JP2019151012A - Three-dimensional object manufacturing apparatus, three-dimensional object manufacturing method, and three-dimensional object manufacturing program - Google Patents

Abstract

To provide a manufacturing apparatus for a three-dimensional object that can manufacture a three-dimensional object with few unsolidified parts inside.SOLUTION: A manufacturing apparatus for a three-dimensional object has molding means for molding a layered object from molding material, light applying irradiation means for applying light to a surface of the layered object molded by the molding means, and measuring means for measuring an amount of the light applied by the light applying means and reflected from the surface of the layered object.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a three-dimensional object manufacturing apparatus, a three-dimensional object manufacturing method, and a three-dimensional object manufacturing program.

  In the powder additive manufacturing method, a layered object is formed by integrating the powdered material layer by layer by melting with an electromagnetic radiation source such as a laser or bonding with a binder resin, and the layered object is stacked to form a three-dimensional object. This is a method for manufacturing a product.

  As a method using an electromagnetic irradiation source, for example, an SLS (Selective Laser Sintering) method in which a powder material is melted and integrated by selectively irradiating the powder material with a laser beam to manufacture a three-dimensional model is known. ing. On the other hand, as a method using a binder resin, for example, there is known a binder jetting method in which an ink containing a binder resin is ejected and integrated with a powder material by a method such as inkjet to produce a three-dimensional model. Yes.

  In these methods, various proposals have been made to improve the quality of a three-dimensional model. For example, a three-dimensional additive manufacturing apparatus that adjusts the height of a modeling table by detecting reflected light of laser light irradiated on the surface of a layered model and suppresses distortion of a three-dimensional model to be modeled has been proposed ( For example, see Patent Document 1).

  An object of this invention is to provide the manufacturing apparatus of the three-dimensional molded item which can manufacture the three-dimensional molded item with few unsolidified parts inside.

  The manufacturing apparatus of the three-dimensional model | molding object of this invention as a means for solving a subject is light on the surface of the said layered modeled object modeled by the modeling means which models a layered modeled object from the modeling material, and the said modeling means Irradiating light irradiating means, and measuring means for measuring the amount of light reflected by the surface of the layered object is irradiated by the light irradiating means.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing apparatus of the three-dimensional molded item which can manufacture the three-dimensional molded item with few internal non-solidified parts can be provided.

Drawing 1 is an explanatory view showing the manufacturing device of the solid fabrication thing in a 1st embodiment. FIG. 2 is a block diagram illustrating a hardware configuration of the manufacturing apparatus for a three-dimensional structure according to the first embodiment. FIG. 3 is a block diagram illustrating a functional configuration of the three-dimensional structure manufacturing apparatus according to the first embodiment. FIG. 4A is a top view showing the relationship between the laser light irradiation position and the optical sensor installation position. FIG. 4B is an explanatory diagram illustrating a solid angle when the laser beam is irradiated to the position P1 in FIG. 4A. FIG. 4C is an explanatory diagram showing a solid angle when the laser beam is irradiated to the position P2 in FIG. 4A. FIG. 5A is a graph showing an example of the relationship between the distance from the laser light irradiation position to the optical sensor and the measured amount of diffusely reflected light. FIG. 5B is a graph showing an example of the relationship between the distance from the laser light irradiation position to the optical sensor and the amount of diffusely reflected light after calibration. FIG. 6A is a perspective view illustrating an example of a relationship between a laser beam irradiation position and an optical sensor installation position at the time of inspection in the first embodiment. 6B is a top view illustrating an example of the relationship between the laser light irradiation position and the optical sensor installation position illustrated in FIG. 6A. FIG. 7 is an explanatory diagram illustrating an example of a method for determining an unsolidified portion in the first embodiment. FIG. 8A is an explanatory diagram illustrating an example of the irradiation direction of the inspection laser beam and the position where the optical sensor is installed. FIG. 8B is a graph illustrating an example of a measurement result of the amount of diffusely reflected light measured with the positional relationship illustrated in FIG. 8A. FIG. 9 is a flowchart showing the flow of the modeling process in the first embodiment. FIG. 10 is a flowchart showing the flow of calibration data acquisition processing in the first embodiment. FIG. 11 is a flowchart showing the flow of the one-layer modeling process in the first embodiment. FIG. 12 is a flowchart showing the flow of the surface state determination process in the first embodiment. FIG. 13 is a flowchart showing the flow of the selective re-irradiation process in the first embodiment. FIG. 14A is a perspective view illustrating an example of a relationship between a laser light irradiation position and an optical sensor installation position at the time of inspection in the second embodiment. 14B is a top view illustrating an example of a relationship between the laser light irradiation position and the optical sensor installation position illustrated in FIG. 14A. FIG. 14C is a top view illustrating another example of the relationship between the laser light irradiation position and the optical sensor installation position. FIG. 15 is an explanatory diagram illustrating an example of a method for determining an unsolidified portion in the second embodiment.

(Manufacturing apparatus for three-dimensional structure, manufacturing method for three-dimensional structure, and manufacturing program for three-dimensional structure)
The apparatus for manufacturing a three-dimensional object of the present invention operates as an apparatus for executing the method for manufacturing a three-dimensional object of the present invention by reading and executing the manufacturing program for the three-dimensional object of the present invention. That is, the three-dimensional object manufacturing apparatus of the present invention has the three-dimensional object manufacturing program of the present invention that causes a computer to execute the same function as the method of manufacturing the three-dimensional object of the present invention.
In other words, the three-dimensional object manufacturing apparatus of the present invention is synonymous with carrying out the method of manufacturing the three-dimensional object of the present invention, and therefore the three-dimensional object of the present invention is explained through the description of the apparatus for manufacturing the three-dimensional object of the present invention. Details of the manufacturing method will be clarified. Moreover, the manufacturing program of the three-dimensional molded item of this invention is implement | achieved as a manufacturing apparatus of the three-dimensional molded item of this invention by using the computer etc. as a hardware resource. For this reason, the details of the manufacturing program for the three-dimensional object of the present invention will be clarified through the description of the manufacturing apparatus for the three-dimensional object of the invention.
In addition, the manufacturing program of the three-dimensional modeled object of the present invention is not limited to be executed by the three-dimensional modeled object manufacturing apparatus of the present invention. For example, the three-dimensional structure manufacturing program of the present invention may be executed by another computer or server, and any one of the three-dimensional structure manufacturing apparatus, other computer, and server of the present invention executes in cooperation. May be.

The manufacturing apparatus for a three-dimensional structure of the present invention includes a modeling unit that models a layered model from a modeling material, a light irradiation unit that irradiates light on the surface of the layered model formed by the modeling unit, and a light irradiation unit. Measuring means for measuring the amount of light reflected by the surface of the layered object, and further having other parts or means as necessary.
The manufacturing apparatus of the three-dimensional structure according to the present invention is based on the knowledge that, even if the distortion of the three-dimensional structure can be suppressed in the prior art, the quality of the solid structure is not improved. Is based.

<Modeling means>
The modeling means models a layered model from a modeling material.

Examples of a modeling method for a three-dimensional model that integrates modeling materials include an SLS (Selective Laser Sintering) method and a binder jet (Binder Jetting) method.
The SLS method is a method of manufacturing a three-dimensional model by melting and integrating the powder material by selectively irradiating the powder material with energy such as laser light.
The binder jet method is a method of manufacturing a three-dimensional structure by discharging ink containing a binder resin onto a powder material by an ink jet method or the like and integrating them.

There is no restriction | limiting in particular as a modeling means used by a SLS system, According to the objective, it can select suitably. Examples of the SLS modeling means include a combination of an electromagnetic radiation source and a mechanism capable of supplying a powder material in layers.
Examples of the electromagnetic radiation source include a CO ₂ laser, an infrared radiation source, a microwave generator, a radiation heater, and an LED (Light Emitting Diode) lamp. These may be used individually by 1 type and may use 2 or more types together.

  There is no restriction | limiting in particular as a modeling means used by a binder jet system, According to the objective, it can select suitably. Examples of the binder jet type modeling means include a combination of an inkjet type discharge head and a mechanism capable of supplying a powder material in layers.

<< Material for modeling >>
There is no restriction | limiting in particular as a modeling material used by a SLS system, According to the objective, it can select suitably, For example, a powder material etc. are mentioned.
The powder material used in the SLS method preferably contains a crystalline thermoplastic resin.

The crystalline thermoplastic resin means a crystalline resin having thermoplasticity, and has a melting peak when measured by ISO 3146 (Plastic Transition Temperature Measurement Method, JIS K7121).
Examples of the crystalline thermoplastic resin include polymers such as polyolefin, polyamide, polyester, polyether, polyphenylene sulfide, liquid crystal polymer (LCP), polyacetal (POM, melting point: 175 ° C.), polyimide, and fluororesin. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the polyolefin include polyethylene and polypropylene (PP, melting point: 180 ° C.). These may be used individually by 1 type and may use 2 or more types together.

  Examples of the polyamide include polyamide 410 (PA410), polyamide 6 (PA6), polyamide 66 (PA66, melting point: 265 ° C.), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 11 (PA11), polyamide 12 ( PA12); semi-aromatic polyamide 4T (PA4T), polyamide MXD6 (PAMXD6), polyamide 6T (PA6T), polyamide 9T (PA9T, melting point: 300 ° C.), polyamide 10T (PA10T) and the like. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the polyester include polyethylene terephthalate (PET), polybutadiene terephthalate (PBT, melting point: 218 ° C.), polylactic acid (PLA), and the like. Among these, an aromatic polyester partially containing terephthalic acid or isophthalic acid is preferable in order to impart heat resistance. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the polyether include polyetheretherketone (PEEK, melting point: 343 ° C.), polyetherketone (PEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), and polyetheretherketoneketone (PEEKK). ), Polyether ketone ether ketone ketone (PEKEKK) and the like. These may be used individually by 1 type and may use 2 or more types together.

  Although it does not specifically limit as melting | fusing point of a powder material, 100 degreeC or more is preferable, It is more preferable that it is 150 degreeC or more, It is especially preferable that it is 200 degreeC or more. In addition, melting | fusing point can be measured using differential scanning calorimetry (DSC) based on ISO 3146 (Plastic transition temperature measuring method, JISK7121).

  The 50% cumulative volume particle size of the powder material is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 5 μm or more and 200 μm or less, and from the viewpoint of dimensional stability, 5 μm or more and 100 μm or less. Is more preferable, and 5 μm or more and 50 μm or less is particularly preferable.

  The volume average particle size / number average particle size (Mv / Mn) of the powder material is preferably 2.00 or less, more preferably 1.50 or less, and more preferably 1.20 or less, from the viewpoint of improvement in modeling accuracy and recoatability. Particularly preferred. The 50% cumulative volume particle size and Mv / Mn can be measured using, for example, a particle size distribution measuring apparatus (Microtrac MT3300EXII, manufactured by Microtrac Bell Co., Ltd.).

  As a powder material, arbitrary fluidizing agents, particle size agents, reinforcing agents and the like may be contained.

There is no restriction | limiting in particular as a modeling material used by a binder jet system, According to the objective, it can select suitably, For example, a powder material, a binder, etc. are mentioned.
The powder material used in the binder jet method preferably contains a substrate coated with a water-soluble organic material, and further contains other components as necessary.

The substrate is not particularly limited as long as it has a powder or particle form, and can be appropriately selected according to the purpose. Examples of the material include metals, ceramics, carbon, polymers, wood, biocompatible materials, and the like. Is mentioned. Among these, metals and ceramics that can be finally sintered are preferable from the viewpoint of obtaining a high-strength three-dimensional model.
As a metal, stainless steel (SUS) steel, iron, copper, titanium, silver etc. are mentioned suitably, for example, As this stainless steel (SUS) steel, SUS316L etc. are mentioned, for example.
Examples of ceramics include metal oxides, and specific examples include silica (SiO ₂ ), alumina (Al ₂ O ₃ ), zirconia (ZrO ₂ ), titania (TiO ₂ ), and the like.
Examples of carbon include graphite, graphene, carbon nanotube, carbon nanohorn, and fullerene.
Examples of the polymer include known resins that are insoluble in water.
Examples of the wood include wood chips and cellulose.
Examples of the biocompatible material include polylactic acid and calcium phosphate.
These materials may be used alone or in combination of two or more.

The average particle size of the substrate is not particularly limited and may be appropriately selected depending on the intended purpose. For example, it is preferably 0.1 μm to 500 μm, more preferably 5 μm to 300 μm, and further preferably 15 μm to 250 μm. preferable.
When the average particle size is 0.1 μm or more and 500 μm or less, the manufacturing efficiency of the three-dimensional structure is excellent, and the handleability and handling properties are good. When the average particle diameter is 500 μm or less, when a thin layer is formed using the powder material, the filling rate of the powder material in the thin layer is improved, and voids or the like are hardly generated in the resulting three-dimensional structure. .
The average particle size of the substrate can be measured according to a known method using a known particle size measuring device such as Microtrac HRA (manufactured by Nikkiso Co., Ltd.).
There is no restriction | limiting in particular as particle size distribution of a base material, According to the objective, it can select suitably.

  The water-soluble organic material is not particularly limited as long as it is soluble in water and has a property capable of being crosslinked by the action of a crosslinking agent, in other words, as long as it is water-soluble and can be crosslinked by the crosslinking agent. And can be appropriately selected according to the purpose.

The average particle size of the powder material is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 3 μm or more and 250 μm or less, more preferably 3 μm or more and 200 μm or less, and further preferably 5 μm or more and 150 μm or less. The thickness is particularly preferably 85 μm or less.
When the average particle size is 3 μm or more, the fluidity of the powder material is improved, the powder material layer is easy to form, and the smoothness of the surface of the laminated layer is improved. There is a tendency that the dimensional accuracy is improved with improvement. Further, when the average particle size is 250 μm or less, the size of the space between the powder material particles becomes small, so that the void ratio of the shaped article becomes small, which contributes to the improvement of the strength. Therefore, an average particle diameter of 3 μm or more and 250 μm or less is a preferable range for achieving both dimensional accuracy and strength.
There is no restriction | limiting in particular as particle size distribution of a powder material, According to the objective, it can select suitably.

There is no restriction | limiting in particular as binder used by a binder jet system, According to the objective, it can select suitably, For example, what contains the crosslinking agent bridge | crosslinked with a water-soluble organic material, and an aqueous medium is mentioned.
Examples of the aqueous medium include water, alcohols such as ethanol, ethers, ketones, and the like. Among these, water is preferable. In addition, as an aqueous medium, water may contain some components other than water, such as alcohol.
The crosslinking agent is not particularly limited as long as it has a property capable of crosslinking a water-soluble organic material, and can be appropriately selected according to the purpose. For example, metal salt, metal complex, zirconia-based crosslinking agent, titanium Examples thereof include a system crosslinking agent, a water-soluble organic crosslinking agent, and a chelating agent.

<< Layered Model >>
The layered shaped article means a shaped article that can be solidified one by one using a laser or binder on a layered powder material, and can be produced by stacking.

<Light irradiation means>
A light irradiation means irradiates light to the surface of the layered modeling thing modeled by the modeling means.
The light irradiation means is not particularly limited and can be appropriately selected according to the purpose. For example, an LED lamp can be used. From the viewpoint of reducing the number of parts, an output from an electromagnetic irradiation source used as a modeling means or the like. It is preferable to use together with weakening to the extent that the modeling material is not integrated.

<Measuring means>
The measuring means measures the amount of light reflected by the surface of the layered object by the light irradiated by the light irradiation means.
Examples of the measuring means include a light receiving element. Examples of the light receiving element include a photodiode.
The measuring means preferably has a plurality of light receiving elements. Thereby, the measurement means can suppress the light receiving sensitivity from being lowered even when there is an influence such as the flatness of the surface of the layered object or the inclination of the layered object itself. For example, when there are two light receiving elements, it is preferable to install the two light receiving elements so that the light receiving axes are orthogonal to each other on a plane parallel to the surface of the layered object. For example, when there are three light receiving elements, the three light receiving elements may be installed so that the light receiving axes of adjacent light receiving elements are 120 ° on a plane parallel to the surface of the layered object. preferable.

  The measuring means is preferably arranged at a position where the regular reflection light reflected by the surface of the layered structure does not enter. Thereby, since a measurement means does not receive strong regular reflection light, it becomes difficult to break. Moreover, the measurement means can detect the unsolidified portion by receiving diffusely reflected light diffusely reflected by the powder material of the unsolidified portion on the surface of the layered structure.

  Preferably, the measuring means measures the light amount before and after the modeling material is integrated by the modeling means. When the measurement means measures the light amount before and after integrating the modeling material, the determination unit described later determines whether or not the portion is an unsolidified portion based on the change in the light amount before and after integrating the modeling material. It can be done reliably.

<Other parts or means>
Other parts or means are not particularly limited and may be appropriately selected depending on the intended purpose. However, it is preferable to have a scanning means, a calibration part, and a determination part.

<< Scanning means >>
The scanning means scans the light applied to the surface of the layered structure. Thereby, the determination part can determine whether it is an unsolidified part for every predetermined coordinate in the range scanned with the scanning means.
Examples of the scanning unit include a reflecting mirror capable of controlling the angle at which the light irradiated from the light irradiation unit is received. In the case of the SLS method, from the viewpoint of reducing the number of parts, it is preferable to use a reflecting mirror that is also used as a modeling means.

<< Calibration section >>
The calibration unit can calibrate the measurement sensitivity of the measurement unit based on the light amount measured by scanning the scanning material with light before the modeling material is integrated by the modeling unit. This is because, as the light irradiation position moves away from the measuring means, the light amount becomes weaker, so as a pretreatment, the light for the modeling material is irradiated so as not to melt, and the light amount with respect to the irradiation position is measured. Calibrate so that the measured irradiation position is constant. Thereby, the determination part can perform determination irrespective of the change of the measured value of the light quantity with respect to the position where light is scanned.

<< determination unit >>
The determination unit determines the state of the surface of the layered object based on the amount of light measured by the measuring unit. Thus, the modeling means can re-integrate the modeling material determined to be an unsolidified portion by the determination unit, so that there is no portion that is not integrated on the surface of the layered modeled object. The quality can be improved in terms of strength.

  Thus, the manufacturing apparatus of the three-dimensional structure of the present invention irradiates the surface of the layered structure formed from the powdered material for modeling, and measures the amount of light reflected by the surface of the layered structure. To do. Thereby, in the manufacturing apparatus of the three-dimensional structure according to the present invention, when the powdered unsolidified portion remains on the surface of the layered structure, the light irradiated to the powder material that is the unsolidified portion is diffusely reflected. The unsolidified portion can be detected by measuring the reflected light. And the manufacturing apparatus of the three-dimensional molded item of this invention can manufacture the three-dimensional molded item with few internal unsolidified parts by laminating | stacking the layered molded item made to resolidify the detected non-solidified part. .

Hereinafter, although embodiment of this invention is described, this invention is not limited to these embodiment at all.
In addition, the number, position, shape, and the like of the following constituent members are not limited to the present embodiment, and can be set to a preferable number, position, shape, and the like in carrying out the present invention.

(First embodiment)
Drawing 1 is an explanatory view showing the manufacturing device of the solid fabrication thing in a 1st embodiment.
As shown in FIG. 1, the three-dimensional structure manufacturing apparatus 100 is an SLS manufacturing apparatus, and includes an electromagnetic radiation source 1, a reflecting mirror 2, a heater 3, a roller 4, a supply tank 5, and a laser. It has a scanning space 6, an optical sensor 7, and a temperature / humidity sensor 8 (not shown). The electromagnetic radiation source 1, the reflecting mirror 2, the heater 3, the roller 4, the supply tank 5, the laser scanning space 6, and the temperature / humidity sensor 8 may be referred to as “modeling means 10”.
In order to manufacture a three-dimensional object, the three-dimensional object manufacturing apparatus 100 first forms a layer of the powder material in the laser scanning space 6 using the roller 4 from the supply tank 5 that stores the powder material as a material for modeling. And supply. Next, the manufacturing apparatus 100 of a three-dimensional molded item irradiates the laser beam for modeling output from the electromagnetic irradiation source 1 by using the reflecting mirror 2 to scan the laser scanning space 6, and uses the heat of the laser beam to irradiate the powder material. To form a layered structure. Next, the manufacturing apparatus 100 for a three-dimensional structure performs scanning while irradiating the surface of the layered object with the weak inspection laser light output from the electromagnetic irradiation source 1, and diffused and reflected from the surface of the layered object. An unsolidified portion is detected by measuring the amount of light with the optical sensor 7. And the manufacturing apparatus 100 of a three-dimensional molded item resolidifies the unsolidified part of the surface of a layered modeled object, and laminates the layered modeled object which suppressed the generation | occurrence | production of the non-solidified part, and there are few inside solidified parts. A model can be manufactured.

The electromagnetic irradiation source 1 irradiates the reflecting mirror 2 with laser light according to an instruction from the control unit 120 described later. The electromagnetic irradiation source 1 has a laser beam intensity controlled by the control unit 120 and has a strength capable of melting the powder material, and a calibration laser beam and an inspection laser having a strength that does not melt the powder material. Can be irradiated.
There is no restriction | limiting in particular as an intensity | strength of a laser beam, Although it can select suitably according to the objective, 10 watts or more and 150 watts or less are preferable.

  Based on the optical system control amount calculated by the control unit 120, the reflection mirror 2 is controlled in reflection angle so as to scan the laser scanning space 6 with the laser light emitted from the electromagnetic irradiation source 1.

  The heater 3 adjusts the temperature of the supply tank 5 and the laser scanning space 6 according to the result of measurement by the temperature / humidity sensor 8 according to an instruction from the control unit 120. The temperature of the supply tank 5 is preferably at least 10 ° C. lower than the melting point of the powder material. The part bed temperature in the laser scanning space 6 is preferably 5 ° C. or more lower than the melting point of the powder material.

  The roller 4 supplies the laser scanning space 6 from the supply tank 5 that stores the powder material according to an instruction from the control unit 120.

  The bottom of the supply tank 5 can be moved up and down. When the powder material on the upper surface is supplied to the laser scanning space 6 by the roller 4 in accordance with an instruction from the control unit 120, the bottom is configured so that the next powder material can be supplied. To rise.

  The bottom of the laser scanning space 6 can be moved up and down. When the powder material supplied by the roller 4 is solidified by laser light, the bottom is lowered so that the next layered structure can be formed. When the powder material is supplied to the laser scanning space 6, the bottom is raised so that the next powder material can be supplied.

  In this embodiment, the optical sensor 7 as a measuring means is a single photodiode, and is arranged at a position where regular reflection light reflected by irradiating the surface of the layered object with laser light for calibration or inspection is not incident. Has been.

FIG. 2 is a block diagram illustrating a hardware configuration of the manufacturing apparatus for a three-dimensional structure according to the first embodiment.
As illustrated in FIG. 2, the three-dimensional object manufacturing apparatus 100 according to the first embodiment includes a CPU 101, a ROM 102, a RAM 103, an NVRAM 104, an ASIC 105, an external I / F 106, an HDD 107, and an I / O 108. Have
In addition, the manufacturing apparatus 100 of the three-dimensional molded item in 1st Embodiment is the electromagnetic irradiation source 1, the reflective mirror 2, the heater 3, the roller 4, the supply tank 5, the laser scanning space 6, and the optical sensor 7. FIG. The temperature / humidity sensor 8 is similar to the description of FIG.

A CPU (Central Processing Unit) 101 is a type of processor and is a processing device that performs various controls and operations. The CPU 101 implements various functions by executing an OS (Operating System) and programs stored in the ROM 102 and the like. That is, in this embodiment, the CPU 101 functions as a control unit 120 described later by executing a liquid supply error detection program.
The CPU 101 is used to control the operation of the entire three-dimensional object manufacturing apparatus 100. In the present embodiment, the apparatus that controls the operation of the entire three-dimensional object manufacturing apparatus 100 is the CPU 101. However, the present invention is not limited to this, and may be, for example, an FPGA (Field Programmable Gate Array). These may be used alone or in combination of two or more.

A ROM (Read Only Memory) 102 stores fixed data such as a manufacturing program for a three-dimensional structure of the present invention executed by the CPU 101 and various programs such as other BIOS (Basic Input / Output System).
In addition, the manufacturing program of a three-dimensional molded item does not necessarily need to be stored in the manufacturing apparatus 100 for a three-dimensional molded item from the beginning. The three-dimensional structure manufacturing program may be stored and executed in, for example, another information processing apparatus that is communicably connected to the three-dimensional structure manufacturing apparatus 100 via the Internet or the like. The three-dimensional object manufacturing program may be stored in, for example, a computer-readable recording medium, and the three-dimensional object manufacturing apparatus 100 may acquire and execute a liquid supply error detection program from this recording medium. Examples of the recording medium include a portable recording medium, a semiconductor memory, and a hard disk. Examples of the portable recording medium include a CD (Compact Disc) -ROM (Read Only Memory), a USB (Universal Serial Bus) memory, and the like. An example of the semiconductor memory is a flash memory.

  A RAM (Random Access Memory) 103 functions as a work range that is developed when various programs are executed by the CPU 101. There is no restriction | limiting in particular as RAM, According to the objective, it can select suitably. Examples of the RAM include DRAM (Dynamic Random Access Memory) and SRAM (Static Random Access Memory).

  An NVRAM (Non-Volatile RAM) 104 is a non-volatile memory for holding data while the power of the apparatus is shut off.

  An ASIC (Application Specific Integrated Circuit) 105 processes image processing for performing various signal processing on image data and other input / output signals for controlling the entire apparatus.

An external I / F (Interface) 106 is connected to the modeling data creation device 600 so as to be communicable, and receives modeling data from the modeling data creation device 600.
The modeling data creation device 600 is a device that creates modeling data (cross-sectional data) that is slice data obtained by slicing a final modeled product (three-dimensional modeled product) for each layered modeled product. Device. The modeling data is data (modeling area data) for forming the model material 301a in each layered model 30 as slice data obtained by slicing the shape of the target three-dimensional model.

  An HDD (Hard Disk Drive) 107 stores and stores various data from the sensor received by the I / O 108 according to an instruction from the control unit 120. The HDD 107 stores various normal operation profiles, which will be described later. The HDD 107 may store the liquid supply error detection program of the present invention.

An I / O (Input Output) 108 receives output signals from the temperature / humidity sensor 8 and the optical sensor 7.
The temperature / humidity sensor 8 measures temperature and humidity as environmental conditions of the apparatus.
The optical sensor 7 measures the amount of diffusely reflected light diffusely reflected from the surface of the layered object irradiated with the calibration laser light or the inspection laser light.

  An operation panel 500 for inputting and displaying necessary information is connected to the three-dimensional structure manufacturing apparatus 100.

FIG. 3 is a block diagram illustrating a functional configuration of the three-dimensional structure manufacturing apparatus according to the first embodiment.
As illustrated in FIG. 3, the three-dimensional object manufacturing apparatus 100 includes a communication unit 110, a control unit 120, a storage unit 130, and an input / output unit 140.

  The communication unit 110 can receive various data using the external I / F 106 and the I / O 108 illustrated in FIG. 2 based on an instruction from the control unit 120.

  The control unit 120 includes a calibration unit 121 and a determination unit 122.

<< Calibration section >>
The calibration unit 121 scans the powder material with the laser beam for calibration with the reflecting mirror 2 and integrates the powder material with the modeling means 10, and based on the light quantity measured by the optical sensor 7, the irradiation position of the laser light It is possible to calibrate the measurement sensitivity of the optical sensor 7 that changes due to the above.

FIG. 4A is a top view showing the relationship between the laser light irradiation position and the optical sensor installation position.
Here, as shown in FIG. 4A, the laser beam is irradiated from the reflecting mirror 2 (not shown) arranged at the position O to the position P1, and the laser beam is emitted from the position P1 in the scanning direction indicated by the arrow A in FIG. 4A. Consider the case of irradiating and irradiating the position P2 with laser light. That is, consider a case where the optical sensor 7 measures the diffuse reflected light DR1 from the position P1 and the diffuse reflected light DR2 from the position P2.

FIG. 4B is an explanatory diagram illustrating a solid angle when the laser beam is irradiated to the position P1 in FIG. 4A. FIG. 4C is an explanatory diagram showing a solid angle when the laser beam is irradiated to the position P2 in FIG. 4A. 4B and 4C, the lens 7a of the optical sensor 7 is shown exaggerated and enlarged for the sake of explanation. Moreover, the optical sensor 7 is arrange | positioned in the position which does not detect regular reflection light R1 and R2 in any figure, and detects diffuse reflection light DR1 and DR2.
As shown in FIG. 4B, when the laser beam L1 is irradiated to the position P1, the diffuse reflected light DR1 is incident on the lens 7a with the size of the solid angle S1. As shown in FIG. 4C, when the laser beam L1 is irradiated to the position P2, the diffuse reflected light DR2 enters the lens 7a with the size of the solid angle S2. When the solid angle S1 and the solid angle S2 shown in FIG. 4B are compared, it can be seen that the solid angle S2 is larger than the solid angle S1. That is, the size of the solid angle changes depending on the distance from the laser irradiation position to the optical sensor 7. Further, since the amount of diffuse reflected light to be measured increases as the solid angle increases, as shown in FIG. 5A, the measured amount of diffuse reflected light and the distance from the laser irradiation position to the optical sensor 7 are proportional to each other. It becomes. When the calibration unit 121 performs calibration so as to cancel this proportional relationship, as shown in FIG. 5B, the amount of diffusely reflected light measured by the distance from the laser irradiation position to the optical sensor 7 can be prevented from changing.

FIG. 6A is a perspective view illustrating an example of a relationship between a laser beam irradiation position and an optical sensor installation position at the time of inspection in the first embodiment. 6B is a top view illustrating an example of the relationship between the laser light irradiation position and the optical sensor installation position illustrated in FIG. 6A.
As shown in FIGS. 6A and 6B, when the inspection laser light L1 is irradiated from the reflecting mirror 2 to the position P1 on the surface of the layered object on the laser scanning space 6, the optical sensor 7 emits the regular reflected light R1. Since it is arranged at a position where it is not detected, the amount of diffuse reflected light DR1 is measured.

<< determination unit >>
The determination unit 122 determines the state of the surface of the layered object based on the amount of light measured by the optical sensor 7.

FIG. 7 is an explanatory diagram illustrating an example of a method for determining an unsolidified portion in the first embodiment.
When the inspection laser beam is scanned on the surface of the layered object as indicated by the broken line arrow at the top in FIG. 7, if there is an unsolidified portion N in addition to the solidified portion M, the light quantity D1 at the bottom in FIG. As shown, the amount of diffusely reflected light is reduced in the solidified portion M, and the amount of light is increased in the unsolidified portion N. In other words, in the light amount D1, the measured value of the diffuse reflected light amount in the unsolidified portion N is close to the diffuse reflected light amount in the unirradiated portion in the powder state. For this reason, the determination part 122 can determine an unsolidified part based on a threshold value by setting predetermined light quantity as a threshold value.

  Specifically, FIG. 8B shows the results of actual measurement of the unmelted powder material and the melted powder material under the inspection conditions shown in FIG. 8A and Table 1. As shown in FIG. 8B, the unmelted powder material obtained a diffuse reflected light output that is about 20% higher than the molten powder material, that is, a diffused light quantity D1. In the case of the diffuse reflected light output as shown in FIG. 8B, the determination unit 122 can determine the unsolidified portion by setting the threshold value to about 2.8V.

  Note that D2 in the lower part of FIG. 7 indicates a case where the absolute value of the light quantity to be measured changes depending on the dirt of the lens of the optical sensor 7 or the shape of the powder material. In such a case, as a method of determining the unsolidified portion, for example, a method of measuring the light amount before and after irradiating the laser beam for modeling and obtaining the difference, a method based on the light amount of the solidified portion, unirradiated Examples include a method in which the portion is 1 and the minimum value of the solidified portion is 0.

  The storage unit 130 stores calibration data 131 and inspection data 132 in the HDD 107 illustrated in FIG. 3 based on an instruction from the control unit 120.

  The input / output unit 140 accepts various instructions to the manufacturing apparatus 100 for a three-dimensional structure based on the operation panel 500 illustrated in FIG.

  FIG. 9 is a flowchart showing the flow of the modeling process in the first embodiment. Here, the flow of the modeling process will be described in accordance with steps represented by S in the flowchart shown in FIG.

  In step S101, when the calibration unit 121 executes the calibration data acquisition process, the process proceeds to S102. The details of the calibration data acquisition process will be described later according to the flowchart shown in FIG.

  In step S102, when the control unit 120 reads the three-dimensional data from the storage unit 130, the control unit 120 proceeds to S103.

  In step S103, when the control unit 120 executes slice processing for calculating slice data obtained by dividing the three-dimensional data read in S102 into parallel sections of a predetermined interval, the process proceeds to S104.

  In step S104, when the control unit 120 supplies the powder material from the supply tank 5 to the modelable region by the roller 4, the process proceeds to S105.

  In step S105, when the control unit 120 executes the one-layer modeling process, the process proceeds to S106. Details of the one-layer modeling process will be described later according to the flowchart shown in FIG.

  In step S106, when the control unit 120 determines that the stacking of the layered objects has not been completed in manufacturing the three-dimensional object, the process proceeds to S104. Moreover, if the control part 120 determines that all lamination | stacking of the layered modeling thing was complete | finished in manufacturing a three-dimensional molded item, this process will be complete | finished.

  FIG. 10 is a flowchart showing the flow of calibration data acquisition processing in the first embodiment. Here, the flow of the calibration data acquisition process executed in S101 will be described according to the steps represented by S in the flowchart shown in FIG.

  In step S201, when the calibration unit 121 sets the coordinates for irradiating the laser beam from the electromagnetic irradiation source 1 to the entire surface of the modelable area, the process proceeds to S202.

  In step S202, when the calibration unit 121 calculates an optical system control amount for controlling the angle of the reflecting mirror 2 in order to irradiate the laser beam on the coordinates set in S201, the process proceeds to S203.

  In step S203, when the calibration unit 121 starts measuring the amount of light using the optical sensor 7, the process proceeds to S204.

  In step S204, the calibration unit 121 scans the calibration laser light emitted from the electromagnetic radiation source 1 by controlling the angle of the reflecting mirror 2 based on the optical system control amount calculated in S202, and performs each coordinate set in S201. If the light amount is measured by the optical sensor 7, the process proceeds to S205.

  In step S <b> 205, the calibration unit 121 stores the light amount data measured in step S <b> 204 in the storage unit 130 as calibration data, and ends this processing.

  FIG. 11 is a flowchart showing the flow of the one-layer modeling process in the first embodiment. Here, the flow of the one-layer modeling process executed in S105 will be described according to the steps represented by S in the flowchart shown in FIG.

  In step S301, when the control unit 120 reads the slice data calculated in step S103 from the storage unit 130, the control unit 120 proceeds to step S302.

  In step S302, when the control unit 120 calculates the coordinates for controlling the angle of the reflecting mirror 2 and the optical system control amount based on the slice data read in S301, the process proceeds to S303.

  In step S303, when the control unit 120 stores the coordinates and optical system control amount calculated in step S302, the control unit 120 proceeds to step S304.

  In step S304, the control unit 120 controls the angle of the reflecting mirror 2 based on the coordinates calculated in step S302 and the optical system control amount to scan the modeling laser beam irradiated from the electromagnetic irradiation source 1, and the laser scanning space 6 When the powder material is melted, the process proceeds to S305.

  In step S305, when the control unit 120 sets the electromagnetic irradiation source 1 to the output of the inspection laser beam, the process proceeds to S306.

  In step S306, when the control unit 120 reads the optical system control amount calculated in step S202, the control unit 120 proceeds to step S307.

  In step S307, the control unit 120 scans the inspection laser light emitted from the electromagnetic irradiation source 1 by controlling the angle of the reflecting mirror 2 based on the optical system control amount calculated in S202, and performs each coordinate set in S201. If the light amount is measured by the optical sensor 7, the process proceeds to S308.

  In step S308, when the control unit 120 saves the light amount data measured in step S307 as inspection data in the storage unit 130, the control unit 120 proceeds to step S309.

  In step S309, the determination part 122 will transfer to S310, if a surface state determination process is performed. The details of the surface state determination process will be described later according to the flowchart shown in FIG.

  In step S310, when the control unit 120 executes the selective re-irradiation process, the process proceeds to S311. The details of the selective re-irradiation process will be described later according to the flowchart shown in FIG.

  In step S311, the control unit 120 ends the process when the heater 3 is turned off and cooled.

  FIG. 12 is a flowchart showing the flow of the surface state determination process in the first embodiment. Here, the flow of the surface state determination process executed in S309 will be described according to the steps represented by S in the flowchart shown in FIG.

  In step S401, when the determination unit 122 reads calibration data at the coordinates (x, y) from the storage unit 130, the determination unit 122 proceeds to S402.

  In step S402, when the determination unit 122 reads the inspection data at the coordinates (x, y) from the storage unit 130, the determination unit 122 proceeds to S403.

  In step S403, when the determination unit 122 compares the calibration data at the coordinates (x, y) and the inspection data, the process proceeds to S404.

  In step S404, when the determination unit 122 determines that the powder material at the coordinates (x, y) is not melted, the process proceeds to S405. If the determination unit 122 determines that the powder material at the coordinates (x, y) is melted, the process proceeds to S406.

  In step S405, when the determination unit 122 sets a flag for the coordinates (x, y), the process proceeds to S406.

  In step S406, if the determination unit 122 determines that the melting determination for all coordinates is not completed, the process returns to S403. Moreover, if the determination part 122 determines with the melting determination in all the coordinates having been complete | finished, this process will be complete | finished.

  FIG. 13 is a flowchart showing the flow of the selective re-irradiation process in the first embodiment. Here, the flow of the selective re-irradiation process executed in S310 will be described according to the steps represented by S in the flowchart shown in FIG.

  In step S501, when the control unit 120 reads from the storage unit 130 the unmelted coordinates or two or more unmelted coordinate groups for which the flag has been set in step S405, the process proceeds to step S502.

In step S502, when the control unit 120 calculates an optical system control amount for controlling the angle of the reflecting mirror 2 in order to irradiate the modeling laser beam read in S501 with the modeling laser light, the process proceeds to S503.
In step S503, based on the optical system control amount calculated in S502, the control unit 120 controls the angle of the reflecting mirror 2 to re-irradiate the modeling laser beam irradiated from the electromagnetic irradiation source 1, and is unmelted. When the powder material at the determined coordinates is melted, the present process is terminated.

  Thus, the manufacturing apparatus 100 of the three-dimensional structure according to the first embodiment is used for inspection on the surface of the layered structure that is formed by integrating the powder material after calibrating the change in the amount of light depending on the irradiation position in advance. Laser light is irradiated and the amount of diffusely reflected light is measured. Thereby, the manufacturing apparatus 100 of the three-dimensional molded item of 1st Embodiment determines whether it is an unsolidified part based on the light quantity diffusely reflected, and when there exists an unsolidified part, it remelts an unsolidified part. Therefore, it is possible to manufacture a three-dimensional structure with few unsolidified parts inside.

In addition, the various processes which the manufacturing apparatus 100 of the three-dimensional molded item in 1st Embodiment performs are performed by the computer which has a control part which forms the manufacturing apparatus 100 of the three-dimensional molded article.
The computer is not particularly limited as long as it is a device equipped with devices such as storage, calculation, and control, and can be appropriately selected according to the purpose. Examples thereof include a personal computer.

(Second Embodiment)
In the first embodiment, it has been described that the amount of diffusely reflected light is measured by one optical sensor, and the selective re-irradiation process is performed on the detected unsolidified portion. In the second embodiment, two light beams are used. An example in which a decrease in light receiving sensitivity can be suppressed by using a sensor will be described.
Below, the point which uses two photosensors which is a different point from 1st Embodiment is demonstrated.

FIG. 14A is a perspective view illustrating an example of a relationship between a laser light irradiation position and an optical sensor installation position at the time of inspection in the second embodiment. 14B is a top view illustrating an example of a relationship between the laser light irradiation position and the optical sensor installation position illustrated in FIG. 14A.
As shown in FIGS. 14A and 14B, the two optical sensors 7A and 7B are arranged on the same short side of the laser scanning space 6 and at positions where the regular reflected light R1 is not detected. For this reason, when the laser beam L1 for inspection is irradiated from the reflecting mirror 2 to the position P1 on the surface of the layered object on the laser scanning space 6, the optical sensors 7A and 7B have diffuse reflection light from the surface of the layered object. The amount of light of DR1 is measured.
As another arrangement example of the optical sensors 7A and 7B, as shown in FIG. 14C, the optical sensors 7A and 7B are installed so that the light receiving axes are orthogonal to each other on a plane parallel to the surface of the layered object. It may be.

FIG. 15 is an explanatory diagram illustrating an example of a method for determining an unsolidified portion in the second embodiment.
As shown in the upper part of FIG. 15, the product of the light amounts measured by the two optical sensors 7A and 7B is calculated. If the product is greater than or equal to a predetermined threshold value, 1 (unsolidified portion) is obtained. (Part)), high-frequency and low-frequency noise is removed, and an unsolidified part can be detected more clearly. Thereby, the determination part 122 determines an unsolidified part more reliably by using the two optical sensors 7A and 7B even if there is an influence such as the flatness of the surface of the layered object or the inclination of the layered object itself. can do.

  Thus, the manufacturing apparatus 100 of the three-dimensional molded item of 2nd Embodiment can suppress the fall of a light reception sensitivity by using the two optical sensors 7A and 7B.

As an aspect of this invention, it is as follows, for example.
<1> modeling means for modeling a layered model from a modeling material;
A light irradiation means for irradiating light on the surface of the layered structure formed by the modeling means;
Measuring means for measuring the amount of light reflected by the surface of the layered object, the light irradiated by the light irradiation means;
It is the manufacturing apparatus of the three-dimensional molded item characterized by having.
<2> The three-dimensional structure manufacturing apparatus according to <1>, wherein the measurement unit is arranged at a position where the regular reflection light reflected by the surface of the layered structure is not incident.
<3> Manufacture of a three-dimensional structure according to any one of <1> to <2>, further including a determination unit configured to determine a surface state of the layered structure based on the light amount measured by the measurement unit. Device.
<4> The measurement unit measures the light amount before and after integrating the modeling material by the modeling unit,
The determination unit is the manufacturing apparatus for a three-dimensional structure according to <3>, wherein the determination is performed based on a change in the light amount before and after the modeling material is integrated.
<5> The 3D model manufacturing apparatus according to any one of <3> to <4>, wherein the modeling unit reintegrates the modeling material based on the determination.
<6> It further has a scanning unit that scans the light applied to the surface of the layered object,
The apparatus for manufacturing a three-dimensional structure according to any one of <3> to <5>, wherein the determination unit performs the determination for each position where the light is scanned by the scanning unit.
<7> Before integrating the modeling material by the modeling unit, the measurement sensitivity of the measuring unit is calibrated based on the light amount measured by scanning the light with the scanning unit with respect to the modeling material. It is a manufacturing apparatus of the three-dimensional molded item as described in said <6> which further has a calibration part to perform.
<8> The three-dimensional structure manufacturing apparatus according to any one of <1> to <7>, wherein the measuring unit includes a plurality of light receiving elements.
<9> A modeling process of modeling a layered model from a modeling material;
A light irradiation step of irradiating light on the surface of the layered structure formed by the modeling step;
A measurement step of measuring the amount of light reflected by the surface of the layered object, the light irradiated by the light irradiation step;
It is a manufacturing method of the three-dimensional molded item characterized by including.
<10> The manufacturing process for a three-dimensional structure according to <9>, wherein in the measurement process, the light amount is measured at a position where the regular reflection light reflected by the surface of the layered structure does not enter.
<11> The manufacturing of the three-dimensional structure according to any one of <9> to <10>, further including a determination step of determining the state of the surface of the layered structure based on the light amount measured in the measurement step. Is the method.
<12> The measurement step measures the light amount before and after integrating the modeling material in the modeling step,
The said determination process is a manufacturing method of the three-dimensional molded item as described in <11> which performs the said determination based on the change of the said light quantity before and after integrating the said modeling material.
<13> The method for manufacturing a three-dimensional structure according to any one of <11> to <12>, wherein the modeling step reintegrates the modeling material based on the determination.
<14> The method further includes a scanning step of scanning the light applied to the surface of the layered object.
The said determination process is a manufacturing method of the three-dimensional molded item in any one of said <11> to <13> which performs the said determination for every position where the said light was scanned by the said scanning process.
<15> A layered object is modeled from the modeling material,
Irradiate light to the surface of the layered modeled object,
Measure the amount of light reflected by the surface of the layered object, the irradiated light,
It is a manufacturing program of the three-dimensional molded item characterized by making a computer perform a process.
<16> The three-dimensional structure manufacturing program according to <15>, wherein the light amount is measured at a position where the regular reflection light reflected by the surface of the layered structure does not enter.
<17> The manufacturing program for a three-dimensional structure according to any one of <15> to <16>, wherein the determination of the surface state of the layered structure is further performed based on the measured light amount.
<18> Measure the light quantity before and after integrating the modeling material,
The manufacturing program for a three-dimensional structure according to <17>, wherein the determination is performed based on a change in the light amount before and after integrating the modeling material.
<19> The manufacturing program for a three-dimensional structure according to any one of <17> to <18>, wherein the modeling materials are integrated again based on the determination.
<20> Scan the light applied to the surface of the layered object,
The manufacturing program for a three-dimensional structure according to any one of <17> to <19>, wherein the determination is performed for each position scanned with the light.

  The manufacturing apparatus for a three-dimensional structure according to any one of <1> to <8>, the method for manufacturing a three-dimensional structure according to any one of <9> to <14>, and <20> to <20> According to the three-dimensional structure manufacturing program described in any one of the above, the above-described problems can be solved and the object of the present invention can be achieved.

JP2015-157420A

1 Electromagnetic irradiation source (light irradiation means)
2 Reflector (scanning means)
3 Heater 4 Roller 5 Supply tank 6 Laser scanning space 7, 7A, 7B Optical sensor (measuring means)
DESCRIPTION OF SYMBOLS 10 Modeling means 100 Manufacturing apparatus of three-dimensional molded item 120 Control part 121 Calibration part 122 Determination part

Claims (10)

Modeling means for modeling a layered model from a modeling material;
A light irradiation means for irradiating light on the surface of the layered structure formed by the modeling means;
Measuring means for measuring the amount of light reflected by the surface of the layered object, the light irradiated by the light irradiation means;
An apparatus for producing a three-dimensional structure, characterized by comprising:   The manufacturing apparatus of the three-dimensional molded item according to claim 1, wherein the measuring unit is arranged at a position where the regular reflection light reflected by the surface of the layered model is not incident.   The manufacturing apparatus of the three-dimensional molded item in any one of Claim 1 to 2 which further has a determination part which determines the state of the surface of the said layered molded item based on the said light quantity measured by the said measurement means. The measuring means measures the light amount before and after integrating the modeling material by the modeling means,
The manufacturing apparatus of the three-dimensional molded item according to claim 3, wherein the determination unit performs the determination based on a change in the light amount before and after the modeling material is integrated.   The manufacturing apparatus of the three-dimensional molded item in any one of Claim 3 to 4 in which the said modeling means unifies the said modeling material again based on the said determination. It further has scanning means for scanning the light to be irradiated onto the surface of the layered structure,
The manufacturing apparatus of the three-dimensional molded item according to any one of claims 3 to 5, wherein the determination unit performs the determination for each position where the light is scanned by the scanning unit.   A calibration unit that calibrates the measurement sensitivity of the measurement unit based on the light amount measured by scanning the light with the scanning unit and measuring the modeling material before integrating the modeling material with the modeling unit. The manufacturing apparatus of the three-dimensional molded item of Claim 6 which has further.   The manufacturing apparatus of the three-dimensional molded item according to any one of claims 1 to 7, wherein the measuring unit includes a plurality of light receiving elements. A modeling process for modeling a layered model from a modeling material;
A light irradiation step of irradiating light on the surface of the layered structure formed by the modeling step;
A measurement step of measuring the amount of light reflected by the surface of the layered object, the light irradiated by the light irradiation step;
The manufacturing method of the three-dimensional molded item characterized by including. A layered model is modeled from the modeling material,
Irradiate light to the surface of the layered modeled object,
Measure the amount of light reflected by the surface of the layered object, the irradiated light,
A manufacturing program for a three-dimensional structure, which causes a computer to execute processing.