JP3155185B2 - Manufacturing method of three-dimensional shaped object - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a three-dimensionally shaped object, and more particularly, to a method for forming and manufacturing an article having a three-dimensional three-dimensional shape using a photocurable resin which is cured by irradiation of light. How to do it.

[0002]

2. Description of the Related Art A method of manufacturing a three-dimensional molded object using a photocurable resin is to form a complicated three-dimensional shape simply and accurately without using a molding die or a special processing tool. It has been considered that the method can be used for manufacturing various product models and three-dimensional models.

[0003] For example, in the method disclosed in Japanese Patent Application Laid-Open No. 63-141724, a vertically movable molding table immersed in a resin liquid is arranged directly below the liquid surface of the resin liquid, and the liquid surface is irradiated with laser light. ,
The resin liquid layer on the molding table is light-cured to form a light-cured layer, and then, after slightly lowering the molding table, the same operation as described above is repeated, whereby a plurality of light-cured layers are formed. Is piled up. In addition to the above prior art, various methods for manufacturing a three-dimensionally shaped object by laminating a photocurable layer have been proposed.

In such a method for manufacturing a three-dimensionally shaped object, a part of the three-dimensional shape has an eaves projecting laterally larger than the lower part, or a hanging part not supported at all at the lower part. When the light-cured layer is present, the light-cured layer that constitutes the eaves and the sag is insufficiently supported, and the light-cured layer is deformed or moved, causing the three-dimensional shape to collapse or lose its shape accuracy. Problems have occurred.

[0005] In order to solve such a problem, it has been considered to provide a support member which is connected to a molded article and is formed by photocuring a photocurable resin in the same manner as the molded article.
Japanese Unexamined Patent Publication No. Hei 6-8342 discloses that the two light-cured layers stacked one above the other are compared with each other in plan view to determine whether or not a support member is necessary for the upper light-cured layer. Then, there is disclosed a technique of additionally setting a light irradiation area corresponding to the support member to a light irradiation area for forming an upper photocurable layer. According to this method, the support member can be arranged at an appropriate position for supporting the modeled object based on the shape data of the modeled object, and the design of the support member can be simply and appropriately performed.

[0006]

In the above prior art, a connecting portion of a support member is connected to a plurality of photocurable layers forming a modeled object on the outer end surface of the photocurable layer forming the modeled object. However, the surface of the modeled object has a stepped shape because the layers are formed by laminating the layers, and when the connecting portion of the support member extending over a plurality of photocurable layers as in the prior art is separated from the modeled object, a mark is formed. There is a problem that remains.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for forming a three-dimensionally shaped object as described above, in which a support member for supporting the shaped object can be appropriately and efficiently designed, and the formed object can be formed from the formed object. An object of the present invention is to make the mark generated on the modeled object side when the support member is cut off inconspicuous.

[0008]

According to the present invention, there is provided a method for forming a three-dimensionally shaped object, comprising irradiating a photo-curable resin with light to form a photo-cured layer, and stacking a plurality of such photo-cured layers. how smell produce a shaped article having a three-dimensional shape
Te, in the preparation of the shaped article, the area in need of support of said molded object, in order to connect the supporting member connecting the fixed structure for supporting the light that require pre-Symbol support For the cured layer , the connecting portion of the support member,
Along the contour of the planar shape of the photocurable layer that requires support
A linear or broken lines, so as to form the same stereolithography and the molded object.

As the photo-curable resin, various photo-curable resins used in a conventional method for forming a three-dimensionally shaped object are used. Specific examples include urethane, urethane-acrylate, epoxy, and epoxy-acrylate-based photocurable resins. Basic techniques for forming a three-dimensionally shaped object, such as a method of supplying a photocurable resin, a method of irradiating light, a method of forming a photocurable layer, and a method of stacking photocurable layers, are known in the art. Any ordinary method or apparatus can be applied as it is.

[0010] The planar shape of each photo-cured layer is usually produced by converting the entire outer shape of the molded article into electronic information using a CAD device or the like, and calculating the planar shape data for each photo-cured layer from this electronic information. Once the plane shape of each light-cured layer is determined, the irradiation area of light for forming each light-cured layer is determined in accordance with this plane shape, and information on the light irradiation area is transmitted to a laser beam scanning control device. The photocurable layer having a required shape can be formed.

The present invention is applied to a structure having a part requiring support at least in a part of a structure. The portions requiring support are the above-mentioned eaves and hanging portions. The portion requiring support is not limited to one location in one modeled object, but may be multiple locations. The support member is formed by irradiating the photocurable resin with light and curing the photocurable resin by the same means as the formation of the photocurable layer forming the three-dimensional shape. The support member is usually formed by laminating a plurality of support layers made of a photocurable resin, but the support member may be constituted by a single support layer.

[0012] The support member is formed so as to connect a portion of the modeled object that needs to be supported and a fixed structure that supports the portion. The fixed structure includes, for example, a surface of a molding table for molding a molded object, an inner wall surface of a resin liquid tank for storing a photo-curable resin liquid, a column or a wall erected around a molding location of the molded object, and the like. Alternatively, a metal, a synthetic resin, or the like may be used, or a structural part having a large rigidity due to its shape and hardly deforming may be used as the fixed structure. Furthermore, a photo-curable resin may be photo-cured around the modeled object to form a peripheral wall or a pillar having sufficient rigidity, and the peripheral wall or the like may be used as a fixed structure.

The shape of the support member may be the structure of various support members used in the conventional method, and may be formed into various shapes of arms or columns in consideration of the required strength and the direction of load application. Can be used. Each support layer that constitutes the support member has a modeled object, that is, a support member connection portion connected to the photocurable layer, and an indirect connection of the upper support member connection portion that is not directly connected to the photocurable layer but is connected directly to the support structure. And a supporting member main body for supporting the photocurable layer.

The supporting member connecting portion is connected to the lower surface of the photocurable layer to be connected, and has a position and a shape suitable for supporting the upper photocurable layer. It is preferable that the supporting member connecting portion is connected to the photocurable layer with a minimum necessary area so that the mark is not conspicuous when the supporting member connecting portion is cut off from the modeled object. As the specific shape of the support member connecting portion,
In addition to the linear shape, a broken line shape, a circular shape, an elliptical shape, a polygonal shape, and other various shapes can be adopted.

The supporting member connecting portion is formed together with the photo-curing layer to be connected, that is, the photo-curing layer underlying the portion of the photo-curing layer requiring support, and the flat surface of the photo-curing layer requiring the support. A part or all of the contour line regions that do not overlap with the planar shape of the lower light-curing layer are formed so as to be connected to the light-curing layer that requires the support. Therefore, the support member connecting portion is connected to the lower surface of the photocurable layer requiring support, but is not connected to the lower photocurable layer. As a result, when separating the support member from the modeled object, it is only necessary to separate the support member connecting portion and the photocurable layer on the upper surface of the support member, and the separated trace remains only on the lower surface side of the photocurable layer, and the separation is performed. The scars overlap with the steps due to the lamination during the formation of the molded article and become inconspicuous.

In particular, if the support member connecting portion has a relatively small unit support layer such as a broken-line support member arranged at intervals, the contact area between the support member connecting portion and the upper photocurable layer is reduced. This facilitates the work of separating the model and the support member at the support member connecting portion. The support member main body is formed below the support member connection portion to support the upper support member connection portion. Therefore, the support member main body is formed according to the arrangement shape of the support member connecting portion. The support member main body preferably has a sufficient size or strength to reliably support the upper photocurable layer and the support member connecting portion. As a specific shape of the support member main body, a cross shape, a frame shape, a honeycomb shape, or the like can be adopted, in addition to a shape having the same planar shape as the support member connecting portion.

In particular, if a relatively small unit supporting layer such as a cross-shaped supporting member is arranged at intervals in the vertical and horizontal directions to constitute the entire supporting member body, the resin liquid can freely flow between the unit supporting layers. Because it is possible, the time from supplying a new resin liquid on the molding table or the previously formed photo-cured layer to smoothing the liquid surface and enabling the next light irradiation can be shortened There are advantages. Further, since the contact area with the supporting member main body formed on the molding table is reduced, the separating operation is facilitated.

Since the support member main body is formed in a region which does not overlap with any of the planar shape of the photocurable layer requiring support and the planar shape of the lower photocurable layer, any of the photocurable layers constituting the modeled object is formed. And are not directly linked. Usually, a support member is formed by laminating one or more support member main bodies and disposing the support member connecting portion. However, it is also possible to configure the support member with only one layer of the support member connection portion.

The photocurable layer connected to the support member connecting portion is
It may be all the photocurable layers constituting the modeled object, or only some of the photocurable layers that need to be supported. That is, the photocurable layers connected to the support member connecting portions may be arranged at intervals above and below the photocurable layers not connected to the support member connecting portions. As the proportion of the photocurable layer connected to the support member connection portion increases, the support effect is improved, but the time and effort for manufacturing the support member increase, and the time required for the process of separating the support member from the modeled object also increases. Normally, it is sufficient to connect the support member connecting portion to only the minimum necessary photocurable layer.

The necessity of forming such a supporting member connecting portion, that is, the layout design of the supporting member can be determined by judging from the shape of the entire shaped object, and the plurality of light-cured layers constituting the shaped object can be determined. It can also be performed based on the result of comparing the planar shapes of two photocurable layers stacked one above the other. Specifically, based on information such as the area of the planar shape of the upper and lower light curing layers, the amount of deviation of the contour line, and the angle, it is possible to provide a support member connecting portion that connects to the upper light curing layer. It can be determined whether it is necessary or not.

For example, the following method can be adopted. First,
An outer contour line when the shaped object is sectioned in the laminating direction of the photocurable layer is determined. Although the external shape of a model formed of a laminate of a number of photocurable layers is microscopically stepped, the external contour is represented by an envelope covering the step of each photocurable layer. The inclination angle between the tangent of the outer contour line at that position and the surface direction of the photocurable layer is determined for each photocurable layer. The support member connecting portion is connected to the photocurable layer at a position where the tilt angle is smaller than a predetermined reference angle. As the inclination angle is smaller, the upper light-cured layer protrudes outward more largely than the lower light-cured layer, and the necessity of the support member is high. The tilt angle is 90
If not less than °, the outer edge of the upper photocurable layer is inside the outer edge of the lower photocurable layer. The reference angle varies depending on conditions such as the shape of the object, the material used, and the purpose of use, but is usually set to 15 ° or less.

The following method can also be used to determine the photo-cured layer connecting the support member connecting portions. For the upper and lower two light-curing layers, when the area of a region that does not overlap the planar shape of the lower light-curing layer in the planar shape of the upper light-curing layer is a light-curing layer that exceeds a predetermined reference area, The support member connecting portion is connected to the upper light curing layer. The larger the area is, the larger the upper photocurable layer is projected to the outside than the lower photocurable layer, and the necessity of support is high. The reference area varies depending on conditions such as the shape of the molded object, the material used, and the purpose of use. The reference area can be defined by a ratio to the area of the upper photocurable layer. For example, when the thickness of the photocurable layer is 0.2 mm, the area of 5 to 10% of the area of the upper photocurable layer can be set as the reference area.

Further, the determination of the photocurable layer connecting the support member connecting portion is made by the above-mentioned prior art, Japanese Patent Application Laid-Open No. 6-8342.
The technology disclosed in Japanese Patent Application Laid-Open Publication No. H10-260, 1993 can also be applied. In addition, the work of determining the necessity of the above-described support member connection portion, determining the arrangement shape of the support member connection portion and the support member main body, and the like, based on information about the external shape of the modeled object input to the CAD device or the like.
This can be performed in advance by performing arithmetic processing on a computer. By simply inputting the overall shape of the modeled object into a CAD device or the like, the necessary configuration of the support members can be determined. Based on the results, it is possible to automate the molding of the three-dimensional modeled object by light irradiation. It is possible.

After the molded article composed of a plurality of light-cured layers and the support member composed of the support member connecting portion and the support member main body are formed as described above, if the support member is separated from the molded article, The desired model is obtained. A separation tool such as a cutter or a nipper can be used to separate the modeled object from the support member. The molded object can be subjected to post-treatment in the production of an ordinary three-dimensional object, such as secondary curing by heating or surface finishing treatment for smoothing the surface.

[0025]

Embodiments of the present invention will be described below with reference to the drawings. [First Embodiment] A method for manufacturing a three-dimensionally shaped object shown in the order of steps in FIGS. 1 to 4 is a method for manufacturing a shaped object 4 having a sectional shape shown in FIG.

As shown in FIG. 1, the elevating member 20 is submerged in the photo-curable resin liquid 10. The elevating member 20 is vertically movable by an actuator (not shown). Lifting member 20
Is mounted with a molding table 22.
Is formed on the object. The molding table 22 is disposed at a position slightly submerged from the liquid surface of the resin liquid 10, and is irradiated with a laser beam 30 from above the liquid surface, thereby forming a layer of the resin liquid 10 existing between the molding table 22 and the liquid surface. Is light cured. Laser light 30
The resin liquid 10 is light-cured according to the irradiation pattern.

On the molding table 22, a photocurable layer 40a to be the first layer of the modeled object 4 and a frame-shaped support member 51a arranged on one side of the photocurable layer 40a are formed. The frame-shaped support member 51a has a substantially rectangular shape with the same width as that of the photocurable layer 40a, and has a shape in which two U-shapes opened toward the photocurable layer 40a are arranged. The frame-shaped support member 51a is a light-cured layer 40a.
Is not connected to the side end surface, and becomes a support member body described later.

As shown in FIG. 2, the laser beam 30 is irradiated at each stage while the molding table 22 is sunk step by step.
A plurality of photocurable layers 40a, 40b, and 40c are sequentially stacked and formed. Simultaneously with the formation of each photocurable layer 40a, frame-shaped support members 51a, 51b, 51c are also formed. The photocurable layers 40a and 40b and the frame-shaped support members 51a and 51b have the same shape. A part of the photocurable layer 40c is stacked on the upper surface of the photocurable layer 40b, and another part projects outside the photocurable layer 40b and is connected to and stacked on the upper surface of the frame-shaped support member 51b. Therefore, a part of the frame-shaped support member 51b is a support member connection part connected to the photocurable layer 40c, and the remaining part is a support member main body not connected to the photocurable layer 40c. Frame-shaped support member 51b
Of the support member connecting portions connected to the photocurable layer 40c,
In the area surrounded by the outline of the planar shape of the photocurable layer 40c, the photocurable layer 40b is arranged in a region that does not overlap with the planar shape of the lower photocurable layer 40b.

As shown in FIG. 3, a photocurable layer 40d to be the uppermost layer is formed. A part of the photocurable layer 40d is connected to the upper surface of the photocurable layer 40c, and the remaining part is a photocurable layer 40c.
And is connected to the upper surface of the frame-shaped support member 51b. After the modeled object 4 composed of the four photocurable layers 40a to 40d is formed, the modeled object 4 is taken out of the photocurable resin liquid 10 as shown in FIG.
The supporting member 5 composed of ５１51c is separated from the modeled object 4.
Specifically, the lower surface of the photocurable layer 40d is separated from the upper surface of the frame-shaped support member 51c serving as a support member connecting portion, and the lower surface of the photocurable layer 40c and the frame-shaped support member 51 serving as a support member connecting portion are separated.
If the upper surface of b is separated, the modeled object 4 and the support member 5 can be separated. Separation mark 42 of the support member 5 remaining on the modeled object 4
Exists along the contour of the lower surface of the photocurable layers 41d and 41c. Therefore, the separation mark 42 is not so conspicuous in appearance.

In the above embodiment, as shown in FIGS. 2 and 3, the shape of the connection surface between the photocurable layer 41d and the frame-shaped support member 51c, and the shape of the connection surface between the photocurable layer 41c and the frame-shaped support member 51b. Each has a U-shape. That is, a flat U-shaped support member connecting portion is employed. Such a U-shaped support member connecting portion is preferable in that it is excellent in strength. Further, in the above-described embodiment, in a portion where the light-cured layer above the lower light-cured layer overhangs outward, the frame-shaped member serving as a support member connecting portion is formed on the lower surface of all light-cured layers, that is, the light-cured layers 41c and 41d. Since the support members 51c and 51d are connected, the support effect is high.

[Second Embodiment] This embodiment is different from the first embodiment in the shape of the support member. As shown in FIG. 5, a first photo-cured layer 40a and a honeycomb-shaped support member 52a composed of vertical and horizontal grids are formed on the molding table 22. Next, as shown in FIG. 6, a second light-cured layer 40b having the same shape as the light-cured layer 40a is laminated on the light-cured layer 40a, and has the same shape as the outer half of the honeycomb-shaped support member 52a. And the linear support member 53b is formed at a position slightly inside the honeycomb-like support member 52b.

As shown in FIG. 7, the third photo-curing layer 40 is formed.
c is connected to the photo-curable layer 40b for the most part, but one end of the linear support member 5 protrudes outside the photo-curable layer 40b.
3b. In other words, the linear support member 53b is arranged in a region surrounded by the outline of the planar shape of the photocurable layer 40c and not overlapping the planar shape of the lower photocurable layer 40b. A linear support member 53c is formed on the honeycomb support member 52b.

As shown in FIG. 8, the fourth photo-curable layer 40
d is mostly connected to the photocurable layer 40c, but one end of the linear support member 5 projects beyond the photocurable layer 40c.
3c. Here, the linear support member 53c is arranged in a region that is not overlapped with the planar shape of the lower photocurable layer 40c in the region surrounded by the outline of the planar shape of the photocurable layer 40d.

As a result, the linear supporting member 53b becomes a supporting member connecting portion connected to the photocurable layer 40c, and the linear supporting member 53c becomes a supporting member connecting portion connected to the photocurable layer 40d. The support members 52a and 52b form a support member body. As shown in FIG. 9, the molded object 4 including the photocurable layers 40 a to 40 d produced in the above process is taken out of the resin liquid 10, and the linear support members 53 b and 53 c which are the support member connecting portions are separated from the molded object 4. For example, the modeled object 4 and the support member 5 can be separated. In the molded article 4, a separation mark 42 remains only on the lower surfaces of the photocurable layers 40d and 40c.

In the above embodiment, the linear support members 53b,
Since the modeled object 4 and the support member 5 are connected only by the narrow upper surface portion 53d, the modeled object 4 and the support member 5 can be easily separated from each other, and the separation mark 42 is small. Since the honeycomb-shaped support members 52a and 52b are excellent in strength, the support effect is high. [Third Embodiment] This embodiment is different from the above embodiment in the shape of the support member.

As shown in FIG. 10, on the molding table 22,
The first photocurable layer 40a and the cross-shaped support member 54a are formed. The cruciform support members 54a are arranged in two rows, each having four unit rows of support members 54a, each of which has a plane cruciform shape, spaced apart from each other. As shown in FIG. 11, a second layer of photocurable layer 40b and a linear support member 53 arranged on a row of cross-shaped support members 54a near the photocurable layer 40b.
b and a cross-shaped support member 54b disposed on the remaining cross-shaped support member 54a. Note that FIG.
When shifting from the state of FIG. 11 to the state of FIG.
Is reduced by one step so that the resin liquid 10 flows onto the photocurable layer 40a and the cross-shaped support member 54a. At this time, since the resin liquid 10 flows freely between the cross-shaped support members 54a, the liquid surface of the resin liquid 10 is quickly smoothed.

As shown in FIG. 12, the third photocurable layer 4
The reference numeral 0c is formed over the second layer of the photocurable layer 40b and the linear support member 53b, and the linear support member 53c is formed on the cross support member 54b. The fourth light-cured layer 40d is formed of the third light-cured layer 40c and the linear support member 53.
c. As a result, the linear support members 53b and 53c become a support member connecting portion, and the cross-shaped support members 54a and 54b become a support member main body.

In the above embodiment, by using the cross-shaped support members 54a and 54b as the support member main body, a sufficient support function can be achieved even with a support member having a relatively small area. [Fourth Embodiment] In this embodiment, a cross-shaped support member similar to that of the above embodiment is employed, but the configuration of the support member is partially different.

As shown in FIG. 13, the cross-shaped support members 54a, 54a are vertically and horizontally spaced over the entire surface of the molding table 22.
a 'is arranged. As shown in FIG. 14, a first layer of the photocurable layer 40b is formed on a part of the cross-shaped support members 54a ', and the upper part of the row of the cross-shaped support members 54a arranged outside the photocurable layer 40b. , A short linear support member is formed for each cross-shaped support member 54a, that is, a support member 55b that is entirely dashed is formed.

As shown in FIG. 15, the second photocurable layer 40c extends over the photocurable layer 40b and the broken-line support member 55b.
Is formed, and a broken line-shaped support member 55c is formed on the cross-shaped support member 54b. Further, a third photocurable layer 40d is formed over the photocurable layer 40c and the broken-line-shaped support member 55c. Therefore, the dashed support members 55b and 55c become the support member connecting portions, and the remaining cross-shaped support members 54
a and 54b become support member main bodies. Further, some of the cross-shaped support members 54a 'have a role of supporting the entire modeled object.

In this embodiment, the connection between the modeled object and the support member is made by the broken-line-shaped support members 55b and 55c, and the area of the connecting portion is small, so that the modeled object is easily separated from the support member. No scars are noticeable. In addition, since the cross-shaped support member 54a 'exists between the first layer of the photocurable layer 40b and the molding table 22, the contact area of the molded object with the molding table 22 is reduced, and the molding from the molding table 22 is performed. Objects can be easily removed.

[Fifth Embodiment] In this embodiment, the support member is connected to only a part of the photocurable layer. FIG.
As shown in the figure, while forming nine light-cured layers of light-cured layers 40-1 to 40-9,
Support members 50-3, 50-5, 50-7, on which linear support members are laminated, are denoted by 3, 40-5, 40-7, and 40-9.
50-9 are formed. That is, every two layers of the photocurable layer 40 are supported by the support member 50.

As described above, the photo-curable layers 40 of a certain number of layers
If the support member 50 is connected to the first member, it is possible to save the trouble of judging the necessity of the support member 50 each time. [Sixth Embodiment] In this embodiment, a method for judging the necessity of supporting each photocurable layer forming a modeled object is described.

As shown in FIG. 17, the photocurable layers 40-1 to 40-1
The support members 50-9 are formed by stacking the support members 40-9.
7 to 50-9. FIG. 18 shows a method of determining a portion requiring support. The vertical cross-sectional shape of the model formed of the photocurable layers 40, that is, the cross-sectional view taken along line XX of FIG. 17 is obtained. In this cross-sectional view, the reference point P at the lower-end corner of each light-cured layer 40 is defined by the light-curing layer 40 on the side where the planar shape of the upper light-cured layer 40 does not overlap the planar shape of the lower light-cured layer 40. An envelope F is drawn by connecting each of the cured layers 40. This envelope F
Represents the outer contour of the modeled object. At the reference point P of each light-cured layer 40, the angle between the tangent to the outline F and the horizontal line H, that is, the inclination angle θ of the tangent is determined. The greater the length of the upper layer of the photocurable layer 40 overhanging the lower layer of the photocurable layer 40, the smaller the tilt angle θ becomes, and the higher the need to support the upper layer of the photocurable layer 40 is.

Then, the reference angle θ ₀ set in advance is compared with the inclination angle θ of each photo-curable layer 40, and if θ <θ ₀ , the support member connecting portion 50 is attached to the photo-curable layer 40. It is determined that it is necessary to connect and support. The reference angle θ ₀ is set to, for example, 15 °. Support member 5 as described above
The method of determining the necessity of forming the support member 5 is simple and accurate by electronically calculating the shape data of the modeled object.
The necessity of 0 can be determined.

[Seventh Embodiment] In this embodiment, another method for judging the necessity of supporting each photocurable layer forming a modeled object will be described. As shown in FIG. 19, when the photocurable layers 40L and 40U are arranged above and below, the upper photocurable layer 40
The plane shape of U (hatched hatching to the right) is overlapped with the plane shape of the lower photocured layer 40L (hatched hatching to the left) in an area indicated by cross hatching. The right and left hatching do not overlap and the photocurable layer 40U
The region 40X indicated only by the hatching is a region where the planar shapes of the upper and lower layers do not overlap. The support member connecting portion is connected to the region 40X.

With such an arrangement, the upper photocurable layer 40U
To determine whether a support member connection is necessary,
The area of the region 40X is determined, and whether or not the area of the region 40X is larger than the reference area is compared. If the area of the region 40X is larger than the reference area, the support member connecting portion is connected to the photocurable layer 40U. It can be determined that it is necessary.

As the reference area, the entire area of the photo-cured layer 40U is used, and when the area of the region 40X with respect to the entire area of the photo-cured layer 40U exceeds a certain ratio, it is necessary to connect and support the supporting member connecting portion. It can also be determined that there is. If it is determined that the support member connecting portion is necessary, as shown in the drawing, the support member connecting portion 50L is placed in a region of the contour region of the region 40X where the upper light curing layer is not overlapped with the region of the lower light curing layer 40L. It is formed to be connected to the layer 40U.

The determination of the necessity of the support based on the area of the region 40X as described above can be easily performed by electronically calculating the CAD data on the modeled object 4. In addition, a combination of both the determination method based on the area and the determination method based on the inclination angle described above is used when either determination method is necessary, or when it is determined that one of the determination methods is necessary. , A supporting member connecting portion may be formed.

[Other Embodiments] In addition to the above-described support member having a support member connecting portion of the present invention, a support member for supporting a modeled object is provided over a plurality of photocurable layers described as a conventional technique. Support members that can be connected can be used together. In this case, for places where there is not much problem with the use of the formed object even if there is a mark on the formed object from which the support member has been separated, use the support member connected over the above-described plurality of layers, and use the appearance member such as an external shape. In a place where it is not necessary to leave a noticeable mark on the modeled object due to the problem, only the support member having the above-described support member connecting portion of the present invention may be used.

[0051]

According to the method of forming a three-dimensionally shaped object according to the present invention, the shaped object can be easily and appropriately supported by the support member formed by the same means as the shaped object, and the supporting member can be removed from the shaped object. It is possible to make the mark generated on the molded object side when separated off inconspicuous. As a result, it is possible to efficiently manufacture a shaped article having high shape accuracy and good appearance.

[Brief description of the drawings]

FIG. 1 shows an embodiment of the present invention, and is a vertical sectional view and a horizontal sectional view showing an initial stage of a molding process.

FIG. 2 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 3 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 4 is a vertical sectional view showing a state where a support member is separated from a modeled object.

FIG. 5 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing an initial stage of a molding process.

FIG. 6 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 7 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 8 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 9 is a vertical cross-sectional view showing a state where a support member is separated from a modeled object.

FIG. 10 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing an initial stage of a shaping process.

FIG. 11 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 12 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 13 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing an initial stage of a shaping process.

FIG. 14 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 15 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 16 is a vertical sectional view showing another embodiment and showing a molding step.

FIG. 17 is a vertical sectional view and a plan view showing another embodiment and showing a forming step.

FIG. 18 is a schematic view illustrating a method for determining the need for support.

FIG. 19 is a schematic view and a plan view illustrating another embodiment and illustrating a method of determining the need for support.

[Explanation of symbols]

 REFERENCE SIGNS LIST 4 molded object 5 support member 10 photocurable resin liquid 20 elevating member 22 forming table 30 laser beam 40 photocurable layer 50 support member 51 frame-shaped support member 52 honeycomb-shaped support member 53 linear support member 54 cross-shaped support member 55 broken line Support member

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-2-251419 (JP, A) JP-A-4-169223 (JP, A) JP-A-4-169222 (JP, A) 506778 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) B29C 67/00

Claims (5)

(57) [Claims] 1. A by irradiating light to the photocurable resin to form a photo hardening layer, in how to produce a shaped article having the desired three-dimensional shape the photocurable layer stacked plurality of layers, the shaped article during manufacturing, the area in need of support of said molded object, in order to connect the supporting member connecting the fixed structure for supporting the respect photocured layer that requires a pre-Symbol support, Of the support member
The three-dimensional shape , wherein the connecting portion of the three-dimensional shape is formed in a linear or broken line shape along the contour of the planar shape of the photocurable layer requiring the support by the same stereolithography method as the molded object. A method for manufacturing a molded article. Wherein the supporting member main body is a portion other than the connection portion of the support member, in the <br/> so as not to contact with the molded object, formed by the same stereolithography and the granulated form thereof Claim 1
3. The method for producing a three-dimensionally shaped object according to item 1. 3. The method for manufacturing a three-dimensionally shaped object according to claim 2, wherein a support member main body having a plane cross shape is formed as the support member main body. 4. The method for manufacturing a three-dimensionally shaped object according to claim 2, wherein a support member body having a planar honeycomb shape is formed as the support member body. As coupling portions component of claim 5 wherein said support member, a manufacturing method of three-dimensionally shaped object according to claim 1 forming a to concatenation unit content such a plane like a dashed line.