JP3330094B2 - 3D shape forming method - 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 forming a three-dimensional shape, and more particularly, to a method for forming and manufacturing a three-dimensional three-dimensional article using a photocurable resin which is cured by light irradiation. It is about.

[0002]

2. Description of the Related Art A method of forming a three-dimensional shape using a photocurable resin can easily and accurately form a complicated three-dimensional shape without using a molding die or a special processing tool. As a method, it has been considered to use it for manufacturing various product models and three-dimensional models. Specifically, for example, Japanese Patent Application Laid-Open Nos.
There is a method disclosed in Japanese Patent No. 141724.

[0003] The method described in JP-A-61-114817 is carried out as follows. A photo-curable resin liquid is supplied into the container to form a resin liquid layer having a certain thickness, and the resin liquid layer is irradiated with laser light from above the liquid surface to partially cover the resin liquid layer. Light cure. At this time, by sequentially moving the focal position of the laser beam, a photocured layer having a predetermined pattern can be formed. Next,
A new resin liquid is supplied on the photo-cured layer to form a new resin liquid layer, and the resin liquid layer is irradiated with laser light again. By repeating such steps and sequentially stacking the photocurable layers, a resin product having a desired three-dimensional shape can be obtained.

However, this method has a problem that it is difficult to accurately and quickly set the thickness of the thin resin liquid layer that determines the thickness of the photocurable layer. That is, in this conventional technique, the thickness of the resin liquid thin layer is determined by the amount of the resin liquid supplied to the storage container, so that the supply amount of the resin liquid must be controlled very accurately. However, it is very difficult to control the supply amount of the resin liquid with high accuracy, and the thickness of the thin resin liquid layer is inevitably varied. If the thickness of the resin thin layer varies, the thickness of the formed photocured layer naturally varies, and the accuracy of the three-dimensional shape decreases.

On the other hand, Japanese Unexamined Patent Publication No.
In the method described in Japanese Patent Application Laid-Open No. 4 (1999) -1999, the control of the resin liquid supply amount unlike the above method is not required. That is, in this method, as shown in FIG. 48, the photocurable resin liquid 1 is stored in the resin liquid tank 6 and the molding table 3 which can be moved up and down is provided. After the molding table 3 is once submerged deeply below the liquid level and then raised to a position slightly below the resin liquid level, a photocuring layer having a thickness corresponding to the required thickness of the photocurable layer is formed on the molding table 3. The liquid resin thin layer 2 is naturally formed. Therefore, the resin liquid thin layer 2 is irradiated with a laser beam 7. Thereby, the first photocurable layer 4 is formed on the molding table 3.
Next, after the molding table 3 is submerged again below the liquid level and then raised to a position slightly lower than the previous stage below the liquid surface, the second light curing layer 4 is formed on the photocured layer 4 formed in the previous stage. A new thin resin liquid layer 2 having a thickness corresponding to the light curing layer of the layer is formed. Therefore, the next light cured layer 4 is formed on the previous light cured layer 4 by irradiating the laser light 7 again. Thereafter, if such a process is repeated the required number of times, a desired three-dimensionally shaped product 5 can be obtained on the forming table 3.

In this method, once the molding table 3 or the photocurable layer 4 is sunk deeply below the liquid level and then raised,
For the following reasons: As shown in FIG. 50, after forming the photocurable layer 4 on the liquid surface, the molding table 3 and the photocurable layer 4 are
Next, if the resin liquid 1 is simply lowered by the thickness of the thin resin liquid layer to be photocured, the resin liquid 1 does not flow upward from the periphery of the photocurable layer 4 due to the surface tension or viscosity of the resin liquid 1 or does not flow. It tends to be inadequate. This tendency becomes more serious as the thin photocurable layer 4 is formed.

However, according to the above method, since the photocurable layer 4 and the molding table 3 are once deeply sunk, the resin liquid 1 flows well above the photocurable layer 4 due to a difference in height from the surrounding liquid level. A sufficient amount of the resin liquid 1 covers the upper part of the photocurable layer 4. Thereafter, in the process of lifting the molding table 3, most of the resin liquid 1 existing above the molded article 5 being formed is naturally discharged to the outside of the molded article 5, and the molding table 3 or the previously formed light-cured resin is cured. Between the layer 4 and the resin liquid surface, the resin liquid thin layer 2 having a constant thickness t determined by the surface tension, viscosity, and specific gravity of the resin liquid, and the interfacial tension between the photocurable layer (or the molding table) and the resin liquid. Are naturally formed. Therefore, it is not necessary to perform strict control of the resin liquid supply amount as in the above-described prior art.

Next, since the photocurable resin contracts when cured, the shape accuracy of the formed photocured layer is deteriorated, and as a result, the dimensional accuracy of the three-dimensional shape is also reduced. is there. In order to solve this problem, as shown in FIG. 53, a filler 1a having a small shrinkage ratio such as diatomaceous earth, carbon whiskers, or glass fibers is mixed with a photo-curable resin liquid 1.
It has been proposed to improve the dimensional accuracy of a three-dimensional shape to be formed by mixing the three-dimensional shape. This method is disclosed in, for example, Japanese Patent Application Laid-Open No. 1-232025.

[0009]

However, it has been found that the prior art described in the preceding section also has the following problems. First, in the method of raising and lowering the molding table in the resin liquid, when the molded article 5 being formed is lifted to just below the liquid level by the molding table 3, the resin liquid 1 above the molded article 5 is raised.
Is removed from the molded product 5 while being lifted up by the molded product 5, but is removed only slowly from the molded product 5 because the resin liquid 1 is a liquid having a high viscosity. Therefore, the molded article 5 immediately after the lifting is completed, that is, the photocured layer 4
Due to the effect of surface tension, the new thin resin liquid layer 2 formed on the upper surface slightly rises from the periphery as shown in the enlarged view of FIG. 49 (a), and both shoulder portions 2a, 2a are rounded. It will not be the same thickness as the inner part 2b. This state cannot be resolved without a considerable time. This is as also shown in FIG.

Therefore, even at the stage of irradiating a laser beam,
The influence of the above state still remains, and the laminated structure of the photocurable layers 4 in the molded article 5 is not an ideal stack of the planar photocurable layers 40 shown in FIG.
As shown in (2), the shoulder portion 2a hangs down and the curable photocurable layers 4 are stacked one upon another, which causes a problem that the shape accuracy of the molded article 5 is deteriorated.

In the above-described method of forming a thin resin liquid layer by supplying a resin liquid, there is a method of precisely controlling the thickness of the thin resin liquid layer by sweeping the liquid surface of the liquid resin with a doctor blade. It is considered. Conventionally, the cutting edge shape of the doctor blade 8 used for such an application is as shown in FIGS. 52 (a) and 52 (b). However, in this case, unless the height position of the doctor blade 8 is accurately controlled, the thickness of the thin resin liquid layer cannot be set accurately. However, since the resin is a high-viscosity liquid, as shown in the figure, with the horizontal movement of the doctor blade 8, the resin liquid 1 penetrates below the doctor blade 8, and flows in such a manner that it rises again on the opposite side. Occurs. Therefore, in one movement of the doctor blade 8, the target liquid level X
However, the doctor blade 8 must be swept several times in order to set the target liquid level X, and there is a problem that it takes a long working time.

Next, in the method in which the filler 1a having a small shrinkage rate is mixed in the photo-curable resin liquid 1, the spot diameter φa of the laser beam 7, the power b
Even when W and the scanning speed s are the same, the curing width H and the curing depth T in the case (a) in which only the photocurable resin liquid 1 is cured.
In contrast, when the filler 1a is mixed (b), the transmittance of the laser beam is reduced by the filler 1a, so that both the curing width h and the curing depth t become smaller. In addition, the dimensional variation of the curing width h and the curing depth t becomes very large, and it is difficult to strictly control the dimensions of the photocurable layer 4.

Accordingly, an object of the present invention is to provide a method of forming a three-dimensional shape as described above, in which the problems of the prior art can be solved and the photocurable layer and the shape accuracy of the three-dimensional shape can be improved. Is to provide. In particular,
In the above-described method of raising and lowering the molding table in the resin liquid, without causing local droop of the photocurable layer, it is possible to form a photocurable layer having a flat and uniform thickness as a whole, and as a result, Another object of the present invention is to provide a method for forming a three-dimensional shape that can improve the shape accuracy of the three-dimensional shape.

Further, in the method of sweeping the liquid surface of the resin liquid with a doctor blade, a method is provided in which the liquid surface can be controlled with high accuracy in a short time, thereby improving the shape accuracy of the photocurable layer and the three-dimensional shape. Is to do. Furthermore, in the method of using a filler to prevent the curing shrinkage of the photocurable resin, the curing shrinkage is small, the curing width and the curing depth are not reduced, and the dimensional variation is not caused. An object of the present invention is to provide a method capable of improving the shape accuracy of a shape.

[0015]

A method for forming a three-dimensional shape which solves the above problems will be described below. The first method is to irradiate the photo-curable resin liquid with light to form a photo-curable layer, stack a plurality of the photo-curable layers, and form a desired three-dimensional shape. On the formed photocurable layer, a thin layer of the resin liquid is formed outside the resin liquid stored in the resin liquid tank, and the formed thin resin liquid layer is mixed with the liquid of the resin liquid in the resin liquid tank. The light-cured layer is formed by irradiating the thin resin layer with light in a state where the liquid surface of the thin resin layer and the liquid surface of the thin resin layer are aligned with each other.

In this method, basically, a laser beam or the like is applied to the vicinity of the liquid surface of the resin liquid while raising and lowering the molding table in the photo-curable resin liquid stored in the resin liquid tank. The light resin layer in the vicinity is light-cured. Therefore, the basic structure and working process of the molding apparatus, the material of the photocurable resin, and the like are the same as those in the case of the ordinary three-dimensional shape forming method. In this method, at the stage of forming the first light-cured layer on the molding table, the molding table is placed at a slight depth below the surface of the resin liquid, that is, the desired light level, as in the conventional method. The resin liquid thin layer may be formed by sinking to a depth corresponding to the thickness of the hardened layer and covering the surface of the molding table with the resin liquid with a uniform thickness. In this case, a certain waiting time is required at least until the surface of the resin liquid thin layer at the portion to be photocured becomes flat. However, when forming the first resin thin layer, the method for forming the second and subsequent resin thin layers described below can also be applied.

That is, instead of forming a thin resin layer while the molding table or the previously formed photocured layer is submerged in the resin liquid, the resin thin layer is formed outside the resin liquid stored in the resin liquid tank. Form a layer. Then, the formed resin liquid thin layer is
It is arranged at the liquid level of the resin liquid in the resin liquid tank, and the liquid level of the resin liquid and the surface of the resin liquid thin layer are matched. After that, light is irradiated to form a photo-cured layer in the same manner as in a normal three-dimensional shape forming method.

As a means for forming the thin resin liquid layer outside the resin liquid, various liquid thin film forming means can be used, and the following method is employed. In the first method, the molding table and the previously formed photocurable layer (the first
At the stage of forming the photocurable layer of the layer, the molding table alone is deeply immersed in the resin liquid, and the molding table or the previously formed photocurable layer (hereinafter, collectively referred to as a photocurable layer). Cover the top with a sufficient amount of resin solution. At this time, the depth at which the surface of the photocurable layer is submerged below the liquid level is at least larger than the thickness of the resin liquid thin layer required for forming the next photocurable layer. If this depth is somewhat deeper, the surface of the photocurable layer can be quickly covered with a resin liquid of a sufficient thickness, but if it is too deep, the effect will not increase so much, and extra operation is necessary for the operation of the molding table. It will take time. Therefore, in practice, the thickness may be slightly deeper than the required thickness of the thin resin liquid layer, although it varies depending on conditions such as the viscosity of the resin liquid.

Next, the molding table and the photocurable layer are raised so that the surface of the photocurable layer is higher than the surface of the resin liquid. Most of the resin liquid covering the photocurable layer flows down, but a part of the resin liquid remains on the surface of the photocurable layer. The amount or thickness of the resin liquid remaining on the surface of the photocurable layer varies depending on conditions such as the depth of submerging the photocurable layer below the liquid surface in the previous step, the area of the photocurable layer, the viscosity and surface tension of the resin liquid. On the surface of the resin liquid layer, the outer peripheral edge portion is in a state of hanging down round.

In this state, the sweeping member is moved in the horizontal direction along the surface of the photocurable layer to remove a part of the resin liquid remaining on the surface of the photocurable layer. After the previous process, the resin liquid remaining on the surface of the photocurable layer will fall off the surface of the photocurable layer over time, so it is necessary to start the sweeping of the resin liquid by the sweeping member. It is set at a point in time when a resin liquid having a thickness greater than or equal to the thickness remains on the surface of the photocurable layer. Dropping of the resin liquid from the surface of the photocurable layer shows different behavior depending on conditions such as the viscosity and surface tension of the resin liquid. Therefore, it is preferable to set the operation timing of the sweeping member in accordance with the behavior.

The sweeping member can be of any shape or material as long as the resin liquid can be removed satisfactorily over the entire surface of the photocurable layer, but a so-called doctor blade is preferable. The doctor blade is made of a band-shaped plate material, and horizontally moves in the thickness direction of the plate with the side edges, that is, the cutting edges set up at right angles to the surface of the photocurable layer, to sweep the resin liquid. As the blade edge shape of the doctor blade, a blade edge shape similar to that of a normal doctor blade, such as a shape obtained by simply cutting a plate or a shape having a tapered tip, can be adopted. Further, a new cutting edge shape described later can be adopted. As the operating mechanism of the doctor blade, a normal operating mechanism similar to a doctor blade employed in a normal film forming technique or the like is used.

The amount of the resin liquid to be removed by the sweeping member is set so that the thickness of the resin liquid remaining on the surface of the photocurable layer after the removal by the sweeping member is about the thickness of the necessary thin resin liquid layer. It is preferable to set to. However, this thickness does not need to be set strictly. That is, at this stage, even if the thickness of the resin liquid is slightly different from the thickness of the required resin liquid thin layer, or the surface of the resin liquid is not flat on the entire surface, Due to the effect of the surface tension of the resin liquid or the like, a slight liquid level difference or unevenness between the resin liquid covering the surface of the photocurable layer and the surrounding resin liquid can be eliminated to some extent. Therefore, in this step, the thickness of the resin liquid layer remaining on the surface of the photocurable layer may be set so as not to burden the next step.

The amount of the resin liquid removed by the sweeping member can be changed or adjusted by controlling the sweeping member and the surface of the photocurable layer or the height position of the molding table. Accurate setting is possible by measuring the positions of the surface of the sweeping member and the photocurable layer or the position of the molding table with various position sensors and controlling the operating position of the sweeping member or the rising position of the molding table.

After removing a part of the resin liquid from the surface of the photocurable layer above the liquid surface as described above, the formed thin resin liquid layer is submerged with the photocurable layer under the liquid surface, The surface position of the layer is arranged at a depth corresponding to the required thickness of the thin resin layer. In other words, the resin liquid thin layer is disposed at the liquid level of the resin liquid. Then, the resin liquid thin layer formed on the surface of the photocurable layer and the resin liquid around it are connected and integrated by an action such as surface tension. The surface of the photocurable layer
After the resin liquid thin layer having the required thickness is covered, and the surface of the resin liquid thin layer is entirely flat in accordance with the liquid level of the surrounding resin liquid, a method for forming a normal three-dimensional shape is used. Similarly, laser light irradiation is performed to form a photocured layer.

By repeating the above steps, a resin molded product having a desired three-dimensional shape can be obtained.
Next, in the second method using the sweeping member, the photocurable layer is not directly submerged in the resin liquid but is positioned outside the resin liquid as it is. In this state, there is no resin liquid layer on the surface of the photocurable layer. When the resin liquid is supplied to the entire surface of the photocurable layer from the fixed amount application nozzle or the like above the photocurable layer,
On the surface of the photocurable layer, a layer of the resin liquid is formed with a certain thickness. The thickness of the resin liquid layer is set to be thicker than the thickness required for forming the next photocurable layer, as in the above-described method. Also in this case, the outer edge of the resin liquid layer hangs down and is rounded. Thereafter, a part of the resin liquid layer is removed by using a sweeping member in the same manner as in the above-described method.
As a means for supplying the resin liquid, a normal liquid applying means is used as long as the resin liquid can be uniformly and rapidly supplied to the entire surface of the photocurable layer, such as a fixed amount application nozzle.

In the above method using the sweeping member, when a part of the resin liquid layer is removed by the sweeping member,
Next, use the sweeping member so that the resin liquid that remains on the tip of the sweeping member, etc. of the removed resin liquid moves onto the thin resin liquid layer and the surface does not have irregularities. It is preferable to remove the adhered resin before the process. As a method of removing the adhering resin from the sweeping member, the adhering resin can be heated to reduce the viscosity and the adhering force, and can be dropped from the sweeping member by its own weight. To heat the adhered resin, a heater is built in the sweeping member,
Hot air may be blown on the surface of the sweeping member.
In addition, the adhering resin can be dropped by vibrating the sweeping member. Furthermore, the adhering resin can be removed by wiping the surface of the wiping member with a wiping member made of a porous material or a highly water-absorbing material.

Further, as another method of removing the adhered resin, there is a method of forming a narrow dummy light-cured layer outside the light-cured layer constituting the three-dimensional shape. Then, before sweeping the resin liquid surface of the photocurable layer constituting the three-dimensional shape with the sweeping member, the resin liquid on the dummy photocurable layer is irradiated with light to be light-cured, and the sweeping member is After sweeping the surface of the dummy photocured layer that has been photocured first, the resin liquid of the photocured layer forming the three-dimensional shape is swept. In this method, the resin adhering to the sweeping member moves onto the dummy light-cured layer, so that the adhered resin does not move to the light-cured layer forming the three-dimensional shape.

Next, in each of the above-described methods, a three-dimensional shape is formed by forming a photocurable layer forming a three-dimensional shape and simultaneously forming a photocurable layer for a peripheral wall surrounding the outer periphery of the light-cured layer. The above-mentioned sagging or roundness is not formed on the outer edge of the thin resin liquid layer formed on the photocurable layer. This is because the resin liquid is accumulated between the photocurable layer for the peripheral wall and the photocurable layer forming the three-dimensional shape. As a result, a thin resin layer having a uniform thickness is formed on the entire inner portion of the layer, so that the thin resin layer of the photocurable layer constituting the three-dimensional shape is flat to the outer edge. Although the outer edge of the photocurable layer for the peripheral wall may be sagged or rounded, it is not a problem because it is not used as a product. Any configuration can be adopted as the arrangement shape and width of the peripheral wall photocurable layer as long as the resin liquid is stored inside the peripheral wall photocurable layer and does not hinder the formation of the photocurable layer forming the three-dimensional shape.

In each of the above-described methods, when the resin liquid thin layer is disposed at the liquid surface position of the resin liquid in the resin liquid tank, the surface of the resin liquid thin layer is temporarily set higher than the liquid surface of the resin liquid. If it is located slightly below, the resin liquid will easily flow from the periphery to the boundary between the two, due to the drop between the surface of the resin liquid layer and the liquid surface of the surrounding resin liquid, and the sag formed at the outer edge of the resin liquid thin layer And roundness are quickly eliminated. If the outer edge of the resin liquid layer is filled to some extent with the resin liquid, the resin liquid layer is raised,
What is necessary is just to make the liquid surface of the resin liquid and the surface of the resin liquid thin layer coincide.
The difference between the surface of the thin resin liquid layer and the liquid surface of the surrounding resin liquid is effective even if it is small, and the time required for raising the thin cured liquid liquid layer may be short. If the head is too large, it will take some time to eliminate surface irregularities due to the head.

When the resin liquid thin layer is placed at the liquid level of the resin liquid in the resin liquid tank and the vicinity of the boundary between the resin liquid thin layer and the liquid surface of the surrounding resin liquid is heated, the resin at the boundary is heated. The viscosity of the liquid decreases, the fluidity increases, and unevenness on the surface is quickly eliminated. Heating may be performed on a portion having irregularities on the surface or in a certain range around the resin liquid supply to the irregularities. As a heating means, irradiating heat rays such as infrared rays,
Hot air may be blown. If a laser generator for heat rays such as an infrared laser is provided together with a laser generator for photo-curing such as an ultraviolet laser, the outer edge portion of the resin liquid thin layer can be satisfactorily heated. In addition, if the sweeping member is provided with a hot-air blowing nozzle, the heating portion can be moved using the operating mechanism of the sweeping member.

The following method has a lot in common with the above-mentioned methods, and the devices and conditions to be used may be almost the same. However, in the above method, while the surface of the photocurable layer was higher than the liquid level, the sweeping member was operated,
In this method, the surface of the molding table or the previously formed photocurable layer is sunk to a depth corresponding to the required thickness of the resin liquid thin layer, and in this state, the photocurable layer is cured near the liquid surface of the resin liquid. The entire liquid level is leveled by a leveling member that moves horizontally from the periphery of the layer upward. Therefore, the step of making the photocurable layer higher than the liquid level is not performed.

That is, the surface of the formed photo-cured layer is
When submerged to a depth corresponding to the thickness of the required resin liquid thin layer, the resin liquid flows upward from the periphery of the photocurable layer, but due to the influence of the viscosity and surface tension of the resin liquid, the surface of the photocurable layer Cannot be covered with a uniform and sufficiently thick resin liquid thin layer, and above the photocured layer, the surface of the photocured layer remains exposed or becomes a liquid level lower than the surrounding liquid level. Occurs. Therefore, a leveling member that moves horizontally from the periphery of the photocurable layer to the upper side is used to supply the resin liquid around the photocurable layer to above the photocurable layer, thereby leveling the entire liquid surface.

The leveling member may have the same structure as the sweeping member in the above method, and the doctor blade is preferably used. That is, in the above method, the resin liquid is used as a sweeping member to remove excess resin liquid, and in this method, it is used as a leveling member to level the entire liquid surface. According to each purpose or function,
It is preferable to select the shape of the doctor blade to be used, particularly the shape of the blade tip.

The operating height of the leveling member is preferably set to be slightly lower than the liquid level of the thin resin liquid layer formed on the surface of the photocurable layer. However, the working height of the leveling member is
Even if the liquid level is slightly shifted up or down, if there is a slight difference in the liquid level or a level difference, after the leveling member moves and before irradiating light, the surface tension of the resin liquid will cause a natural effect. There is no problem because it is corrected.

If the horizontal movement of the leveling member is repeated a plurality of times, and the position of the lower end of the leveling member is raised stepwise in each time, the liquid level of the resin liquid thin layer can be leveled efficiently. As a result, the time required for leveling the entire liquid surface is reduced. The method described below uses a cylinder and a piston that moves up and down along the inner surface of the cylinder, and supplies a resin liquid to a step portion between the upper surface of the piston or a photocured layer formed on the upper surface of the piston and the upper surface of the cylinder. The resin liquid on the upper surface of the cylinder is removed by the sweeping member that moves horizontally along the upper surface, and a thin resin liquid layer necessary for forming the next light-cured layer is formed on the upper surface of the cylinder or the surface of the light-cured layer. .

The cylinder may have any shape, such as a cylinder, an elliptical cylinder, a square cylinder, or any other cylinder as long as the desired photocurable layer can be formed in the inner space. The piston is formed so as to conform to the inner surface shape of the cylinder, the upper surface is formed flat, and a photocurable layer is formed on the upper surface and stacked. The piston raising and lowering mechanism only needs to be able to raise and lower the piston accurately and intermittently by the height equivalent to the thickness of the resin liquid layer, similar to a normal mechanical device that uses hydraulic power, electromagnetic force or other driving force. An elevating mechanism can be used.

The sweeping member may have the same structure as that used in each of the above methods. However, in this method, since the sweeping member operates while being guided along the upper surface of the cylinder, it is not necessary to precisely control the height position of the sweeping member. In the following method, the shape of the blade of the doctor blade as used in each of the above-described methods is set so that a flow in which the resin liquid is constantly scooped in the traveling direction is formed. This structure can be applied to a conventionally known three-dimensional shape forming method or any doctor blade used as a sweeping member or a leveling member in the method disclosed in this application.

[0038] The shape of the cutting edge so that the flow of the resin liquid is always scooped in the advancing direction is specifically, for example, a beak-shaped cutting edge having a tapered shape is directed obliquely downward. If formed, the resin liquid flows so as to be scooped up along the inclined surface of the cutting edge. The behavior of the resin liquid changes by changing the taper opening angle of the cutting edge portion or the overall inclination angle, and the characteristics such as the accuracy of setting the liquid surface and the time required for flattening the liquid surface change.

The blade tip may be provided only in the direction of movement of the doctor blade, but when the doctor blade moves in both the front and rear directions, it is preferable to provide symmetrical blade tips on both sides. In addition, if a plurality of cutting edges are provided on one side with a step at the top and bottom, the plurality of cutting edges will scoop up the resin liquid in a step-by-step manner, making it possible to operate more smoothly and efficiently. it can. in this case,
It is also possible to make a difference in the inclination angle or the opening angle between the upper and lower cutting edges.

In the following method, a plurality of photocurable layers are formed by combining the following steps A and B, and then the stacked photocurable layers are uncured resin remaining inside the lattice of the lattice-shaped photocurable layer. Including the liquid, cure all at once. (A) The resin liquid thin layer is photo-cured in a grid form to form a grid-shaped photo-cured layer, and the grid space of the grid-shaped photo-cured layer is filled with a filler made of a non-shrinkable material. The surfaces of the photocured layer and the filler are leveled.

(B) The entire surface of the thin resin liquid layer is photo-cured to form a planar photo-cured layer. Step B is the same as the above-described methods or the conventional method of forming a photocurable layer. The entire surface of the thin resin liquid layer may be photocured without any gap by scanning a laser beam or the like. In the step A, when scanning the thin resin layer with a laser beam, only a so-called lattice-shaped portion is light-cured by scanning only a band-shaped area intersecting vertically and horizontally. In the lattice space formed between the lattices, an uncured resin liquid is left without being light-cured. The pattern such as the width and spacing of the lattice can be freely set, but at least the outer peripheral edge of the lattice-shaped photocurable layer needs to be photocured. The size of the lattice space only needs to be such that a necessary amount of a filler described later can be filled. It is sufficient that at least one lattice space is formed in one lattice-shaped photocurable layer. However, if the relatively small lattice spaces are evenly arranged, shrinkage of the entire photocurable layer can be favorably prevented.

The filler is a non-shrinkable material capable of suppressing the shrinkage of the photocurable layer, and is a fine powder or a material in the form of a strip or fiber that can be filled in the lattice space. . The non-shrinking property means that the shrinking property is sufficiently smaller than that of the photocurable resin, and the non-shrinking property in the strict sense of not shrinking at all is not necessarily required. Specific examples of the filler include alumina powder, other metal oxides, glass, ceramics, and metals. The filler is filled in the lattice space by spraying or applying the filler over the lattice-shaped photocurable material. It is preferable that each lattice space is evenly filled with a filler. Since the uncured resin liquid is stored in the lattice space, the filler is mixed with the resin liquid.

To level the surfaces of the lattice-shaped photocurable layer and the filler, the leveling member or doctor blade used in each of the above-described methods is used. Step A described above
Alternatively, in step B, a planar light-cured layer or a lattice-shaped light-cured layer is formed, and these light-cured layers are combined and stacked into a plurality of layers to form a desired three-dimensional shape. At this time, only the lattice-shaped photocurable layer may be stacked, but if the lowermost layer and the uppermost photocurable layer are formed of a planar photocurable layer, they are placed in the lattice space of the intermediate lattice-shaped photocurable layer. The filled filler and resin liquid do not flow out or leak.
Further, when a large number of lattice-shaped photocurable layers are stacked, the lattice spaces of the lattices communicate with each other up and down, and the filler in the lattice spaces may sink and accumulate at the bottom of the communicated lattice spaces. . In such a case, communication of the lattice space can be cut off by interposing the planar light-cured layer at an appropriate number of lattice-shaped light-cured layers.

The stacked photo-cured layers are cured at once. Batch curing is a process called so-called after-curing.The entire photo-cured layer is placed in an after-curing room or the like and irradiated with a curing lamp, etc. The whole including the inside is hardened at once. In this batch curing, unlike the irradiation of laser light, not only a part of the surface to which light reaches is cured,
The entire photocurable layer is uniformly cured, including the resin liquid in the lattice space inside the lattice-shaped photocurable layer.

In the following method, ultrasonic vibration or minute vibration is applied to the resin liquid. To apply vibration to the resin liquid, place the resin liquid inside the resin liquid tank or on the wall surface of the resin liquid tank.
What is necessary is just to attach a vibration generator. In addition, a vibration generator can be connected to the molding table, and vibration can be applied to the resin liquid via the molding table and the photocurable layer. The resin liquid that gives the vibration only needs to be at least around the photo-cured layer that affects the formation of the thin resin liquid layer. Frequency and vibration direction,
Vibration conditions such as amplitude may be freely set according to the characteristics of the resin liquid as long as the movement of the thin resin layer covering the photocurable layer or the flattening of the liquid surface can be promoted.

Vibration is applied to the resin liquid when the photocurable layer is disposed at a predetermined position below the liquid surface or when the resin liquid is supplied to the surface of the photocurable layer. It is sufficient that the movement of the resin liquid is necessary for the formation, and it is not necessary to apply vibration when irradiating light. This method can be applied to conventionally known methods for forming various ordinary three-dimensional shapes, but when used in combination with the above-described methods, the operation and effect thereof can be further enhanced.

[0047]

[Function] In the method of forming a resin liquid thin layer outside the resin liquid stored in the resin liquid tank, the resin liquid thin layer of a required thickness can be formed quickly and accurately without being disturbed by excess resin liquid. Can be formed. Since the resin liquid thin layer thus formed is arranged at the liquid surface position of the resin liquid to be irradiated with light, for example,
Compared to the conventional method, the light-cured layer is simply moved to a predetermined position below the liquid surface and waits for the surrounding resin liquid to flow completely until the surface of the light-cured layer is completely covered. It is a target. If there is a thin resin liquid layer on the surface of the photocurable layer, the surrounding resin liquid will only flow to the extent that it fills gaps between the resin liquid thin layer on the surface of the photocurable layer and eliminates slight differences in liquid level. And a desired resin liquid thin layer can be formed much more quickly than in the conventional method. Further, even if the thickness of the resin liquid thin layer is set to be thin or the viscosity or surface tension of the resin liquid is large, there is no problem that the resin liquid does not flow into the surface of the photocurable layer at all.

In the conventional method in which the photocurable layer is immersed deeply from the liquid surface and then arranged at a predetermined position slightly below the liquid surface, an extra thickness is added on the photocurable layer. A thin resin layer is formed. In this method, the thickness of the thin resin layer can be adjusted in advance, so that when the thin resin layer is arranged at a predetermined position, the thin resin layer has a substantially predetermined thickness. Since it is set, it does not take a long time until the liquid level of the resin liquid thin layer is averaged with the surrounding liquid level.

The surface of the photo-cured layer on which the resin liquid is placed is once
After setting the liquid level higher than the liquid level and removing excess resin liquid with a sweeping member to form a thin resin liquid layer, place the thin liquid resin layer at the liquid level position to raise and lower the light-cured layer and sweep it. A resin liquid thin layer having a predetermined thickness is quickly formed only by a simple operation of operating members. Completely separate from the resin liquid in the resin liquid tank,
After the resin liquid is supplied on the photocurable layer to form a thin resin liquid layer, if the excess resin liquid is removed by the sweeping member, the same operation as in the method can be performed, and the resin in the method can be used. The step of deeply submerging the photocurable layer in the liquid can be omitted. However, this method requires a resin liquid supply unit.

If the resin liquid adhering to the sweeping member is removed, the resin adhering to the sweeping member will be removed when the resin liquid layer on the photocured layer is swept in the next process cycle. And the problem of forming irregularities on the surface of the thin resin liquid layer is solved. In the method of forming the photocurable layer for the peripheral wall, the resin liquid is accumulated inside the photocurable layer for the peripheral wall, and the thin resin liquid layer formed on the photocurable layer forming the three-dimensional shape and the peripheral portion thereof are formed. The liquid surface is always continuous and uniformly flat. Therefore, no droop or roundness is formed on the outer edge of the thin resin liquid layer.

By providing a slight step between the surface of the thin resin liquid layer and the liquid surface of the surrounding resin liquid, the resin liquid easily flows into the boundary between the thin resin liquid layer and the surrounding resin liquid, The dent formed on the outer edge of the liquid thin layer is quickly eliminated. By heating the vicinity of the boundary between the resin liquid thin layer and the liquid surface of the surrounding resin liquid, the fluidity of the resin liquid in this portion is increased,
The effect of eliminating irregularities can be promoted.

After arranging the photocurable layer at a predetermined position slightly below the liquid surface, the leveling member is operated, the surrounding resin liquid is forcibly moved, and is supplied onto the photocurable layer. A resin liquid thin layer having a predetermined thickness is quickly and reliably formed on the surface of the photocurable layer. After setting a step on the upper surface of the cylinder and piston and supplying the resin liquid above the piston, the sweeping member is operated along the upper surface of the cylinder to remove the excess resin liquid. Thus, the thickness of the resin thin layer can be precisely controlled, and a resin thin layer having an arbitrary thickness can be accurately formed. Also, in the conventional method,
Since the resin liquid itself uses the function of flattening the liquid surface, a certain waiting time is absolutely necessary. However, in this method, forcible flattening by the sweeping member or adjustment of the liquid surface is performed. There is almost no need for a waiting time from the formation of the resin liquid thin layer to the irradiation of light in the next step.

By setting the shape of the blade edge of the doctor blade so that a flow in which the resin liquid is always scooped in the traveling direction is formed, the resin liquid goes around the back side of the blade edge as the blade edge passes. Nothing. If the resin liquid does not flow, the liquid level is accurately set to the height of the lower end of the cutting edge, so that the setting of the liquid level by the doctor blade is performed satisfactorily. In addition, if the resin liquid is scooped at the cutting edge, a large amount of resin liquid can be moved at a time by the operation of the doctor blade, so that the resin liquid can be swept and the liquid leveling work can be efficiently performed. Become like
If the blades are provided symmetrically on both sides of the doctor blade, the above function can be exerted even if the doctor blade is moved in any of the front and rear directions. If a plurality of cutting edges provided on one side of the doctor blade are provided with a step on the top and bottom, the burden on each cutting edge will be lighter compared to scooping up the resin liquid with only one cutting edge, It can be operated more efficiently.

By filling the lattice space of the photocurable layer with a filler made of a non-shrinkable material, the entire photocurable layer can be prevented from shrinking. As a result, a photocured layer having a dimension or shape according to a preset shape can be formed as a scanning pattern of a laser beam, and the shape accuracy of a three-dimensional shape can be improved. Moreover, since the formation of the photo-cured layer itself is performed by irradiating only the resin liquid containing no filler with light, the light penetrates to a sufficient depth to efficiently and accurately form the thin resin liquid layer. Can be light cured in shape. Therefore, it is possible to solve the problem that, as in the case where the filler is mixed into the entire resin liquid, the photocuring is adversely affected and the three-dimensional shape accuracy is reduced. In addition, even in this method, the resin liquid in the lattice space is mixed with the filler, but this portion can be satisfactorily cured regardless of the presence of the filler by collective curing in a later step. .

By vibrating the resin liquid and finely shaking it, the resin liquid can easily move, against factors such as viscosity and surface tension which hinder the movement of the resin liquid. This is because a very viscous liquid requires a very large amount of energy when starting to move from a stationary state.However, if the liquid is allowed to make a small movement by vibration, the liquid will start moving. This is probably because the required energy is much smaller. Since the resin liquid originally intended to naturally flatten the liquid surface by the action of gravity, etc., if this movement was assisted by the vibration, the liquid surface would be quickly and reliably flattened, and as a result, the surface would be flattened. A resin thin layer having a flat and accurate thickness can be formed. In each of the above methods,
Since the resin liquid is moved naturally or forcibly by a sweeping member or a leveling member, if this method is used together, the resin liquid can be moved smoothly, and a thin resin liquid layer is formed. Can be performed more efficiently.

[0056]

Embodiments of the present invention will be described below with reference to the drawings. —Method of Making Photocurable Layer Deeper in Resin Liquid and Making it Higher than Liquid Level— FIG. 1 shows a process flow chart. First, as shown in the process, the molding table 3 is placed in the resin liquid 1 stored in the resin liquid tank 6.
And the molding table 3 is disposed at a position slightly below the liquid surface of the resin liquid 1 to form the first layer of the photocurable layer 4. This is the same as the conventional ordinary method.
In order to form a uniform thin resin liquid layer on the surface, the molding table 3 is arranged at a predetermined position, and after a sufficient waiting time, light is irradiated.

Next, in the process, the molding table 3 is sunk sufficiently deep. In the process, the molding table 3 is raised to make the surface of the photocured layer 4 formed earlier to be higher than the liquid level. In the figure, the molding table 3 has risen to a level considerably higher than the liquid level, but it is sufficient that at least the surface of the photocurable layer 4 is above the liquid level. Most of the resin liquid 1 existing above the photocurable layer 4 drops off from the photocurable layer 4 and returns to the resin liquid tank 6, but a part of the resin liquid 1a is layered on the surface of the photocurable layer 4. Will be left in the state. The thickness of the resin liquid layer 1a is thicker than the thickness of the resin liquid thin layer necessary for forming the next photocurable layer. The surface of the resin liquid layer 1a is in a state in which the outer peripheral edge hangs down round.

In the process, the doctor blade 8 serving as a sweeping member is moved in the horizontal direction above the photocurable layer 4 to remove a part of the resin liquid layer 1a near the surface in thickness. The thin resin liquid layer 2 remains on the surface of the photocurable layer 4. The height of the doctor blade 8 is set so that the thickness of the resin thin layer 2 is substantially the same as the required thickness of the resin thin layer. The surface of the resin liquid thin layer 2 also has both shoulder portions 2a,
Although 2b has a round and hanging shape, the curvature is considerably smaller than the state of the resin liquid layer 1a described above.

In the process, the molding table 3 is immersed in the liquid surface, and the space between the surface of the photocurable layer 4 and the liquid surface is arranged so as to correspond to the required thickness of the resin liquid thin layer. At this stage, as shown in part A, the outer peripheral edge of the resin liquid thin layer 2 covering the surface of the photocurable layer 4 is hanging down in a round shape, and the resin liquid
Also, since the photocured layer 4 is submerged, the inner peripheral edge hangs down due to the surface tension. However, immediately, by the action of the surface tension and gravity of the resin liquid 1, the thin resin liquid layer 2 covering the surface of the photocurable layer 4 and the surrounding resin liquid 1 are connected and integrated with each other, and as shown in the process, The liquid level becomes flat in a continuous state.

FIG. 2 shows an enlarged view of the behavior in the above-mentioned part A. FIG. 2A shows a stage in which the photocurable layer 4 is arranged at a predetermined position. Since the shoulder portion 2a of the thin resin liquid layer 2 and the inner peripheral edge of the surrounding resin liquid 1 hang down from each other, the wedge is formed. -Shaped gap is slightly open. However, as shown in FIGS. 2 (b) to 2 (d), since the resin liquid is supplied from both sides of the gap, the gap is immediately filled and the entire liquid surface is continuously flat. This is compared with FIG. 26 showing the case of the conventional method described above. In this method, since the resin liquid thin layer 2 is present on the photocurable layer 4, the amount of the surrounding resin liquid 1 is small. The liquid level is flattened only by being supplied to the gap, and the time required for flattening the liquid level is remarkably reduced. In addition, as can be seen from the above description,
The resin liquid thin layer 2 formed on the surface of the photocurable layer 4 can be formed in the above-mentioned steps 1 to 3 even if it is not strictly set to a thickness necessary for forming the next photocurable layer. Liquid 1
Due to the flattening action of the liquid level between the two, the thickness is naturally adjusted to the required thickness.

Thereafter, a new light-cured layer 4 is formed by irradiating the resin liquid thin layer 2 covering the surface of the light-cured layer 4 with laser light in the process. By repeating these steps sequentially, the photocurable layers 4 are stacked, and a resin molded product having a desired three-dimensional shape is formed. —Method of Supplying Resin to Surface of Photocurable Layer on Liquid Surface— Description of portions common to the above method is omitted.

First, from the state shown in FIG.
The molding table 3 is raised above the level of the resin liquid 1. At this stage, the resin liquid 1 does not exist on the photocurable layer 4. Next, as shown in FIGS. 3 and 4, above the molding table 3,
Fixed amount application nozzle 2 having a width corresponding to the entire width of molding table 3
From 00, the fixed amount application nozzle 200 is moved in parallel while supplying the resin liquid onto the photocurable layer 4. When the fixed amount application nozzle 200 moves so as to cover the entire surface of the photocurable layer 4, the resin liquid layer 1a having a constant thickness is formed on the entire surface of the photocurable layer 4. Excess resin liquid flows down from the photocurable layer 4 and is collected in the resin liquid tank 6. Resin liquid layer 1a formed
Is thicker than the required thickness of the thin resin liquid layer 2. This state is the same as the state of FIG. Thereafter, in the same manner as described with reference to FIG. 1, the formation of the resin liquid thin layer 2 having a predetermined thickness by the sweeping member 8, the arrangement of the resin liquid 1 at the liquid surface position, the irradiation of laser light, and the like are performed. Do.

-Method for Removing Resin Liquid Adhered to Sweeping Member-In the above method, the following step is added to the step of FIG. 1, that is, the step of partially removing the resin liquid layer 1a by the sweeping member. You. As shown in FIG. 5, when a part of the thick resin liquid layer 1 a formed on the photocurable layer 4 is removed by the sweeping member 8 and the resin liquid thin layer 2 having a predetermined thickness is formed, A part 1x of the removed resin liquid remains attached to the tip of the sweeping member 8.

As shown in FIG. 6, when the sweeping member 8 with the applied resin liquid 1x applied is moved on the resin liquid layer 1a in the next process cycle in the opposite direction to the above cycle, Adhesive resin liquid 1x existing at the tip of sweeping member 8
Touches the formed resin liquid thin layer 2 and moves onto the resin liquid thin layer 2, and the convex portion 2 x is formed on the surface of the resin liquid thin layer 2. When the placement of the resin thin layer 2 on the liquid surface of the resin liquid 1, which is a post-process shown in FIGS. Are slow to flatten. In the above process, the sweeping member 8 is moved in the opposite direction every cycle.
If the sweeping member 8 is always moved in the same direction, a step of returning the sweeping member 8 to the original position is required for each cycle, and an extra work time is required.

Therefore, if the adhering resin liquid 1x attached to the sweeping member 8 is removed, the protrusions 2 are formed on the surface of the resin liquid thin layer 2.
x is not formed, and smoothing of the surface is promoted. In the embodiment shown in FIG. 7, a heater 86 is built in the sweeping member 8, and the adhered resin liquid 1x attached to the surface is heated. The heated adherent resin liquid 1x has a low viscosity and a small adhesive force to the sweeping member 8, and is naturally dropped from the sweeping member 8 and removed.

In the embodiment shown in FIG. 8, a blowing nozzle (not shown) for hot air is provided near the sweeping member 8, and hot air 87 is blown on the surface of the sweeping member 8. The adhered resin liquid 1x is heated and acts in the same manner as described above, and is moved by the force of the wind to be dropped and removed from the surface of the sweeping member 8. In the embodiment shown in FIG. 9, the sweeping member 8 is finely vibrated to promote the natural fall of the adhered resin liquid 1x. The vibrating direction may be any direction, but vibrating in the up-down direction can efficiently remove the adhered resin liquid 1x.

In the embodiment shown in FIG. 10, the surface of the sweeping member 8 is wiped with a wiping member 88 made of a water-absorbing material to remove the adhered resin liquid 1x. Next, FIGS.
In the embodiment shown in FIG. 5, the photocurable layer 4 forming a three-dimensional shape
A dummy light-cured layer 46 is formed outside the substrate, and the attached resin liquid 1x is removed by the dummy light-cured layer 46. FIG.
As shown in FIG. 7, the dummy light-cured layer 46 is
Before the sweeping member 8 passes over the photocurable layer 4, the sweeping member 8 is disposed at a position and a shape in which the sweeping member 8 passes thereover. As long as the dummy light-cured layer 46 has a width enough to maintain its shape, the narrower the width, the easier the formation and the waste of the resin liquid 1. In the figure, the photocurable layer 4
The dummy light-cured layer 46 curved in a crescent shape is provided before and after the above, which is effective for increasing the strength of the dummy light-cured layer 46 having a small width. The arrangement shape of the dummy light curing layer 46 can be freely changed according to the shape of the light curing layer 4.

In this embodiment, the basic working steps are the same as those of the embodiment shown in FIG.
Then, a dummy photo-cured layer 46 is formed. Figure 1
As shown in FIG. 13 corresponding to the step, when the molding table 3 is raised from below the liquid level, the resin liquid on the photocurable layer 4 having a large area does not easily escape to the periphery. The resin liquid on the dummy light-cured layer 46, which has a large thickness on the dummy light-cured layer 46, quickly escapes to the left and right, so that a thin resin liquid layer is quickly formed on the dummy light-cured layer 46. Therefore, at the stage when the resin liquid thin layer is formed on the dummy light-cured layer 46, in other words, the surface of the light-cured layer 46 is moved from the liquid level to a depth corresponding to the thickness of the next layer of the light-cured layer 4. At the lower position, only the portion where the dummy light cured layer 46 is to be formed is irradiated with the laser light 7 to form the dummy light cured layer 46 in advance.

Thereafter, when the molding table 3 is raised above the liquid level, a thick resin liquid layer 1a is formed on the photocurable layer 4 as in FIG. At this time, no resin liquid exists on the dummy photocurable layer 46. As shown in FIG. 14, the sweeping member 8 is operated to remove the excess resin liquid on the photocurable layer 4 to form the resin liquid thin layer 2. Before passing over 4,
It passes over the dummy photocurable layer 46.

As shown in FIG. 15, when the sweeping member 8 with the adhered resin liquid 1x attached passes over the dummy light cured layer 46, the adhered resin liquid 1x comes into contact with the surface of the dummy light cured layer 46. Therefore, the adhered resin liquid 1x is
Moves over 6. That is, the adhered resin liquid 1x is removed from the sweeping member 8. Thereafter, when the sweeping member 8 passes over the photocurable layer 4, the adhered resin liquid 1x does not transfer to the resin liquid thin layer 2 on the photocurable layer 4, and the surface remains smooth. is there.

-Method of Preparing Light Curing Layer for Peripheral Wall- As shown in FIGS. 16 and 17, a light curing layer 48 for the peripheral wall is formed so as to surround the light curing layer 4 forming a three-dimensional shape. Is done. The specific operation procedure may be the same as the method shown in FIGS. In FIG. 18 corresponding to the process of FIG. 1, when the sweeping member 8 is operated, the thin resin layer 2 is formed on the photocurable layer 4 and the photocurable layer 48 for the peripheral wall. At this time, the resin liquid existing in the space between the photocurable layer 48 for the peripheral wall and the photocurable layer 4 cannot escape because it is surrounded by the photocurable layer 48 for the peripheral wall. It remains inside the hardened layer 48. Resin liquid thin layer 2
Among them, the outer peripheral edge of the photocurable layer for peripheral wall 48 is hung down or rounded.

As shown in FIG. 19, the molding table 3 is lowered,
When the resin liquid thin layer 2 is arranged on the liquid surface of the resin liquid 1, a recess is formed between the resin liquid thin layer 2 and the surrounding resin liquid 1 at the round shoulder portion 2 a of the resin liquid thin layer 2 as shown in an enlarged manner in FIG. However, the surface of the resin liquid thin layer 2 is smooth around the photocurable layer 4. Therefore, even if the resin thin layer 2 is cured by irradiating it with laser light without waiting for the round shoulder portion 2a of the outer peripheral edge of the resin thin layer 2 to be naturally smoothed, the desired light The cured layer 4 can be formed well. As a result, the waiting time until the shoulder portion 2a of the thin resin liquid layer 2 is smoothed becomes unnecessary, and the working time can be shortened accordingly. In addition, the photocurable layer for peripheral wall 48 is formed in a state in which the outer peripheral edge is rounded, and the outer shape of the photocurable layer for peripheral wall 48 has an outer shape as long as the resin liquid 1 can be stored. There is no problem with a little inaccuracy.

-Method of lowering the surface of the resin liquid thin layer slightly below the liquid surface of the resin liquid-This method is also basically performed in the working steps described with reference to FIGS. As shown in FIG. 21 corresponding to the step of FIG. 1, when the molding table 3 on which the resin liquid thin layer 2 is formed and the photocurable layer 4 are arranged on the liquid surface of the resin liquid 1, as shown in FIG. Next, the resin liquid thin layer 2 is further lowered from a position where the surface of the resin liquid thin layer 2 coincides with the liquid level of the resin liquid 1 so that the surface of the resin liquid thin layer 2 and the periphery thereof are arranged as shown in FIG. A step h is formed between the liquid levels of the resin liquid 1. As described above, the recess formed between the round shoulder portion 2a of the resin liquid thin layer 2 and the surrounding resin liquid 1 tries to fill by filling the resin liquid on both sides, and at this time, it corresponds to the step h. Since the surrounding resin liquid 1 having potential energy flows vigorously to the lower side, the dent is rapidly filled.

When the dents have been eliminated to some extent, (c) to (d)
As shown in (2), the resin liquid thin layer 2 is raised, and the surface of the resin liquid thin layer 2 is arranged at a predetermined position corresponding to the liquid level of the resin liquid 1. Then, the step h between the resin liquid thin layer 2 and the surrounding resin liquid 1 is also eliminated, and the surface of the resin liquid thin layer 2 is
It becomes smooth by integrating with the liquid level of In the above embodiment,
The larger the step h is, the stronger the flow of the resin liquid into the recessed portion becomes. However, the time required for lowering and raising the resin liquid thin layer 2 once and the level of the liquid having the step h become flatter. Therefore, the effect does not improve even if the step h is made too large. Specifically, it is most effective to set the step h to a thickness corresponding to the thickness of the resin liquid thin layer 2.

FIG. 22 shows a method of heating the boundary between the resin liquid thin layer and the surrounding resin liquid. FIG.
At the liquid surface of the resin liquid 1. In this state, a round shoulder portion 2a formed on the outer peripheral edge of the resin liquid thin layer 2 is formed.
The resin liquid 1 has a dent at its boundary. Therefore,
(a) As shown in FIG.
Is irradiated. The infrared laser beam 72 heats the resin liquid at the boundary, reduces its viscosity, and increases its fluidity. As a result, as shown in (b) to (c), the resin liquid flows into the boundary portion from both sides quickly, and the surface of the resin liquid thin layer 2 and the liquid surface of the resin liquid 1 are separated. Immediately smooth. Thereafter, as shown in (d), the formation of the photo-cured layer 4 with the laser light 7 made of ordinary ultraviolet light for photo-curing is performed by:
It is the same as the method described above.

Infrared laser beam 7 for heating the resin liquid
Reference numeral 2 may irradiate a boundary portion between the resin liquid thin layer 2 and the resin liquid 1 so as to irradiate a range in which the liquid surface is depressed or a range slightly wider than that. Since the resin liquid flowing to eliminate the dent on the liquid surface is only around the boundary, the infrared laser light 7
There is no effect even if the irradiation range of No. 2 is further extended. Also,
The infrared laser beam 72 does not need to be controlled with high precision as in the case of the laser beam 7 for photocuring.

FIG. 23 shows a laser device for performing the above operation. A normal photo-curing laser generator 70 for irradiating ultraviolet rays or the like and a heating laser generator 74 for irradiating infrared rays are provided side by side. A pair of folding mirrors 76 and 77 are provided in front of the laser generators 70 and 74. One folding mirror 77 is provided movably to the left and right.

As shown in (a), when the laser beam 7 is irradiated from the photo-curing laser generator 70, the folding mirror 77 is moved out of the irradiation path of the laser beam 7, so that it is completely normal. It can work as if it were. (b) As shown in FIG.
When the laser beam 2 is irradiated, the folding mirror 77 is moved on the irradiation path of the laser 7. Then, the infrared laser light 72 is transmitted to the pair of folding mirrors 76 and 7.
The laser beam 7 is reflected twice and irradiates the same path as the laser beam 7.

FIG. 24 shows another structure of the laser device. Also in this embodiment, the ordinary laser beam 7 and the infrared laser beam 72 are separately generated by using the laser generator for photo-curing and the laser generator for heating. Then, the two laser beams 7 and 72 irradiated by different paths are passed through the prism 78 from directions different by an angle θ. The direction of the light output from the prism 78 changes depending on the difference in the refractive index depending on the wavelength of the transmitted light. Since the infrared laser light 72 has a longer wavelength than the laser light 7 made of ordinary ultraviolet light or the like, the direction can be more greatly bent in the prism 78. As a result, after the laser light 7 and the infrared laser light 72 incident on different paths are output from the prism 78,
Irradiation will follow exactly the same path.

If the laser beam 7 and the infrared laser beam 72 can be irradiated on the same path as in each of the above-described devices, the focus adjustment and scanning control of the laser beams 7 and 72 can be shared, and the structure of the device can be simplified. And can be miniaturized. Next,
In the embodiment shown in FIG. 25 and FIG.
Is provided with a hot air blowing nozzle 180. Then, as shown in FIG. 25, similarly to each of the above-described embodiments, after the sweeping member 8 has passed over the photocurable layer 4 to form the resin liquid thin layer 2, as shown in FIG. With the thin resin liquid layer 2 disposed on the liquid surface of the resin liquid 1, when returning the slightly raised sweeping member 8 back to the original position over the thin resin liquid layer 2, Hot air is blown from the blowing nozzle 180. The hot air heats the resin liquid thin layer 2 and the vicinity of the liquid surface of the resin liquid 1 around the resin liquid 1 to lower the viscosity of the resin liquid. As a result, the smoothing of the resin liquid thin layer 2 is promoted similarly to the above embodiment. In this method, hot air may be blown from the hot air blowing nozzle 180 only when passing through the outer peripheral edge portion of the resin liquid thin layer 2, but hot air may be constantly blown while the sweeping member 8 is moving. .

-Method of Using Leveling Member Near Liquid Surface- FIG. 27 shows a process flow chart. First, as shown in the process, the step of forming the first layer of the photocurable layer 4 on the molding table 3 is the same as the above-described method or the conventional method. In the process, the molding table 3 is lowered, and the distance between the photocurable layer 4 and the liquid surface is set to a distance corresponding to the thickness of the photocurable layer formed as the next layer. However, as described above, at this stage, the surrounding resin liquid 1 does not sufficiently flow onto the photocurable layer 4, and a wall is formed in a state where the inner peripheral edge of the surrounding resin liquid 1 hangs down round.

Accordingly, in the process, the lower end of the doctor blade 8 serving as a leveling member is arranged at a position slightly higher than the light curing layer 4 around the light curing layer 4 and is moved in the horizontal direction. When the doctor blade 8 moves, the resin liquid 1 is pushed and moved, and is supplied from around the photocurable layer 4 to above the photocurable layer 4. In this way, when the resin liquid 1 is supplied above the photocurable layer 4, the liquid surface is naturally flattened by the action of the surface tension and gravity of the resin liquid 1 itself, and the light The surface of the hardened layer 4 is covered with the resin liquid thin layer 2 having a predetermined thickness and a flat surface.

The operation of the doctor blade 8 need only pass once over the photocurable layer 4, but it is preferable to perform the operation as shown in FIG. That is, at the stage, the lower end of the doctor blade 8 is arranged at a height substantially close to the surface of the photo-cured layer 4 and is horizontally moved, and the resin liquid 1 is pushed and moved by the depth at which the doctor blade 8 is inserted, It is supplied above the photocurable layer 4. The deeper the insertion depth of the doctor blade 8, the greater the amount of resin liquid that can be moved. However, at this stage, after the doctor blade 8 has passed, it is difficult to supply the resin liquid 1 to a portion above the lower end of the doctor blade 8, so that the entire surface of the photocurable layer 4 has the same height as the surrounding liquid level. It is difficult to supply the resin liquid 1. Therefore, as shown in the stage, the resin liquid 1
Is leveled to a state where the upper part of the photocurable layer 4 is slightly depressed. In this state, the liquid level is flattened after a while, but as shown in the step, the height of the doctor blade 8 is raised to near the liquid level, and when the doctor blade 8 is horizontally moved again, the light hardened layer 4 The resin liquid 1 is supplied to the upper recess, and the entire liquid surface is quickly flattened as shown in the step.

As described above, by repeatedly moving the doctor blade 8 horizontally and stepwise, the light-cured layer 4
The predetermined resin liquid thin layer 2 can be quickly formed on the surface of the device, and the working time can be further reduced. The number of repetitions of the operation of the doctor blade 8 can be set to an arbitrary number of two or more times until the thickness and flattening of the resin liquid thin layer 2 are achieved.

—Method of Applying Vibration to Resin Liquid or Photocurable Layer— FIG. 29 shows a process flow chart. First, the first photocurable layer 4 is formed on the molding table 3 from step to step or step 'in the same manner as in the above-described methods or the conventional method.
The process is a case where the molding table 3 is placed at a predetermined position below the liquid level after being deeply sunk, and the liquid level rises as described above. Step ′ is a case where the molding table 3 is immediately placed at a predetermined position below the liquid level, and the resin liquid 1 is not sufficiently supplied above the photocurable layer 4.

In this state, when ultrasonic waves or minute vibrations are applied to the resin liquid 1 as shown in the steps and ′,
The resin liquid 1 is finely moved back and forth and right and left. As a result, the resin liquid easily moves from a portion having a high liquid level to a portion having a low liquid surface, and the liquid surface is quickly flattened. In order to move the resin liquid 1, a vibration generator may be attached to the resin liquid tank 6 to apply vibration to the entire resin liquid 1, or the vibration generator may be attached to the molding table 3 or its supporting mechanism. In this case, the resin liquid 1 may be shaken via the molding table 3 or both means may be used in combination. Vibration of the resin liquid 1 is caused by sinking the molding table 3 and
May be started after being disposed at a predetermined position, or the resin liquid 1 or the molding table 3 may be vibrated while the molding table 3 is being operated.

After the liquid surface is flattened, the laser light is applied to the liquid surface in the process as described above. After forming the resin thin layer outside the liquid level, the method of arranging it on the liquid level, or the method of using a leveling member near the liquid level, and the method of applying this vibration together, Needless to say, planarization can be further promoted.

-Method Using Piston and Cylinder- FIG. 30 shows the structure of the device used. Base 12
A cylindrical cylinder 11 is installed on the
The piston 10 slides along the inner surface of the piston and has a flat upper surface. A doctor blade 8 is provided above the cylinder 11 and moves horizontally along the upper surface of the cylinder 11. Above the cylinder 11, a resin liquid supply nozzle 100 is provided.

FIG. 31 shows a process flow chart of a method using the above apparatus. In the process, the upper surface of the piston 10 is arranged so that the depth from the upper surface of the cylinder 11 corresponds to the thickness of the thin resin liquid layer necessary to form the target photocurable layer. That is, in FIG. 6, the thickness of the resin thin layer is set by the step T ₀ between the upper surface of the piston 10 and the upper surface of the cylinder 11. In this state, the resin liquid 1 is supplied above the piston 10. The resin liquid 1 overflowing from the upper surface of the cylinder 11 spills out, and the resin liquid 1 accumulates on the upper surface of the cylinder 11.

In the process, along the upper surface of the cylinder 11,
The doctor blade 8 is moved in the horizontal direction. The resin liquid 1 raised on the upper surface of the cylinder 11 is swept away, and a thin resin liquid layer 2 having a predetermined thickness remains between the upper end of the cylinder 11 and the upper surface of the piston 10. Next, by irradiating the laser light 7 to the resin liquid thin layer 2 in the process, the intended photo-cured layer 4 is formed.

Next, in the process, the piston 10 is slightly lowered, and the distance T ₀ between the formed photo-cured layer 4 and the upper end of the cylinder 11 is set to a _value corresponding to the photo-cured layer formed in the next layer. Set to thickness. Thereafter, as shown in steps 1 to 3, if the operation of the doctor blade 8 and the irradiation of the laser beam 7 are performed in the same manner as described above, a new photocured layer 4 is formed. By repeating such a process, the photocurable layers 4 are stacked, and a resin molded product having a desired three-dimensional shape is obtained.

The method of improving the shape of the blade of the doctor blade The doctor blade 8 is used to sweep and remove the resin liquid, supply it to a required place, or level the surface in each of the above methods. Used for Specifically, FIG. 1, FIG. 14, FIG. 18, FIG. 25, FIG.
This is the process shown in FIG.

FIG. 32 shows the shape of the cutting edge of the doctor blade 8 and the state of use thereof. The beak-shaped cutting edge portion 80 having a tapered point is directed obliquely downward instead of vertically downward. When the doctor blade 8 having such a cutting edge shape is moved in a horizontal direction at a position at a certain depth from the liquid surface of the resin liquid 1, the resin liquid 1 moves so as to scoop with the curved beak-shaped cutting edge portion 80. And after the doctor blade 8 has passed,
It becomes difficult for the resin liquid 1 to flow behind the doctor blade 8, and the passing position of the tip of the cutting edge 80 becomes the liquid surface X as it is. Comparing this state with the case of the conventional cutting edge shape shown in FIG. 52, it can be seen that the setting accuracy of the liquid level X is clearly improved.

In the embodiment shown in FIG. 32, the above-described operation and effect can be achieved only when the doctor blade 8 is moved in the direction in which the tip of the cutting edge 80 faces. Therefore,
As shown in FIG. 33, the doctor blade 8 may be moved in any of the front and rear directions if the beak-shaped cutting edges 80, 80 are formed symmetrically in the front-back direction of the doctor blade 8. become.

As shown in FIG. 34, a plurality of cutting edges 81,
82 and 83 are gradually reduced from the inside to the outside by a step ΔX ₁ ,
If formed with ΔX ₂ , roughing can be performed at the first cutting edge 81, medium finishing at the second cutting edge 82, and final finishing at the third cutting edge 83. As a result, the amount of resin liquid to be swept by one blade edge portion 81 is reduced, so that the resin liquid can be smoothly and smoothly swept with high accuracy, and the liquid level X can be set more accurately. By operating the doctor blade 8 only once, it becomes possible to quickly and accurately sweep the resin liquid having a sufficient thickness. Also in this embodiment, a plurality of cutting edge portions 81 are formed symmetrically on both front and rear sides of the doctor blade 8.

-Method of Using Non-Shrinkable Filler- As shown in FIG. 35, a resin molded product 5 having a drum-shaped cross section in which a plurality of photocurable layers 4 are stacked. As the molding device, the above-described device including the cylinder 11 and the piston 10 is used. The specific structure of the molding apparatus is shown in FIG.
And the description related thereto.

As shown in FIG. 39, the first photo-cured layer 40 is formed on the piston 10 in the same manner as in the above embodiment. The photo-cured layer 40 is a planar photo-cured layer 40 in which the entire surface is irradiated with the laser beam 7 and the entire surface is photo-cured. After lowering the piston 10, the resin liquid 1 is supplied from the resin liquid supply nozzle 100, and as shown in FIG. 40, the doctor knife 8 is operated to form the resin liquid thin layer 2 having a predetermined thickness. This is the same as the above embodiment.

Next, as shown in FIG.
Is irradiated in a lattice form, whereby the resin liquid thin layer 2 is photocured in a lattice form to form a lattice-shaped photocurable layer 42. A lattice space 43 in which the uncured resin liquid 1 remains is formed inside the lattice-shaped photocurable layer 42. At least the outer peripheral edge of the lattice-shaped photocurable layer 42 needs to be cured over the entire periphery, but the inside may be formed in a lattice shape with an arbitrary shape or arrangement pattern. In the figure, although the lattice spaces 43 on a square form a lattice arranged vertically and horizontally, the shape or arrangement of the lattice spaces 43 can be freely changed.

As shown in FIG. 42, the filler supply nozzle 1
From 20, a low-shrink filler material 122 such as alumina powder is supplied above the piston 10 or the cylinder 11. The lattice space 43 of the lattice-shaped photocurable layer 42 and the photocurable layers 40 and 42
The filler 122 enters the outer periphery of the resin liquid 1 and is mixed with the resin liquid 1 existing in that portion. Only the filler 122 is deposited on the mixture 1 + 122. In addition, cylinder 1
When the filler 122 is mixed into the resin liquid 1 having a liquid level at the upper end of the cylinder 1, the liquid level of the resin liquid 1 may rise and become higher than the upper surface of the cylinder 11.

As shown in FIG. 43, when the doctor blade 8 is actuated along the upper surface of the cylinder 11, excess filler 122 is swept away. When the liquid level of the resin liquid 1 rises, the excess resin liquid 1 is also swept at the same time. As shown in FIG. 44, the lowering of the piston 10 and the supply of the resin liquid 1 are performed, and as shown in FIG. Supply and sweeping by the doctor blade 8 are performed in the same manner as in FIGS. These steps are repeated.

As a result, as shown in FIG. 46, a plurality of lattice-like photocurable layers 42 are stacked, and a lattice space 43 of each lattice-like photocurable layer 42 has a mixture of filler and resin liquid 1 + 1.
The desired three-dimensional shape filled with 22 is constructed. Since the planar light-cured layer 40 is formed on the lowermost layer, that is, the first layer and the uppermost layer, there is no fear that the mixture 1 + 122 in a flowing state in the lattice space 43 leaks or flows out. In addition, even in the middle layer, if the planar light-cured layer 40 is interposed as necessary, the filler 122 does not sink into the lower lattice space 43 and does not have an uneven distribution.

As shown in FIG. 47, the entire photo-cured layers 40 and 42 are placed in an after-curing chamber 140 and irradiated with a lamp 142 to be cured at once. As a result, the resin liquid 1 remaining in the lattice space 43 of the lattice-shaped photocurable layer 42
The uncured portion is completely cured while surrounding the filler 122. In this manner, a three-dimensional resin molded product 5 as shown in FIG. 35 is obtained.

In the above embodiment, the resin liquid thin layer 2 is formed by using the cylinder 11 and the piston 10. However, as in the above-described embodiments, the resin liquid thin layer 2 is usually formed by using the molding table 3 which can move up and down. It goes without saying that the means for forming the resin liquid thin layer 2 in the various three-dimensional shape forming methods can be used.

[0104]

According to the method for forming a three-dimensional shape according to the present invention described above, the photocurable layer can be formed quickly and accurately, and as a result, the shape accuracy of the formed three-dimensional shape can be improved. it can. In particular, after arranging the photocurable layer at a predetermined position slightly below the liquid surface, the leveling member is operated,
If the surrounding resin liquid is forcibly moved and supplied onto the photocurable layer, a thin resin liquid layer having a predetermined thickness is quickly and reliably formed on the surface of the photocurable layer.

By improving the shape of the blade of the doctor blade, the movement of the resin liquid or the control of the liquid level by the sweeping member or the leveling member, which plays a very important role in the method of forming a three-dimensional shape, can be performed with high accuracy. This can be performed in a short time in a good manner, and in various three-dimensional shape forming methods using a doctor blade, the three-dimensional shape accuracy and work efficiency can be greatly improved.

If the resin liquid thin layer is formed outside the resin liquid and then arranged on the liquid surface of the resin liquid, the resin liquid thin layer can be formed quickly and accurately without being affected by the surrounding resin liquid. As a result, a photocured layer having an accurate shape and thickness can be formed, and the shape accuracy of the formed three-dimensional shape can be improved. By combining the raising and lowering operation of the molding table and the operation of the sweeping member, a thin resin liquid layer having an accurate thickness and a flat surface can be quickly formed, and as a result, the same effect as described above can be exhibited.

By removing the resin liquid adhering to the sweeping member,
The transfer of the adhered resin liquid of the sweeping member to the thin resin liquid layer is eliminated, and the flattening of the thin resin liquid layer is promoted. As a result, the same effect as described above can be exhibited. By forming the photocurable layer for the peripheral wall, the resin liquid thin layer in the portion to be the photocurable layer constituting the three-dimensional shape has no irregularities and is flattened. As a result, the same effect as described above can be exhibited.

By lowering the resin liquid thin layer once below the liquid surface of the resin liquid and making it coincide with the liquid surface, flattening of the liquid surface at the outer peripheral edge of the resin liquid thin layer can be promoted. The same effect as above can be exhibited. By heating the boundary portion between the thin resin liquid layer and the surrounding liquid surface to increase the fluidity of the resin liquid, the flattening of the liquid surface in this portion can be promoted, and as a result, the same effect as described above is exhibited. it can.

By forming the thin resin layer at the step between the piston and the cylinder and operating the sweeping member, setting of the thickness of the thin resin layer and flattening of the surface can be performed quickly and accurately. Therefore, the three-dimensional shape can be improved in shape accuracy and work efficiency without being affected by differences in characteristics such as viscosity and surface tension of the resin liquid. By using a filler, the curing shrinkage of the photocurable resin can be reliably prevented, and since the photocuring is performed only on the resin liquid that does not contain the filler, the curing state such as the curing depth when irradiated with light Does not adversely affect As a result, the formation of the photocurable layer can be performed efficiently and accurately, without lowering the quality performance and characteristics of the resin molded product. It becomes possible to manufacture.

By simply applying vibration to the resin liquid, the resin liquid thin layer can be formed quickly and accurately without any change in other steps. As a result, the photocurable layer and the three-dimensional shape accuracy can be improved. And the overall work efficiency can be improved.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing an embodiment in the order of steps.

FIG. 2 is a schematic cross-sectional view showing the behavior in a part A of FIG.

FIG. 3 is a schematic sectional view showing another embodiment.

FIG. 4 is a schematic cross-sectional view from the side of the above.

FIG. 5 is an enlarged explanatory view of a main part in a state where a resin liquid adheres to a sweeping member.

FIG. 6 is an enlarged explanatory view of a main part in a state where the adhered resin liquid has moved to the resin liquid thin layer.

FIG. 7 is a schematic explanatory view of a sweeping member provided with means for removing the adhered resin liquid.

FIG. 8 is a schematic explanatory view showing another embodiment of the means for removing the adhered resin liquid.

FIG. 9 is a schematic explanatory view showing another embodiment of the means for removing the adhered resin liquid.

FIG. 10 is a schematic explanatory view showing another embodiment of the means for removing the adhered resin liquid.

FIG. 11 is a schematic plan view of an embodiment using a dummy photocurable layer.

FIG. 12 is a schematic cross-sectional view of the same as seen from the front.

FIG. 13 is a schematic cross-sectional view showing a step of forming a dummy photocurable layer.

FIG. 14 is a schematic sectional view showing an operation process of the sweeping member.

FIG. 15 is an explanatory diagram showing a step of removing the adhered resin liquid in a stepwise manner.

FIG. 16 is a schematic sectional view showing an embodiment of a method for forming a photocurable layer for a peripheral wall.

FIG. 17 is a plan view of the above.

FIG. 18 is a schematic sectional view showing an operation process of the sweeping member.

FIG. 19 is a schematic cross-sectional view showing a state in which a thin resin liquid layer is disposed on the liquid surface.

FIG. 20 is an enlarged view of a main part of the above.

FIG. 21 is a schematic explanatory view showing stepwise an embodiment of a method of lowering the resin liquid thin layer below the liquid level.

FIG. 22 is a schematic explanatory view showing an embodiment using an infrared laser in a stepwise manner.

FIG. 23 is a schematic perspective view showing an embodiment of a laser device.

FIG. 24 is an explanatory view of an operation of a prism portion showing another embodiment of the laser device.

FIG. 25 is a schematic sectional view showing an embodiment using a hot air blowing nozzle.

FIG. 26 is a schematic sectional view showing an operation state of the above.

FIG. 27 is a schematic sectional view showing another embodiment in the order of steps.

FIG. 28 is a schematic sectional view showing a main part of a step in another embodiment.

FIG. 29 is a schematic sectional view showing another embodiment in the order of steps.

FIG. 30 is a perspective view of a molding apparatus used in another embodiment.

FIG. 31 is a schematic cross-sectional view showing the use method of the above in order of steps.

FIG. 32 is a schematic sectional view showing an embodiment of a doctor blade and its operation.

FIG. 33 is a schematic sectional view showing another embodiment of the doctor blade and its operation.

FIG. 34 is a schematic sectional view showing another embodiment of the doctor blade and its operation.

FIG. 35 is a perspective view showing the shape of a resin molded product obtained in another embodiment.

FIG. 36 is a schematic sectional view of the first step, showing the molding steps in the order of steps;

FIG. 37 is a schematic sectional view of a step subsequent to FIG. 36;

FIG. 38 is a schematic sectional view of a step subsequent to FIG. 37;

FIG. 39 is a schematic sectional view of a step subsequent to FIG. 38;

40 is a schematic sectional view of a step subsequent to FIG. 39.

FIG. 41 is a schematic cross-sectional view of the next step of FIG. 40 and a plan view of a lattice-shaped photocurable layer.

FIG. 42 is a schematic cross-sectional view of the next step of FIG. 41 and FIG.
Enlarged sectional view

FIG. 43 is a schematic cross-sectional view showing a step subsequent to FIG. 42 and FIG.
Enlarged sectional view

FIG. 44 is a schematic sectional view showing a step subsequent to FIG. 43 and FIG.
Enlarged sectional view

FIG. 45 is a schematic sectional view of a step subsequent to FIG. 44;

FIG. 46 is a schematic cross-sectional view of stacked photocurable layers.

FIG. 47 is a schematic sectional view of a batch curing step.

FIG. 48 is a schematic sectional view showing a conventional example.

FIG. 49 is an enlarged cross-sectional view of a part A in FIG. 24 and a cross-sectional view of an ideal photocurable layer.

FIG. 50 is a schematic sectional view showing another conventional example in a stepwise manner.

FIG. 51 is a schematic sectional view showing another conventional example stepwise.

FIG. 52 is a schematic sectional view showing another conventional example.

FIG. 53 is a schematic sectional view showing another conventional example.

FIG. 54 is an explanatory view showing another conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Resin liquid 1x Adhesive resin 2 Resin liquid thin layer 3 Molding stand 4 Photocurable layer 5 Resin molded article 7 Laser beam 8 Doctor blade (sweeping member or leveling member) 10 Piston 11 Cylinder 40 Plane photocurable layer 42 Lattice Light curing layer 43 Lattice space 46 Dummy light curing layer 48 Peripheral wall light curing layer 72 Infrared laser beam 86 Heater 87 Hot air 88 Wiping material 122 Filler 180 Hot air blowing nozzle 200 Fixed amount application nozzle

────────────────────────────────────────────────── ─── Continuation of the front page Examiner Hiroshi Nakamura (56) References JP-A-3-246025 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 67/00

Claims (4)

(57) [Claims] 1. A method of forming a desired three-dimensional shape by irradiating a photocurable resin liquid with light to form a photocurable layer, stacking a plurality of the photocurable layers, and forming a desired three-dimensional shape. The blade shape of the doctor blade that moves the resin liquid
A cutting edge with an inclined surface facing downward and outward is provided.
The resin liquid always tilts with respect to the direction of travel of the
Method of forming a three-dimensional shape, characterized in that set so as to be formed to flow is found raised rake the surface. 2. The method according to claim 1, wherein the surface of the photocurable layer formed on the molding table or the resin liquid required for forming the next layer of the photocurable layer relative to the liquid surface of the resin liquid. After submerging to a depth corresponding to the thickness of the thin layer, near the liquid surface of the resin liquid,
The doc that moves horizontally from the periphery of the photocured layer to the top
A method for forming a three-dimensional shape, wherein the entire liquid surface is leveled by a leveling member comprising a tar blade . 3. The method according to claim 1 , wherein the doctor blade has a plurality of symmetrical blades on both sides of the doctor blade. 4. The method according to claim 3, wherein a step is provided in the plurality of cutting edges.