JP2018103405A - Three-dimensional molding apparatus and three-dimensional molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional molding apparatus that can form a three-dimensional object by laminating a plurality of layers formed by photo-curing, and can solve a problem of requiring a long time for three-dimensional molding because it is difficult to promptly replenish a liquid resin material for forming a next layer to a three-dimensional formation area.SOLUTION: A plurality of protrusions 31 are formed on an inner surface of a light transmission window 4, that is, on the side in contact with a liquid photo-curable resin 2. A plurality of protrusions 31 and spaces 32 are arranged so that the spaces 32 separating the protrusions 31 communicate with an outside of the light transmission window 4 when viewed in a horizontal direction. The protrusions 31 are formed of a material which permeates curing light and a curing inhibitor. The provided spaces 32 make it possible to reduce a flow resistance of the liquid photo-curable resin to promptly replenish the liquid resin material for forming the next layer.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a three-dimensional modeling apparatus that manufactures a three-dimensional structure by projecting an exposure image onto a photocurable liquid resin material.

  In recent years, expectations for so-called 3D printers have increased. In particular, the development of a device for producing a three-dimensional structure by projecting an exposure image onto a photocurable liquid resin material is actively performed.

  For example, Patent Document 1 discloses an apparatus for forming a resin-cured layer having a desired shape by making a bottom of a container filled with a liquid photocurable resin material light-transmissive and projecting an exposure image onto the resin through the bottom. It is disclosed. In such an apparatus, when one cured resin layer is formed, the modeled object is lifted, and a liquid photocurable resin is poured between the modeled object and the bottom of the container to replenish, and when the replenishment is completed, the next exposure image is displayed. The resin cured layer is laminated by projecting. Such a process was repeated to form a three-dimensional structure. In such an apparatus, since light is irradiated through the bottom of the container, there is an advantage that the optical exposure conditions are not affected even if the liquid level of the resin fluctuates.

  Further, in Patent Document 1, by supplying a polymerization inhibitor through a light transmissive container bottom, a polymerization prohibition region is formed in the liquid resin material near the container bottom, and the cured resin adheres to the container bottom. Techniques for preventing this have been proposed.

JP-T-2006-509996

By the way, there is an increasing demand for a 3D printer to increase the modeling speed, and a method using a photocurable liquid resin material as a raw material is no exception.
In general, the thickness of a cured layer formed by irradiating a photocurable liquid resin material with light is about 0.02 mm to 0.2 mm per layer, and a large number of layers are laminated to complete a model. There is a need. Therefore, in order to increase the three-dimensional modeling speed, it is important how to complete the preparation process for forming the next hardened layer in a short time after forming one hardened layer. In other words, it is important how to supply the next one layer of liquid resin material to the modeling region at high speed. This is because a photocurable liquid resin material generally has a high viscosity and thus takes a long time to flow.

  In particular, when forming a large three-dimensional structure, the area of the modeling region is increased, and therefore the time required for replenishing the photocurable liquid resin material for forming the next layer is increased. Further, since the number of layers to be stacked is increased, the number of times of replenishment is increased accordingly, and the time required for completing the three-dimensional structure is increased.

  In the case of the apparatus of Patent Document 1, the thickness of the polymerization prohibition region formed in the vicinity of the bottom of the container is as small as about 30 μm to 100 μm, and when the hardened layer is lifted for preparation of the next layer formation, The conductance is small because the distance between the hardened layers is narrow. Therefore, there is a problem that it takes time to replenish the liquid resin material from the surroundings.

In order to solve this problem, attempts have been made to use a liquid resin material having a low viscosity, but the shrinkage at the time of solidification is increased, resulting in deformation of the molded article, and sufficient strength without increasing the degree of polymerization at the time of photocuring. Cannot be obtained or the heat resistance is lowered. As a post-processing step of modeling by photocuring, a post-cure method in which the strength is improved by applying light or heat has been attempted, but there has been a problem of deterioration in dimensional accuracy and deformation.
Also, attempts have been made to increase the temperature of the entire liquid resin material filled in the container to increase the fluidity, but the resin material deteriorates or hardens due to heat, and the molded object is cooled by cooling after solidification. There was a problem of deformation.

  For this reason, when laminating a plurality of layers to form a three-dimensional structure, there has been a demand for a method of quickly replenishing the modeling region without deteriorating the liquid resin material for layer formation.

  The three-dimensional modeling apparatus of the present invention includes a container that holds a liquid photocurable resin, a base that supports a three-dimensional modeled photocured liquid photocurable resin, and the base is moved. And a light source unit that emits curing light that cures the liquid photocurable resin, and is provided between the light source unit and the base as a part of the container, and the liquid photocurable A light transmissive window in contact with the resin, the light transmissive window comprising a base made of a material that transmits the curing light and the curing inhibitor, and the liquid photocurable resin made of a material that transmits the curing light and the curing inhibitor. A plurality of convex portions in contact with each other, and a space separating the convex portions of the plurality of convex portions communicates with the outside of the light transmitting window in a plane parallel to the main surface of the light transmitting window. It is characterized by.

  The three-dimensional modeling method of the present invention includes a container that holds a liquid photocurable resin, a base that supports a three-dimensional modeled product obtained by photocuring the liquid photocurable resin, and the base. A moving part for moving; a light source unit that emits light for photocuring the liquid photocurable resin; and the liquid light provided between the light source unit and the base as a part of the container. A three-dimensional modeling method using a three-dimensional modeling apparatus having a light transmission window in contact with a curable resin, wherein the liquid photocurable resin is held in the container by causing the light source unit to emit light. After the part is photocured, the base is moved in a direction away from the light transmission window, and the liquid photocurable resin is transmitted through the curing light and the curing inhibitor provided in the light transmission window. The liquid is passed through a space between a plurality of convex portions made of material. Characterized by a light curable resin replenished between the 3D object and the light transmission window.

  According to the present invention, when forming a three-dimensional structure, the liquid resin material for layer formation can be quickly replenished in the modeling area without deteriorating. Therefore, the time required for forming the three-dimensional structure can be greatly shortened.

1 is a schematic cross-sectional view of a three-dimensional modeling apparatus according to a first embodiment. The control block diagram of the three-dimensional modeling apparatus concerning 1st embodiment. (A) The typical sectional view of the perpendicular direction of the light transmission window of a first embodiment. (B) The schematic step surface figure of the horizontal direction of the light transmission window of 1st embodiment. The typical sectional view of the three-dimensional fabrication device concerning a second embodiment. (A) The typical sectional view of the perpendicular direction of the light transmission window of a second embodiment. (B) The schematic step surface figure of the horizontal direction of the light transmissive window of 2nd embodiment. (A) The typical cross section of the perpendicular direction of the light transmission window of 3rd embodiment. (B) The schematic step surface figure of the horizontal direction of the light transmissive window of 3rd embodiment.

Embodiments of the present invention will be described with reference to the drawings.
In the following description, a liquid photocurable resin that is not solidified is referred to as a liquid photocurable resin. Moreover, the solid modeling thing which photocured liquid photocurable resin is described as a three-dimensional modeling thing. The three-dimensional structure includes not only a finished product but also a semi-finished product at a stage where layers are laminated to the middle.

[First embodiment]
FIG. 1 is a diagram schematically showing a cross section of the apparatus for explaining the structure of the three-dimensional modeling apparatus according to the first embodiment of the present invention.

(Device configuration)
In FIG. 1, 1 is a container, 2 is a liquid photocurable resin, 3 is a resin supply unit, 4 is a light transmission window, 5 is a light shielding unit, 6 is a convex formation region, 7 is a light source, 8 is a mirror unit, 9 Is a lens unit, 10 is a light source unit, 11 is a base, 12 is a lifting arm, 13 is a lifting unit, and 14 is a three-dimensional structure.
The container 1 is a container for holding the liquid photocurable resin 2, and is formed of a material that blocks light in a wavelength region that solidifies the liquid photocurable resin.
The resin supply unit 3 includes a tank and a pump for storing the liquid photocurable resin, and supplies the liquid photocurable resin so that an appropriate amount of the liquid photocurable resin 2 is held in the container 1.

  The liquid photocurable resin 2 is a liquid resin that is cured (solidified) when irradiated with light in a specific wavelength range. The liquid photocurable resin 2 is filled in the container 1 having the light transmission window 4 and the light shielding portion 5 as the bottom, and is held so that bubbles do not enter. The light transmission window 4 and the light shielding part 5 function as the bottom of the container 1.

  The light transmission window 4 is a window that transmits light in a wavelength region that solidifies the liquid photocurable resin 2 and transmits gas that inhibits the curing of the liquid photocurable resin. For example, PFA, PTFE, PE, etc., such as fluoropolymer or silicone polymer, or porous glass is used as a material.

  The liquid photocurable resin in the vicinity of the light transmission window 4 is less sensitive to photocuring due to the action of the curing inhibiting gas that has passed through the light transmission window 4. Since the gas exhibiting the curing inhibiting action is, for example, oxygen, it is sufficient that normal air exists outside the light transmission window 4. However, in order to make the action of gas more effective, a mechanism for controlling the composition and pressure of the outside air of the light transmission window may be provided.

  More specifically, in order to cure the photocurable resin to obtain a cured product, the portion of the photocurable resin to be cured is irradiated with energy rays. Then, first, the polymerization initiator contained in the photocurable resin is cleaved by irradiation with energy rays, and radicals are generated. Next, the polymerization inhibitor and dissolved oxygen contained in the photocurable resin react with the radicals and are consumed together with the radicals. If this state continues, it will eventually reach a state where there is almost no polymerization inhibitor or dissolved oxygen contained in the photocurable resin. Subsequently, when the energy beam irradiation is continued, the generated radicals react with the polymerizable compound contained in the photocurable resin to cause radical polymerization reaction. Thereafter, a radical polymerization reaction occurs in a chain, whereby the low molecular weight polymerizable compound is polymerized. In view of the above chemical reaction as a physical phenomenon, when the photocurable resin that has been in a liquid state is irradiated with energy rays, the photocurable resin is cured and becomes a solid state.

  On the other hand, when a photocurable resin is irradiated with energy rays in a gas containing oxygen, for example, in the atmosphere, a phenomenon occurs in which the surface portion in contact with the atmosphere is not cured even when the energy rays are sufficiently irradiated. This is because the polymerization inhibitor and dissolved oxygen contained in the photocurable resin react with radicals and are consumed by irradiation of energy rays, and at the same time, oxygen in the atmosphere continues to dissolve in the photocurable resin and there is no dissolved oxygen. It does not reach the state. This is because the radical does not react with the polymerizable compound.

By always supplying a curing inhibitor of a photocurable resin from the light transmission window, a curing inhibition region (uncured layer) can be maintained between the light transmission window and the modeled object. By using this phenomenon, it is possible to easily form a continuous three-dimensional structure. For example, a material having a high oxygen transmission coefficient [m ³ · m / m ² · s · Pa] is used as a material for the light transmission window, and a gas containing oxygen on the side of the transmission window that is not in contact with the photocurable resin, for example, Fill the atmosphere. Thereby, oxygen can always be supplied from the light transmission window, a curing inhibition area can be maintained between the light transmission window and the modeled object, and a three-dimensional modeled object can be continuously modeled.

  Here, the thickness of the uncured layer is defined at a position where supply of oxygen and consumption of oxygen are balanced. Factors that control the supply of oxygen mainly include the oxygen partial pressure, the oxygen transmission coefficient of the light transmission window, and the oxygen transmission coefficient of the photocurable resin. Factors that control the consumption of oxygen mainly include energy ray intensity, polymerization initiator concentration, and cleavage energy of the polymerization initiator. About these control factors, using a material having a sufficient oxygen transmission coefficient as a light transmission window, using atmospheric pressure of 1 atm, and using a photocurable resin and a process generally used for optical modeling, it is about 30 μm. An uncured layer is maintained. On the other hand, when pure oxygen at 1 atm is used and the energy ray intensity is set to a quarter of the normal condition that is the minimum possible level, an uncured layer of about 100 μm is maintained.

  Next, the light shielding portion 5 is a portion made of a member that blocks light in a wavelength region that solidifies the liquid photocurable resin 2. In the present embodiment, the light transmission window 4 is provided in a portion serving as the optical path between the light source unit 10 and the base 11 in the portion functioning as the bottom of the container, and the light shielding portion 5 is provided in the other region. .

  On the upper surface of the light transmission window 4, that is, the surface in contact with the liquid photocurable resin, a convex portion forming region 6 that transmits UV light as energy rays and oxygen gas as a curing inhibitor is provided. The convex portion forming region 6 will be described in detail later.

  The light source 7, the mirror unit 8, and the lens unit 9 constitute a light source unit 10 for irradiating the liquid photocurable resin with light corresponding to the shape of the three-dimensional model to be modeled. The light source 7 is a light source that emits light in a wavelength region that solidifies the liquid photocurable resin. For example, when a material having sensitivity to ultraviolet light is used as the photocurable resin, an ultraviolet light source such as a He—Cd laser or an Ar laser is used. The mirror unit 8 is a part that modulates the light emitted from the light source 7 in correspondence with the shape of the three-dimensional model to be modeled, and a device in which micromirror devices are arranged in an array is used. The lens unit 9 is a lens for condensing the modulated light at a predetermined position above the curing inhibition region near the light transmission window. The liquid photocurable resin 2 in a predetermined position is cured when irradiated with a condensed ultraviolet light having a sufficient intensity.

  In order to ensure the accuracy of the shape of the cured product, it is desirable that the focal position of the condenser lens is in the vicinity of the light transmission window. Therefore, it is desirable that the focal position of the lens unit 9 is set 60 μm to 110 μm above the upper surface of the light transmission window 4.

  The light source unit 10 may have any function for modulating the light in the wavelength region for solidifying the liquid photocurable resin in accordance with the shape of the three-dimensional model to be modeled and condensing it at a predetermined position. However, the present invention is not limited to the above example. For example, a combination of an ultraviolet light source and a transmissive liquid crystal shutter or a reflective liquid crystal element, a semiconductor laser diode array, a scanning mirror, an imaging mirror, or the like may be used.

  The base 11 is a base that supports the three-dimensional structure 14 by suspending it on the lower surface thereof, and is connected to the lift unit 13 via the lift arm 12. The elevating unit 13 is a mechanism that adjusts the height of the base 11 by moving the elevating arm 12 up and down, and is a moving unit that moves the base.

  FIG. 2 is a block diagram of the three-dimensional modeling apparatus. 21 is a control unit, 22 is an external device, 23 is an operation panel, 3 is a resin supply unit, 10 is a light source unit, and 13 is an elevating unit.

The control unit 21 includes a CPU, a ROM which is a non-volatile memory storing a control program and a numerical value table for control, a RAM which is a volatile memory used for calculation, an I / O port for communicating with each unit and the outside, Etc. The ROM stores a program for controlling basic operations of the three-dimensional modeling apparatus.
From the external device 22, the shape data of the three-dimensional structure is input to the control unit 21 of the three-dimensional structure apparatus via the I / O port.

The operation panel 23 includes an input unit for an operator of the 3D modeling apparatus to give an instruction to the apparatus and a display unit for displaying information to the operator. The input unit includes a keyboard and operation buttons. The display unit includes a display panel that displays an operation status of the three-dimensional modeling apparatus.
The control part 21 can control the resin supply part 3, the light source unit 10, and the raising / lowering part 13, and can perform a three-dimensional modeling process.

(Projection formation area)
The upper surface of the light transmission window 4, that is, the surface in contact with the liquid photocurable resin is provided with a convex portion forming region 6. FIG. 3A is a cross-sectional view schematically showing the vicinity of the light transmission window 4 of FIG.
The convex portion forming region 6 includes a plurality of convex portions 31 that transmit the curing light and the curing inhibitor, and a space 32 that communicates with the outside of the light transmission window in a plan view and is filled with the liquid photocurable resin 2. .

  FIG. 3B is a top view schematically showing an enlarged part of the horizontal section along the dotted line A in FIG. A dotted line A indicates a plane parallel to the main surface of the light transmission window. FIG. 3A is a side view schematically showing a vertical section along the dotted line B in FIG. Since these drawings are schematically shown for convenience of explanation, the number, shape, and arrangement of the convex portions are not necessarily shown accurately.

In the first embodiment, the base portion and the convex portion 31 of the light transmission window 4 are integrally formed of the same material. The base thickness t1 is usually set to 1 mm to 10 mm. The hexagonal columnar convex portions 31 are arranged in a hexagonal close-packed manner at intervals.
The convex part formation area 6 has the following aspects.
(1) The space 32 that separates the convex portions communicates with the outside of the light transmission window in the horizontal direction, that is, in a plane parallel to the main surface of the light transmission window.
(2) Desirably, the distance L1 between adjacent convex portions is in the range of 60 μm to 200 μm.
(3) Desirably, the cross-sectional area (horizontal cross-sectional area) of the convex portion in the cross section parallel to the main surface of the light transmitting window is relative to the area of the region irradiated with the curing light on the main surface of the light transmitting window. 45% or more and 80% or less.

  Providing the convex formation area in this mode maintains a sufficiently thick curing inhibition area between the light transmission window 4 and the three-dimensional structure 14, and simultaneously forms a curing inhibition area in the space 32. can do.

  Here, since the space 32 communicates with the outside of the light transmission window in plan view, when the three-dimensional structure 14 is moved away from the light transmission window, that is, in the Z direction, the space 32 is three-dimensional. It can be set as the flow path for supplying liquid photocurable resin to a modeling area | region. In the first embodiment, as shown in FIG. 3B, the space 32 communicates with the upper space of the light shielding portion 5 around the light transmission window, and therefore exists in the upper space of the light shielding portion 5. The liquid photocurable resin easily flows into the space 32 through the communication path. By providing the convex portion forming region 6, conductance when supplying the liquid photocurable resin to the three-dimensional modeling region can be increased.

  Here, it is desirable that the distance separating the convex portions is 200 μm or less, and the ratio of the horizontal sectional area of the convex portions 31 is 45% or more.

  The ratio of the horizontal sectional area of the convex part 31 is the ratio of the hatched part in the total area of the light transmission window 4 in FIG. In the first embodiment, the columnar convex portion 31 has the same horizontal cross-sectional area at any height in the Z direction, but uses a convex portion whose cross sectional area changes depending on the height. Shall calculate the ratio of the horizontal cross-sectional area with the smallest cross-sectional area.

  By setting the ratio of the horizontal sectional area to 45% or more, it is possible to maintain a sufficiently thick curing-inhibiting region on the light transmission window. Further, not only the upper surface of the protrusion 31 but also the side surface diffuses oxygen as a curing inhibitor and is supplied to the liquid photocurable resin, so that a curing inhibition region can be formed and maintained in the space 32.

  On the other hand, if the distance separating the convex portions is larger than 200 μm, the oxygen supply to the liquid photocurable resin filling the space 32 becomes insufficient, and it becomes difficult to maintain the curing inhibition region in the space 32. The flatness of the hardening inhibition area above 31 and the space 32 is also reduced. For this reason, it is desirable that the distance separating the convex portions be 200 μm or less.

  In addition, it is desirable that the distance L1 separating the convex portions be 60 μm or more and sufficiently ensure the conductance of the flow path. This is because if the distance L1 separating the convex portions is smaller than 60 μm, the flow path becomes narrow and a sufficient effect as a supply path cannot be obtained.

  Moreover, it is preferable that the ratio of the horizontal direction cross-sectional area of the convex part 31 is 45 to 80% of range. This is because if the ratio of the horizontal cross-sectional area of the convex portion 31 is greater than 80%, the flow path becomes narrow and the space 32 cannot exhibit a sufficient effect as a photocurable resin supply path. More preferably, it is in the range of 45% to 70%.

  Moreover, it is preferable that the vertical height t2 of the convex portion 31 is in the range of 50 μm or more and 800 μm or less. If the height t2 of the convex portion 31 is smaller than 50 μm, the space 32 that can be used as a flow path is small, and a sufficient effect as a supply path cannot be obtained. Moreover, it is because it will become difficult to maintain the hardening inhibition area | region in the space 32 when height t2 is larger than 800 micrometers.

  As described above, according to the present embodiment provided with the convex portion forming region, when the three-dimensional structure 14 is moved in the direction away from the light transmission window, that is, in the Z direction, the liquid photocurable resin is formed in the three-dimensional structure region. The speed for supplying is increased, and the time required for three-dimensional modeling can be remarkably shortened.

(Photo-curing resin)
The photocurable resin used in the present embodiment contains at least a polymerizable compound, and in addition, various kinds of resin materials, polymerization initiators, polymerization inhibitors, antioxidants, heat stabilizers, light stabilizers, release agents, and the like. An additive may be included.
Examples of the polymerizable compound used in the present invention include, but are not limited to, acrylic compounds, methacrylic compounds, vinyl compounds, and the like.

Examples of the resin material include acrylic resin, methacrylic resin, polyolefin resin, polyester resin, polyamide resin, polycarbonate resin, and polyimide resin. These may be used alone or in combination of two or more.
The content of the resin contained in the photocurable resin of the present invention is preferably 0.0% by weight or more and 99% by weight or less, and more preferably 0.0% by weight or more and 50% by weight or less.

  Examples of the polymerization initiator include, but are not limited to, those that generate radical species by irradiation with light, those that generate cationic species, and those that generate radical species by heat. Examples include, but are not limited to, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -1-butanone, 1-hydroxy-cyclohexyl-phenyl ketone, and the like.

  The addition ratio of the photopolymerization initiator to the polymerizable resin component can be appropriately selected according to the amount of light irradiation and further the additional heating temperature. Moreover, it can also adjust according to the average molecular weight made into the target of the polymer obtained.

  The addition amount of the photopolymerization initiator used for curing / molding the optical material of the present embodiment is preferably in the range of 0.01 wt% to 10.00 wt% with respect to the polymerizable component. The photopolymerization initiator can be used alone or in combination of two or more depending on the reactivity of the resin and the wavelength of light irradiation.

(Three-dimensional modeling process)
Next, a three-dimensional modeling process using the above three-dimensional modeling apparatus will be described.
First, the control unit 21 confirms whether a predetermined amount of the liquid photocurable resin is accommodated in the container 1 using a sensor (not shown). If it is insufficient, the resin supply unit 3 is operated to replenish the liquid photocurable resin 2 to a predetermined level in the container 1.

  Next, the control unit 21 operates the elevating unit 13 to set the position of the base 11 so that the height of the upper surface of the base 11 is slightly above the focal position of the light source unit 10 in the Z direction. To do. For example, when the thickness of one layer when forming a three-dimensional structure by layered modeling is 40 μm, the upper surface of the base 11 is adjusted to be 10 μm to 30 μm above the focal position of the lens in the Z direction. To do.

  The control unit 21 creates shape data (slice data) of each layer used in the additive manufacturing process based on the 3D modeling model shape data input from the external device 22.

  Then, the light source unit 10 is driven to emit light, and the liquid photocurable resin 2 is irradiated with ultraviolet light modulated based on the shape data of the first layer of the three-dimensional structure. The liquid photocurable resin 2 at the irradiated site is cured, and the first layer portion of the three-dimensional structure is formed on the lower surface of the base 11.

  As long as it is an energy ray that can cure the liquid photocurable resin, it may not be ultraviolet light. Preferably used. The intensity of the energy beam is not particularly limited, but is preferably 0.1 mW / cm 2 to 1000 mW / cm 2, and more preferably 1 mW / cm 2 to 100 mW / cm 2.

  Next, as preparation for forming the second layer, the control unit 21 operates the elevating unit 13 to move the base 11 on which the first layer portion is formed away from the light transmission window, that is, the Z direction. Is raised by 40 μm. The liquid photocurable resin 2 flows from the surroundings into the space between the rising base 11 and the light transmission window 4.

  The moving operation of the base 11 can be performed by speed control or load control alone or in combination. The speed of the moving operation is preferably 0.001 mm / second to 10 mm / second, and more preferably 0.01 mm / second to 1 mm / second. The load during the moving operation is preferably 0.01N to 10000N, and more preferably 0.1N to 1000N.

  According to the present embodiment, since the convex portion forming region is provided on the upper surface of the light transmission window 4, that is, the surface in contact with the liquid photocurable resin 2, the flow resistance of the liquid photocurable resin 2 is reduced. Yes. For this reason, the inflow speed of the liquid photocurable resin 2 is fast, and it is possible to shorten the time required for the preparation process for forming the second layer.

  At the timing when the liquid photocurable resin 2 flows into the three-dimensional modeling area, that is, when the replenishment is completed, the control unit 21 drives the light source unit 10 based on the shape data of the second layer of the three-dimensional modeling object. Irradiate modulated ultraviolet light. The liquid photocurable resin 2 at the irradiated portion is cured, and the second layer portion is laminated on the first layer of the three-dimensional structure.

  Hereinafter, by repeating the same process, it is possible to laminate a large number of layers and form a three-dimensional structure having a desired shape. The obtained three-dimensional structure may be washed to remove adhesion of unreacted photocurable resin. In addition, in order to relieve the curing of the insufficiently cured photo-curable resin or the residual stress at the time of molding, heating annealing, additional irradiation with ultraviolet rays, heating in an oxygen-free atmosphere, ultraviolet irradiation, or the like may be performed.

  In addition, as described above, the movement of the base 11 and the irradiation of the energy beam may be alternately repeated and sequentially stacked from the first layer. However, the energy beam is irradiated simultaneously while moving the base 11, You may deposit a three-dimensional structure continuously. In that case, two-dimensional shape data for a preset position is projected in accordance with the position of the base 11. As a method of matching the position of the base 11 with the projection of the desired two-dimensional shape, for example, a method of matching the moving speed of the base 11 and the projection speed of the two-dimensional shape in advance, or the position of the base 11 is measured. There is a method of projecting a two-dimensional shape with respect to a measured position.

  In the present embodiment, a liquid photocurable resin can be introduced into the inner surface of the light transmission window from the periphery through a communication path between a plurality of convex portions that transmit UV light and a curing inhibitor and between the plurality of convex portions. By providing the space, replenishment of the liquid photocurable resin to the three-dimensional modeling region can be speeded up.

[Second Embodiment]
FIG. 4 is a diagram schematically showing a cross section of the apparatus for explaining the structure of the three-dimensional modeling apparatus according to the second embodiment of the present invention.

(Device configuration)
In the first embodiment, the light transmission window functions as the bottom of the container. However, in the second embodiment, the light transmission window is provided in the upper part of the container and functions as a lid. In the second embodiment, the light source unit 10 is disposed above the light transmission window 44, and the base 11 supports the three-dimensional structure 14 on the upper surface.

  As in the first embodiment, in the second embodiment, a material having a property of transmitting a gas such as oxygen, which is a curing inhibitor, is used for the light transmission window, and the liquid photocuring property in the vicinity of the light transmission window is used. Gas is supplied to the resin through the light transmission window. As the liquid photocurable resin, for example, a radical polymerization type resin material whose photocuring sensitivity is lowered when a gas such as oxygen is included is used, and a region where the curing is inhibited is formed in the vicinity of the light transmission window.

In FIG. 4, 1 is a container, 2 is a liquid photocurable resin, 3 is a resin supply part, 44 is a light transmission window, 5 is a light shielding part, 46 is a convex part forming area, 7 is a light source, 8 is a mirror part, 9 Is a lens unit, 10 is a light source unit, 11 is a base, 12 is a lifting arm, 13 is a lifting unit, and 14 is a three-dimensional structure.
Parts having the same functions as those of the apparatus of the first embodiment are assigned the same numbers. Detailed description of these will be omitted.
Moreover, since the control block of the three-dimensional modeling apparatus of 2nd embodiment is the same as that of FIG. 2 demonstrated in 1st embodiment, description is abbreviate | omitted.

(Projection formation area)
The lower surface of the light transmission window 44, that is, the surface in contact with the liquid photocurable resin is provided with a convex portion forming region 46. FIG. 5A is a cross-sectional view schematically showing the vicinity of the light transmission window 44 in FIG. 4 in an enlarged manner.
The convex portion forming region 46 includes a plurality of convex portions 51 that transmit the curing light and the curing inhibitor, and a space 52 that communicates with the outside of the light transmission window in a plan view and is filled with the liquid photocurable resin 2. .

  FIG. 5B is a top view schematically showing an enlarged part of a horizontal cross section along the dotted line C in FIG. A dotted line C indicates a plane parallel to the main surface of the light transmission window. FIG. 5A is a side view schematically showing a vertical cross section along the dotted line D in FIG. Since these drawings are schematically shown for convenience of explanation, the number, shape, and arrangement of the convex portions are not necessarily shown accurately.

In the first embodiment, the base portion and the convex portion 31 of the light transmission window are integrally formed of the same material. However, in the second embodiment, the base portion and the convex portion 51 of the light transmission window 44 are different types. It is made of material.
In the first embodiment, the hexagonal columnar projections are arranged in a hexagonal close-packed manner, but in the second embodiment, the columnar projections are arranged in a lattice pattern.

Also in 2nd embodiment, the convex part formation area | region 46 has the following aspects.
(1) The space 52 that separates the protrusions communicates with the outside of the light transmission window in the horizontal direction, that is, in a plane parallel to the main surface of the light transmission window.
(2) Desirably, the distance L1 between adjacent convex portions is in the range of 60 μm to 200 μm.
(3) Desirably, the cross-sectional area (horizontal cross-sectional area) of the convex portion in the cross section parallel to the main surface of the light transmitting window is relative to the area of the region irradiated with the curing light on the main surface of the light transmitting window. 45% or more and 80% or less.

  Providing the convex formation area 46 of this aspect maintains a curing inhibition area having a sufficient thickness between the light transmission window 44 and the three-dimensional structure 14, and at the same time, provides a curing inhibition area in the space 52. Can be formed.

  Here, since the space 52 communicates with the outside of the light transmission window in a plan view, the space 52 is moved when the three-dimensional structure 14 is moved away from the light transmission window, that is, in the direction opposite to the Z direction. And it can be set as the flow path for supplying liquid photocurable resin to a three-dimensional modeling area | region. Also in the present embodiment, as shown in FIG. 5B, the space 52 communicates with the lower space of the light shielding portion 5 around the light transmission window, so that the liquid existing in the lower space of the light shielding portion 5 is present. The photocurable resin easily flows into the space 52 through the communication path. By providing the convex formation region 46, the conductance when supplying the liquid photocurable resin to the three-dimensional modeling region can be increased.

  Here, it is desirable that the distance separating the convex portions is 200 μm or less, and the ratio of the horizontal sectional area of the convex portions 51 is 45% or more.

  The ratio of the cross-sectional area in the horizontal direction of the convex portion 51 is the ratio of the hatched portion in the entire area of the light transmission window 44 in FIG. In the first embodiment, the convex portion 51 has the same horizontal cross-sectional area at any height in the Z direction, but when using a convex portion in which the size of the cross-sectional area changes depending on the height, The ratio of the horizontal cross-sectional area shall be calculated with the smallest cross-sectional area.

  By setting the ratio of the horizontal sectional area to 45% or more, it is possible to maintain a sufficiently thick curing-inhibiting region under the light transmission window. Further, not only the lower end surface of the convex portion 51 but also the oxygen as a curing inhibitor is diffused from the side surface and supplied to the liquid photocurable resin, and a curing inhibition region can be formed and maintained in the space 52. .

  On the other hand, if the distance separating the convex portions is larger than 200 μm, the oxygen supply to the liquid photocurable resin filling the space 52 becomes insufficient, and it becomes difficult to maintain the curing inhibition region in the space 52. The flatness of the hardening inhibition area below 51 and the space 52 is also lowered. For this reason, it is desirable that the distance separating the convex portions be 200 μm or less.

  In addition, it is desirable that the distance L1 separating the convex portions be 60 μm or more and sufficiently ensure the conductance of the flow path. This is because if the distance L1 separating the convex portions is smaller than 60 μm, the flow path becomes narrow and a sufficient effect as a supply path cannot be obtained.

  Moreover, it is preferable that the ratio of the horizontal cross-sectional area of the convex part 51 is in the range of 45% to 80%. This is because if the ratio of the cross-sectional area in the horizontal direction of the convex portion 51 is larger than 80%, the flow path becomes narrow, and the space 52 cannot exhibit a sufficient effect as a photocurable resin supply path. More preferably, it is in the range of 45% to 70%.

  The vertical height t2 of the convex portion 51 is preferably in the range of 50 μm or more and 800 μm or less. If the height t2 of the convex portion 31 is smaller than 50 μm, the space 32 that can be used as a flow path is small, and a sufficient effect as a supply path cannot be obtained. Moreover, it is because it will become difficult to maintain the hardening inhibition area | region in the space 32 when height t2 is larger than 800 micrometers.

  In the second embodiment, the base portion and the convex portion 51 of the light transmission window 44 are formed of different materials. In the first embodiment, the convex portion 31 is formed of the same material as the base portion, and since the liquid photocurable resin is present in the space 32, the optical path of the curing light when the difference between the refractive indexes is large. There is a possibility that the accuracy of the modeling shape is deteriorated due to disturbance.

  In the second embodiment, a material that transmits the curing inhibitor and has a refractive index closer to the photocurable resin than the base of the light transmission window 44 is used for the convex portion 51. Preferably, a plate-shaped resin member is prepared as the base of the light transmission window, and the convex portion 51 is formed on the surface thereof using another type of resin having a refractive index close to that of the liquid photocurable resin.

  As the liquid photocurable resin, it is possible to use the same material as that of the first embodiment, and various types exist with a refractive index Nd in the range of 1.3 to 1.5. Examples of materials that transmit oxygen and ultraviolet light include fluoropolymers (Nd = 1.3 to 1.4), silicone polymers (Nd = 1.35 to 1.45), and porous glass (Nd = 1. 3-1.4). Therefore, if there is a difference in the refractive index between the base of the light transmissive window and the liquid photocurable resin used as the raw material, a material with a higher refractive index than the base is selected to form the convex portion. do it.

(Three-dimensional modeling process)
The second embodiment is different from the first embodiment in that the base is moved in the direction opposite to the Z direction in the process of three-dimensional modeling, but the other details are the same and will not be described in detail.

  As described above, according to the present embodiment including the convex portion formation region, the curing inhibition region is maintained when the three-dimensional structure 14 is moved in the direction away from the light transmission window, that is, in the direction opposite to the Z direction. However, the speed | rate which supplies liquid photocurable resin to a three-dimensional modeling area | region increases. For this reason, the time required for three-dimensional modeling can be significantly shortened. In addition, even when the difference in refractive index between the base material of the light transmission window and the photocurable resin is large, the irradiation characteristics of the curing light may be deteriorated by forming the convex portion with a material having a refractive index close to that of the photocurable resin. The shape accuracy of the three-dimensional structure can be kept good.

[Third embodiment]
3rd embodiment uses the three-dimensional modeling apparatus of FIG. 1, FIG. 2 similarly to 1st embodiment. The description of FIG. 1 and FIG. 2 is common and will be omitted.
The third embodiment is different from the first embodiment in the shape of the light transmission window, and will be described with reference to FIG.

(Projection formation area)
The upper surface of the light transmission window 4, that is, the surface in contact with the liquid photocurable resin is provided with a convex portion forming region 6. FIG. 6A is a cross-sectional view schematically showing an enlarged vicinity of the light transmission window 4 of FIG.
The convex portion forming region 6 includes a plurality of convex portions 61 that transmit the curing light and the curing inhibitor, and a space 62 that communicates with the outside of the light transmission window in a plan view and is filled with the liquid photocurable resin 2. .

  FIG. 6B is an enlarged top view schematically showing a part of the horizontal cross section along the dotted line E in FIG. A dotted line E indicates a plane parallel to the main surface of the light transmission window. FIG. 6A is a side view schematically showing a cross section in the vertical direction along the dotted line F in FIG. Since these drawings are schematically shown for convenience of explanation, the number, shape, and arrangement of the convex portions are not necessarily shown accurately.

  In the first embodiment, the base portion and the convex portion 31 of the light transmission window are integrally formed of the same material. However, in the third embodiment, the convex portion 61 has a refractive index higher than that of the base portion 64. It is made of a material close to a liquid photocurable resin. Furthermore, the bottom surface of the space 62 is also formed of the same material as the convex portion 61.

  In the first embodiment, the convex portion 31 is formed of the same material as the base portion, and since the liquid photocurable resin is present in the space 32, the optical path of the curing light when the difference between the refractive indexes is large. There is a possibility that the accuracy of the modeling shape is deteriorated due to disturbance.

In the third embodiment, a material that transmits the curing inhibitor and has a refractive index closer to that of the photocurable resin than the base portion 64 of the light transmitting window 4 is formed in the portion that becomes the bottom surface of the convex portion 61 and the space 62. Use. Preferably, a plate-like resin member is prepared as the base portion 64 of the light transmission window, and another type of resin having a refractive index closer to that of the liquid photocurable resin is formed on the surface thereof at a constant thickness. The convex part 61 is formed and used.
In the first embodiment, the hexagonal columnar convex portions are arranged in a hexagonal close-packed manner, but in the third embodiment, the rectangular parallelepiped convex portions are arranged in parallel.

Also in 3rd embodiment, the convex part formation area 6 has the following aspects.
(1) The space 62 separating the protrusions communicates with the outside of the light transmission window in the horizontal direction, that is, in a plane parallel to the main surface of the light transmission window.
(2) Desirably, the distance L1 between adjacent convex portions is in the range of 60 μm to 200 μm.
(3) Desirably, the cross-sectional area (horizontal cross-sectional area) of the convex portion in the cross section parallel to the main surface of the light transmitting window is relative to the area of the region irradiated with the curing light on the main surface of the light transmitting window. 45% or more and 80% or less.

  Providing the convex formation region 6 of this aspect maintains a curing inhibition region having a sufficient thickness between the light transmission window 4 and the three-dimensional structure 14, and at the same time, provides a curing inhibition region in the space 62. Can be formed.

  Here, since the space 62 communicates with the outside of the light transmission window in plan view, when the three-dimensional structure 14 is moved away from the light transmission window, that is, in the Z direction, the space 62 is It can be set as the flow path for supplying liquid photocurable resin to a modeling area | region. In the present embodiment, the space 62 extends along the Y direction, but communicates with the upper space of the light shielding portion 5 at both ends of the space, and is a liquid photocurable resin that exists in the upper space of the light shielding portion 5. Easily flows into the space 62 through the communication path. By providing the convex portion forming region 6, conductance when supplying the liquid photocurable resin to the three-dimensional modeling region can be increased.

  Here, it is desirable that the distance separating the convex portions is 200 μm or less, and the ratio of the horizontal sectional area of the convex portions 61 is 45% or more.

  The ratio of the cross-sectional area in the horizontal direction of the protrusion 61 is the ratio of the hatched portion in the entire area of the light transmission window in FIG. In the third embodiment, the convex portion 61 has the same horizontal cross-sectional area at any height in the Z direction, but when using a convex portion in which the size of the cross-sectional area changes depending on the height, The ratio of the horizontal cross-sectional area shall be calculated with the smallest cross-sectional area.

  By setting the ratio of the horizontal sectional area to 45% or more, it is possible to maintain a sufficiently thick curing-inhibiting region on the light transmission window. Further, not only the upper end surface of the convex portion 61 but also the side surface diffuses oxygen, which is a curing inhibitor, and is supplied to the liquid photocurable resin, so that a curing inhibition region can be formed and maintained in the space 62. .

  On the other hand, if the distance separating the convex portions is larger than 200 μm, the oxygen supply to the liquid photocurable resin filling the space 62 becomes insufficient, and it becomes difficult to maintain the curing inhibition region in the space 62. The flatness of the curing inhibition region above 61 and the space 62 is also reduced. For this reason, it is desirable that the distance separating the convex portions be 200 μm or less.

  In addition, it is desirable that the distance L1 separating the convex portions be 60 μm or more and sufficiently ensure the conductance of the flow path. This is because if the distance L1 separating the convex portions is smaller than 60 μm, the flow path becomes narrow and a sufficient effect as a supply path cannot be obtained.

  Moreover, it is preferable that the ratio of the horizontal direction cross-sectional area of the convex part 61 is in the range of 45% to 80%. This is because if the ratio of the horizontal cross-sectional area of the convex portion 61 is greater than 80%, the flow path becomes narrow, and the space 62 cannot exert a sufficient effect as a photocurable resin supply path. More preferably, it is in the range of 45% to 70%.

  The vertical height t2 of the convex portion 61 is preferably in the range of 50 μm to 800 μm. If the height t2 of the convex portion 61 is smaller than 50 μm, the space 62 that can be used as a flow path is small, and a sufficient effect as a supply path cannot be obtained. Moreover, it is because it will become difficult to maintain the hardening inhibition area | region in the space 62 when height t2 is larger than 800 micrometers.

(Three-dimensional modeling process)
Also in this embodiment, the liquid photocurable resin can use the same material as in the first embodiment. Since the three-dimensional modeling process of the third embodiment is common to the first embodiment, detailed description is omitted.

  As described above, according to the present embodiment including the convex portion forming region, the three-dimensional structure 14 is moved in the direction away from the light transmission window, that is, in the Z direction, and the three-dimensional shape is maintained while maintaining the curing inhibition region. The speed at which the liquid photo-curing resin is supplied to the modeling region is increased. For this reason, the time required for three-dimensional modeling can be significantly shortened.

[Other Embodiments]
The shape of the convex portion of the window may not be a hexagonal column as in the first embodiment, and may be another polygonal column such as a quadrangular column. Further, the cross-sectional shape may not be a perfect circular cylinder as in the second embodiment, and the cross-sectional shape may be an ellipse. In short, the shape and arrangement of the protrusions may be configured so that the space separating the plurality of protrusions communicates with the light transmission window.

  The material of the base material and the convex part of the light transmission window may be the same material as in the first embodiment, or different materials as in the second and third embodiments. The material and the cross-sectional shape are not limited to the examples of combinations of the above-described embodiments, and can be changed as appropriate.

The three-dimensional modeling apparatus is not limited to the examples of the first embodiment and the second embodiment, and can be changed as appropriate. For example, the light transmission window may be provided on the side surface instead of the bottom surface or top surface of the liquid photocurable resin container.
The arrangement position of the light transmission window of the three-dimensional modeling apparatus and the combination of the light transmission windows are not limited to the example of the above-described embodiment, and can be changed.

Examples of the present invention will be described below.
As an example of the present invention, three-dimensional modeling is performed using various light transmission windows using the three-dimensional modeling apparatus having the layout of FIG. 1, and the three-dimensional modeling speed and the shape accuracy of the obtained three-dimensional model are obtained. evaluated.

As the photocurable resin, UV-curable resin clear MR-CL12 (product name) for optical modeling 3D printer manufactured by Mutoh Engineering Co., Ltd. was used.
An LED having a wavelength of 405 nm was used as a light source of the energy beam irradiation device. As an image forming element, a Full-HD digital mirror device (product name) manufactured by Texas Instruments Incorporated was used. As the projection lens, a lens designed as an optical system for enlarging and projecting the size of one pixel to 60 μm × 60 μm was used. The maximum size irradiated with energy rays is approximately 115 mm × 65 mm.

  First, 100 ml of light transmitting resin was put into the liquid tank. Next, the base was moved closer to the light transmission window until the distance became 50 μm. Subsequently, the energy ray was irradiated to the photocurable resin through the light transmission window so that the projected image had a diameter of 30 mm. At this time, the intensity of the energy beam was 50 mW / cm 2. Three seconds after the start of the energy beam irradiation, the base was separated from the light transmission window by 150 N load control while continuing the energy beam irradiation. When the base was separated from the 30 mm light transmission window, the irradiation of energy rays was stopped. Thereafter, the base was sufficiently separated from the light transmission window, and the three-dimensional structure was peeled off from the base to obtain a three-dimensional structure having a diameter of about 30 mm and a height of about 30 mm.

[Example 1]
As a light transmission window of the three-dimensional modeling apparatus, a Teflon AF2400 [product name] made by DuPont, a flat plate having a size of 80 mm × 80 mm × 1 mm thickness, and having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed pattern, the hexagonal prism spacing is 120 μm, the convex height is 400 μm, the horizontal cross-sectional area near the top surface of the convex is 45%, and the bottom horizontal The ratio of the directional cross-sectional area is 52%. Three-dimensional modeling was carried out with the above apparatus to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base was an average of 0.82 mm / sec under a load control of 150 N.

[Example 2]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex cylinders are arranged in a grid pattern, the convex spacing is 120 μm, the convex height is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex is 48%, the bottom horizontal direction The ratio of the cross-sectional area is 60%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base was 0.53 mm / sec under a load control of 150 N.

[Example 3]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. It is a repeating structure of walls that are grooves and convex portions, the interval between the convex portions is 120 μm, the height of the convex portions is 400 μm, the ratio of the horizontal sectional area near the top surface of the convex portions is 45%, and the horizontal sectional area of the bottom portion Is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.44 mm / second.

[Example 4]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed structure, the spacing between the convex portions is 60 μm, the height of the convex portions is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex portions is 45%, and the bottom horizontal The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base was 0.33 mm / sec under a load control of 150 N.

[Example 5]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Hexagonal cylinders that are convex portions are arranged in a hexagonal close-packed structure, the spacing between the convex portions is 200 μm, the height of the convex portions is 400 μm, the ratio of the horizontal sectional area near the top surface of the convex portions is 45%, The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.86 mm / sec.

[Example 6]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed structure, the spacing between the convex portions is 120 μm, the height of the convex portions is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex portions is 62%, the bottom horizontal The ratio of the directional cross-sectional area is 70%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.38 mm / sec.

[Example 7]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Hexagonal cylinders that are convex portions are arranged in a hexagonal close-packed pattern, the spacing between the convex portions is 120 μm, the height of the convex portions is 50 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex portions is 45%, and the bottom horizontal The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base was 0.31 mm / sec under a load control of 150 N.

[Example 8]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed pattern, the spacing between the convex portions is 120 μm, the height of the convex portions is 800 μm, the ratio of the horizontal cross-sectional area in the vicinity of the top surface of the convex portions is 45%, the bottom horizontal The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 1.40 mm / sec.

[Example 9]
As the light transmission window, one having the following structure on the light transmission window upper surface was used. Hexagonal cylinders that are convex parts are arranged in a hexagonal close-packed pattern, the spacing between the convex parts is 120 μm, the height of the convex parts is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex parts is 60%, the bottom horizontal The ratio of the directional cross-sectional area is 80%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.22 mm / sec.

[Example 10]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed structure, the spacing between the convex portions is 300 μm, the height of the convex portions is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex portions is 45%, and the bottom horizontal The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.86 mm / sec.

[Example 11]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. Convex hexagonal prisms are arranged in a hexagonal close-packed structure, the spacing between the convex portions is 120 μm, the height of the convex portions is 400 μm, the ratio of the horizontal cross-sectional area near the top surface of the convex portions is 35%, and the bottom horizontal The ratio of the directional cross-sectional area is 52%. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.83 mm / sec.

[Comparative Example 1]
As the light transmission window, a flat window having no convex portion formation region on the upper surface of the light transmission window was used. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.16 mm / second.

[Comparative Example 2]
As the light transmission window, one having the following structure on the upper surface of the light transmission window was used. It is a structure in which cylindrical recesses are arranged in a hexagonal close-packed pattern, with a repeating pitch of 120 μm and a depth of the recesses of 400 μm. The recess is filled with a liquid photocurable resin, but each recess is disposed in isolation, and the recess does not communicate with the periphery of the light transmissive window as viewed in the horizontal direction. Except for the light transmission window, three-dimensional modeling was performed with the same apparatus as in Example 1 to obtain a three-dimensional modeled object. At this time, the separation speed from the light transmission window of the base with a load control of 150 N was 0.16 mm / second.

[result]
The obtained results are shown in Table 1 for each example and comparative example.
In Table 1, what is shown as the modeling speed is a magnification based on the speed of the comparative example with respect to the separation speed from the light transmission window of the base, that is, the speed at which the liquid photocurable resin is supplied to the modeling area.

  Further, the shape accuracy is a result of measuring the shape accuracy of the outer surface that is not in close contact with the base for the obtained three-dimensional structure. A surface roughness whose maximum value Rz is 10 μm or less is indicated as A, and a surface roughness larger than 10 μm is indicated as B.

  As is clear from the results in Table 1, in the 3D modeling apparatus of the present invention and the 3D modeling method using the same, 3D modeling can be performed at high speed, and the shape accuracy of the obtained 3D modeled object is obtained. Is good. In particular, in Examples 1 to 9, extremely good results were obtained in both the modeling speed and the shape accuracy.

  DESCRIPTION OF SYMBOLS 1 ... Container / 2 ... Liquid photocurable resin / 3 ... Resin supply part / 4 ... Light transmission window / 6 ... Convex part formation area / 10 ... Light source unit / 11. .. Base / 12 ... Lifting arm / 14 ... Three-dimensional structure / 21 ... Control part / 31 ... Convex part / 32 ... Space / 44 ... Light transmission window / 46 ... Projection formation area / 51 ... Projection / 52 ... Space / 61 ... Projection / 62 ... Space

Claims (11)

A container for holding a liquid photocurable resin;
A base supporting a three-dimensional structure obtained by photocuring the liquid photocurable resin;
A moving unit for moving the base;
A light source unit that emits curing light for curing the liquid photocurable resin;
A light transmission window provided between the light source unit and the base as a part of the container, and in contact with the liquid photocurable resin;
The light transmission window has a base portion made of a material that transmits curing light and a curing inhibitor, and a plurality of convex portions that are made of a material that transmits the curing light and the curing inhibitor and are in contact with the liquid photocurable resin. ,
The space separating the convex portions of the plurality of convex portions communicates with the outside of the light transmitting window in a plane parallel to the main surface of the light transmitting window.
A three-dimensional modeling apparatus characterized by this. The plurality of protrusions are arranged such that the distance between adjacent protrusions is 60 μm or more and 200 μm or less.
The three-dimensional modeling apparatus according to claim 1. The cross-sectional area of the plurality of convex portions in a cross section parallel to the main surface of the light transmission window is 45% or more and 80% with respect to the area of the region irradiated with the curing light on the main surface of the light transmission window. Is
The three-dimensional modeling apparatus according to claim 1 or 2, characterized in that The height of the convex portion is 50 μm or more and 800 μm or less.
The three-dimensional modeling apparatus according to any one of claims 1 to 3, wherein: The base includes any of a fluoropolymer, a silicone polymer, and porous glass,
The three-dimensional modeling apparatus according to any one of claims 1 to 4, wherein the three-dimensional modeling apparatus is characterized. The base and the convex are formed of the same material,
The three-dimensional modeling apparatus according to any one of claims 1 to 5, wherein the three-dimensional modeling apparatus is characterized. The convex portion is formed of a material whose refractive index is closer to that of the liquid photocurable resin than the base portion.
The three-dimensional modeling apparatus according to any one of claims 1 to 5, wherein the three-dimensional modeling apparatus is characterized. The three-dimensional modeling apparatus according to claim 1, wherein the convex portion includes a polygonal column. The convex portion includes a hexagonal column,
The three-dimensional modeling apparatus according to any one of claims 1 to 7, wherein The convex portion includes a cylinder,
The three-dimensional modeling apparatus according to any one of claims 1 to 7, wherein A container for holding a liquid photocurable resin;
A base supporting a three-dimensional structure obtained by photocuring the liquid photocurable resin;
A moving unit for moving the base;
A light source unit that emits light for photocuring the liquid photocurable resin;
A three-dimensional modeling method using a three-dimensional modeling apparatus provided between the light source unit and the base as a part of the container and provided with a light transmission window in contact with the liquid photocurable resin,
After light-curing a part of the liquid photocurable resin held in the container by emitting light from the light source unit,
Moving the base in a direction away from the light transmission window;
The liquid photocurable resin passes through the space between a plurality of convex portions made of a material that transmits the curing light and the curing inhibitor provided in the light transmitting window, and the liquid photocurable resin passes through the light transmitting resin. Replenish between the window and the three-dimensional structure,
A three-dimensional modeling method characterized by this.

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