JP3856654B2 - Manufacturing method of three-dimensional shaped object - Google Patents

Description

[0001]
[Technical field to which the invention belongs]
The present invention relates to a method for manufacturing a three-dimensional shaped object. Specifically, the present invention relates to a method for producing a shaped article having a desired three-dimensional shape by forming a molten layer by irradiating a light beam onto an inorganic or organic powder material and stacking the molten layers.
[0002]
[Prior art]
A method for producing a three-dimensional shaped object by irradiating an inorganic powder (metal) or organic powder (resin) with a light beam such as a directional energy beam or a laser beam, and then laminating a cured layer. For example, this is disclosed in Japanese Patent No. 2620353.
[0003]
In this method, first, the portion corresponding to the first cross section of the target object is sintered on the powder deposition layer by irradiating with a light beam. Subsequently, a second powder layer is deposited on the first powder layer, and a portion corresponding to the second cross section of the target object is irradiated with a light beam again, and the sintered powder in the first powder layer is obtained. Join. This operation is continuously performed as many times as necessary to produce a target shaped article, and then the non-sintered powder existing around is removed to take out the shaped article.
[0004]
However, in this method, there is a problem that each layer is deformed by the shrinkage of the powder during sintering, and an accurate shaped article cannot be obtained. Further, when the corresponding shrinkage prevention structure is used, there is a problem that the quality of the surface of the molded article is deteriorated.
[0005]
In order to solve such a problem, Japanese Patent Application Laid-Open No. 8-504139 discloses that in each layer, the core region and the shell region are separated and the characteristics of both regions are different. A method of manufacturing a shaped article by irradiating a light beam so that subsequent deformation of the object is minimized and irradiating the light beam so as to generate a surface that is as flat and precise as possible in the shell region is disclosed.
[0006]
In this method, a relatively stable shell can be produced by the laminated shell region, and the core region can be produced by minimizing deformation without degrading the stability of the molded object, and a flat and precise surface is generated. it can.
[0007]
[Problems to be solved by the invention]
However, in the above-described method, the light beam must be controlled so that both characteristics are different between the shell region and the core region in each deposited layer, and the operation is troublesome. Moreover, it is necessary to irradiate the entire region of a desired shape for each layer to laminate a sintered layer (molten layer), and it takes time to complete a molded article.
[0008]
The present invention has been made in view of the above-mentioned problems of the prior art, and an object of the present invention is to obtain a three-dimensional shaped object as a metal mold with high accuracy in a short time and increase the strength. The object is to prevent deformation of the model.
[0009]
[Means for Solving the Problems]
In the method for producing a three-dimensional shaped object according to the present invention, a molten layer is formed by irradiating a predetermined portion of an inorganic or organic powder layer with a light beam and melting it, and the powder is formed on the molten layer. By coating the layer and irradiating a predetermined portion of the powder with a light beam to melt, a molten layer integrated with the lower molten layer is formed, and by repeating this, a plurality of molten layers are laminated and integrated. In the method of manufacturing a three-dimensional shaped object, a melted region that is irradiated with a light beam and melted in the powder layer and a non-melted region that is not irradiated with a light beam are provided, and the melted part in which the powder is melted and the Forming a non-melted portion in which the powder was not melted, and gradually decreasing the non-melted region at the upper end of the non-melted portion every time the non-melted portion is laminated, so that the ridge line angle is more than 45 degrees. Heard approximately formed in a triangular pyramid shape or a substantially hemispherical shape, and characterized by forming a non-molten portion as the cavity of the internal recess or molded article is open to the bottom side of the shaped article.
[0010]
In particular, in the present invention, it is preferable that the non-melting portions are continuously provided from the lowermost layer. For example, the melting portions are arranged in a three-dimensional plane lattice, and the non-melting portions positioned above and below are disposed between them. It can be made to communicate in the non-melting part formed in the partial area | region of the fusion | melting part located in this. In addition, it is desirable to gradually reduce the non-melted region every time it is laminated.
[0011]
Alternatively, the melted portion inside the shaped article can be formed into a honeycomb structure or a structure in which a large number of cylinders are arranged in parallel.
[0012]
Furthermore, it is also possible to arrange a large number of melted portions in the portion where the stress is applied to the completed three-dimensional structure and to arrange a few melted portions in the portion where the stress is not applied.
[0013]
In these methods, after the modeling object is completed, an opening is formed in the modeling plate, and a different material is injected and / or impregnated into the non-melting region from the opening, or the powder in the non-melting region is injected from the opening. After removal, it is preferable to inject a different material. In this case, the powder may be removed by suction.
[0014]
As the different material to be injected or impregnated, a metal material having a melting point lower than that of a resin material or a powder used for modeling can be used.
[0015]
Further, in the present invention, it is advantageous to mount and form a modeling table having an opening in a region corresponding to the non-melting region of the first layer on a non-opening molding table.
[0016]
The manufacturing method of the three-dimensional structure of the present invention is characterized in that the three-dimensional structure is a mold.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the drawings. First, as shown in the reference example of FIG. 1, the shaped article 1 obtained by the manufacturing method of the present invention includes a molten portion 2 in which a powder material 5 is irradiated with a light beam such as a laser beam and the powder 5 is melted and sintered. The non-melting portion 3 remains in a powder state without being irradiated with a light beam. The manufacturing method of the present invention is a method that is substantially the same as the three-dimensional modeling method shown in the prior art, and that corresponds to the desired cross-sectional shape of the modeled object 1 on the layer of the powder 5 laminated to a predetermined thickness. Of these, only a necessary region is irradiated with a light beam. The powder 5 in the region irradiated with the light beam is melted and sintered to become a molten region. The region that has not been irradiated with the light beam remains in the powder state as it is and becomes a non-molten region. Next, a layer of the powder 5 is laminated to a predetermined thickness, and a region corresponding to the cross-sectional shape of the shaped article 1 is irradiated with a light beam to form a molten region. By repeating this in sequence, the melted regions are continuously laminated to form the melted portion 2, and the non-melted regions are continuously laminated to form the non-melted portion 3. In the present invention, the melted region to be irradiated with the light beam varies depending on the structure or the like of the target modeled object 1, and at least the region to be the surface of the modeled object 1 is irradiated with the light beam. The non-melting region to be formed is arbitrarily set according to the purpose.
[0018]
More specifically, for example, metal powder is spread on the modeling plate 11 made of a metal plate having an appropriate thickness to a thickness of about 0.05 mm, and a light beam is irradiated on the entire surface of a desired shape region. The metal powder is melted to form a lowermost molten layer (melting region) on the modeling plate 11. At this time, for example, iron powder having a maximum particle size of 50 μm and an average particle size of 20 to 30 μm is used as the metal powder, and a CO <SUB> 2 </ SUB> laser, a YAG laser, or the like is used as the light beam. .
[0019]
Subsequently, a metal powder is further spread on the molten layer in a thickness of about 0.05 mm, and a desired shape region is irradiated with a light beam to melt the metal powder, and a molten region integrated with the lower molten region. Form. This process is repeated until a non-melting region appears to form a part of the melting part 2. If a non-melting region appears, only the desired region is irradiated with a light beam to form a melting region and a non-melting region. Further, a metal powder is laminated to form a melting region and a non-melting region, and in the uppermost layer, a light beam is irradiated on the entire predetermined region so as to have a desired shape, thereby forming a melting region. In this way, as shown in the reference example of FIG. 1, it is possible to obtain a shaped article 1 in which the non-molten portion 3 that is in a powder state without being melted inside is confined.
[0020]
According to such a method, the time for irradiating the light beam is reduced, and the modeling time can be shortened. In addition, since the entire surface is not melt-sintered in each layer, thermal deformation can be reduced, and shrinkage of the obtained shaped article 1 can be suppressed.
[0021]
Next, Oite the reference example of FIG. 2, the non-fused portion 3 is formed continuously from the bottom layer, the non-fused portion 3 is provided in the cylindrical shape. The non-melting portion 3 is obtained by sequentially stacking non-melting regions in each layer, and is obtained by irradiating a light beam so as to overlap with a melting region in a layer immediately below the irradiation layer. In the model 1, as shown in the reference example of FIG. 2B , in each layer, a light beam is irradiated so that each non-melting region draws a circle, and a melting region is formed. Is provided. As a result, an opening 6 having the same shape as that of the reference example of FIG. Therefore, in this method, the powder material 5 of the non-molten portion 3 that has not been sintered after shaping can be taken out from the opening 6, and a cavity or recess having a complicated structure such as a metal mold is formed inside. It is possible to easily and accurately produce the shaped article 1 that has it. In the present invention, the non-melted portion 3 where the powder was not melted means that the powder 5 is filled as shown in the reference example of FIG. 1 or that the powder 5 is removed to become a cavity. Needless to say, the concept includes a material filled with a different material 7 instead of the powder 5 as described below.
[0022]
For example, in the example shown in the reference example of FIG. 3 , the melting portions 2 are arranged in a three-dimensional plane lattice, and the non-melting portions 3 positioned above and below are formed in a partial region of the melting portion 2 positioned therebetween. It is made to communicate in the melting part 3. The inside of the shaped article 1 is configured in a so-called cell shape, and has a structure in which the non-melting portion 3 surrounded by a surface that is the melting portion 2 is arranged in three dimensions, and is non-melting positioned above and below The part 3 has a structure in which it communicates with a cylindrical part 3a (non-melting part 3) provided in the melting part 2 on the upper and lower surfaces. That is, the shaped object 1 forms a first layer of cellular layers by forming a plurality of layers until a certain thickness is obtained by forming a melting region in a lattice shape in the first layer. Next, a layer of the powder 5 is laminated on the first-stage cellular layer, and a circular non-melting region is formed in the approximate center of the non-melting region of the first-stage cellular layer, A plurality of layers are laminated until the melted portion 2 has a certain thickness. As a result, the cylindrical part 3a is formed in the melting part 2 located on the upper surface of the first-stage non-melting part 3. Next, a second-stage cellular layer is formed in the same manner as the first-stage cellular layer. And the cylindrical part 3a which is the non-melting part 3 is formed corresponding to the approximate center of the non-melting area | region of a 2nd step | paragraph cellular layer. By repeating this, it is possible to form a structure in which the melting part 2 has a three-dimensional plane lattice shape, and the cell-shaped non-melting parts 3 arranged in the vertical direction are opened in the melting part 2 located between them. It will be in the state connected by the non-melting part 3 (cylindrical part 3a). By forming the melted part 2 in such a three-dimensional surface lattice shape, it can be made strong against pressure from the upper side and side surfaces in the stacking direction. Also in this case, the powder 5 remaining inside the obtained shaped object 1 can be taken out from the opening 6 on the lower surface of the shaped object 1. In FIG. 3, the powder 5 is abbreviated.
[0023]
Next, in the reference example of FIG. 4, the non-melting portion 3 is formed in a truncated cone shape as shown in FIG. 4B, and the non-melting region is gradually reduced as each layer made of the powder material 5 approaches the upper layer. It has been made. When laminating from the lower layer to the upper layer with a large non-melting region, if there is a large uncured region in the lower layer, the upper layer is likely to warp and deform due to heat effects during irradiation, etc. Is weak in strength and may be damaged by the stress when the powder 5 is supplied in the upper layer. Therefore, by increasing the melting region with the upper layer as shown in the figure, the strength is increased and deformation of the shaped article 1 is prevented.
[0024]
In this case, as shown in the embodiment of FIGS. 5A and 5B, if the non-melting region is gradually reduced at the upper end portion (overhanging portion) of the non-melting portion 3, the modeling becomes easier. In FIG. 5A, the shape is formed in a substantially triangular pyramid shape, but in this case, the angle of the ridge line is preferably set to 45 ° or more. In addition, as shown in FIG. 5B, when forming a hemispherical shape, the region is preferably set to be at least 10 mm in the height direction.
[0025]
In these shaped objects 1, a non-melting portion 3 connected in a cylindrical shape is formed from the lower layer to immediately below the uppermost molten layer. Therefore, the modeled object 1 completed from the modeled plate 11 is removed, and the internal powder 5 is taken out from the lower surface of the modeled object 1 to inject a different material into the non-melting part 3, or a different material can be obtained without taking out the powder 5. It can also be impregnated by injection.
[0026]
In the method shown in the reference example of FIG. 6, after removing the modeling plate 11 from the modeling apparatus, the dissimilar material is injected and / or impregnated without removing the modeled object 1. That is, from the lower surface of the modeling plate 11 removed from the modeling apparatus, an opening 12 is opened with a drill or the like in accordance with the position of the lowermost non-melting region, and the dissimilar material 7 is injected without taking out the non-melting powder 5. . In this case, as the dissimilar material 7, for example, a resin material such as an epoxy resin or a urethane resin, and a liquid material in which a metal powder or a ceramic powder is mixed with these resin materials are preferably used. Generally, since the filling rate of the powder 5 in each layer is 60 to 80%, a liquid type can be sufficiently impregnated and impregnated. As a result, the strength of the obtained shaped article 1 is improved. Further, depending on the different material 7, the thermal conductivity can be increased. Further, when impregnated with a resin-based material, it is possible to reduce the weight without reducing the strength by forming a cavity.
[0027]
Further, as the dissimilar material 7, a metal material having a melting point lower than that of the powder material 5, for example, a copper material, a solder, or a brazing material can be used for the iron powder material 5. In this case, not only the strength can be improved, but also the electrical performance such as thermal conductivity and conductivity can be improved.
[0028]
Moreover, after removing the powder 5 of the non-melting part 3 as shown in the reference example of FIG. 7A , the different material 7 may be filled as shown in the reference example of FIG. In this case, for example, as shown in the reference example of FIG. 8 , for example, a suction device 13 provided with a funnel-shaped suction tool 13 a for sucking powder is used, and the non-molding plate 11 with the opening 12 is opened from below. The powder 5 in the melting part 3 can be sucked. In this way, the non-molten powder 5 can be recovered and reused as the powder 5 again.
[0029]
In these embodiments or reference examples, it is decided to open the opening 12 in the modeling plate 11 after modeling, but it is also possible to use the modeling plate 11 provided with the opening 12 in advance corresponding to the lowermost non-melting region. . Although reference example of FIG. 9 is a diagram illustrating the method, in this case it may be provided an opening 12 in the shaping plate 11, as shown in reference example of the FIG. 9 (a), the reference for FIG (b) As shown in the example, the modeling plate 11 may be placed on the molding table 14 in which no opening is provided. According to this method, the modeling object 1 can be taken out together with the modeling plate 11 after modeling, and the subsequent powder removal operation, injection of the different material 7 and impregnation operation can be performed extremely easily.
[0030]
In the embodiment or the reference example , the shape of the non-melting portion 3 has been mainly described. However, in the present invention, the light beam irradiation area is adjusted for each layer and shaped, and the melting portion 2 and the non-melting portion are formed. Three structures are defined. Therefore, it is possible to provide a melted region in a predetermined shape for each layer and laminate them so that the melted portion 2 of the honeycomb structure is formed inside the shaped article 1 as shown in the reference example of FIG. Further, as shown in the reference example of FIG. 11, a large number of cylindrical melting portions 2 can be formed inside the molded article 1. By setting it as such a structure, while the intensity | strength of the molded article 1 can be improved, the irradiation area | region of a light beam can be reduced significantly. As a result, modeling time can be greatly reduced.
[0031]
Further, the shape of the melted part 2 is not limited to a specific shape, and as shown in the reference example of FIG. 12, depending on the purpose of use of the shaped object 1 that is the final target, It is also possible to dispose a large number of 2 and arrange the melted portion 2 in a portion where the stress is low. For example, since a particularly large stress is applied to the gate portion of the mold, it is preferable to design such that a large number of melting portions 2 are arranged in such a gate portion.
[0032]
As described above, in the present invention, the layer of the powder 5 is provided with the melting region where the light beam is irradiated and the non-melting region where the light beam is not irradiated. Can be provided. As a result, for example, by providing the non-melting part 3 so that the opening 6 is formed on the bottom surface of the modeled object 1, the modeled object 1 having a complicated recess such as a mold can be easily obtained. . Further, the strength of each part of the shaped article 1 can be changed variously by injection, impregnation of the different material 7, adjustment of the part where the melted part 2 is formed, and the like. In the manufacturing method of the present invention, the modeling object 1 can be easily manufactured with high accuracy by shortening the modeling time very much and reducing the deformation due to thermal deformation or shrinkage.
[0033]
【The invention's effect】
According to the present invention, in the powder layer, the melting region where the light beam is irradiated and the non-melting region where the light beam is not irradiated are provided, and the melting portion and the non-melting portion are formed. The area to be irradiated is reduced, and the modeling time can be shortened. In addition, the formation of the non-melting region reduces the thermal shrinkage in the layer, thereby preventing thermal deformation as a whole. Further, since the non-melting region at the upper end portion of the non-melting portion is gradually reduced every time the non-melting portion is laminated, the non-melting portion upper end portion is formed in a substantially triangular pyramid shape or a substantially hemispherical shape having a ridge line angle larger than 45 degrees. In addition, the non-melting region can be formed small, and deformation due to the thermal effect at the time of irradiation can be prevented, thereby facilitating modeling. In addition, since the non-melting part is formed as a recess opening on the bottom side of the modeled object or a cavity inside the modeled object, it opens to the inside of the cavity such as a metal mold, or to the bottom side. A shaped object having a recess can be easily and accurately produced.
[0034]
In this case, by continuously forming the non-melted portion from the lowermost layer, the unmelted powder can be taken out and removed from the lowermost non-melted region. As a result, a cavity or a recess having a complicated shape can be easily provided inside the mold or the like.
[0035]
Alternatively, an opening is provided in the modeling plate corresponding to the region, and a different material such as a resin material is injected and / or impregnated from the opening into the non-molten portion, thereby increasing strength, thermal conductivity, conductivity, etc. It is possible to control the characteristics.
[0036]
Alternatively, by removing the powder in the non-melted portion and injecting a different material, it is possible to reduce the weight of the molded article without significantly reducing the strength.
[0037]
In the present invention, the shape of the non-melting part and the melting part can be formed in a desired shape, for example, a structure in which the melting parts are arranged in a three-dimensional surface lattice, a honeycomb structure, or a structure in which a large number of cylinders are arranged in parallel. By doing so, a non-melting part can be enlarged and intensity | strength can be increased further. Moreover, the damage at the time of shaping | molding can be prevented by making it reduce gradually whenever a non-melting area | region is laminated | stacked. Furthermore, depending on the purpose of the finished model, such as a mold that is partially stressed, it is possible to arrange a large number of melting parts in the part where the stress is applied and to arrange a few melting parts in the part where the stress is not applied. .
[0038]
As described above, the present invention controls the irradiation region irradiated with the light beam in various ways, so that a specific object such as a mold is required to have high strength, or a modeled object having a complicated shape can be accurately and in a short time. And it can be manufactured extremely easily.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a manufacturing method according to a reference example of the present invention .
FIGS. 2A and 2B are explanatory views showing a manufacturing method according to another reference example, wherein FIG. 2A is a cross-sectional explanatory view thereof, and FIG. 2B is a vertical cross-sectional explanatory view thereof.
3A and 3B are explanatory views showing a manufacturing method according to still another reference example, wherein FIG. 3A is a partially broken explanatory view, and FIG. 3B is a cross-sectional explanatory view. .
FIG. 4 is an explanatory diagram showing a manufacturing method according to still another reference example .
FIGS. 5A and 5B are explanatory views showing a manufacturing method according to an embodiment of the present invention .
FIG. 6 is an explanatory view showing a manufacturing method according to still another reference example .
FIGS. 7A and 7B are explanatory views showing a manufacturing method according to still another reference example .
8 is a schematic configuration diagram of a manufacturing apparatus used in the manufacturing method of FIG.
FIGS. 9A and 9B are explanatory views showing a manufacturing method according to still another reference example, wherein FIG. 9A is a perspective view of a modeling plate, and FIG. 9B is the modeling It is a figure which shows the state using a plate.
FIG. 10 is an explanatory diagram showing a manufacturing method according to still another reference example .
FIG. 11 is an explanatory diagram showing a manufacturing method according to still another reference example .
FIG. 12 is an explanatory diagram showing a manufacturing method according to still another reference example .

Claims (14)

A molten layer is formed by irradiating and melting a predetermined portion of the inorganic or organic powder layer with a light beam, and covering the molten layer on the molten layer and applying a light beam to the predetermined portion of the powder. In the method for producing a three-dimensional shaped object in which a molten layer integrated with a lower molten layer is formed by irradiation and melted, and a plurality of molten layers are laminated and integrated by repeating this, the powder And a non-melting region in which the powder is melted and a non-melting region in which the powder is not melted are formed by providing a melted region in which the light beam is melted and a non-melting region in which the light beam is not irradiated. the unmelted portion of the non-fused portion upper part is gradually decreased every time the laminated non-melting region in the upper portion is formed in a substantially triangular pyramid shape or a substantially hemispherical greater than 45 ° ridge angle, the non-soluble Method for producing a three-dimensionally shaped object, and forming a part as a cavity inside the recess or molded article is open to the bottom side of the shaped article.   The method for producing a three-dimensional shaped article according to claim 1, wherein the non-melting portion is continuously provided from the lowermost layer.   3. The melted portions are arranged in a three-dimensional plane lattice, and the non-melted portions located above and below are communicated with each other in a non-melted portion formed in a partial region of the melted portion located therebetween. Manufacturing method of three-dimensional structure.   The method for producing a three-dimensional structure according to claim 2, wherein the non-melting region is gradually reduced every time the non-melting region is laminated.   The method for manufacturing a three-dimensional shaped article according to claim 2, wherein the melted portion inside the shaped article has a honeycomb structure.   3. The method for producing a three-dimensional shaped object according to claim 2, wherein the melted part inside the shaped object has a structure in which a large number of cylinders are arranged in parallel.   3. The method for producing a three-dimensional structure according to claim 2, wherein a large number of melting portions are arranged in a portion where stress is applied to the three-dimensional structure after completion, and a small number of melting portions are arranged in a portion where stress is not applied.   8. The modeling plate according to claim 2, 3, 4, 5, 6 or 7, wherein an opening is provided in the modeling plate after the modeling object is completed, and different materials are injected and / or impregnated into the non-melting region from the opening. The manufacturing method of the three-dimensional structure according to any one of the above.   8. The modeling plate is provided with an opening after completion of the modeling object, and after removing the powder in the non-melting region from the opening, a different material is injected. The manufacturing method of the three-dimensional structure according to any one of the above.   The method for producing a three-dimensional structure according to claim 9, wherein the powder is removed by suction.   The method of manufacturing a three-dimensional structure according to any one of claims 8, 9 and 10, wherein the different material is a resin material.   The method for producing a three-dimensional structure according to claim 8, 9 or 10, wherein the different material is a metal material having a melting point lower than that of the powder.   3. The method for producing a three-dimensional structure according to claim 2, wherein a modeling plate having an opening in an area corresponding to the lowermost non-melting area is placed on a non-opening molding table. .   The method of manufacturing a three-dimensional structure according to any one of claims 1 to 13, wherein the three-dimensional structure is a mold.

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