JP2021138976A - Method for manufacturing three-dimensionally shaped molding - Google Patents

Abstract

To provide a method for manufacturing a three-dimensionally shaped molding having a ventilation part capable of favorably ventilating with the outside.SOLUTION: A method for manufacturing a three-dimensionally shaped molding comprises alternately and repeatedly laminating powder layers and solidified layers by performing a process (i) of irradiating a prescribed portion of a powder layer with light beam L and sintering or melting and solidifying powder in the prescribed portion so as to form a solidified layer, and a process (ii) of forming a new powder layer on the obtained solidified layer and irradiating the prescribed portion of the new powder layer with light beam to form a further solidified layer. Specifically, the method manufactures the three-dimensionally shaped molding having a high-density part and a low-density part, uses at least part of the low density part as a ventilation part, and re-irradiates an edge part forming a hole area at least composing part of the ventilation part with the light beam during or after formation of the solidified layer by irradiation of the light beam.SELECTED DRAWING: Figure 4

Description

The present invention relates to a method for manufacturing a three-dimensional shaped object. More specifically, the present invention relates to a method for producing a three-dimensional shaped object that forms a solidified layer by irradiating a powder layer with a light beam.

A method of producing a three-dimensional shaped object by irradiating a powder material with a light beam (generally referred to as a "powder bed melt bonding method") has been conventionally known. In such a method, powder layer formation and solidification layer formation are alternately and repeatedly carried out based on the following steps (i) and (ii) to produce a three-dimensional shaped object.
(I) A step of irradiating a predetermined portion of the powder layer with a light beam and sintering or melt-solidifying the powder at the predetermined portion to form a solidified layer.
(Ii) A step of forming a new powder layer on the obtained solidified layer and similarly irradiating with a light beam to form a further solidified layer.

According to such a manufacturing technique, it is possible to manufacture a complicated three-dimensional shaped object in a short time. When an inorganic metal powder is used as the powder material, the obtained three-dimensional shaped object can be used as a mold. On the other hand, when an organic resin powder is used as the powder material, the obtained three-dimensional shaped model can be used as various models.

Take, for example, a case where a metal powder is used as a powder material and a three-dimensional shaped object obtained by the metal powder is used as a mold. As shown in FIG. 12, first, the squeezing blade 23 is moved to form a powder layer 22 having a predetermined thickness on the modeling plate 21 (see FIG. 12A). Next, a predetermined portion of the powder layer 22 is irradiated with a light beam L to form a solidified layer 24 from the powder layer 22 (see FIG. 12B). Subsequently, a new powder layer is formed on the obtained solidified layer and irradiated with a light beam again to form a new solidified layer. When the powder layer formation and the solidified layer formation are alternately and repeatedly performed in this way, the solidified layer 24 is laminated (see FIG. 12 (c)), and finally, the three-dimensional structure composed of the laminated solidified layer 24 is formed. A shaped object can be obtained. Since the solidified layer 24 formed as the lowermost layer is in a state of being bonded to the modeling plate 21, the three-dimensional shaped model and the modeling plate 21 form an integrated product, and the integrated product can be used as a mold.

Special Table No. 1-502890

For example, according to the powder bed melt-bonding method, a three-dimensional shaped object 300' having a low-density portion 100a'and a high-density portion 200a' may be manufactured and used as a mold. In this case, in order to supply gas into the mold cavity or remove the generated gas from the mold cavity to the outside, the low-density portion 100a'extends in a predetermined direction so as to be ventilated to the outside. (See FIGS. 15 (a) to 15 (d)).

Here, the inventor of the present application has newly found that the following technical problems may occur when the obtained three-dimensional shaped object 300'has a venting portion 100'. Specifically, from the viewpoint of preventing the resin material from entering the ventilation portion 100'during the molding, the ventilation portion 100'forms a fine space, and the fine space is larger than a predetermined size. It can be smaller. This is due to the fact that powder or the like located in the unirradiated portion of the light beam adheres to the melt-solidified portion when the solidified layer including the low-density region forming a part of the ventilation portion 100'is formed. As a result, it may not be easy to suitably supply the gas into the mold cavity through the ventilation portion or to appropriately remove the generated gas from the mold cavity to the outside.

The present invention has been made in view of such circumstances. That is, an object of the present invention is to provide a method for manufacturing a three-dimensional shaped object having a venting portion that is suitably ventilated to the outside.

In order to achieve the above object, in one embodiment of the present invention,
(I) A step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt and solidify the powder at the predetermined portion to form a solidified layer, and (ii) a new powder on the obtained solidified layer. A three-dimensional shaped product is manufactured by alternately and repeatedly laminating the powder layer and the solidified layer by forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer. How to do
Manufacture the three-dimensional shaped object having a high-density portion and a low-density portion,
At least a part of the low density part is used as a ventilation part.
During the formation of the solidified layer by the irradiation of the light beam or after the formation of the solidified layer, the re-irradiation of the light beam is performed on at least the edge portion forming the hole region forming a part of the ventilation portion. , A method for manufacturing a three-dimensional shaped object is provided.

According to one embodiment of the present invention, it is possible to manufacture a three-dimensional shaped object having a venting portion that is suitably ventilated to the outside.

Schematic cross-sectional view showing the formation mode of the powder layer Schematic cross-sectional view showing the formation mode of the solidified layer Schematic cross-sectional view of powder removal mode Schematic cross-sectional view of the re-irradiation mode of the light beam Schematic cross-sectional view of the re-irradiation mode of the light beam Schematic plan view of the re-irradiation mode of the light beam Schematic plan view of the sequential re-irradiation mode of the light beam Schematic diagram of the irradiation path direction of the light beam Schematic plan view of the sequential re-irradiation mode of the light beam Schematic plan view of the batch re-irradiation mode of the light beam Schematic perspective view of the batch re-irradiation mode of the light beam Schematic plan view of the mode of cutting off deposits by re-irradiation of the light beam Schematic plan view of the evaporation mode of deposits due to re-irradiation of the light beam A cross-sectional view schematically showing a process mode of stereolithography composite processing in which the powder bed melt-bonding method is carried out (FIG. 12 (a): at the time of forming a powder layer, FIG. 12 (b): at the time of forming a solidified layer, FIG. c): During stacking) Perspective view schematically showing the configuration of the stereolithography multi-tasking machine Flowchart showing general operation of stereolithography multi-tasking machine Schematic diagram showing the technical problems of the present application (FIG. 15 (a): schematic overall perspective view of a three-dimensional shaped object including a vent, FIG. 15 (b): schematic top view of the vent, FIG. 15 (c). : Schematic cross-sectional view of the vent, FIG. 15 (d): Enlarged view of the schematic portion of the vent)

Hereinafter, one embodiment of the present invention will be described in more detail with reference to the drawings. The forms and dimensions of the various elements in the drawings are merely examples and do not reflect the actual forms and dimensions.

As used herein, the term "powder layer" means, for example, a "metal powder layer made of metal powder" or a "resin powder layer made of resin powder". Further, the “predetermined location of the powder layer” substantially refers to the region of the three-dimensional shaped object to be manufactured. Therefore, by irradiating the powder existing at the predetermined location with a light beam, the powder is sintered or melt-solidified to form a three-dimensional shaped object.

Further, the "up and down" direction described directly or indirectly in the present specification is, for example, a direction based on the positional relationship between the modeling plate and the three-dimensional shaped object, and is three-dimensional with respect to the modeling plate. The side on which the shaped object is manufactured is referred to as "upward", and the opposite side is referred to as "downward".

[Powder bed melt bonding method]
First, the powder bed melt-bonding method, which is the premise of the production method of the present invention, will be described. In particular, the stereolithography composite processing in which the cutting process of the three-dimensional shaped object is additionally performed in the powder bed fusion bonding method will be given as an example. FIG. 12 schematically shows a process mode of stereolithography composite processing, and FIGS. 13 and 14 are flowcharts of main configurations and operations of a stereolithography composite processing machine capable of performing a powder bed melt bonding method and a cutting process. Are shown respectively.

As shown in FIG. 13, the stereolithography composite processing machine 1 includes a powder layer forming portion 2, a light beam irradiating portion 3, and a cutting portion 4.

The powder layer forming portion 2 is for forming a powder layer by laying a powder such as a metal powder or a resin powder with a predetermined thickness. The light beam irradiating unit 3 is for irradiating a predetermined portion of the powder layer with the light beam L. The cutting portion 4 is for cutting the surface of the laminated solidified layer, that is, the surface of the three-dimensional shaped object.

As shown in FIG. 12, the powder layer forming portion 2 mainly includes a powder table 25, a squeezing blade 23, a modeling table 20, and a modeling plate 21. The powder table 25 is a table that can be raised and lowered in a powder material tank 28 whose outer circumference is surrounded by a wall 26. The squeezing blade 23 is a blade capable of horizontally moving the powder 19 on the powder table 25 onto the modeling table 20 to obtain the powder layer 22. The modeling table 20 is a table that can be raised and lowered in a modeling tank 29 whose outer circumference is surrounded by a wall 27. The modeling plate 21 is a plate that is arranged on the modeling table 20 and serves as a base for a three-dimensionally shaped object.

As shown in FIG. 13, the light beam irradiation unit 3 mainly includes a light beam oscillator 30 and a galvanometer mirror 31. The optical beam oscillator 30 is a device that emits an optical beam L. The galvanometer mirror 31 is a means for scanning the emitted light beam L on the powder layer 22, that is, a means for scanning the light beam L.

As shown in FIG. 13, the cutting portion 4 mainly includes an end mill 40 and a drive mechanism 41. The end mill 40 is a cutting tool for scraping the surface of a laminated solidified layer, that is, the surface of a three-dimensional shaped object. The drive mechanism 41 moves the end mill 40 to a desired position to be cut.

The operation of the stereolithography compound processing machine 1 will be described in detail. As shown in the flowchart of FIG. 14, the operation of the stereolithography composite processing machine 1 is composed of a powder layer forming step (S1), a solidified layer forming step (S2), and a cutting step (S3). The powder layer forming step (S1) is a step for forming the powder layer 22. In the powder layer forming step (S1), first, the modeling table 20 is lowered by Δt (S11) so that the level difference between the upper surface of the modeling plate 21 and the upper end surface of the modeling tank 29 is Δt. Next, after raising the powder table 25 by Δt, the squeezing blade 23 is moved horizontally from the powder material tank 28 toward the modeling tank 29 as shown in FIG. 12 (a). As a result, the powder 19 arranged on the powder table 25 can be transferred onto the modeling plate 21 (S12), and the powder layer 22 is formed (S13). Examples of the powder material for forming the powder layer 22 include "metal powder having an average particle size of about 5 μm to 100 μm" and "resin powder such as nylon, polypropylene, or ABS having an average particle size of about 30 μm to 100 μm". can. After the powder layer 22 is formed, the process proceeds to the solidified layer forming step (S2). The solidified layer forming step (S2) is a step of forming the solidified layer 24 by irradiation with a light beam. In the solidified layer forming step (S2), the light beam L is emitted from the light beam oscillator 30 (S21), and the light beam L is scanned to a predetermined position on the powder layer 22 by the galvanometer mirror 31 (S22). As a result, the powder at a predetermined position in the powder layer 22 is sintered or melt-solidified to form the solidified layer 24 as shown in FIG. 12 (b) (S23). As the light beam L, a carbon dioxide gas laser, an Nd: YAG laser, a fiber laser, ultraviolet rays, or the like may be used.

The powder layer forming step (S1) and the solidified layer forming step (S2) are alternately and repeatedly carried out. As a result, as shown in FIG. 12 (c), a plurality of solidified layers 24 are laminated.

When the laminated solidified layer 24 reaches a predetermined thickness (S24), the process proceeds to the cutting step (S3). The cutting step (S3) is a step for cutting the surface of the laminated solidified layer 24, that is, the surface of the three-dimensional shaped object. The cutting step is started by driving the end mill 40 (see FIGS. 12 (c) and 13) (S31). For example, when the end mill 40 has an effective blade length of 3 mm, a cutting process of 3 mm can be performed along the height direction of the three-dimensional shaped object. Therefore, if Δt is 0.05 mm, it is equivalent to 60 layers. The end mill 40 is driven when the solidified layers 24 are laminated. Specifically, the surface of the laminated solidified layer 24 is subjected to a cutting process while the end mill 40 is moved by the drive mechanism 41 (S32). At the final stage of such a cutting step (S3), it is determined whether or not a desired three-dimensional shaped object is obtained (S33). If the desired three-dimensional shaped object has not yet been obtained, the process returns to the powder layer forming step (S1). After that, by repeating the powder layer forming step (S1) to the cutting step (S3) to further stack the solidified layer and perform the cutting process, a desired three-dimensional shaped product is finally obtained.

[Characteristic part of the present invention]
Hereinafter, a method for manufacturing a three-dimensional shaped object according to an embodiment of the present invention will be described. It is premised that one embodiment of the present invention manufactures a three-dimensional shaped object having a low-density portion and a high-density portion, and uses at least a part of the low-density portion as a ventilation portion. ..

The inventors of the present application have diligently studied a method for producing a three-dimensional shaped object having a venting portion that is suitably ventilated to the outside. As a result, the inventors of the present application have come up with the present invention having the following technical ideas.

(Technical Idea of the Present Invention)
Specifically, the inventors of the present application stated, "The edge portion forming a hole region forming at least a part of the ventilation portion during the formation of the solidified layer which is a component of the three-dimensional shape model or after the formation of the solidified layer. However, we have come up with the present invention having the technical idea of "re-irradiating the light beam" (see FIG. 4 and the like).

According to such a technical idea, the light beam is re-irradiated to at least the edge portion forming the hole region forming a part of the ventilation portion. Therefore, by re-irradiating the light beam, the edge portion forming the pore region can be remelted. As a result, it is possible to remelt the deposits such as powder located in the unirradiated portion of the light beam L, which adheres to the portion that melts and solidifies when the solidified layer is formed. As a result, the finally obtained fine space between the outside and the ventilated portion can be made into a predetermined size, and gas can be suitably supplied into the mold cavity through the vented portion, or the mold cavity can be used. It is possible to suitably remove the generated gas to the outside.

The "high density portion" as used herein refers to a solidification density of 95 to 100%, and the "low density portion" refers to a solidification density of 0 to 95%. The "low-density portion" as used herein refers to a component of a three-dimensional shaped object, and at least a part of all of the low-density parts that are the component is used as a ventilation portion. That is, the "low-density portion" as used herein also includes a low-density portion used for purposes other than the ventilation portion.

The "hole region" as used herein refers to a component of a ventilation portion formed in a finally obtained three-dimensional shaped object and formed in a predetermined solidified layer. The “pore region” as used herein refers to a region corresponding to a low density portion and having a solidification density of 0% to 40%. As used herein, the "edge portion forming the pore region" refers to the contour portion of the pore region formed in the solidified layer or the outer edge portion thereof.

The "solidification density (%)" as used herein substantially means the solidification cross-sectional density (occupancy rate of the solidification material) obtained by performing image processing on a cross-sectional photograph of a three-dimensional shaped object. The image processing software used is Scion Image ver. 4.0.2 (freeware manufactured by Scion), and after binarizing the cross-sectional image into a solidified part (white) and a hole (black), the image is displayed. By counting the total number of pixels P x _{all and the number of pixels P x white} in the solidified portion (white), the solidified cross-sectional density ρ _S can be obtained by the following equation 1.
[Equation 1]

Hereinafter, the manufacturing method according to the embodiment of the present invention will be specifically described with reference to the drawings.

(Formation of powder layer)
First, as shown in FIG. 1, the squeezing blade 23 is moved in the horizontal direction to newly form a powder layer 22 having a predetermined thickness on the solidified layer 24 already formed or on a predetermined modeling plate. In the illustrated embodiment, the precursor 100X (corresponding to the low-density portion) of the ventilation portion and the precursor 200X (corresponding to the high-density portion) of the body portion of the modeled object have already been formed before the formation of the new powder layer 22. Point to. Specifically, in the illustrated embodiment, the powder layer 22 is newly formed on the solidified layer 24 having _{the high-density portion 24A 1} and the low-density portion 24B _{1 before the formation of the new powder layer 22.}

(Formation of solidified layer)
Next, as shown in FIG. 2, after the powder layer 22 is newly formed, the light beam L is irradiated to a predetermined portion of the powder layer 22 to have a high-density portion 24A ₂ and a low-density portion 24B _2. A new solidified layer 24 is formed.

Next, as shown in FIG. 3, after the formation of the new solidified layer 24, when the solidified density of the low-density portion used as the ventilation portion is 0%, the powder 19 located in the solidified layer 24 is removed. As a method for removing the powder 19, for example, the suction unit 50A and / or the magnet unit 50B is used to remove the powder 19.

(Re-irradiation of light beam)
Next, as shown in FIGS. 4, 5A and 5B, the light beam L is re-irradiated to the edge portion 61 forming the hole region 60 forming at least a part of the ventilation portion.

By re-irradiating the light beam, the edge portion forming the pore region is remelted, and the powder 19 or the like located in the unirradiated portion of the light beam L is attached, which adheres to the portion that melts and solidifies when the solidified layer is formed. The kimono can be remelted. As a result, the finally obtained fine space between the outside and the ventilated portion can be made into a predetermined size. As a result, the gas can be suitably supplied into the mold cavity through the ventilation portion, and the generated gas can be suitably removed from the mold cavity to the outside.

The target of re-irradiation of the light beam L is a new solidified layer 24 _{composed of a pore region of the low density portion 24B 2} of the new solidified layer 24 having a low density portion and a high density portion, and a low density region. It can be the pore region of the low density portion 24B _{2 of the.}

After the re-irradiation of the light beam, the modeling table is lowered by one step, and the above-mentioned powder layer formation, solidification layer formation, and light beam irradiation are repeated in this order. As described above, the three-dimensional shaped object according to the embodiment of the present invention can be finally manufactured.

Hereinafter, the re-irradiation mode of the above-mentioned light beam will be specifically described. The re-irradiation mode of the light beam can be roughly divided into a mode of sequentially re-irradiating and a mode of batch re-irradiation.

1. 1. Sequential re-irradiation mode First, a mode of sequential re-irradiation will be described.

In such an embodiment, the light beam L1 is sequentially re-irradiated along the edge portion 61 forming the pore region 60 (see FIGS. 6 to 8).

In this embodiment, the edge portion 61 is focused and the re-irradiation of the light beam is sequentially performed. That is, the edge portion 61 is sequentially re-irradiated with the light beam, but the hole region 60 is not re-irradiated with the light beam. Preferably, the light beam is sequentially re-irradiated by focusing on the edge portion 61 “only”. Since such sequential re-irradiation is re-irradiation focusing on the edge portion 61, the edge portion 61 can be remelted intensively and locally. As a result, deposits such as powder 19 located in the unirradiated portion of the light beam L, which adheres to the portion that melts and solidifies when the solidified layer is formed, can be remelted intensively and locally. As a result, the finally obtained fine space of the ventilated portion with the outside can be preferably made into a predetermined size.

Since this aspect is a re-irradiation mode focusing on the edge portion 61, the light beam is not irradiated to the hole region 60 which does not particularly require remelting. Therefore, it is possible to avoid unnecessary light beam irradiation, thereby avoiding consumption / use of unnecessary light beam energy.

In order to preferably perform re-irradiation focusing on the edge portion 61, the focusing diameter of the light beam L1 at the time of sequential re-irradiation may be made relatively smaller than the focusing diameter of the light beam before sequential re-irradiation. preferable. Without being limited to this, by increasing the operation speed of the light beam or widening the operation pitch of the light beam, it is possible to perform re-irradiation focusing on the edge portion 61.

Where residual stress can be generated in the solidified layer obtained by irradiating a light beam, by generating a stress that acts in the direction opposite to the direction in which the residual stress acts, the residual stress that can be generated in the solidified layer as a whole is generated. It can be relaxed. In order to realize such relaxation, for example, the direction of the irradiation path of the light beam used for forming the solidified layer 24 and the direction of the irradiation path of the light beam used for the sequential re-irradiation are opposite to each other. Is preferable (see FIG. 7).

Further, in a plan view, a case where at least two hole regions 60 are formed in at least one of the vertical direction and the horizontal direction at a predetermined interval is taken as an example (see FIG. 8). That is, a case where the body portion (for example, a high-density portion) surrounding the hole region forming a part (or a component) of the ventilation portion in a plan view forms a lattice structure (that is, a lattice structure) is taken as an example. In this case, the light beam L1 may be sequentially re-irradiated on at least one side of the body portion of the solidified layer located between the adjacent hole regions 60A and the other pore regions 60B.

In such an embodiment, as shown in FIG. 8, both sides of the body portion (for example, the high-density portion 24A) of the solidified layer 24 may be sequentially re-irradiated substantially simultaneously along at least two irradiation paths. By adjusting so that at least two light beams are used and re-irradiated substantially at the same time, the light beam re-irradiation time can be shortened as a whole as compared with the case where one light beam is used.

Without being limited to this, both sides of the body portion of the solidified layer 24 may be sequentially re-irradiated along one irradiation path. In this case, if a light beam having irradiation conditions substantially the same as those used when forming the body portion of the solidified layer 24 (for example, the high-density portion 24A) is irradiated so as to trace the body portion of the solidified layer 24, Both sides of the body portion of the solidified layer 24 can be sequentially re-irradiated along one irradiation path. As a result, by irradiating both sides of the body portion of the solidified layer 24 with one light beam, it is possible to relatively reduce the irradiation energy used as compared with the case of using two light beams.

2. A mode of batch re-irradiation Next, a mode of batch re-irradiation will be described.

In such an embodiment, the entire edge portion 61 forming the hole region 60 is collectively re-irradiated with the light beam L2 (see FIG. 9A).

In this embodiment, the entire edge portion 61 forming the hole region 60 is collectively re-irradiated with the light beam. That is, the edge portion 61 is also re-irradiated with the light beam, and the hole region 60 is also re-irradiated with the light beam. Since such re-irradiation is a batch re-irradiation, the edge portion 61 can be totally remelted at one time. As a result, deposits such as powder 19 located in the unirradiated portion of the light beam L, which adheres to the portion that melts and solidifies when the solidified layer is formed, can be totally remelted at once. Therefore, the time required to remelt all of the deposits can be shortened as compared with the case of sequentially remelting along the edge portion.

In addition, in order to re-irradiate the entire edge portion 61 at once, the focusing diameter of the light beam L2 at the time of batch re-irradiation is relatively larger than the focusing diameter of the light beam before batch re-irradiation. It is preferable to do so. Without being limited to this, by lowering the operation speed of the light beam or narrowing the operation pitch of the light beam, it is possible to perform batch re-irradiation of the entire edge portion 61.

Since the hole region 60 is a space or a void portion, even if the light beam L2 is re-irradiated in such a region, it does not directly contribute to the remelting. Therefore, at the time of batch re-irradiation, the edge portion 61 is irradiated with the light beam. The energy may be made relatively larger than the irradiation energy of the light beam with respect to the pore region 60 (see FIG. 9B). In other words, the irradiation energy of the light beam on the hole region 60 may be made relatively smaller than the irradiation energy of the light beam on the edge portion 61. Thereby, the batch re-irradiation of the edge portion 61 can be effectively and efficiently performed.

Further, in both the sequential re-irradiation and the batch re-irradiation, if the irradiation energy for the edge portion 61 is substantially the same as or relatively larger than the irradiation energy of the light beam used for forming the solidified layer, the following concerns arise. Can occur. Specifically, there is a possibility that deposits such as powder 19 located in the unirradiated portion of the light beam L may reattach to the melt-solidified portion. Therefore, it is preferable that the irradiation energy of the light beam at the time of re-irradiation of the light beam is relatively smaller than the irradiation energy of the light beam before the re-irradiation.

Although one embodiment of the present invention has been described above, it merely illustrates a typical example of the scope of application of the present invention. Therefore, those skilled in the art will easily understand that the present invention is not limited to this, and various modifications can be made.

For example, as shown in FIG. 10, the mode is not limited to the mode in which the deposit is remelted by the light beam. For example, even if the deposits located at the edge portion 61 forming the hole region 60 are cut off by the light beam L from the viewpoint of preferably setting the fine space of the ventilated portion that can be ventilated with the outside finally obtained to a predetermined size. good. Further, as shown in FIG. 11, for example, the edge portion 61 forming the hole region 60 by the light beam L from the viewpoint of preferably setting the fine space of the ventilated portion that can be ventilated with the outside finally obtained to a predetermined size. The deposits located in may be laser-evaporated by a light beam having high irradiation energy.

300'Three-dimensional shape model 200a' High density part 100a' Low density part 100 Ventilation part (low density part)
22 Powder layer 24 Solidified layer 24A ₁ , 24A ₂ High-density part of solidified layer
24B ₁ , 24B ₂ Low density part of solidified layer
60 Pore area formed in the low-density part of the solidified layer and forming a part of the ventilation part of the three-dimensional shape model 61 Edge part L, L1, L2 light beam forming the hole area

Claims (13)

(I) A step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt and solidify the powder at the predetermined portion to form a solidified layer, and (ii) a new powder on the obtained solidified layer. A three-dimensional shaped product is manufactured by alternately and repeatedly laminating the powder layer and the solidified layer by forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer. How to do
Manufacture the three-dimensional shaped object having a high-density portion and a low-density portion,
At least a part of the low density part is used as a ventilation part.
During the formation of the solidified layer by the irradiation of the light beam or after the formation of the solidified layer, the re-irradiation of the light beam is performed on at least the edge portion forming the hole region forming a part of the ventilation portion. , A method for manufacturing a three-dimensional shaped object. The manufacturing method according to claim 1, wherein the edge portion forming the pore region is remelted by re-irradiation of the light beam. The production according to claim 1 or 2, wherein when the solidification density of the low-density portion used as the ventilation portion is 0%, the powder located in the solidification layer is removed prior to re-irradiation of the light beam. Method. The production method according to any one of claims 1 to 3, wherein the re-irradiation of the light beam is sequentially carried out along the edge portion forming the hole region. In a plan view, at least two of the hole regions are formed at a predetermined interval in at least one of the vertical direction and the horizontal direction.
The manufacturing method according to claim 4, wherein at least one side of the body portion of the solidified layer located between the adjacent pore regions is sequentially re-irradiated with the light beam. The production method according to claim 4 or 5, wherein both sides of the body portion of the solidified layer are sequentially re-irradiated along one irradiation path. The production method according to claim 5, wherein both sides of the body portion of the solidified layer are sequentially re-irradiated substantially simultaneously along at least two irradiation paths. The production according to any one of claims 4 to 7, wherein the focusing diameter of the light beam at the time of sequential re-irradiation of the light beam is relatively smaller than the focusing diameter of the light beam before sequential re-irradiation. Method. Any of claims 4 to 8, wherein the direction of the irradiation path of the light beam used for forming the solidified layer and the direction of the irradiation path of the light beam used for the sequential re-irradiation are opposite to each other. The manufacturing method described in. The manufacturing method according to any one of claims 1 to 3, wherein the entire edge portion forming the hole region is collectively re-irradiated with the light beam. The manufacturing method according to claim 10, wherein the focusing diameter of the light beam at the time of batch re-irradiation of the light beam is made relatively larger than the focusing diameter of the light beam before the batch re-irradiation. The production method according to any one of claims 1 to 11, wherein the irradiation energy of the light beam at the time of re-irradiation of the light beam is made relatively smaller than the irradiation energy of the light beam before the re-irradiation. The manufacturing method according to any one of claims 1 to 12, wherein the venting portion is formed so as to extend in a predetermined direction so as to be ventilated to the outside.

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