JP2024060191A - Forming method and support member - Google Patents

Abstract

[Problem] To increase the degree of freedom in designing a molded object. [Solution] A molding method includes step S4 of arranging a support member 2 including a molding support surface that is aligned with a region to be molded, where the lower surface of a second molding part is to be molded, and step S5 of molding a second molding part continuous with the first molding part by supplying powder material P and an energy beam E onto the main molding support surface 22a of the support member 2. The support member 2 has a molding support part 22 including the main molding support surface 22a, and legs 21 including a portion not in contact with the first molding part and for determining the position of the molding support part 22 relative to the first molding part. [Selected Figure] Figure 4

Description

This disclosure relates to a molding method and a support member used in the molding method.

In the field of casting, for example, one method for obtaining hollow-shaped products is the use of so-called cores. Patent Document 1 discloses a method for manufacturing a resin-integrated core and a mold manufacturing method that uses the resin-integrated core.

JP 2018-164934 A

In the deposition modeling method, for example, energy is supplied to the powder material while the powder material is being supplied. The powder material melts when energy is supplied, and then solidifies.

For example, hollow manufactured products have eave-shaped parts known as overhangs. When attempting to create these overhangs using a deposition-based modeling method, there is a possibility that molten powder material will drip off. Therefore, when creating a shape that cannot be realized in a single deposition-based modeling operation, the part is divided into multiple parts and then integrated by welding or the like. In other words, the deposition-based modeling method places certain limitations on the shapes that can be created.

This disclosure describes a modeling method that can increase the degree of freedom in designing objects and a support member used in the modeling method.

A modeling method according to one aspect of the present disclosure is a modeling method for forming a model having a first modeling portion and a second modeling portion that is continuous with the first modeling portion and extends in a direction intersecting the direction in which the first modeling portion extends. The modeling method includes the steps of arranging a support member including a modeling support surface that is aligned with a region to be modeled where the lower surface of the second modeling portion is to be modeled, and forming the second modeling portion that is continuous with the first modeling portion by supplying material and an energy beam onto the modeling support surface of the support member. The support member has a modeling support portion that includes the modeling support surface, and a leg portion that includes a portion that does not contact the first modeling portion and that determines the position of the modeling support portion relative to the first modeling portion.

In this modeling method, a second modeling portion that is continuous with the first modeling portion is modeled on the modeling support surface of the support member. The support member prevents dripping during modeling of the second portion, making it possible to model the second portion. As a result, the degree of freedom in designing the object can be increased.

The modeling method further includes a step of modeling a first modeling section prior to the step of placing the support member. In this case, the support member is not placed during modeling of the first modeling section. This increases the degree of freedom in the placement of the device for modeling, making it easier to model the first modeling section.

In the modeling method, after the step of forming the second modeling portion is performed, a hole is formed in the modeled object that leads to a space defined by the inner surface of the first modeling portion and a portion of the support member that does not contact the first modeling portion. The modeling method further includes a step of removing the support member through the hole after the step of forming the second modeling portion. This makes it possible to form a modeled object with a hollow structure. It also makes it possible to design the position of the hole taking into account the strength required of the modeled object.

In the modeling method, the modeling support surface is a flat surface. In this case, the surface roughness of the flat surface is transferred to the underside of the second modeling part of the model. Therefore, by improving the surface roughness of the modeling support surface, the surface roughness of the underside of the second modeling part can be improved.

A support member according to another aspect of the present disclosure is a support member used in a modeling method for modeling an object having a first modeling portion and a second modeling portion that is continuous with the first modeling portion and extends in a direction intersecting the direction in which the first modeling portion extends. The support member includes legs extending in a predetermined direction and a modeling support portion supported at the tip of the leg. The modeling support portion has a modeling reference surface that is spaced apart from the leg side surface between the tip of the leg and the base end of the leg along a direction perpendicular to the predetermined direction in which the leg extends, a modeling support surface that extends in a direction intersecting the predetermined direction in which the leg extends so as to be continuous with the modeling reference surface, and a modeling corner portion formed in a portion where the modeling reference surface and the modeling support surface are continuous.

This support member is positioned so that the first modeling portion of the object is in contact with the modeling reference surface. In this state, modeling can be performed on the modeling support surface. The modeling reference surface, modeling support surface, and modeling corners can prevent dripping from the modeling support surface during modeling. As a result, the degree of freedom in designing the object can be increased.

The molding method disclosed herein and the support members used in the molding method allow for greater freedom in designing the object.

FIG. 1 is a schematic diagram showing the configuration of a molding apparatus. FIG. 2 is a diagram showing an example of an outline of a support member and a cross-sectional structure of a material supply nozzle. FIG. 3 is a diagram showing another example of the cross-sectional structure of the material supply nozzle. FIG. 4 is a flowchart showing an example of a method for forming a sealed container. 5A to 5C are diagrams showing an example of a cross section of a sealed container during shaping, each of which illustrates an example of a cross section of the sealed container at a corresponding stage of shaping. 6A to 6C are diagrams showing an example of a cross section of a sealed container during shaping, each of which illustrates an example of a cross section of the sealed container at a corresponding stage of shaping. 7A and 7B are diagrams showing an example of a conventional modeling method. Fig. 7A shows an example of modeling an object without tilting it. Fig. 7B shows an example of modeling an object with tilting it. Fig. 7C shows another example of modeling an object with further tilting it. 8A and 8B are diagrams showing a comparison example of cross sections of a sealed container, in which (a) is a diagram showing an example of a cross section of a sealed container manufactured by the molding method of the present disclosure, and (b) is a diagram showing an example of a cross section of a sealed container manufactured by a conventional molding method.

Embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the same or equivalent parts in each drawing are given the same reference numerals, and duplicated explanations will be omitted.

The modeling device 1 shown in FIG. 1 is a 3D (three-dimensional) printer. The modeling device 1 manufactures a three-dimensional object M. The object M may be, for example, a machine part or other structure. The modeling device 1 employs a so-called deposition method. The modeling device 1 supplies an energy beam E to the powder material P while supplying the powder material P to a planned modeling area that will model a desired portion of the object M. The energy beam E is, for example, a laser, an electron beam, an arc, or the like.

The powder material P is a metal powder such as titanium-based metal powder, nickel powder such as Inconel powder, aluminum powder, and steel material powder such as stainless steel alloy. The powder material P is not limited to a metal powder. The powder material P may be a powder containing carbon fiber and resin, such as CFRP (Carbon Fiber Reinforced Plastics). The powder material P may be other powders having electrical conductivity. The powder material P in this disclosure is not limited to those having electrical conductivity. For example, when a laser is used as the energy beam E, the powder material P may not have electrical conductivity.

The powder material P is melted or sintered as the temperature increases due to the supply of the energy beam E. The powder material P is solidified as the temperature decreases over time. In this disclosure, "solidifying the powder material P" includes a situation in which the powder material P is heated to a temperature higher than the melting point and becomes liquid, and is solidified, and a situation in which the powder material P is heated to a temperature lower than the melting point and is sintered.

The material of the object M may be, for example, a wire. The modeling device 1 supplies an energy beam E to the wire, for example, while the wire is in contact with the region to be modeled. Alternatively, the modeling device 1 generates a plasma arc, for example, while the tip of the wire is directed toward the region to be modeled. The wire is melted by the plasma arc and then solidifies.

The modeling device 1 includes an arm 11, a material supply nozzle 12, and a positioner 13. The arm 11 is, for example, a multi-axis robot or an orthogonal robot. The arm 11 adjusts the material supply nozzle 12 so that it is positioned above the planned modeling area. The material supply nozzle 12 supplies powder material P and an energy beam E to the planned modeling area. The positioner 13 is a work table for modeling the object M. The positioner 13 adjusts the position, angle, and inclination of the planned modeling area. The modeling device 1 may perform various controls in accordance with, for example, control signals transmitted from a control device (not shown).

A disk-shaped table 131, for example, is attached to the positioner 13. The table 131 is located at the top of the positioner 13 and faces the material supply nozzle 12. The positioner 13 changes the position and angle of the table 131. For example, the positioner 13 may rotate the table 131 around a rotation axis passing through the center of the table 131. The positioner 13 may raise and lower the table 131 along the rotation axis. The positioner 13 may tilt the table 131. The positioner 13 may move the table 131 along a direction intersecting the rotation axis. For example, a metal base plate B or the like is placed on the table 131. The object M is molded continuously on the base plate B or the like that serves as the base material of the object M.

The modeling device 1 models the object M while changing the relative position between the object M and the material supply nozzle 12. For example, the arm 11 positions the material supply nozzle 12 above the positioner 13. The positioner 13 changes the position and angle of the table 131. Accordingly, the position and angle of the base plate B on the table 131 and the object M on the base plate B are changed. As a result, the relative position between the object M and the material supply nozzle 12 changes. The material supply nozzle 12 supplies powder material P and energy beam E to the planned modeling area. A molten pool, which is a pool of the molten base material and powder material P, is formed in the planned modeling area. The powder material P solidifies over time, and the object M is modeled. When modeling is completed in the entire planned modeling area of the object M, the object M is manufactured.

Figure 2 is a diagram showing an overview of the support member 2 and an example of the cross-sectional structure of the material supply nozzle 12. The material supply nozzle 12 is formed, for example, in a tubular shape. The material supply nozzle 12 has a nozzle tip 121 that tapers at one end. The nozzle tip 121 is directed toward the planned printing region. The planned printing region is located on an extension of the beam axis L, which is the central axis of the material supply nozzle 12. The material supply nozzle 12 is provided with a beam output hole 122 and a powder ejection hole 123.

The beam output hole 122 is a hole passing through the beam axis L. The beam output hole 122 leads to the nozzle tip 121. The beam output hole 122 leads to an energy beam source on the opposite side of the nozzle tip 121. When a laser is used as the energy beam, the energy beam source is a laser oscillator and optical elements such as a mirror. When an electron beam is used as the energy beam, the energy beam source may be an electron gun. The electron gun generates an electron beam according to the potential difference generated between the cathode and the anode. When welding is used as the energy, the modeling device 1 generates a plasma arc between the wire and the model M.

The powder ejection hole 123 is a hole provided around the beam axis L. The powder ejection hole 123 is connected to the nozzle tip 121. The powder ejection hole 123 is inclined near the nozzle tip 121 so as to approach the beam axis L. The powder ejection hole 123 is connected to a raw material tank or the like on the opposite side of the nozzle tip 121. The raw material tank stores the powder material P. The powder ejection hole 123 may be connected to the raw material tank via piping or the like.

The modeling method of the present disclosure uses a support member 2 in at least some of the steps. The support member 2 is, for example, a free-standing base made of ceramics. The support member 2 is placed, for example, on an already modeled surface of the modeled object M, or on a base plate B, etc. The support member 2 has a modeling support main surface 22a (modeling support surface) that is aligned with the planned modeling area where the lower surface M1 of the modeled object M is to be modeled. The support member 2 has a shape that corresponds to, for example, the placement position and the planned modeling area, etc. The support member 2 is manufactured, for example, by a manufacturing method using a mold, or a so-called binder jet type 3D printer, etc.

The material supply nozzle 12 supplies powder material P and energy beam E onto the main support surface 22a. For example, the material supply nozzle 12 outputs the energy beam E from the beam output hole 122 toward the outside of the nozzle tip 121. The material supply nozzle 12 ejects the powder material P from the powder ejection hole 123 toward the outside of the nozzle tip 121. The ejection direction of the powder material P is adjusted so as to approach the beam axis L along the inclination of the powder ejection hole 123. The ejected powder material P is heated by the energy beam E on the beam axis L outside the material supply nozzle 12. The powder material P is heated to a temperature at which the object M can be formed. A molten pool MP is formed on the main support surface 22a by the base material and the powder material P. The base material in FIG. 2 is a part of the object M that has already been formed. The molten pool MP solidifies over time to form the object M.

The modeling device 1 may be equipped with a material supply nozzle 12A shown in FIG. 3 instead of the material supply nozzle 12. The material supply nozzle 12A differs from the material supply nozzle 12 in that the powder material P is supplied from the nozzle center and the energy beam E is supplied from the periphery of the nozzle center. Below, the differences from the material supply nozzle 12 will be mainly described. The material supply nozzle 12A has a nozzle tip 121A that tapers at one end. The material supply nozzle 12A is provided with a beam output hole 122A and a powder ejection hole 123A.

The beam output hole 122A is a hole provided around the central axis of the material supply nozzle 12A. The beam output hole 122A leads to the nozzle tip 121A. The beam output hole 122A leads to an energy beam source on the opposite side of the nozzle tip 121A. The beam output hole 122A is inclined near the nozzle tip 121A to approach the central axis of the material supply nozzle 12A.

The powder ejection hole 123A is a hole that passes through the central axis of the material supply nozzle 12A. The powder ejection hole 123A is connected to the nozzle tip 121A. On the opposite side of the nozzle tip 121A, the powder ejection hole 123A is connected to a raw material tank or the like.

The material supply nozzle 12A supplies powder material P and energy beam E onto the main support surface 22a. For example, the material supply nozzle 12A outputs the energy beam E from the beam output hole 122A toward the outside of the nozzle tip 121A. The material supply nozzle 12A ejects the powder material P from the powder ejection hole 123A toward the outside of the nozzle tip 121A. The output direction of the energy beam E is adjusted so that it approaches the central axis of the material supply nozzle 12A along the inclination of the beam output hole 122A.

An example of a method for manufacturing a sealed container T will be described with reference to Figures 4 to 6. The sealed container T is an example of a molded object M, and is, for example, a rectangular or round container with a lid. Figure 4 is a flowchart showing an example of a method for manufacturing a sealed container T. Figures 5 and 6 are diagrams showing an example of a cross section of a sealed container T in the process of being molded. In the following description, the sealed container T in the process of being molded will be referred to as an "intermediate product TA." For example, nickel-based alloy powder is used as the material for the sealed container T.

The modeling device 1 models the bottom 5 having a hole H of the intermediate product TA as shown in FIG. 5(a) (step S1). The bottom 5 has a bottom upper surface 51 and a bottom lower surface 52. The bottom upper surface 51 faces the inside of the intermediate product TA. The bottom lower surface 52 is the surface opposite to the bottom upper surface 51. The hole H penetrates a part of the bottom 5 from the bottom upper surface 51 to the bottom lower surface 52. The modeling device 1 models the bottom 5 on, for example, a base plate B serving as a substrate. The material supply nozzle 12 supplies the powder material P and the energy beam E to the region to be modeled where the bottom 5 is to be modeled. The material supply nozzle 12 models the bottom 5 while avoiding the region where the hole H is to be provided. The positioner 13 adjusts the position of the region to be modeled, for example, by moving or rotating the table 131.

The modeling device 1 models the side 6 of the intermediate product TA as shown in FIG. 5(a) (step S2). The side 6 is continuous with the bottom 5 and extends in a wall shape along the central axis CL. The side 6 has a side inner surface 61, a side outer surface 62, a side base end 63, and a side tip 64. The side inner surface 61 faces the inside of the intermediate product TA. The side outer surface 62 is the surface opposite to the side inner surface 61. The side base end 63 is an end portion that is continuous with the bottom 5. The side tip 64 is an end portion opposite to the side base end 63. The modeling device 1 models the side 6 so as to be continuous with the bottom 5 that serves as the base material. The material supply nozzle 12 supplies the powder material P and the energy beam E to the region to be modeled where the side 6 is to be modeled. The positioner 13 adjusts the position of the region to be modeled, for example, by lowering the table 131.

The modeling device 1 temporarily stops modeling the intermediate product TA (step S3). The material supply nozzle 12 temporarily stops supplying the powder material P and the energy beam E. Next, in the modeling method, a support member 2 as shown in FIG. 5(b) is placed in the intermediate product TA (step S4). If necessary, before the support member 2 is placed in the intermediate product TA (i.e., between steps S3 and S4), machining or the like may be performed on the intermediate product TA. As an example, machining or polishing may be performed on the bottom upper surface 51, bottom lower surface 52, and side inner surface 61 of the intermediate product TA.

The support member 2 has legs 21 extending in a predetermined direction. The legs 21 are at least one columnar member. The legs 21 extend, for example, along the central axis CL of the intermediate product TA. The legs 21 determine the position of the shaping support part 22 relative to the side part 6. The legs 21 have a leg tip 21a, a leg base end surface 21b, and a leg side surface 21s. The leg tip 21a is one end of the leg 21. The leg base end surface 21b is the other end of the leg 21. The leg side surface 21s is a side surface provided between the leg tip 21a and the leg base end surface 21b.

The support member 2 includes a modeling support part 22 supported by the leg tip part 21a. The modeling support part 22 has a modeling reference surface 22s that is spaced apart from the leg side surface 21s along a direction perpendicular to the predetermined direction in which the leg part 21 extends. The modeling support part 22 has a modeling support main surface 22a that extends in a direction intersecting the predetermined direction in which the leg part 21 extends so as to be continuous with the modeling reference surface 22s. In the modeling support part 22, the surface opposite to the modeling support main surface 22a is a modeling support back surface 22b. The modeling support part 22 has a modeling corner part 22e formed in a portion where the modeling reference surface 22s and the modeling support main surface 22a are continuous. The modeling support main surface 22a is a flat surface. The "flat surface" here is not limited to a flat surface. The modeling support main surface 22a may include a curved surface within the allowable range indicated by the geometric tolerance as a flat surface.

As an example of the arrangement of the support member 2, the leg base end surface 21b is in contact with the bottom upper surface 51 of the bottom 5. The leg base end surface 21b is arranged in a position that does not block the hole H. The leg side surface 21s is spaced from the side inner surface 61. In other words, the leg side surface 21s does not contact the side 6. In another example, the leg side surface 21s may be in contact with the side 6. The modeling reference surface 22s is in contact with the side inner surface 61. The modeling corner portion 22e is in contact with the side tip 64.

The modeling device 1 models the lid portion 7 of the intermediate product TA as shown in FIG. 5(c) (step S5). The lid portion 7 is continuous with the side portion 6 and extends in a direction intersecting the direction in which the side portion 6 extends. More specifically, the lid portion 7 is continuous with the side portion tip 64 and extends in a canopy shape relative to the side portion 6. The lid portion 7 has a lid portion back surface 71 and a lid portion main surface 72. The lid portion back surface 71 faces the modeling support main surface 22a. The modeling device 1 models the lid portion 7 on the modeling support main surface 22a so as to be continuous with the side portion tip 64 of the side portion 6 that serves as the base material. The modeling support main surface 22a is along the modeling planned area K (see FIG. 5(b)) in which the lid portion back surface 71 of the lid portion 7 is to be modeled. The material supply nozzle 12 supplies powder material P and energy beam E to the modeling planned area K in which the lid portion 7 is to be modeled. The positioner 13 adjusts the position of the intended shaping region K, for example by moving or rotating the table 131. The surface roughness of the shaping support main surface 22a is transferred to the lid back surface 71 of the lid 7 shaped in this manner.

The internal space A1 of the intermediate product TA after the lid 7 is formed includes an area A11 not occupied by the support member 2 and an area A12 occupied by the support member 2. When viewed from the support member 2, the support member 2 has a portion that contacts the inner surface of the intermediate product TA and a portion that does not contact the inner surface of the intermediate product TA. More specifically, the modeling reference surface 22s of the support member 2 contacts the side inner surface 61. The modeling support main surface 22a also contacts the lid back surface 71. The leg base end surface 21b also contacts the bottom upper surface 51. Conversely, the leg side surface 21s of the support member 2 does not contact the side inner surface 61. The modeling support back surface 22b also does not contact the bottom upper surface 51.

As a result, inside the intermediate product TA, a non-contact space is formed as an area A11 not occupied by the support member 2, surrounded by the bottom upper surface 51, the inside of the leg side surface 21s, and the modeling support back surface 22b. The hole H is connected to this area A11 not occupied by the support member 2.

The area not occupied by the support member 2 may be defined as a non-contact space surrounded by the side inner surface 61, the bottom upper surface 51, the outside of the leg side surface 21s, and the modeling support back surface 22b.

In the modeling method, a strong alkaline solution 100 is poured into the intermediate product TA as shown in FIG. 6(a) (step S6). The intermediate product TA is turned upside down so that the bottom 5 is located above the lid 7. The strong alkaline solution 100 is poured into the intermediate product TA through the hole H. Examples of the strong alkaline solution 100 include an aqueous solution of sodium carbonate, sodium hydroxide, or potassium hydroxide. The support member 2 is immersed in the strong alkaline solution 100.

In the modeling method, the support member 2 dissolves (step S7). The support member 2 immersed in the strong alkaline solution 100 dissolves over time. The intermediate product TA made of nickel-based alloy powder is resistant to corrosion by the strong alkaline solution 100 and does not dissolve.

At least a portion of the support member 2, excluding the modeling support portion 22, may have a lattice structure. A lattice structure is a three-dimensional structure in which lattices are periodically arranged. In a support member 2 with a lattice structure, the mass is reduced and the surface area that is immersed in the strong alkaline solution 100 is increased. Therefore, the time required for dissolving the support member 2 is shortened.

In the modeling method, the strong alkaline solution 101 that has dissolved the support member 2 is discharged from the intermediate product TA as shown in FIG. 6(b) (step S8). The intermediate product TA is returned to its original orientation so that the lid portion 7 is positioned above the bottom portion 5. The strong alkaline solution 101 is discharged from the intermediate product TA through the hole H. This removes the dissolved support member 2 from the intermediate product TA.

In the modeling method, the inside of the intermediate product TA is cleaned and dried (step S9). This removes the strong alkaline solution 101 remaining in the intermediate product TA.

The molding device 1 closes the hole H by forming a closing portion 9 (step S10). This completes the sealing of the intermediate product TA, and an airtight container T is obtained. The closing portion 9 may be formed by welding the hole H to a closing member that is made as a separate member by machining or the like to match the size of the hole H.

Below, we will point out the problems with conventional molding methods and then explain the effects of the molding method disclosed herein.

Figure 7 is a diagram showing an example of a conventional modeling method. The conventional modeling method differs from the modeling method of the present disclosure in that a support member 2 is not used. (a) of Figure 7 shows an example of modeling without tilting the object M. The positioner 13C lowers the table 131C along the beam axis L as the modeling of the object M progresses in response to the supply of powder material P from the material supply nozzle 12C.

Figure 7 (b) shows an example of forming an object M by tilting it. The forming device 1C forms the object M in a state in which the object M is tilted by an angle θ1 (θ1 > 0°) with respect to the beam axis L. As the forming of the object M progresses, the positioner 13C moves the table 131C along the tilted direction of the object M.

(c) of FIG. 7 shows another example in which the object M is further tilted when being molded. The molding apparatus 1C molds the object M in a state inclined at an angle θ2 (θ2 > θ1) with respect to the beam axis L. As the molding of the object M progresses, the positioner 13C moves the table 131C along the tilted direction of the object M. Because the angle θ2 is too large, dripping D occurs from the molten pool MP. In other words, the deposition-type molding method cannot mold the object M in a state inclined at an angle θ2 with respect to the beam axis L.

According to the above-mentioned molding method, a sealed container TC as shown in FIG. 8(b) can be manufactured. FIG. 8(b) is a diagram showing an example of a cross section of a sealed container TC manufactured by a conventional molding method. The sealed container TC has a bottom 5C, a side 6C, and a lid 7C. In the sealed container TC, the lid 7C extends in a direction intersecting with the side 6C. Inside the sealed container TC, the lid 7C and the side 6C form an angle θ4C (θ3<θ4C).

Conventional deposition-based manufacturing methods had limitations on the angle of inclination relative to the beam axis L. As a result, it was difficult to manufacture overhang-shaped parts using conventional manufacturing methods. Conventional manufacturing methods required, for example, separately manufacturing the overhang member and a member other than the overhang member, and then integrating the two members by welding or the like to manufacture the object. Such objects could be subject to deterioration in quality due to, for example, shrinkage, cracks, or residual stresses that accompany welding.

The modeling method of the present disclosure models a model M (sealed container T) having a first modeling portion (side portion 6) and a second modeling portion (lid portion 7) that is continuous with the first modeling portion and extends in a direction intersecting the direction in which the first modeling portion extends. The modeling method includes a step S4 of arranging a support member 2 including a modeling support main surface 22a along a planned modeling area in which the lower surface (lid portion back surface 71) of the second modeling portion is to be modeled, and a step S5 of modeling the second modeling portion that is continuous with the first modeling portion by supplying a material (powder material P) and an energy beam E onto the modeling support main surface 22a of the support member 2. The support member 2 has a modeling support portion 22 including the modeling support main surface 22a, and legs 21 that include a portion that does not contact the first modeling portion and that determine the position of the modeling support portion 22 relative to the first modeling portion.

In this modeling method, a second modeling portion that is continuous with the first modeling portion is modeled on the main modeling support surface 22a of the support member 2. The support member 2 prevents dripping during modeling of the second portion (step S2), making it possible to model the second portion. As a result, the degree of freedom in designing the model M can be increased.

According to the molding method of the present disclosure, it is possible to mold a sealed container T as shown in (a) of FIG. 8. (a) of FIG. 8 is a diagram showing an example of a cross section of a sealed container T manufactured by the molding method of the present disclosure. In the sealed container T, the lid portion 7 extends in a direction intersecting with the side portion 6. The lid portion 7 is continuous with the side portion 6 in a canopy shape. Inside the sealed container T, the lid portion 7 and the side portion 6 form an angle θ3 (e.g., 90°<θ3). This angle θ3 is smaller than the angle θ4C of the sealed container TC molded by the conventional molding method shown in (b) of FIG. 8. In other words, the angle θ3 is closer to 90° than the angle θ4C. In other words, it can be seen that the molding method of the present disclosure increases the degree of freedom of the shape that can be molded.

The modeling method further includes steps S1 and S2 of modeling a first modeling part before step S4 of placing the support member 2. In this case, the support member 2 is not placed during modeling of the first modeling part. This improves the degree of freedom in the placement of the modeling device (modeling device 1), making it easier to model the first modeling part.

In the molding method, after performing step S5 of forming the second molding portion, a hole H is formed in the molded object M, which leads to a space defined by the inner surface of the first molding portion and a portion of the support member 2 that does not contact the first molding portion. The molding method further includes step S6 of removing the support member 2 through the hole H, after step S5 of forming the second molding portion. This makes it possible to mold a molded object M with a hollow structure. In addition, it is possible to design the position of the hole H taking into account the strength required for the molded object M.

In the modeling method, the main modeling support surface 22a is a flat surface. In this case, the surface roughness of the flat surface is transferred to the underside of the second modeling part of the model M. Therefore, by improving the surface roughness of the main modeling support surface 22a, the surface roughness of the underside of the second modeling part can be improved.

The support member 2 disclosed herein is used in a modeling method for modeling an object M having a first modeling portion and a second modeling portion that is continuous with the first modeling portion and extends in a direction intersecting the direction in which the first modeling portion extends. The support member 2 includes a leg 21 extending in a predetermined direction and a modeling support portion 22 supported at the tip of the leg 21. The modeling support portion 22 has a modeling reference surface 22s that is spaced apart from the leg side surface 21s between the tip of the leg 21 (leg tip portion 21a) and the base end of the leg 21 (leg base end surface 21b) along a direction perpendicular to the predetermined direction in which the leg 21 extends, a modeling support main surface 22a that extends in a direction intersecting the predetermined direction in which the leg 21 extends so as to be continuous with the modeling reference surface 22s, and a modeling corner portion 22e formed in a portion where the modeling reference surface 22s and the modeling support main surface 22a are continuous.

The support member 2 is positioned so that the first modeling portion of the object M is in contact with the modeling reference surface 22s. In this state, modeling can be performed on the modeling support main surface 22a (step S5). The modeling reference surface 22s, the modeling support main surface 22a, and the modeling corner portion 22e can prevent dripping from the modeling support main surface 22a during modeling. As a result, the degree of freedom in designing the object M can be increased.

Note that the support member 2 of the present disclosure is different from a core used in the field of casting. For example, the core enables the production of a hollow-shaped product by preventing the intrusion of molten metal. The entire surface of the core contacts the inner surface of the hollow-shaped product. In contrast, the entire surface of the support member 2 does not need to contact the inner surface of the molded object M. For example, the leg base end surface 21b, the molding reference surface 22s, the molding support main surface 22a, the molding corner portion 22e, etc. of the support member 2 contact the inner surface of the molded object M, but other parts of the support member 2 do not contact the inner surface of the molded object M. In another example, the support member 2 may have the leg base end surface 21b, the molding reference surface 22s, the molding support main surface 22a, the molding corner portion 22e, etc. contact the inner surface of the molded object M, and the leg side surface 21s contact the side inner surface 61 of the molded object M. When the intermediate product TA is tilted during molding, the support member 2 is supported by the inner side surface 61, which prevents the support member 2 from shifting out of position.

The angle θ3 in the sealed container T can be shaped to be smaller than the angle θ4C in the sealed container TC. It can be said that the lid portion 7 of the sealed container T is closer to horizontal than the lid portion 7C of the sealed container TC. The surface roughness of the shaping support main surface 22a is transferred to the lid portion back surface 71. In contrast, in the lid portion 7C, the lid portion back surface 71C that faces the inside of the sealed container TC cannot be processed by polishing or the like.

The molding method and support member 2 of the present disclosure are not limited to the above-described embodiment, and various modifications are possible without departing from the scope of the present disclosure. For example, in the embodiment, an example in which the support member 2 is placed after the side portion 6 is molded has been described, but the support member 2 may be placed before the side portion 6 is molded.

In the embodiment, an example has been described in which the support member 2 in the sealed container T is dissolved and removed, but the method of removing the support member 2 is not limited to this. For example, the support member 2 may be destroyed and removed in the sealed container T. In one example, vibrations that match the natural frequency of the support member 2 may be applied to the sealed container T. The support member 2 resonates in the sealed container T and is destroyed. The destroyed support member 2 may be removed from the hole H.

In the embodiment, an example has been described in which the hole H of the sealed container T is provided in conjunction with the shaping of the bottom portion 5, but the method and position of providing the hole H are not limited to this. For example, the bottom portion 5 and the side portion 6 may be shaped without providing the hole H. The hole H may be provided in the bottom portion 5 or the side portion 6 by a drill.

In the embodiment, a sealed container T is given as an example of the object M, but the example of the object M is not limited to this. The molding method of the present disclosure is applicable to any object M having an overhanging portion. If the object M is not a sealed container T, there is no need to provide a hole H.

In the embodiment, an example has been described in which the object M is molded continuously onto the base plate B, but the object M may also be molded continuously onto another product, etc.

As another example, a surface plate may be used instead of the positioner 13. The surface plate fixes the position of the object M. The arm 11 changes the position of the material supply nozzle 12. The material supply nozzle 12 moves relative to the object M.

Reference Signs List 1 Molding device 2 Support member 5 Bottom portion 6 Side portion 7 Lid portion 11 Arm 12 Material supply nozzle 13 Positioner 21 Leg portion 22 Molding support portion 22s Molding reference surface 22a Main molding support surface (molding support surface)
22e Corner portion 71 Lid back surface 72 Lid main surface 131 Table 121 Nozzle tip 122 Beam output hole 123 Powder ejection hole 21a Leg tip 21b Leg base end surface 21s Leg side surface B Base plate E Energy beam H Hole M Object P Powder material T Airtight container TA Intermediate product K Planned object formation area

Claims (5)

A method for forming a shaped object having a first shaping portion and a second shaping portion that is continuous with the first shaping portion and extends in a direction intersecting a direction in which the first shaping portion extends, the method comprising the steps of:
A step of disposing a support member including a modeling support surface along a modeling region where a lower surface of the second modeling unit is to be modeled;
forming the second feature contiguous with the first feature by supplying material and an energy beam onto the build support surface of the support member;
Including,
The support member is
A shaping support portion including the shaping support surface;
a leg portion including a portion not in contact with the first modeling portion and determining the position of the modeling support portion relative to the first modeling portion. The molding method according to claim 1, further comprising a step of molding the first molding portion before the step of placing the support member. a hole communicating with a space defined by an inner surface of the first forming portion and a portion of the support member not in contact with the first forming portion is formed in the formed object after the step of forming the second forming portion is performed;
The method of claim 2 , further comprising the step of removing the support member through the hole after the step of forming the second forming portion. The molding method according to claim 3, wherein the molding support surface is a flat surface. A support member used in a modeling method for forming a modeled object having a first modeling portion and a second modeling portion that is continuous with the first modeling portion and extends in a direction intersecting an extension direction of the first modeling portion,
A leg portion extending in a predetermined direction;
A shaped support portion supported on the tip of the leg portion,
The shaping support portion is
A shaping reference surface that is spaced apart from a leg side surface between a tip end of the leg and a base end of the leg along a direction perpendicular to the predetermined direction in which the leg extends;
A support surface for shaping extends in a direction intersecting the predetermined direction in which the leg portion extends so as to be continuous with the reference surface for shaping;
a support member having a printing corner portion formed at a portion where the printing reference surface and the printing support surface are continuous.

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