JP4049654B2 - 3D modeling apparatus and 3D modeling method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a three-dimensional modeling apparatus and method thereof, and more particularly, to a three-dimensional modeling apparatus and method thereof that can reduce modeling time.
[0002]
[Prior art]
In modeling methods called rapid prototyping machines such as optical molding, powder molding, sheet lamination, etc., the model is considered to be an assembly of fine cross-sectional shapes, and the entire model has a certain thickness in the Z direction (vertical direction) (about The model is formed by slicing at 0.1 mm) and superposing (stacking) the moldings for each cross-sectional data.
[0003]
Such a three-dimensional modeling apparatus is disclosed in the following document 1, for example.
[0004]
A conventional three-dimensional modeling method will be described with reference to FIG. Referring to FIG. 8, in the conventional three-dimensional modeling method, laser light L is emitted from projector 57, which is a laser light source for emitting ultraviolet laser light L provided on one side above tank 51, and a mirror. The deflection angle of the deflection mirror 58 controlled by the drive mechanism 59 is configured to be driven by the control circuit 60 in synchronization. Then, the laser light L from the projector 57 is scanned with a deflection mirror 58 in a two-dimensional plane in a predetermined pattern to cure a desired portion of the photocurable resin 52 stored in the tank 51 with the laser light L. As a result, desired three-dimensional modeling was performed.
[0005]
[Patent Document 1]
JP-A-9-150459 (paragraph numbers 0009 and 0010, FIG. 1)
[0006]
[Problems to be solved by the invention]
In the conventional means for drawing single beam light with a mechanical scanning mechanism as described above, the work is one-dimensional, and drawing of one plane requires a great amount of projection time and performs two-dimensional scanning. Therefore, a complicated mechanical drive mechanism is necessary.
[0007]
In order to reduce the burden on the drive system by reducing the weight and simplifying the optical system, there has been a problem that even more strict safety considerations are required when a laser is used as the light source.
[0008]
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a three-dimensional modeling apparatus and method that can shorten the total molding time.
[0009]
[Means for Solving the Problems]
The three-dimensional modeling apparatus includes a light source and a mirror device that receives light from the light source. The mirror device is arranged in a matrix direction, and includes a plurality of fine movable mirrors that each receive an electric signal and change a reflection surface. Means for arbitrarily controlling the respective reflecting surfaces of the fine movable mirror, and the light reflected by the mirror device is directed to the photocurable material.
[0010]
By applying an electric signal, light is irradiated to a mirror device having a plurality of fine movable mirrors that can change the reflection angle, and each mirror controls the reflection angle, and light is applied to the photocurable material as a surface light source. Irradiated. Since a surface light source is used, two-dimensional scanning of the beam becomes unnecessary.
[0011]
As a result, it is possible to provide a three-dimensional modeling apparatus capable of high-speed modeling by greatly reducing the projection time required for drawing for each plane.
[0012]
Further, since it is not necessary to use a laser as the light source, the structure of the apparatus is simplified and the reliability is improved.
[0013]
Furthermore, since the fine movable mirror can be controlled to an arbitrary angle, the projection image can be adjusted, and a desired image can be projected.
[0014]
Preferably, the control means controls the respective reflecting surfaces of the fine movable mirror separately for those that totally reflect and those that reflect at a desired angle . The amount of irradiation to the photo-curable resin is controlled by controlling the respective reflecting surfaces of the fine movable mirror separately for those that are totally reflected and those that are reflected at a desired angle . As a result, a smooth three-dimensional structure is obtained.
[0015]
In addition, the control means may include a means for creating 3D modeling data in advance, and the control means may control the reflection angles of the plurality of fine movable mirrors based on the created 3D modeling data.
[0016]
More preferably, the reflection angle of each of the fine movable mirrors is automatically changed according to the ratio of light to be projected onto each mirror.
[0017]
In another aspect of the present invention, a digital mirror element device that is arranged in a matrix direction and has a plurality of fine movable mirrors each receiving an electric signal and changing a reflecting surface is used, and the reflected light is applied to a photocurable material. This is a three-dimensional modeling method for modeling a three-dimensional object by irradiation. The three-dimensional modeling method includes (a) a step of controlling each of the fine movable mirrors to an arbitrary angle, (b) a step of irradiating light from the light source to the digital mirror element device, and (c) irradiation by the mirror device. Forming a new layer of photocurable material on the photocurable material, and forming a three-dimensional shape by repeating (a) to (c).
[0018]
By applying an electrical signal, light is applied to a mirror device having a plurality of fine movable mirrors that can change the reflection angle, and the reflection angle is controlled so that each mirror corresponds to a point pixel for drawing. The light curable material is irradiated with light as a surface light source. Since a surface light source is used, two-dimensional scanning of the beam becomes unnecessary.
[0019]
As a result, it is possible to provide a three-dimensional modeling method capable of high-speed modeling by greatly reducing the projection time required for drawing for each plane.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic diagram showing an overall configuration of an embodiment of a three-dimensional modeling apparatus according to the present invention.
[0021]
Referring to FIG. 1, a three-dimensional modeling apparatus 20 is abbreviated as a drawing data input unit 21 for inputting drawing data created in advance, a digital mirror element (fine movable mirror) 22, and a digital mirror (hereinafter abbreviated as “DM”). A light source 23 for irradiating the element 22 with light, a lens 24 for collimating the light from the light source 23 and irradiating the digital mirror element, a lens 26 for converging the reflected light 25 from the digital mirror element 22, and photocuring And a photocurable resin container 30 that holds the curable resin 31. The drawing data input to the drawing data input unit 21 is stored in a memory (not shown).
[0022]
The digital mirror element 22 includes a movable mirror group 22a arranged in a matrix, a row control unit 22b that controls the movable mirror group 22a in the row direction, a column control unit 22c that controls the movable mirror group 22a in the column direction, And a control unit 22d for controlling the control unit 22b and the column control unit 22c.
[0023]
Each of the movable mirrors of the movable mirror group 22a constituting the DM element 22 can have an angle of the reflecting surface arbitrarily set, and the photocuring in which the reflected light 25 from the light source 23 is accommodated in the photocurable resin container 30. The angle can be changed from the angle at which the light is completely reflected to the curable resin liquid 31 to the angle at which the photocurable resin liquid is not irradiated.
[0024]
Here, each movable mirror controls its reflection angle so as to correspond to a point pixel for drawing. Further, the reflection angle of each movable mirror at the corresponding pixel position is arbitrarily controlled based on the brightness information of the image data.
[0025]
Note that image data for drawing is input to the drawing data input unit 21 from the image data creation device 10 provided separately.
[0026]
Next, the operation content of the image data creation apparatus 10 that supplies image data to the three-dimensional modeling apparatus 20 will be described with reference to FIGS. 2 and 3. FIG. 2 is a flowchart showing the operation content of the image data creation device 10, and FIG. 3 is a diagram showing the specific content of the operation. Referring to FIG. 2, first, three-dimensional data is first created (step S11, the following steps are omitted).
[0027]
Specifically, as shown in FIG. 3A, drawing data for the X axis, the Y axis, and the Z axis is prepared. Here, for example, an H-shaped columnar shape is created. This three-dimensional data is created using, for example, CAD. Next, the created three-dimensional data is developed into two-dimensional data in which projected sections from one direction are continuous (S12). Specifically, as shown in FIG. 3B, the H-shaped columnar shape is developed into a plurality of “H” -type two-dimensional image data continuous in the Z-axis direction. And it inputs into the drawing data input part 21 of the three-dimensional modeling apparatus 20 as image data (S13). Specifically, it is sent to the three-dimensional modeling apparatus 20 as continuous image (bitmap) data.
[0028]
Next, the operation of the three-dimensional modeling apparatus 20 will be described with reference to FIG. First, drawing data is input from the drawing data input unit 21 (S21). Next, the DM element 22 is controlled (S22), and the level of the photocurable resin 31 is controlled (S23).
[0029]
Next, the control content of the DM element 22 shown in S22 of FIG. 4 will be described. FIG. 5 is a flowchart showing the control contents of the DM element 22. Referring to FIG. 5, first, each of the matrix DM elements is initialized (S31). Next, the control unit 22d reads out the data for each point (i, j) of the matrix-like DM element from the memory (not shown) according to the data input in S21 (S32), and the row control unit according to the data. The mirror angle of the point (i, j) is determined via 22b and the column controller 22c (S33). And light is irradiated from the light source 23, and light is reflected on the liquid level 33 (S34).
[0030]
FIG. 6 is a diagram illustrating a change state of the liquid level of the photocurable resin container 30. First, as shown in FIG. 6A, a shape image formed by reflecting light from the DM element with the reflected light from 22 is exposed on the liquid surface 33 of the photocurable material to form a first layer. Next, the movable table 32 is pulled down by a driving device (not shown), and a photocurable resin is infiltrated into the cured first layer surface to prepare for the second layer curing (FIG. 6B). Thereafter, a desired three-dimensional shape is formed by repeating the above steps.
[0031]
Next, a specific control method for the DM element 22 will be described. FIG. 7 is a schematic diagram showing the relationship between the input data 41 in which the control state of the DM element is created and the positions 42 of the individual movable mirrors corresponding thereto. FIG. 7A shows a state in which H-shaped data is input. Here, the input data 41 indicates H-shaped data, and in this case, the input data can be represented by a rectangle, and therefore on / off of each movable mirror can be controlled by the input data. Therefore, it is only necessary to control the movable mirror indicated by hatching to be on, that is, totally reflected.
[0032]
FIG. 7B shows a case where a circular shape is created. Although depending on the resolution, in this case, if the input drawing data 43 input to the drawing data input unit 21 is associated with each of the corresponding movable mirrors in a 1: 1 ratio, a desired image may not be projected. Therefore, in such a case, control is performed separately for each movable mirror that is totally reflected (indicated by diagonal lines) and that is reflected at a desired angle (indicated by ×). By controlling in this way, fine adjustment is possible, and a shape close to a desired shape can be created even when the resolution is high.
[0033]
The reflection angle may be automatically changed according to the ratio of light to be projected onto one movable mirror.
[0034]
Next, another embodiment of the present invention will be described. In this embodiment, the resolution is changed by controlling the on / off ratio of the operation of changing the irradiation angle of each movable mirror and controlling the irradiation amount to the photocurable resin. That is, when the on-ratio is increased, the amount of curing per unit time is increased, and when the off-ratio is increased, the amount of curing per unit time is reduced, so that the amount of curing can be adjusted more finely than simple on-off.
[0035]
By controlling in this way, a modeled object that is finished in a concavo-convex shape with a rough resolution can have a smooth shape because the amount of light can be changed by the on / off repetition rate of the movable mirror.
[0036]
In the above embodiment, the image data creation apparatus and the three-dimensional modeling apparatus have been described as separate apparatuses. However, the present invention is not limited to this, and the apparatus may be integrated as an apparatus.
[0037]
Although one embodiment of the present invention has been described with reference to the drawings, the present invention is not limited to the illustrated embodiment. The present invention is not limited to the same scope or equivalent form. Various modifications can be made to the illustrated embodiment within the same scope or equivalent scope as the present invention.
[Brief description of the drawings]
FIG. 1 is a schematic diagram showing a configuration of a three-dimensional modeling apparatus according to an embodiment of the present invention.
FIG. 2 is a flowchart showing a procedure for creating image data.
FIG. 3 is a schematic diagram showing a specific procedure for creating image data.
FIG. 4 is a flowchart showing the operation of the three-dimensional modeling apparatus.
FIG. 5 is a flowchart showing control contents of a digital mirror element.
FIG. 6 is a schematic diagram showing a molding operation of a photocurable resin.
FIG. 7 is a schematic diagram showing a relationship between input data for which a control state of a digital mirror element is created and positions of individual mirrors corresponding to the input data.
FIG. 8 is a diagram showing a conventional three-dimensional modeling method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Image data production apparatus, 20 3D modeling apparatus, 21 Drawing data input part, 22 Digital mirror (DM) element, 23 Light source, 24 Lens, 25 Reflected light, 26 Lens, 30 Photocurable resin container, 31 Photocurable Resin, 32 tables

Claims (4)

A light source;
A mirror device that receives light from the light source, the mirror device is arranged in a matrix direction, each of which comprises a plurality of fine movable mirrors that receive an electric signal and change a reflecting surface,
Control means for controlling each reflecting surface of the fine movable mirror to an arbitrary angle,
The light reflected by the mirror device is directed to the photocurable material,
The control means is a three-dimensional modeling apparatus that controls each of the reflecting surfaces of the fine movable mirror separately for one that totally reflects, one that reflects at a desired angle, and one that turns off . A three-dimensional shaped object is formed by irradiating the photocurable material with a mirror device that has a plurality of fine movable mirrors arranged in a matrix direction and each receiving an electric signal to change a reflecting surface. A 3D modeling method,
(A) controlling each of the fine movable mirrors to an arbitrary angle;
(B) irradiating the mirror device with light from a light source;
(C) forming a new layer of photocurable material on the photocurable material irradiated by the mirror device;
(D) repeating the steps (a) to (c),
The controlling step includes a step of controlling each reflecting surface of the fine movable mirror into a total reflecting portion, a reflecting portion at a desired angle, and a turning off portion, and simultaneously controlling the three-dimensional shape. A three-dimensional modeling method for modeling objects. A light source;
A mirror device that receives light from the light source, and the mirror device is arranged in a matrix direction, each of which includes a plurality of fine movable mirrors that receive an electric signal and change a reflection surface,
Control means for controlling each reflecting surface of the fine movable mirror to an arbitrary angle,
The light reflected by the mirror device is directed to the photocurable material,
The said control means is a three-dimensional modeling apparatus which controls the ratio of the time which maintains the irradiation angle of the said fine movable mirror on, and the time which maintains it off . A three-dimensional shaped object is formed by irradiating a photocurable material with a mirror device having a plurality of fine movable mirrors arranged in a matrix direction and each receiving an electric signal to change a reflecting surface. A 3D modeling method,
(A) controlling each of the fine movable mirrors to an arbitrary angle;
(B) irradiating the mirror device with light from a light source;
(C) forming a new layer of photocurable material on the photocurable material irradiated by the mirror device;
(D) repeating the steps (a) to (c),
The step of controlling includes a step of controlling a ratio of a time during which the irradiation angle of the fine movable mirror is kept on and a time during which the fine movable mirror is kept off .

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