numerical value taken up by this embodiment is a reference numerical value, Comprising: This invention is not limited.

<Embodiment 1>
FIG. 1 shows a configuration of a three-dimensional modeling apparatus for manufacturing a three-dimensional modeled object as a cross-sectional structure in the first embodiment. In FIG. 1, a photocurable resin 1 in a molten (uncured) state is accommodated in a container 5.

  The photocurable resin 1 is, for example, an acrylate material as a radical polymerization resin material. Particularly in that case, the material of the photocurable resin 1 is selected from urethane acrylate, epoxy acrylate, polyester acrylate, acrylic acrylate, and the like as the oligomer.

  In this embodiment, from the state in which the modeling stage 3 (base plate) is immersed (or at least in contact) with the photocurable resin 1, light irradiation is performed from the bottom direction of the container 5 to perform one-layer modeling. After that, the modeling stage 3 is moved upward in the figure by the lifting device 4 for modeling of the next layer, and the photocurable resin 1 is supplied below the modeled object generated on the lower surface of the modeling stage 3. Light irradiation for layer formation.

  Although the detailed illustration of the lifting device 4 is omitted in FIG. 1, the lifting device 4 can be composed of a rotational drive source such as a motor and a transmission (or transmission) system such as a rack and pinion. The elevating device 4 can move the modeling stage 3 to an arbitrary height along the vertical direction of the drawing based on the control of a control device (for example, the CPU 601) described later.

  In the present embodiment, light irradiation for curing the photocurable resin 1 is performed from the bottom direction of the container 5, and therefore the bottom of the container 5 is made of a light transmissive material. Further, the side wall portion of the container 5 can also be made of a light transmissive material for the purpose of visually recognizing the progress of modeling (or photographing with a camera not shown). In particular, in this embodiment, the bottom of the container 5 is constituted by a light transmission plate 6 (light transmission member) and a gas permeable sheet 7 (gas transmission member) as described in detail below.

  The curing light is irradiated from a light irradiation unit including a light source 8, a mirror unit 9, and a lens unit 10, for example. The light source 8 is, for example, a laser light source, and when the photocurable resin 1 is, for example, an ultraviolet curable type, the wavelength of the irradiation light of the light source 8 is suitable for conditions such as the material of the photocurable resin 1, for example. It is selected in the range of about 200 to 450 nm. Typical ultraviolet wavelengths used for this type of resin curing include 254 nm, 365 nm, 420 nm, and the like. However, the wavelength of the irradiation light of the light source 8 is not necessarily limited to the ultraviolet region, and irradiation light in other wavelength regions may be used depending on the material of the photocurable resin 1. The mirror unit 9 is constituted by a galvanometer mirror unit or the like, and scans the irradiation spot of the light source 8 in the XY directions via the lens unit 10. Thereby, the site | part corresponding to the shape for one layer corresponding to the specific height of the molded article 2 of the photocurable resin 1 can be hardened.

  Note that the light irradiation unit is not limited to the light irradiation method by plane scanning of the laser spot as described above, and the light irradiation unit may irradiate a moving image according to characteristics such as the material and viscosity of the photocurable resin 1. You may comprise as a projector. However, in the case of the moving image projection method, measures such as using a frame rate that can follow the operation of deforming the gas permeable sheet 7 described later are required. For example, if the time required for the deformation operation of the gas permeable sheet 7 described later is 0.5 sec to 2.0 sec, the frame of the moving image projected by the light source 8 is a frame projection corresponding to the time required for such a deformation operation. Adopt spacing.

  The space between the light transmission part at the bottom of the container 5 and the lower surface of the model 2 below the modeling stage 3 moves the modeling stage 3 upward, while photocuring the parts corresponding to the layers of the model 2. This corresponds to the modeling area 14 (modeling space) where the resin 1 is cured one after another.

  In the present embodiment, the light transmitting portion at the bottom of the container 5 faces the light transmitting plate 6 that constitutes the outermost part of the container 5 and the photocurable resin 1 in the container 5, and is a predetermined distance from the light transmitting plate 6. The gas permeable sheet 7 is disposed so as to be spaced apart and substantially parallel to each other. The gas permeable sheet 7 is a gas permeable member having a property of transmitting a gas (gas) containing a curing (polymerization) inhibitor in the direction of the photocurable resin 1 in the container 5. As a material for such a gas permeable sheet 7, materials such as PFA, PTFE, PP or PE are conceivable. In addition, the gas permeable sheet 7 needs to have the light transmittance especially with respect to the light of the emission wavelength of the light source 8. In general, the gas permeable sheet 7 is made of an uncolored transparent material as described above.

  The gas permeable sheet 7 is selected so that it can be easily deformed by pressure reduction control of the pressure chamber 11 described later. For example, if it is resin of the above materials, the thickness of the gas-permeable sheet 7 can be about 1.0 mm to 10 mm.

  On the other hand, the material of the light transmission plate 6 may be a glass or a quartz plate. In the present embodiment, it is preferable that the light transmission plate 6 is rather rigid. For this reason, the thickness of the light transmission plate 6 can be 10 mm to 30 mm.

  Further, in the present embodiment, the light transmissive plate 6 and the gas permeable sheet 7 which are spaced apart from each other by a predetermined distance (for example, on the order of mm) define the pressure chamber 11 therebetween. The pressure chamber 11 is configured so that a gas (gas) as a curing (polymerization) inhibitor can be supplied by the pressure control device 12. Moreover, the pressure control device 12 is configured to control (pressurization / decompression) the pressure of the gas (gas) filled in the pressure chamber 11 as the modeling process proceeds as described later.

  The gas (gas) as a curing (polymerization) inhibitor is allowed to permeate from the pressure chamber 11 through the gas permeable sheet 7 to the photocurable resin 1 inside the container 5. This is for suppressing the curing of the photocurable resin 1 in the region. As a result, the photocurable resin 1 adheres to the bottom of the container 5, particularly the gas permeable sheet 7, making it difficult to move the shaped object 2, or the photocurable resin 1 for the next layer can be supplied smoothly. You can avoid the problem of being lost.

  A gas that fills the pressure chamber 11 may be a gas containing oxygen, ozone, air, nitrogen, argon, or the like, depending on the material of the photocurable resin 1. For example, when a radical polymerization type material that is generally used as the photocurable resin 1 is used, a gas containing oxygen as a simple substance, such as oxygen or ozone, can be considered. In this case, as the gas filled in the pressure chamber 11, for example, air (atmosphere) or the like, pure oxygen, air whose ozone concentration is increased using ozone generated by an ozone generator, or the like can be used. .

  If the gas filled in the pressure chamber 11 is air, the pressure control device 12 can be composed of a compressor, a vacuum pump, a control valve, and the like for pressure increase / decrease (detailed illustration is omitted). In the case of using a gas such as pure oxygen, the pressure controller 12 further includes a tank for storing and supplying the gas. When ozone is used, an ozone generator or the like can be added to the gas flow path of the pressure control device 12.

  As shown in FIG. 2, a pressure sensor 31 for measuring the internal pressure of the pressure chamber 11 can be disposed inside the pressure chamber 11. In pressurization or depressurization control by the pressure control device 12 described later, the CPU 601 or the pressure control unit 606 can control the internal pressure of the pressure chamber 11 to the target pressure value using the pressure measurement value output from the pressure sensor 31. .

  As shown in FIG. 1, the pressure control device 12 and the pressure chamber 11 are communicated with each other by a gas flow path 13, and the pressure control device 12 controls the internal pressure of the pressure chamber 11 through the gas flow path 13. For example, in the modeling control described later, when the curing light is irradiated, the pressure control device 12 preferably generates a positive pressure of about 100 to 150 PSI (or about 10 atm). Accordingly, a necessary amount of gas as a curing (polymerization) inhibitor is supplied to a portion of the modeling region 14 of the photocurable resin 1 facing the gas permeable sheet 7, for example, unnecessary light near the light transmissive member. Suppresses solidification, fixation and viscosity reduction of the curable resin.

  Moreover, in this embodiment, the pressure control apparatus 12 controls the inside of the pressure chamber 11 to a negative pressure (negative pressure), and the gas-permeable sheet 7 is formed in the modeling region 14 or the modeling object 2 as shown in FIG. Retract from the shaped part and deform in the direction away. By this depressurization operation, a negative pressure is generated in the photocurable resin 1 in the modeling region 14 via the gas permeable sheet 7, and the negative pressure portion is rapidly and smoothly from the periphery of the molded portion of the molded article 2. The photocurable resin 1 which becomes a material for the next layer can be supplied.

  FIG. 5 shows the configuration of the control system of the modeling apparatus of FIG. 1 (the same applies to the configuration of Embodiment 2 in FIG. 3 described later).

  In the configuration of FIG. 5, a ROM 602, a RAM 603, interfaces 604 and 608, a network interface 609, and the like are arranged around a CPU 601 responsible for the main function of the control device.

  Connected to the CPU 601 are a ROM 602, a RAM 603, and various interfaces 604, 608, and 609. The ROM 602 stores basic programs such as BIOS. The storage area of the ROM 602 may include a rewritable device such as E (E) PROM. The RAM 603 is used as a work area for temporarily storing the calculation processing result of the CPU 601. The CPU 601 executes a later-described modeling control procedure by executing a program recorded (stored) in the ROM 602.

  When a program for executing the modeling control procedure described later is recorded (stored) in the ROM 602, this recording medium constitutes a computer-readable recording medium storing a control procedure for carrying out the present invention. Note that a program for executing the control procedure described later is stored in a fixed recording medium such as the ROM 602 or a removable computer-readable recording medium such as various flash memories or optical (magnetic) disks. May be. Such a storage form can be used when a program for executing a control procedure for carrying out the present invention is installed or updated. Further, when installing or updating such a control program, a method of downloading a program from the network 611 via the network interface 609 can be used in addition to using the removable recording medium as described above.

  The CPU 601 can communicate with other resources on the network 611 that perform communication using a protocol such as TCP / IP, for example, via the network interface 609. The network interface 609 can be configured by various network communication methods such as a wired connection (such as IEEE802.3) and a wireless connection (such as IEEE802.xx). Further, a modeling control program described later can be downloaded from a server arranged in the network 611 and installed in a program memory such as the ROM 602, or an already installed program can be updated to a new version.

  Three-dimensional (3D) data for three-dimensionally (3D) modeling the modeling object 2 is transmitted from the host device 610 via the interface 608 in a data format such as 3DCAD, for example. The interface 608 can be configured based on various serial or parallel interface standards, for example. The host device 610 can supply modeling data to the modeling device in the same manner even when connected to the network 611 as a network terminal.

  The CPU 601 inputs a light irradiation control unit 605 that controls the light source 8 through the interface 604, inputs a detection value of the pressure sensor 31, controls a pressure control unit 606 that controls the pressure control device 12, and controls elevation of the lifting device 4. It communicates with the stage control unit 607. CPU601 advances the whole modeling process by controlling these each part according to a predetermined modeling sequence.

  The interface 604 can be configured based on various serial or parallel interface standards, for example. In FIG. 5, the interface 604 is shown as one block for simplification. However, the interface 604 may be configured by interface circuits having different communication schemes according to the communication specifications of each unit illustrated on the right side of the interface 604.

  Next, the operation in the above configuration will be described with reference to FIG. 1, FIG. 2, and FIG. FIG. 4 shows the flow of the modeling control procedure in the apparatus of FIG. The procedure in FIG. 4 is described as a control program that can be read and executed by the CPU 601 (control device: computer), for example, and can be stored in, for example, the ROM 602 (or an external storage device not shown). The flow in the left column (S10 to S15) in FIG. 4 shows the main control procedure of modeling control, and the flow in the right column (S20 to S23) in FIG. 4 includes the pressure control device 12 or further the pressure sensor 31. The pressure (pressure / decompression) control in the pressure chamber 11 used is shown.

  Prior to modeling, a photocurable resin 1 in a liquid (uncured) state is supplied into the container 5. This procedure may be performed manually by an operator or may be injected into the container 5 via a resin supply device (not shown). Moreover, in the structure which supplies the photocurable resin 1 with a resin supply apparatus, according to the output of the suitable liquid level detection means which detects the liquid level of the photocurable resin 1, the photocurable resin 1 in the container 5 is used. Automatic control may be performed so that the amount is automatically controlled to an appropriate amount. Further, in the case of arranging the resin supply device, a resin recovery device that sucks and discharges the photocurable resin 1 from the container 5 is added, and the resin recovery device further transmits the light to the resin supply device and again to the container 5. A configuration in which the curable resin 1 is circulated may be employed.

  The steps shown as steps S <b> 10 to S <b> 15 in FIG. 4 correspond to a control procedure for modeling one layer of the modeled object 2. By repeatedly executing these steps S10 to S15, the model 2 can be modeled in a stacked manner.

  Prior to step S10 in FIG. 4, in step S20, the CPU 601 controls the pressure controller 12 and the pressure sensor 31 to pressurize the gas in the pressure chamber 11 (initial pressurization). Here, based on the internal pressure of the pressure chamber 11 detected by the pressure sensor 31, the CPU 601 controls gas supply by the pressure control device 12. The target pressure in the pressure chamber 11 by this pressurization control is preferably 100 to 150 PSI (around 10 atm), for example. When the pressure value detected by the pressure sensor 31 reaches this target pressure, the CPU 601 stops the gas supply by the pressure control device 12 and closes the valve arranged upstream of the gas flow path 13 to complete the pressurization control. . This pressurization control completion process corresponds to a pressurization completion process (S23) related to the pressurization control (S22) described later, but in FIG. 4, illustration of step S20 is omitted because of space.

  In step S <b> 10 of FIG. 4, the CPU 601 turns on the light source 8 and causes the mirror unit 9 to scan the irradiation light of the light source 8 according to the shape of the modeling layer. Thereby, the curing light from the light source 8 is transmitted from the mirror unit 9 and the lens unit 10 through the light transmission plate 6, the pressure chamber 11, and the gas permeable sheet 7, and is irradiated to the photocurable resin 1 near the modeling region 14, The part is cured. The 3D modeling data of the model 2 is transmitted in advance from the host device 610 or the like. By converting the 3D modeling data into, for example, (cross-sectional) shape data of a plurality of modeling layers, modeling data for one layer is obtained. Is generated.

  During this light irradiation step, the gas in the pressure chamber 11 (curing-inhibiting) is pressurized as described above, and permeates (permeates) below the modeling region 14 through the gas permeable sheet 7. It suppresses that the photocurable resin 1 of the site | part hardens | cures or raises an undesirable viscosity rise. In the pressurization period in which the pressure chamber 11 is pressurized, when the amount of resin in the container 5 is large, the pressure inside the pressure chamber 11 is increased to prevent deformation of the gas permeable sheet 7 due to the resin load. May be performed. For example, when liquid level detection means (not shown) for detecting the liquid level of the photocurable resin 1 is arranged, the pressure control device 12 increases or decreases the internal pressure of the pressure chamber 11 according to the detected value. Take control.

  When the irradiation light scanning for curing one modeling layer is completed, in step S11, the CPU 601 stops the light irradiation of the light source 8 (light irradiation stop). Thereafter, in step S <b> 21, the CPU 601 operates the decompression mechanism of the pressure control device 12 while monitoring the pressure detection value of the pressure sensor 31 to decompress the pressure chamber 11. In the present embodiment, this decompression is performed in order to deform the gas permeable sheet 7 in a direction away from the modeling region 14, in particular, the molded part of the model 2 as shown in FIG. 2. For this reason, the pressure in the pressure chamber 11 at the time of decompression is selected to an appropriate value, for example, equal to or lower than atmospheric pressure, depending on the material, rigidity, thickness, and the like of the gas permeable sheet 7. The pressure value in the pressure chamber 11 at the time of decompression is such that, for example, a negative pressure value at which the gas permeable sheet 7 causes the desired concave deformation in a state where an appropriate amount of the photocurable resin 1 is accommodated in the container 5 in advance is obtained. It can be obtained by conducting an experiment. When the pressure value detected via the pressure sensor 31 becomes the predetermined negative pressure value, the CPU 601 stops the pressure reduction (suction) mechanism of the pressure control device 12 in step S12 (gas permeable sheet position movement completion).

  Thereafter, in steps S13 and S14, the CPU 601 controls the lifting device 4 to raise the modeling stage 3 by a height necessary for modeling the next layer (stage movement and stage movement completion). At this time, the distance for moving (raising) the modeling stage 3 for modeling the next layer is a relatively small distance of about 15 μm to 0.1 mm, although it varies depending on the shape of the model 2 and modeling specifications. Supply of the photocurable resin 1 to the space generated by the stage movement is performed by the viscosity of the resin itself, the atmospheric pressure, its own weight, and the negative pressure accompanying the pulling. However, as described above, the space for the resin to enter is small, and the force for the resin to enter is not so large. For this reason, it has conventionally required a relatively long time on the order of 10 to several tens of seconds to supply the melted photocurable resin 1 from the periphery or below to such a “thin” space.

  On the other hand, in this embodiment, during the movement control process (S13, S14) of the modeling stage 3, the gas permeable sheet 7 is deformed into a concave surface as shown in FIG. 2 by the pressure reducing process (steps S21, S12). That is, the gas permeable sheet 7 is deformed in a direction away from the modeling region 14, in particular, from the molded part of the modeled object 2. Thereby, the substantial volume of the modeling area | region 14 is expanded during the movement control process (S13, S14) of the modeling stage 3, for example. That is, the space below the shaped part of the modeling stage 3 or the modeled object 2 below it is enlarged, and the pressure (or density) of the photocurable resin 1 at that part is the pressure of the photocurable resin 1 at other parts. It is lower than (or density). Thereby, as the modeling stage 3 moves upward, the molten photocurable resin 1 for modeling the next layer is smoothly applied to the modeling region 14, particularly the space below the modeled portion of the modeled object 2. And can be supplied rapidly.

  In the conventional configuration in which the gas permeable sheet 7 is not controlled to be concavely deformed by the pressure reduction in the pressure chamber 11, the resin for modeling the next layer is supplied to the modeling region 14 only by the movement (rise) of the model 2. Therefore, the resin supply rate as high as that of the present embodiment cannot be expected. According to the present embodiment, as described above, the gas permeable sheet 7 is concavely deformed by the pressure reduction of the pressure chamber 11, and the volume of the modeling region 14 is expanded, so that the photocurable resin 1 enters the modeling region 14. It becomes easy, and the photocurable resin 1 is supplied more smoothly and rapidly than in the past. The supply rate of the photocurable resin 1 varies depending on the type of resin used, the viscosity, the shape of the molded object 2 (on the lower surface thereof), and the like, but it is 0.3 ml / sec to 30 ml / sec depending on the decompression control of this embodiment. A degree of speed can be achieved.

  In step S14 (stage movement completion), after moving the modeling stage 3 by a predetermined amount (in the case of this embodiment, it is raised), the CPU 601 adds the pressure chamber 11 using the pressure control device 12 and the pressure sensor 31. The pressurization control process (S22, S23) to press is performed. The control content at this time is the same as that described in the initial pressurization (S20), and the method for determining the target pressure is the same as described above. Thereby, the movement of the position of the gas permeable sheet 7 is completed (step S15), and it is possible to loop to step S10 and shift to modeling of the next layer. The pressurizing pressure at this time is set to such an extent that unnecessary sticking (or increase in viscosity) can be suppressed from the pressure chamber 11 through the gas permeable sheet 7 into the container 5. The pressure value at this time may be, for example, about 10 atm. However, at the same time, at least the gas permeable sheet 7 is selected so that it can be deformed to a convex shape upward from the concave deformation state as shown in FIG. Such positive pressure value control is necessary to effectively perform pressure reduction during movement of the modeling stage 3 by operating the gas permeable sheet 7 as a diaphragm as described above.

  As described above, according to the first embodiment, after the light irradiation, for example, when the modeling stage 3 is moved, the pressure-permeable chamber 11 is depressurized to separate the gas permeable sheet 7 from the stage or the modeled part. The volume of the modeling area | region 14 can be expanded by making it deform | transform to the direction to do. Thereby, the speed | rate which fills the space for next layers with uncured photocurable resin can be improved. In addition, for example, when the movement of the modeling stage 3 (the molded part) is completed and light irradiation is performed, the photocurable resin is transmitted through the gas permeable member by pressurizing the gas having a curing inhibition property in the pressure chamber. be able to. Thereby, for example, the hardening of the photocurable resin in the vicinity of the transmission window of the curing light (modeling light), the fixation and the decrease in viscosity can be suppressed, and the filling rate improvement of the photocurable resin after irradiation can be gasified by this, The modeling stage can be performed smoothly. As described above, according to the first embodiment, the time required for the modeling control between the modeling layers can be shortened, and the three-dimensional modeling speed can be greatly improved.

  Further, according to the present embodiment, a hardware configuration is adopted in which the pressure chamber 11 is arranged on the lower surface of the gas permeable sheet 7 and the internal pressure is increased or decreased by the pressure control device 12. For this reason, the gas permeability of the gas permeable sheet 7 can be efficiently exhibited during the pressurization period, and, for example, a large-scale apparatus configuration is required to control the pressure of a large chamber containing the entire apparatus to a high pressure. There is no advantage.

<Embodiment 2>
In the first embodiment, as shown in FIGS. 1 and 2, light irradiation for curing the photocurable resin 1 is performed from below the container 5, and the modeling stage 3 is moved upward by the lifting device 4 for each layer formation. The structure to move was illustrated. However, the direction of light irradiation for curing the photocurable resin 1 and the moving direction of the modeling stage 3 are not necessarily limited to the above directions.

  For example, as shown in FIG. 3, even in a configuration in which light irradiation for curing the photocurable resin 1 is performed from above the container 5 and the modeling stage 3 is moved downward by the lifting device 4 for each layer formation. A configuration that exhibits the same effects as those of the first embodiment is conceivable.

  The modeling apparatus shown in FIG. 3 is composed of members having the same reference numerals as those in FIGS. 1 and 2, and the difference from the first embodiment regarding the modeling operation is mainly the light irradiation direction as described above. , Only the moving direction of the modeling stage 3 performed for each layer modeling. The configuration of FIG. 3 may be considered as a configuration in which the top and bottom of the configuration of FIG. In FIG. 3, the material of each member given the same reference numeral as that in FIGS. 1 and 2 is the same as or equivalent to that in the first embodiment.

  In the configuration of FIG. 3, the gas permeable sheet 7 and the light transmissive plate 6 are arranged so as to cover the upper part of the container 5 filled with the photocurable resin 1. These are arranged in the order of the gas permeable sheet 7 and the light transmissive plate 6 when viewed from the photocurable resin 1 side, and the space between the gas permeable sheet 7 and the light transmissive plate 6 becomes the pressure chamber 11. Yes. It is assumed that the function of pressurizing and depressurizing the curing-inhibiting gas inside the pressure chamber 11 by the pressure control device 12 through the gas flow path 13 is the same as that of the first embodiment.

  The control system of the modeling apparatus of FIG. 3 can be configured in the same manner as in FIG. 5 of the first embodiment, and the modeling control and the accompanying pressure increase / decrease control are executed by the CPU 601 as generally shown in the flowchart of FIG. be able to. However, in that case, the description of FIG. 4 in the first embodiment only needs to be read, for example, only in that the moving direction of the modeling stage 3 after the one-layer modeling is “downward” instead of “upward” in the first embodiment. Needless to say.

  Even in the configuration as shown in FIG. 3, mainly in the curing light irradiation period from the light source 8, the inside of the pressure chamber 11 is pressurized, and the vicinity of the upper portion of the modeling region 14 above the container 5 through the gas permeable sheet 7. It is possible to permeate (penetrate) a curing-inhibiting gas. In addition, during the movement period of the modeling stage 3 after one layer curing, the inside of the pressure chamber 11 is depressurized, and the photocurable resin 1 as a material for the next layer is rapidly and smoothly supplied near the modeling region 14. can do.

  As described above, even in a configuration in which the irradiation direction of the curing light at the time of modeling and the moving direction of the modeling stage with the progress of modeling are different, the same configuration as that of the above-described first embodiment can be realized. Expected effects. In addition, even if it is a case where the irradiation direction of the hardening light at the time of modeling and the moving direction of the modeling stage accompanying modeling progress differ from both of Embodiment 1 and this Embodiment 2, this invention can be implemented. For example, even in a configuration in which light irradiation from the side of the container 5 and stage movement to the opposite side are performed, a configuration in which a part of the container 5 is a gas permeable sheet and the pressure chamber 11 is disposed outside thereof can be implemented. Needless to say.

  The present invention supplies a program that realizes one or more functions of the above-described embodiments to a system or apparatus via a network or a storage medium, and one or more processors in a computer of the system or apparatus read and execute the program. It can also be realized by processing. It can also be realized by a circuit (for example, ASIC) that realizes one or more functions.

  DESCRIPTION OF SYMBOLS 1 ... Photocurable resin, 2 ... Modeling object, 3 ... Modeling stage, 4 ... Elevating device, 5 ... Container, 6 ... Light transmission board, 7 ... Gas-permeable sheet, 8 ... Light source, 9 ... Mirror unit, 10 ... Lens unit, 11 ... pressure chamber, 12 ... pressure control device, 13 ... gas flow path, 14 ... modeling area.

Claims (14)

A container containing a photocurable resin;
A light irradiation device for performing light irradiation on the photocurable resin contained in the container;
A gas permeable member facing the photocurable resin inside the container and transmitting the irradiation light of the light irradiation device;
A light transmissive member disposed outside the container relative to the gas permeable member;
A moving device for moving a shaped part cured by light irradiation of the light irradiation device in a direction away from the gas permeable member;
A pressure chamber defined by the gas permeable member and the light transmissive member;
A pressure control device for controlling the pressure of the gas inside the pressure chamber;
A control unit for controlling the light irradiation device, the moving device, and the pressure control device;
3D modeling device. The three-dimensional modeling apparatus according to claim 1,
The controller is
After the photocurable resin is cured by light irradiation of the light irradiation device, the pressure controller controls the pressure when moving the shaped part in a direction away from the gas permeable member by the moving device. Depressurize the gas inside the chamber and deform the gas permeable member in a direction away from the shaped part,
After the movement of the shaped part by the moving device is finished, the pressure inside the pressure chamber is pressurized by the pressure control device, and the gas inside the pressure chamber is photocured through the gas permeable member. 3D modeling device that allows permeation into a functional resin.   The three-dimensional modeling apparatus according to claim 1 or 2, wherein the gas contains oxygen or ozone.   The three-dimensional modeling apparatus according to any one of claims 1 to 3, wherein the photocurable resin is an acrylate radical polymerization resin material.   5. The three-dimensional modeling apparatus according to claim 4, wherein the acrylate-based photocurable resin is an urethane acrylate-based, epoxy acrylate-based, polyester acrylate-based, acrylic acrylate-based, or a composite system thereof as an oligomer 3. Dimensional modeling device.   The three-dimensional modeling apparatus according to any one of claims 1 to 5, wherein a material of the gas permeable member is PFA, PTFE, PP, or PE. A container containing a photocurable resin, a light irradiation device for irradiating light to the photocurable resin stored in the container, and facing the photocurable resin inside the container; A gas permeable member that transmits irradiation light, a light transmissive member that is disposed outside the container with respect to the gas permeable member, and a shaped part that is cured by light irradiation of the light irradiating device is separated from the gas permeable member. A pressure device configured to move in a moving direction, the gas permeable member, and the light transmissive member, a pressure control device that controls the pressure of the gas inside the pressure chamber, and the light irradiation device In the manufacturing method of a three-dimensional structure, the manufacturing apparatus includes the moving device, and a control unit that controls the pressure control device.
A light irradiation step in which the control unit cures the photocurable resin by light irradiation of the light irradiation device;
After the light irradiation step, when the controller moves the shaped part in a direction away from the gas permeable member by the moving device, the pressure inside the pressure chamber is reduced by the pressure control device. And a pressure reducing step for deforming the gas permeable member in a direction away from the shaped part,
After the movement of the shaped part by the moving device is finished, the control unit pressurizes the gas inside the pressure chamber by the pressure control device, and the inside of the pressure chamber through the gas permeable member. A pressurizing step for allowing gas to pass through the photocurable resin;
A method for producing a three-dimensional structure including   The method for manufacturing a three-dimensional structure according to claim 7, wherein the three-dimensional structure is formed by repeatedly executing the light irradiation step, the decompression step including movement of a shaped part by the moving device, and the pressurization step. A manufacturing method of a three-dimensional structure that forms an object in a stacked manner.   The method for manufacturing a three-dimensional structure according to claim 7 or 8, wherein the gas contains oxygen or ozone.   The manufacturing method of the three-dimensional structure according to any one of claims 7 to 9, wherein the photocurable resin is an acrylate radical polymerization resin material.   The method of manufacturing a three-dimensional structure according to claim 10, wherein the acrylate-based photocurable resin is an urethane acrylate-based, epoxy acrylate-based, polyester acrylate-based, acrylic acrylate-based, or a composite system thereof as an oligomer. A method for manufacturing a three-dimensional structure.   The method for manufacturing a three-dimensional structure according to any one of claims 7 to 11, wherein the material of the gas permeable member is PFA, PTFE, PP, or PE.   The control program for making the said control part perform each process of the manufacturing method of the three-dimensional structure according to any one of claims 7 to 12.   A computer-readable recording medium storing the control program according to claim 13.

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