JP3515419B2 - Optical three-dimensional molding method and apparatus - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method and an apparatus for optically producing a three-dimensional object using a photocurable resin composition. More specifically, the present invention relates to a method and apparatus for optically forming a three-dimensional object using a plurality of light beams, and according to the present invention, regardless of the size of the three-dimensional object. , A three-dimensional object with excellent dimensional accuracy without distortion and warpage, a three-dimensional object with excellent mechanical properties such as strength and hardness, a three-dimensional object with high interlayer adhesion between photo-curing layers, and a multicolored three-dimensional object Can be manufactured with high productivity at high modeling speed.

[0002]

2. Description of the Related Art Generally, a liquid photocurable resin composition is widely used as a coating agent (particularly a hard coating agent), a photoresist, a dental material and the like. Recently, three-dimensional CAD
A method for stereoscopically modeling a photocurable resin composition based on the data input to a 3D model can accurately manufacture a 3D model having a desired shape and size, and has a complicated structure. Even so, it has attracted particular attention because it can be shaped. Regarding the optical three-dimensional modeling technology, a required amount of controlled light energy is supplied to a liquid photo-curable resin to cure it in a thin layer, and then a liquid photo-curable resin is further applied to the liquid photo-curable resin, and then light is controlled under control. An optical three-dimensional modeling method for producing a three-dimensional model by repeating the steps of irradiating and curing in a thin layer is disclosed in JP-A-56-14.
No. 4478, and its basic practical method is further proposed by Japanese Patent Laid-Open No. 60-247515. After that, a number of proposals concerning optical three-dimensional modeling technology have been made.

As a method for optically producing a three-dimensional object, an ultraviolet laser controlled by a computer is selected so that a desired pattern can be obtained on the liquid surface of the liquid photocurable resin composition in a molding bath. And then cured to a predetermined thickness, and then a liquid photocurable resin composition for one layer is supplied on the photocurable layer and similarly irradiated with an ultraviolet laser to perform the same procedure as described above. A method and apparatus for curing and repeating the above-mentioned laminating / photocuring operation until a desired three-dimensional model is obtained are generally widely used.

However, in the conventional optical three-dimensional modeling technique, since the photocurable resin composition is generally cured by one laser beam (light beam), the three-dimensional model to be manufactured is large. If so, there is a problem that it takes a long time for modeling, and the obtained three-dimensional model is likely to be warped or distorted, resulting in low dimensional accuracy.
Therefore, for the purpose of solving the above-mentioned problems in stereolithography of a large three-dimensional object, a laser beam emitted from one light source is divided into a plurality of laser beams by a spectroscope,
A method has been proposed in which the plurality of laser beams are arranged apart from each other in the liquid surface direction of the photocurable resin and the photocuring of each region is shared (Japanese Patent Laid-Open No. 4-113828). However, even with this method, the dimensional accuracy of the three-dimensional model,
The physical properties such as strength, color tone, etc. are not sufficiently satisfactory, and the range of selection of the laser beam to be used is narrow, and the usage form is limited.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to produce a three-dimensional object which is free of distortion and warpage and has excellent dimensional accuracy, regardless of the size of the three-dimensional object, with high productivity and high productivity. An object of the present invention is to provide an optical three-dimensional modeling method and device capable of performing the above. Further, an object of the present invention is to provide a three-dimensional object excellent in mechanical properties such as strength and hardness, a three-dimensional object excellent in mechanical properties and dimensional stability with high interlayer adhesion strength between photocured layers, at a high modeling speed. An object of the present invention is to provide an optical three-dimensional modeling method and apparatus that can be manufactured with high productivity. An object of the present invention is to provide an optical three-dimensional modeling method and apparatus capable of smoothly producing a multi-colored three-dimensional modeled object and a three-dimensional modeled object rich in variation with a colored pattern at a high modeling speed. It is to be.

[0006]

The present inventor has made various studies in order to achieve the above object. as a result,
The photocurable resin composition applied in one layer is irradiated with light to form a photocurable layer, and a photocurable resin composition is further formed thereon.
When manufacturing a three-dimensional object by repeating the process of applying the layers and performing photo-curing, it is possible to move in the plane direction (X direction and Y direction), or to move in the plane direction (X direction and Y direction) and the height direction ( movable in the Z direction), and that the irradiation range can be achieved a plurality of light beams performs the various purposes of the using overlapping at least a part, in particular when the
When irradiating the plurality of light beams, the light beams
By arranging multiple irradiation position sensors of
Measure at two or more points and use each optical beam based on the measured values.
By correcting the position of the beam, the misalignment between the light beams is suppressed.
Or, it can be reduced to obtain a three-dimensional object with excellent dimensional accuracy.
It was found to be. Furthermore, the present inventor uses , as the plurality of light beams, ones emitted from different light sources, the type of light beam, wavelength, energy intensity,
The spot diameter, the depth of penetration into the surface of the photocurable resin composition, the irradiation pitch, the irradiation speed, the irradiation timing, etc. can be selected and combined in various ways according to the type, shape, structure, etc. of the three-dimensional model to be manufactured. Therefore, it is possible to produce a three-dimensional object excellent in dimensional accuracy, mechanical properties such as strength and hardness, and interlayer adhesion strength between photo-curing layers with high productivity at high molding speed, and to produce patterns and multicolored changes. It has been found that rich three-dimensional objects can be obtained.

Further, the present inventor, when performing optical three-dimensional modeling with the plurality of light beams, performs photo-curing on the contour portion of a predetermined pattern by one or more of the plurality of light beams. And photocuring the inner portion surrounded by the contoured portion with another one of the plurality of light beams.
It was found that when three or two or more light beams are used, warpage or distortion due to photocuring shrinkage is reduced, a three-dimensional object with excellent dimensional accuracy is obtained, and the modeling time is shortened. Then, the present inventor, when performing optical three-dimensional modeling with the plurality of light beams, uses one or more light beams of the plurality of light beams from one end side of the predetermined pattern to the end. Light-curing to the end side opposite to the end side, and at the same time from the end side opposite to the one end by another one or two or more light beams of the plurality of light beams. It has been found that when photo-curing is performed to the end side of the, the three-dimensional modeled article with excellent warp and distortion generation and excellent dimensional accuracy is obtained, and the modeling time is shortened. In addition, the present inventor, when performing the optical three-dimensional modeling by the plurality of light beams, one layer of the light curable resin composition by one or two or more light beams of the plurality of light beams. Of the plurality of light beams and one or more light beams of the plurality of light beams are included in a portion including an interface between one layer of the surface and a photo-curing layer located thereunder. It has been found that when photocuring is performed, a three-dimensional object having excellent mechanical properties with increased adhesive strength between the photocurable layers and excellent dimensional stability can be manufactured at a high modeling speed.

Further, the present inventor: In carrying out the optical three-dimensional modeling by the plurality of light beams, the photocurable resin composition contains a color former which develops a specific color tone by irradiation with light of a specific wavelength. Using the photocurable resin composition to irradiate a predetermined position on the surface of the photocurable resin composition with a light beam having a wavelength for coloring the color former, and another light beam that does not cause the color former to develop color. When a light-curable resin composition surface is irradiated with a position different from the above, a three-dimensional object having a colored portion at a predetermined position can be obtained; When one type of color former that develops different color tones depending on the irradiation wavelength is used as the photocurable resin composition and a plurality of light beams having different wavelengths are irradiated to different positions on the surface of the photocurable resin composition, Obtaining a three-dimensional object having parts colored in different color tones; When performing optical three-dimensional object formation with the plurality of light beams, as a photocurable resin composition, a plurality of color formers that develop different colors at different wavelengths When using a photocurable resin composition containing, the different positions of the surface of the photocurable resin composition is irradiated with a plurality of light beams having different wavelengths, a three-dimensional object having parts colored in different color tones is obtained. Was found;

Further, the present inventor uses, as the plurality of light beams, those having a photo-curing action and the one having a heating action when performing the optical three-dimensional modeling with the plurality of light beams, and Preheating of the photocurable resin composition and / or aging of the photocured product by the light beam possessed improves the photocuring speed, and thus the photofabrication speed, and the physical properties of the obtained three-dimensional molded article. The inventors have found that they can be achieved, and completed the present invention based on the various findings described above.

That is, according to the present invention, (1) (i) the surface of the layered photocurable resin composition is irradiated with light under control to form a photocurable layer having a predetermined pattern and thickness; ii) Applying one layer of the photocurable resin composition on the photocurable layer formed in (i), and irradiating light under control so that a predetermined amount is formed on the photocured layer formed in (i). A photocurable layer having a pattern and a thickness is integrally laminated, and (iii) one layer of the photocurable resin composition is applied onto the photocurable layer formed in (ii) above, and light is irradiated under control. Then, a photocurable layer having a predetermined pattern and a thickness is integrally laminated on the photocurable layer formed in (ii), and (iv) the above-mentioned (iii) is formed until a desired three-dimensional molded object is formed. In manufacturing a three-dimensional model by repeating the step of forming a photocurable layer, the steps (i) to (iv) described above are performed. Light irradiation, or the X direction is movable in X and Y directions, movable in Y and Z directions, the emission range performed using a plurality of light beams that overlap at least in part in, Arrange multiple light beam irradiation position sensors
Then, the position of each light beam is measured at two or more points.
The position of each light beam is corrected based on the
A method for manufacturing a three-dimensional object characterized by suppressing or reducing the positional deviation between the frames .

[0011] The present invention method for manufacturing a three-dimensional object (2) a plurality of light beams, which is the one in which emitted from separate light sources (1); encompasses a preferred embodiment the.

Further, according to the present invention, ( 3 ) photocuring of a contour portion of a predetermined pattern is performed by one or two or more light beams of the plurality of light beams, and an inner side surrounded by the contour portion. ( 4 ) A method for producing a three-dimensional object according to (1) or (2) , which comprises performing photo-curing of a portion with another one or two or more light beams of the plurality of light beams; One or more light beams of the light beams perform photo-curing from one end side of a given turn to the opposite end side of the predetermined turn, and another one of the plurality of light beams. (1) or (2), which comprises photocuring from one end side opposite to the one end side by one or two or more light beams to the one end side
( 5 ) Photocuring one layer on the surface of the photocurable resin composition with one or two or more light beams of the plurality of light beams, and (1) The photocuring of a portion including a boundary surface between one layer of the surface and a photocuring layer located thereunder is performed by another one or two or more light beams of the light beams. ) Or (2) the method for producing a three-dimensional molded article;

The present invention also provides ( 6 ) a photocurable resin composition containing a color-forming agent that develops a specific color tone when irradiated with light having a specific wavelength, as the photocurable resin composition, The light-curing resin composition surface is irradiated with a light beam having a wavelength that causes the color-forming agent to develop a color, and another light beam having a wavelength that does not cause the color-forming agent to develop color is applied to the photo-curable resin composition surface. Is irradiated to another position to manufacture a three-dimensional object having a colored portion at a predetermined position. ( 7 ) A method for producing a three-dimensional object according to any one of (1) to ( 5) above; As the curable resin composition, a photocurable resin composition containing one type of color former that develops a different color tone depending on the irradiation wavelength is used, and a plurality of light beams having different wavelengths are provided at different positions on the surface of the photocurable resin composition. Irradiate the beam, different colors It consists of producing a three-dimensional object having a colored portion in the (1) to the production method of any of the three-dimensional object (5); a (8) the photocurable resin composition, the different wavelengths of light By using a photocurable resin composition containing a plurality of color forming agents each of which develops a different color by irradiation, different positions of the photocurable resin composition surface are irradiated with a plurality of light beams having different wavelengths, respectively, (1) to (3), which comprises producing a three-dimensional modeled object having portions that are colored in different colors
The method for producing a three-dimensional molded article according to any one of ( 5) .

Further, according to the present invention, ( 9 ) a combination of a light beam having a photo-curing effect and a light beam having a heating effect is used as a plurality of light beams, and the photo-curable resin composition is produced by the light beam having a heating effect. After performing preheating or heating at the same time, photocuring is performed with a light beam having a photocuring effect, or after heat curing is performed with a light beam having a photocuring effect, heating aging is performed with a light beam having a heating effect. The method for producing a three-dimensional object according to any one of (1) to ( 8) above, which comprises performing

The present invention also provides ( 10 ) photocuring for sequentially supplying one layer of the photocurable resin composition onto a mounting table or a photocurable layer formed by curing the photocurable resin composition. Supply device for a water-soluble resin composition ;
Movable in X and Y directions or X direction for repeatedly forming and laminating a photo-curing layer having a predetermined pattern and thickness until a final three-dimensional object is formed. A light irradiation device for irradiating the surface of the photocurable resin composition with a plurality of light beams that are movable in the Y direction and the Z direction and have their irradiation ranges at least partially overlapping ; a plurality of light beams For detecting and measuring the irradiation position of
For multiple sensors and detection / measurement values of the multiple sensors
Correct the position of each light beam based on
Having a device for suppressing or reducing misalignment;
The stereolithography apparatus is characterized by .

The present invention includes ( 11) the stereolithography apparatus according to ( 10) , which has a plurality of light sources, and the plurality of light beams are emitted from each of the plurality of light sources.

The present invention provides ( 12 ) means for moving / irradiating one or more light beams of a plurality of light beams along a contour portion of a predetermined pattern to be photo-cured, and The stereolithography apparatus according to ( 10) or (11) , further comprising means for moving and irradiating another one or more light beams of the plurality of light beams in an inner portion surrounded by the contour portion; ( 13 ) One or more light beams of the plurality of light beams are gradually moved and irradiated from one end side of a predetermined turn to be photocured to the other end side, And a means for gradually moving and irradiating another one or two or more light beams of the plurality of light beams from the end portion side facing the one end portion to the one end portion side. The optical modeling apparatus according to ( 10) or (11) above. ( 14 ) The reaching depth of one or two or more light beams of the plurality of light beams is set to 1 on the surface of the photocurable resin composition.
And a boundary surface between one light layer of the surface and a light hardening layer located below the light beam reaching the depth of arrival of one or more light beams of the plurality of light beams. The optical modeling apparatus according to ( 10) or (11) above, which has a control device having a depth including.

( 15) The optical molding device according to any one of ( 10) to (14) , wherein the light irradiation device emits a plurality of light beams having different wavelengths; ( 16) Light curing of the plurality of light beams having different wavelengths. ( 15) The stereolithography apparatus having a controller for irradiating different positions on the surface of the resin composition, ( 17 ) The light irradiator photocures a light beam having a photocuring effect and a light beam having a heating effect. The optical modeling apparatus according to any one of ( 10) to (16) above, which is an apparatus for irradiating the functional resin composition.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below. In the present invention, a photocurable resin composition supply device for sequentially supplying one layer of the photocurable resin composition on a mounting table or a photocurable layer formed by curing the photocurable resin composition, and Using an optical modeling apparatus equipped with a light irradiation apparatus for repeatedly forming and laminating a photo-curing layer having a predetermined pattern and thickness until a final three-dimensional model is formed, (i) layered The surface of the photocurable resin composition described above is irradiated with light under control to form a photocurable layer having a predetermined pattern and thickness, and (ii) 1 is formed on the photocurable layer formed in (i) above. A layer of the photocurable resin composition is applied and light is controlled to irradiate the photocurable layer formed in the step (i) to integrally laminate a photocurable layer having a predetermined pattern and a thickness, iii) One layer of photocurable resin set on the photocurable layer formed in (ii) above The composition is applied and light is irradiated under control to form a photocurable layer having a predetermined pattern and a thickness integrally on the photocurable layer formed in (ii),
(Iv) Until the desired three-dimensional object is formed, the above (ii)
A three-dimensional structure is manufactured by repeating the step of forming a laminate of the photocurable layer of i).

In the production of the above-mentioned three-dimensional molded object, in the present invention, the light irradiation to the surface of the photocurable resin composition in the steps (i) to (iv) is performed using a plurality of light beams. The irradiation pitch, the irradiation range, the irradiation depth on the surface of the photocurable resin composition, the spot diameter, the wavelength, the irradiation speed, the irradiation timing, and the like during modeling of the plurality of light beams can be changed according to each situation. . The plurality of light beams may be those emitted separately from each of the plurality of light sources, or the light emitted from one light source may be separated into a plurality of light beams by a spectroscope or the like. It is desirable to use multiple light beams emitted from each of multiple light sources. When a plurality of light beams emitted from each of a plurality of light sources are separately adopted as the plurality of light beams, types of the plurality of light beams, wavelengths, energy intensities, spot diameters, irradiation pitches,
Since the depth of penetration into the surface of the photocurable resin composition, the moving form, the moving range, the irradiation speed, the irradiation timing, etc. can be individually adjusted, and in some cases, both can be adjusted in conjunction with each other. ,desirable. The number of light beams used in the present invention may be any number as long as it is two or more, and an appropriate number can be selected according to the size, shape, structure, etc. of the three-dimensional model to be manufactured.
However, if the number of light beams is too large, the stereolithography process and apparatus become complicated, so the number of light beams is generally two.
It is preferably about 5 to 5 beams, and more preferably about 2 to 4 beams.

All of the plurality of light beams used in the present invention are movable in the X direction and the Y direction (plane direction) or in the X direction, the Y direction and the Z direction (plane direction and depth and / or height). The photocurable resin composition surface is irradiated with light to be photocured while being moved in the direction along the photocurable resin composition surface, and in some cases heated. . The moving method of the light beam is not particularly limited. The light may be moved in the -Y-Z direction to irradiate the surface of the photocurable resin composition, or the light beam may be irradiated by a projector method to move the projector in the XY direction or the XYZ direction. The light beam in the XY direction or X
It may be moved in the -Y-Z direction to irradiate the surface of the photocurable resin composition, may be performed by an XY plotter system, or may be performed by another system.

In the present invention, the irradiation ranges of the plurality of light beams are overlapped at least in part, so that the respective photo-cured portions formed by the irradiation of the plurality of light beams are overlapped at least in part to form one light beam. The hardened layer, and thus one solid model is formed. In that case, the overlapping portions of the irradiation ranges of the plurality of light beams may be formed simultaneously with the irradiation of the plurality of light beams, or one or more of the plurality of light beams may be formed on the surface of the photocurable resin composition. To form a photocurable layer and then another one or more light beams are formed at least in part with the photocurable layer formed above by the photocurable layer formed by the latter light beam. Irradiation may be performed while overlapping. In short, in the photo-cured layer having a predetermined pattern and depth formed by irradiating the plurality of light beams, the photo-cured portions formed by the irradiation of the plurality of light beams are at least partially overlapped. It should be.

[0023] In the present invention, to suppress or reduce the positional deviation of the plurality of light beams, excellent dimensional accuracy is obtained and the shape of as intended <br/>, structure, the three-dimensional object having the physical properties and color tone smoothly for, the irradiation position sensor of the plurality of light beams leave plurality arranged, the position of each light beam is measured at two points or more, to perform the positional correction of the optical beam based on the measured value Make it mandatory. In that case, the number and position of the light beam irradiation position sensors are determined by the shape, structure, size, number of light beams, moving method, moving direction, moving range of the three-dimensional object for manufacturing. It is desirable to decide according to the irradiation speed. However, it is necessary to arrange the irradiation position sensor at a position that does not interfere with the stereolithography, and therefore, the plural irradiation position sensors are arranged at the outer peripheral portion surrounding the maximum moving range (maximum moving surface) of the plurality of light beams. It is good to provide and arrange. The plurality of irradiation position sensors may be fixedly arranged at a predetermined position, or may be arranged so that the positions can be moved in association with the progress or situation of the stereolithography. The type of the light beam irradiation position sensor is not particularly limited, and any sensor that can accurately detect the light beam irradiation position can be used, and examples thereof include a CCD sensor and a PSD sensor. Then, based on the values measured by the plurality of irradiation position sensors, the position correction of each light beam is automatically performed, and the optical shaping is performed while suppressing or reducing the positional deviation between the light beams.

In the present invention, the movement / irradiation form of a plurality of light beams can be determined according to the shape, structure, size, etc. of a three-dimensional object for manufacturing. For example, a plurality of light beams are arranged in parallel. Even if light irradiation is performed while moving, light irradiation is performed by moving a plurality of light beams while gradually approaching from opposite directions, light irradiation is performed by moving a plurality of light beams while gradually moving away. , The light irradiation may be performed while moving a plurality of light beams in an overlapping manner, the light irradiation may be performed while moving each of the plurality of light beams completely separately, or a method other than the above may be adopted. .

In particular, in the present invention, when the manufacturing method of the above ( 3 ) and the optical molding apparatus of the above ( 12 ) therefor are adopted, a three-dimensional molded article which is free from distortion and warpage and has excellent dimensional accuracy can be smoothly processed at a high molding speed. Can be manufactured. That is, although not limited thereto, as illustrated in the schematic view of FIG. 1, a contour portion (surrounding portion) of a predetermined pattern.
Is formed by using one or two or more light beams (preferably one and at most two light beams) of the plurality of light beams, and at the same time, the contour portion The formation of the light-cured portion b corresponding to the inner portion surrounded by the light-cured portion a corresponds to another one of the plurality of light beams.
One or two or more light beams (preferably 1 to 3 light beams) are used to manufacture a three-dimensional object, and the peripheral portion of the pattern is photo-cured (the contour of the pattern is neat). Since the inner portion is photo-cured, a three-dimensional object having no distortion or warpage and excellent dimensional accuracy can be smoothly obtained at a high modeling speed. At that time, when the photocuring of the inner portion is performed while the photocuring of the contour portion of the predetermined pattern is completed at the initial stage of the formation of the photocurable layer corresponding to the pattern, warpage or It is possible to more effectively prevent the occurrence of distortion.

Further, in the present invention, when the method ( 4 ) and the optical modeling apparatus ( 13 ) are adopted instead of the method ( 3 ) and the optical modeling apparatus ( 12 ), the warp It is possible to manufacture a three-dimensional object having little dimensional distortion and excellent dimensional accuracy at a high modeling speed with high productivity. That is, although not limited thereto, as illustrated in the schematic view of FIG. 2, one or two or more light beams of the plurality of light beams may be connected to one end side of a predetermined turn. Photocuring to the opposite end side (direction A in FIG. 2) and facing the one end side by another one or two or more light beams of the plurality of light beams. When photo-curing is performed from one end side to the one end side (direction B in FIG. 2), photo-curing is simultaneously performed from both sides of the pattern in a balanced state. It is possible to manufacture a three-dimensional object having less warpage and distortion and excellent dimensional accuracy as compared with the conventional general-purpose optical modeling technique in which light curing is sequentially performed from only one end of the pattern using a beam. Moreover, in the case of this method, if the photo-curing is performed from both ends of the pattern at the same time, the molding speed becomes twice or more as compared with the case of using one light beam, the molding speed becomes extremely high, and the productivity becomes Greatly improved.

Further, in the present invention, when the stereolithography is carried out by adopting the method ( 5 ) and the stereolithography apparatus of ( 14 ), mechanical strength and dimensional stability with high adhesive strength between the photocurable layers are obtained. It is possible to smoothly manufacture an excellent three-dimensional molded item. That is, one layer of the plurality of light beams or two or more of the light beams is used to perform photocuring for one layer on the surface of the photocurable resin composition, and another one of the plurality of light beams is used. Alternatively, only one photo-curing layer on the surface is formed by photo-curing a portion including a boundary surface between one layer on the surface and a photo-curing layer located therebelow by two or more light beams. However, the photo-curing at the interface between the photo-curing layer on the surface and the photo-curing layer existing thereunder is sufficiently performed,
The adhesive strength between the photo-curing layers is increased, and a three-dimensional molded article having excellent mechanical properties and dimensional stability can be obtained. In that case, the formation of a photo-cured layer for one layer on the surface by a plurality of light beams and the photo-curing of the portion including the boundary surface between the photo-cured layer on the surface and the photo-cured layer existing thereunder are performed simultaneously. It is possible to carry out or to carry out the photo-curing of the portion including the boundary surface subsequently to the formation of the photo-cured layer for one layer on the surface,
The latter method is preferably used because both the formation of the photocured layer on the surface and the photocuring at the boundary surface are smoothly performed.
Although not limited thereto, as illustrated in the schematic view of FIG. 3, the light beam c forms one photo-curing layer C on the surface one by one, and the light beam d has a small time lag from that.
By sequentially performing the photo-curing of the portion including the boundary surface E between the photo-cured layer C on the surface and the photo-cured layer D existing thereunder, the effect obtained by using a plurality of light beams can be sufficiently utilized while being high. A three-dimensional object having high adhesive strength between the photo-curing layers can be manufactured more smoothly at the modeling speed.

Further, in the present invention, the above ( 6 ) to
By carrying out stereolithography by adopting the method of any one of ( 8 ) and the stereolithography apparatus of ( 15 ) and ( 16 ) described above, a colored portion is provided at a predetermined position or a color tone different from each other is formed. It is possible to smoothly produce a three-dimensional object having various portions and having various changes at a high modeling speed.
That is, using a photocurable resin composition containing a color former that develops a specific color tone by irradiation with light of a specific wavelength,
A pattern or figure that is intended to develop a light beam having a wavelength that causes the color former to develop and another light beam having a wavelength that does not cause the color former to appear at different positions on the surface of the photocurable resin composition. According to the above, by irradiating simultaneously or sequentially, it is possible to smoothly manufacture a three-dimensional object having a portion where a desired pattern or figure is colored at a predetermined position. As a method different from the above, a photo-curable resin composition containing one type of color-forming agent that develops a different color tone depending on the irradiation wavelength is used, and the photo-curable resin composition is expressed at different positions on the surface. Depending on the pattern to be designed, etc., a plurality of light beams having different wavelengths may be irradiated simultaneously or sequentially to smoothly manufacture a three-dimensional object having a predetermined pattern or figure colored in different color tones. You can Further, as the photocurable resin composition, use a photocurable resin composition containing a plurality of color formers that develop different colors at different wavelengths, and let it be expressed at different positions on the surface of the photocurable resin composition. Even when irradiating multiple light beams with different wavelengths simultaneously or sequentially according to the pattern or figure to be created, it is possible to smoothly manufacture a three-dimensional object having a predetermined pattern or figure that develops different color tones. You can In any of the above three cases, since the three-dimensional object is manufactured using a plurality of light beams, the desired colored or patterned three-dimensional object can be produced at a high modeling speed. It can be manufactured well. In the above case, the type of color former that develops color upon irradiation with a light beam is not limited at all, and the color tone to be expressed,
It can be selected according to the wavelength of the light beam used. Although not limited thereto, the above ( 6 )
By the method described above, for example, as shown in the schematic view of FIG. 4, the colored and photocured pattern portion F can be formed in the photocured pattern G.

Further, in the present invention, the above ( 9 )
By using the above method and the stereolithography apparatus of ( 17 ) described above, it is possible to produce a three-dimensional molded article excellent in physical properties at a high modeling rate with high productivity while improving the photocuring rate. That is, using a plurality of light beams having a light beam having a photo-curing action and a light beam having a heating action, after performing preheating of the photo-curable resin composition by the light beam having a heating action or performing heating. At the same time, by performing the photo-curing with the light beam having the photo-curing action, the photo-curing is performed in a shorter time, so that the modeling speed can be increased. Further, by performing light curing with a light beam having a photo-curing effect and then performing heat aging with a light beam having a heating effect, it is possible to obtain a three-dimensional object that is sufficiently cured and has excellent mechanical characteristics and dimensional accuracy. You can

The type of the photocurable resin composition used in the present invention is not particularly limited, and may be any photocurable resin composition that can be used in the optical three-dimensional molding technique. Although not limited, examples of the photocurable resin composition used in the present invention include an acrylate-based photocurable resin composition, a urethane acrylate-based photocurable resin composition,
Examples thereof include an epoxy photocurable resin composition, an epoxy acrylate photocurable resin composition, and a vinyl ether photocurable resin composition. In that case, the photocurable resin composition may contain only 1 type of a photopolymerizable compound, or may contain 2 or more types. Depending on the type of the photopolymerizable compound contained in the photocurable resin composition, the type of the photopolymerization initiator also includes, for example, a photoradical polymerization initiator, a photocationic polymerization initiator, a photoradical polymerization initiator and a photocation. It can be appropriately selected such that a polymerization initiator is used in combination.

The photocurable resin composition used in the present invention may be liquid or solid.
When performing photolithography of the present invention using a liquid photocurable resin composition, for example, a molding bath filled with a photocurable resin composition liquid is used, and a plurality of light beams are applied to the liquid surface of the molding bath. It is possible to employ a method of sequentially repeating the step of irradiating light to form a photo-cured layer.

In the present invention, the kind of light (light beam) to be irradiated is not particularly limited, and any light used in optical three-dimensional modeling can be used, for example, Ar laser and He.
Any of active energy rays generated from a -Cd laser, a xenon lamp, a metal halide lamp, a mercury lamp, a fluorescent lamp or the like can be used. Among them, the laser beam is preferably used from the viewpoint of molding speed, high molding accuracy due to high condensing property, and the like. Also, the intensity of the light beam to irradiate,
The distance between the surface of the photocurable resin composition and the light source, the spot diameter, etc. can be appropriately set according to each situation.

According to the method and apparatus of the present invention, for precision parts, electric / electronic parts, furniture, building structures, automobile parts, various containers, castings, dies, mother dies, etc. High modeling speed and dimensional accuracy of models, parts for designing complicated heat medium circuits, parts for analysis planning of heat medium behavior of complicated structures, and other various 3D objects with complicated shapes and structures It can be manufactured smoothly.

[0034]

EXAMPLES The concept of the stereolithography apparatus usable in the present invention will be illustrated below with reference to FIG. 5, but the stereolithography apparatus of the present invention is not limited thereto. The stereolithography apparatus shown in FIG.
It is an example of a schematic diagram of a stereolithography apparatus configured to emit two light beams 2a and 2b from two light sources 1a and 1b. The light beam 2a emitted from the light source 1a is reflected by the mirror 3
The scanner constituted by a is adapted to irradiate the liquid surface of the photocurable resin composition filled in the modeling bath 4, and the light beam 2 emitted from the light source 1b.
b is irradiated onto the liquid surface of the photocurable resin composition filled in the modeling bath 4 by a scanner including a mirror 3b. The mirrors 3a and 3b have variable angles or variable angles and positions, whereby the light beams 2a and 2b move in the XY plane and the liquid surface of the photocurable resin composition, respectively. The irradiation depth can be changed. Further, 5 is a mounting table on which a modeled object can be mounted and which can be raised and lowered.

Further, in the stereolithography apparatus shown in FIG. 5, the irradiation position sensors 6a and 6b for detecting the irradiation positions of the two light beams 2a and 2b are provided around the irradiation areas of the light beams 2a and 2b to obstruct the stereolithography. The light beam 2 is arranged so that it does not come into contact with each other by the irradiation position sensors 6a and 6b.
The positions of a and 2b are measured at two or more points, and the angles and positions of the mirrors 3a and / or 3b are corrected based on the measurement results, thereby suppressing or reducing the positional deviation of the respective light beams 2a and 2b. . By performing various optical shaping operations of the present invention using the optical shaping apparatus as shown in FIG. 5, a three-dimensional shaped article excellent in dimensional accuracy, mechanical characteristics, adhesive strength between photocured layers, and the like can be obtained. It is possible to manufacture a three-dimensional object having a predetermined color tone and pattern manifestation form at a high modeling speed with high productivity.

[0036]

According to the present invention, regardless of the size or shape of a three-dimensional object, a three-dimensional object having no distortion or warpage and excellent dimensional accuracy can be manufactured with high productivity and high productivity. it can. In the case of the present invention, a three-dimensional object excellent in mechanical properties such as strength and hardness, a three-dimensional object having a high interlayer adhesion strength between photo-curing layers, a colored three-dimensional object and a multi-color patterned three-dimensional object. Can be manufactured with high productivity at high modeling speed.

Particularly, in the present invention, irradiation of a plurality of light beams is performed.
Positioning multiple position sensors to position each light beam at two points
Measured above, based on the measured value of each light beam
Corrects the irradiation position to suppress positional deviation between light beams.
Since it is controlled or reduced, it is a three-dimensional structure with excellent dimensional accuracy.
Shapes can be manufactured smoothly. Further , in the present invention, when a plurality of light beams emitted from different light sources are used, types of light beams, wavelength, energy intensity, spot diameter, irradiation pitch, and depth of penetration into the photocurable resin composition surface. , The moving form, moving range, irradiation speed, irradiation timing, etc. are selected and combined according to the type, shape, structure, etc. of the three-dimensional object to be manufactured, and the mechanical properties such as dimensional accuracy, strength and hardness are selected. It is possible to manufacture a three-dimensional object excellent in characteristics, interlayer adhesion strength between photo-curing layers, etc. at a high molding speed with high productivity, and to smoothly manufacture a three-dimensional object rich in coloring and patterning. You can

Further, the light curing of the contour portion of the predetermined pattern is performed by one or more light beams among the plurality of light beams, and the light curing of the inner portion surrounded by the contour portion is performed by the plurality of light beams. According to the method and apparatus of the present invention in which one or more light beams among them are used, it is possible to obtain a three-dimensional object excellent in dimensional accuracy with less warpage and distortion due to photocuring shrinkage. It can be manufactured smoothly, and the modeling time can be shortened. Then, one or two or more light beams of the plurality of light beams are photo-cured from one end side of the predetermined pattern to the end side opposite to the predetermined pattern, and at the same time, another one of the plurality of light beams is In the case of the method and apparatus of the present invention in which one or two or more light beams of the above are used to perform photo-curing from the end side opposite to the one end side to the one end side, warpage or It is possible to manufacture a three-dimensional object with reduced distortion and excellent dimensional accuracy, and since the photo-curing is performed from both end sides, it is possible to significantly reduce the modeling time. In addition, one or two or more light beams of the plurality of light beams are used to perform photocuring for one layer on the surface of the photocurable resin composition, and another one of the plurality of light beams or In the case where the method and the apparatus of the present invention are adapted to perform photo-curing on a portion below the boundary between one layer of the surface and the photo-curing layer located thereunder by two or more light beams, the photo-curing layer It is possible to manufacture a three-dimensional object excellent in mechanical properties with increased adhesive strength and dimensional stability at a high modeling speed.

Further, a photo-curable resin composition containing a color-developing agent that develops a specific color tone upon irradiation with light of a specific wavelength is used as the photo-curable resin composition, and has a wavelength at which the color-developing agent develops color. The light beam was irradiated to a predetermined position on the surface of the photocurable resin composition, while another light beam that did not cause the color forming agent to be irradiated was irradiated to a position different from the above on the surface of the photocurable resin composition. According to the method and apparatus of the present invention, it is possible to obtain a three-dimensional object having a coloring portion at a predetermined position. Moreover, at that time, by performing the photocuring of the colored portion and the non-colored portion at the same time or with a small time difference,
It is possible to improve the molding speed. Further, as the photo-curable resin composition, one type of color-developing agent that develops different color tones depending on the irradiation wavelength is used, and different positions of the photo-curable resin composition surface are irradiated with a plurality of light beams having different wavelengths. According to the method and apparatus of the present invention, it is possible to obtain a three-dimensional molded article having portions colored in different color tones, and at that time, it is high if both the color tone portions are photocured at the same time or with a small time difference. The above-mentioned three-dimensional molded item can be manufactured at a molding speed. Then, using a photocurable resin composition containing a plurality of color formers that develop different colors by different wavelengths as the photocurable resin composition,
In the case of the method and apparatus of the present invention in which different positions of the surface of the photocurable resin composition are irradiated with a plurality of light beams having different wavelengths, a three-dimensional object having parts colored in different color tones is smoothly formed. It can be manufactured. Moreover, at this time, the three-dimensional molded article can be manufactured with high productivity at a high modeling speed by simultaneously performing photocuring on both color tone portions or with a small time difference.

Furthermore, a plurality of light beams having a photo-curing action and a light beam having a heating action are used to preheat the photo-curable resin composition and / or to age the photo-cured product by the light beams having the heating action. In the case of the method and apparatus of the present invention that is performed, it is possible to improve the photo-curing speed, and thus the photo-molding speed, and it is possible to improve the physical properties of the obtained three-dimensional model.

[Brief description of drawings]

FIG. 1 is a diagram showing an example of a case where light curing of a contour portion of a predetermined pattern and light curing of an inner portion surrounded by the contour portion are performed using different light beams.

FIG. 2 is a diagram showing an example of a case where light curing is performed by irradiating light beams from both ends of one end of a predetermined pattern and the other end opposite to the same.

FIG. 3 shows one layer of light on the surface of a photocurable resin composition, which is cured by one light beam, and another layer of light and a photocurable layer located therebelow. It is a figure which shows an example at the time of photo-curing the part containing the boundary surface.

FIG. 4 is a photocurable resin composition containing a color-forming agent that develops color when irradiated with light of a specific wavelength.
It is a figure which shows an example of the photocured pattern which has a colored pattern obtained by irradiating the remaining part of the surface of a photocurable resin composition with another light beam which does not color the said color former, and photocuring it.

FIG. 5: Two light beams are respectively emitted from two light sources, and each light beam is emitted in the XY direction or XYZ.
It is a figure showing an example of a stereolithography device of the present invention which is movable in a direction and has two irradiation position sensors arranged around the irradiation of a light beam.

[Explanation of symbols]

a Light curing part corresponding to the contour part b Light-cured portion of the inner portion surrounded by the light-cured portion a c light beam d light beam A Light beam irradiation direction B Light beam irradiation direction One layer of photo-curing layer on C surface D Light-curing layer under the light-curing layer on the surface E boundary surface F colored pattern part G light curing pattern 1a light source 1b light source 2a light beam 2b light beam 3a mirror 3b mirror 4 modeling bath 5 Mounting table 6a Light beam irradiation position sensor 6b Light beam irradiation position sensor

─────────────────────────────────────────────────── --- Continuation of the front page (56) References JP-A-4-113828 (JP, A) JP-A-6-126843 (JP, A) JP-A-6-270265 (JP, A) JP-A-5- 212806 (JP, A) JP-B 6-98689 (JP, B2) JP-A 7-501998 (JP, A) JP-A 4-506110 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 67/00

Claims (17)

(57) [Claims] 1. A photocurable layer having a predetermined pattern and thickness is formed by (i) irradiating the surface of a layered photocurable resin composition with light under controlled conditions, and (ii) in the above (i). A photocurable resin composition for one layer is applied onto the formed photocurable layer, and light is controlled to irradiate the photocurable resin composition to form a photocurable layer having a predetermined pattern and thickness on the photocured layer formed in (i). The layers are integrally laminated, and (iii) one layer of the photocurable resin composition is applied on the photocurable layer formed in the above (ii), and light is controlled to irradiate the photocurable resin composition. A photocurable layer having a predetermined pattern and thickness is integrally laminated on the formed photocurable layer, and (i
v) The above (iii) until the desired three-dimensional model is formed.
In manufacturing a three-dimensional structure by repeating the step of forming a laminated layer of a photocurable layer, the light irradiation in the steps (i) to (iv) can be moved in the X direction and the Y direction, or the X direction, Moveable in Y and Z directions,
This is done by using multiple light beams whose irradiation areas overlap at least partially, and the irradiation position sensor for the light beams is duplicated.
Place several units and measure the position of each light beam at two or more points.
Correct the position of each light beam based on the measured values,
A method for manufacturing a three-dimensional object, comprising suppressing or reducing a positional deviation between light beams . 2. The method for manufacturing a three-dimensional object according to claim 1, wherein the plurality of light beams are emitted from different light sources. 3. A photocuring of a contour portion of a predetermined pattern is performed by one or more light beams of the plurality of light beams, and a plurality of light curing of an inner portion surrounded by the contour portion is performed. The method for producing a three-dimensional object according to claim 1 or 2, which is performed by using another one or two or more light beams of the above-mentioned light beams. 4. One or two or more light beams of a plurality of light beams are photo-cured from one end side of a predetermined turn to an end side opposite thereto, and the plurality of light beams are provided. claim consists of performing another one or more photocurable from an end portion side opposite to the one end side said by the light beam to one end side said of the beam 1 or 2
The method for producing a three-dimensional molded item according to. 5. The surface of the photocurable resin composition is treated with one or more light beams of a plurality of light beams.
A layer of light-curing and including an interface between one layer of the surface and the underlying photo-curing layer by another one or more light beams of the plurality of light beams. The method for producing a three-dimensional object according to claim 1 or 2 , which comprises performing photo-curing on a part. 6. A photo-curable resin composition containing a color-forming agent that develops a specific color tone when irradiated with light of a specific wavelength is used as the photo-curable resin composition. A light beam having the same is applied to a predetermined position on the surface of the photocurable resin composition, and another light beam having a wavelength that does not cause color formation of the color former is applied to a position different from the above on the surface of the photocurable resin composition. Te process according to claim 1 three-dimensional object according to any one of 5 which comprises producing a three-dimensional shaped object having a colored portion in place. 7. A photocurable resin composition containing one type of color former that develops a different color tone depending on an irradiation wavelength is used as the photocurable resin composition, and the photocurable resin composition is provided at different positions on the surface thereof. Irradiate multiple light beams with different wavelengths,
Method for producing different shades consists of producing a three-dimensional object having a colored portion in Claim 1 three-dimensional object according to any one of 5. 8. A photocurable resin composition comprising a plurality of color-forming agents that develop different colors upon irradiation with light of different wavelengths is used as the photocurable resin composition. 2. A three-dimensional molded object having different colored tones, which are produced by irradiating different positions with a plurality of light beams having different wavelengths.
The manufacturing method of the three-dimensional molded object according to any one of to 5 . 9. A light beam having a photo-curing effect and a light beam having a heating effect are used together as a plurality of light beams,
After preheating the photocurable resin composition with a light beam having a heating effect or at the same time as heating, photocuring is performed with a light beam having a photocuring effect, or photocuring with a light beam having a photocuring effect. method for producing a three-dimensional object according to any one of claims 1-8 which consists in performing a heat aging by light beam having a heating effect after the. 10. A photocurable resin composition supply device for sequentially supplying one layer of the photocurable resin composition onto a mounting table or a photocurable layer formed by curing the photocurable resin composition. ; Movable in the X and Y directions or in the X direction for repeatedly forming and laminating a photo-curing layer having a predetermined pattern and thickness until a final three-dimensional object is formed a plurality of light irradiation instrumentation <br/> location irradiating light beam to the photocurable resin composition surface and the irradiation range can be moved in the Y direction and the Z direction to overlap at least in part; and a plurality Multiple for detecting and measuring the irradiation position of the light beam of
Based on the detection and measurement values of multiple sensors
Position of each light beam to correct the position between each light beam.
A device for suppressing or reducing this;
Stereolithography device to collect. 11. The stereolithography apparatus according to claim 10 , further comprising a plurality of light sources, wherein the plurality of light beams are emitted from each of the plurality of light sources. 12. One or two of a plurality of light beams
Means for moving and irradiating one or more light beams along a contour portion of a predetermined pattern to be photocured, and another one or more light beams of the plurality of light beams, the contour portion The optical modeling apparatus according to claim 10 or 11 , further comprising means for moving and irradiating the inner portion surrounded by. 13. One or two of a plurality of light beams
One or more light beams are gradually moved and irradiated from one end side of the predetermined turn to be photocured to the other end side, and another one of the plurality of light beams or The stereolithography apparatus according to claim 10 or 11 , further comprising means for gradually moving and irradiating two or more light beams from an end portion side facing the one end portion to the one end portion side. 14. One or two of a plurality of light beams
The arrival depth of one or more light beams corresponds to one layer on the surface of the photocurable resin composition, and another one of the plurality of light beams is used.
12. The control device according to claim 10 or 11 , further comprising a control device that sets a depth of arrival of one or more light beams to a depth including a boundary surface between one layer of the surface and a photo-curing layer located thereunder. Stereolithography equipment. 15. The stereolithography apparatus according to claim 10 , wherein the light irradiation device emits a plurality of light beams having different wavelengths. 16. The stereolithography apparatus according to claim 15 , further comprising a control device that irradiates a plurality of light beams having different wavelengths to different positions on the surface of the photocurable resin composition. 17. The light irradiation device, in any one of claims 10 to 16 the light beam is a device for irradiating the photocurable resin composition having a light beam and heating action having a light hardening effect The described stereolithography apparatus.