JP4259123B2

JP4259123B2 - Manufacturing method of three-dimensional shaped object

Info

Publication number: JP4259123B2
Application number: JP2003019507A
Authority: JP
Inventors: 喜万東; 諭阿部; 隆史松尾; 卯三太田; 光弘新郷; 広吉原
Original assignee: Panasonic Corp; Matsushita Electric Works Ltd
Current assignee: Panasonic Corp; Panasonic Electric Works Co Ltd
Priority date: 2003-01-28
Filing date: 2003-01-28
Publication date: 2009-04-30
Anticipated expiration: 2023-01-28
Also published as: JP2004231997A

Description

【０００１】
【発明の属する技術分野】
本発明は、造形プレート上の金属粉末層を光ビームで焼結硬化させることで三次元形状を有する造形物を製造し、後加工により必要形状の造形物と造形プレートとを一体に切り出すための三次元形状造形物の製造方法に関するものである。
【０００２】
【従来の技術】
従来より、金属粉末材料に光ビームを照射して硬化層を形成し、その硬化層を積層して三次元形状造形物を製造する方法が知られている（例えば、特許文献１参照）。他の従来例として金属粉末焼結部品の表面仕上げを行なう方法（例えば、特許文献２参照）や、粉末層を所定の境界内部において選択的に焼結させて、相互に焼結された複数層からなる部品を製造する方法（例えば、特許文献３参照）も知られている。
【０００３】
【特許文献１】
特開２００２−１１５００４号公報
【特許文献２】
特開２０００−７３１０８号公報
【特許文献３】
特許第２６２０３５３号公報
【０００４】
【発明が解決しようとする課題】
ところで、従来においては、図１９のように、材料タンク１３内の昇降テーブル８上に金属粉末材料２を投入し、造形タンク１０内の昇降テーブル１４に固定した造形プレート１上に平板ブレード１５を矢印Ｈに向かって移動させることにより、造形プレート１上に金属粉末材料２を供給し、光ビームＬを金属粉末層２ａの硬化させたい箇所に照射してレーザー焼結を行ない、硬化層３を形成する。その後、昇降テーブル１４を１層分の厚みＥだけ下降させて金属粉末層２ａの供給、光ビームＬの照射を行なうことで２層目の硬化層３を形成する。このような材料供給工程と光ビームＬ照射工程とを繰り返すことによって、造形プレート１上に上下複数の硬化層３が順次堆積されていき、三次元形状を有する造形物４（硬化積層物）を製造するものである。
【０００５】
ここで、造形プレート１は造形終了後に造形物４（硬化積層物）から切り離すのではなく、造形物４の一部として利用するのが一般的である。例えば図２０のように、造形プレート１’の上に一体化された造形物４を図２０に示すモールドベース１７に組み込み、金型の型部として用いるようにしている。
【０００６】
ここで、図２１（ａ）のように造形プレート１の位置と造形物４が造形される位置とが一致し、且つ造形物４の基準軸方向Ｊ（Ｊ’）と造形プレート１の基準軸Ｋ（Ｋ’）とが平行であれば、造形プレート１に対する造形位置は決定されるが、実際には、造形プレート１を固定する基準がないため、図２２のように造形物４の基準軸方向Ｊ（Ｊ’）と造形プレート１の基準軸Ｋ（Ｋ’）とがズレやすくなり、結果図２１（ｂ）に示すａ×ｂサイズの造形プレート１に造形物４がズレて造形されてしまうことがある。このため数μｍオーダーで図２１（ａ）のように造形する位置を造形プレート１に対して合わせるのは困難である。
【０００７】
そこで、本発明者らは本発明に至る過程で、図２１（ｃ）、図２３（ａ）のように必要形状よりも大きい造形プレート１上に造形物４を造形し、後加工によりワイヤカット装置などを用いて、図２１（ｄ）、図２３（ｂ）のようにワイヤカット装置などで必要形状の造形プレート１’を切り出す方法を考えた。
【０００８】
ところが、図２１（ｄ）のように造形物４自体が切り出す際の加工基準となるストレート端面１ｍ，１ｎを有している場合は、ストレート端面１ｍから距離ｇをあけ、ストレート端面１ｎから距離ｆをあけて所定寸法ｃ，ｄで切り出すことで、造形プレート１の位置に対して造形物４の基準軸方向Ｊ（Ｊ’）が決まるが、例えば図２１（ｅ）のような造形物４自体が加工基準を持たない場合は、必要形状に切り出すことができなくなるという問題がある。
【０００９】
本発明は、上記の従来例の問題点に鑑みて発明したものであって、その目的とするところは、造形時に必要形状の造形物と造形プレートとを一体に切り出す加工基準を設けることによって、造形プレートの位置を造形物の造形位置に正確に合わせる必要がなく、しかも加工基準を造形物と一緒に焼結造形できて造形時間を短縮できるようにした三次元形状造形物の製造方法を提供することにあり、他の目的とするところは、表面除去機構を利用して切り出し基準加工を行なったり、加工基準となるマーキングができる三次元形状造形物の製造方法を提供することにあり、他の目的とするところは、画像処理を用いて造形プレート上の本来の位置に造形物を造形させることができ、しかも後加工で造形プレートを必要形状に切り出す必要がなく、加工基準を造形焼結によって形成する必要もなく、造形時間を一層短縮できる三次元形状造形物の製造方法を提供することにあり、他の目的とするところは、画像処理を用いて造形プレートの位置を認識し、位置ズレ量に応じて造形プレートの位置を修正することで、造形プレート上の本来の位置に造形させることができる三次元形状造形物の製造方法を提供することにあり、更に他の目的とするところは、造形プレートの位置決め固定を造形タンクを利用して行なうことができる三次元形状造形物の製造方法を提供することにある。
【００１０】
【課題を解決するための手段】
上記課題を解決するために本発明は、造形プレート１上に供給された金属粉末層２ａの所定箇所に光ビームＬを照射して焼結させることによって硬化層３を形成し、この硬化層３の上に更に金属粉末層２ａを被覆して金属粉末層２ａの所定箇所に光ビームＬを照射して下の硬化層３と一体となった上の硬化層３を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層３が一体化された三次元形状を有する造形物４を製造し、造形終了後に造形プレート１を必要形状にカットして必要形状の造形物４と造形プレート１’とを一体に切り出す三次元形状造形物の製造方法であって、上記必要形状の造形物４と造形プレート１’とを一体に切り出す際の加工基準となる基準形状部５を造形物４と同時に焼結造形することを特徴としており、このように構成することで、造形終了後に必要形状の造形物４と造形プレート１’とを一体に切り出す際に、造形物４と一緒に造形された基準形状部５を加工基準とすることができ、基準形状部５によって後加工で必要形状の切り出しが可能となり、本方法によって成形金型や部品の加工を行なうことができ、しかも造形開始前に造形プレート１の位置を造形物４の造形位置に正確に合わせる必要がないものであり、そのうえ造形物４と同時に基準形状部５を造形することで、造形時間を短縮できる。
【００１１】
また上記基準形状部５を、造形物４とは別の位置に焼結造形するのが好ましく、この場合、造形物４の形状には制約されないで、加工基準となる基準形状部５を独立して任意の形状に造形できる。
【００１２】
また上記基準形状部５を複数に分散させて配置するのが好ましく、この場合、大きな基準形状部５を焼結造形する必要がなくなる。
【００１３】
また上記基準形状部５を、造形物４と一体に形成するのが好ましく、この場合、造形物４自体が加工基準を持つようになり、余分な加工基準を造形物４とは別に別途造形する必要がなくなる。
【００１４】
また本発明は、造形途中で硬化層３の表面除去加工を行なう表面除去機構６に、必要形状の切り出し基準加工或いは造形プレート１への加工基準となるマーキングのいずれかを行なう機能を持たせたことを特徴としており、このように構成することで、加工基準となる基準形状部５を焼結造形により別途形成する必要がなくなる。さらに、造形物４の表面除去加工を行なうための表面除去機構６を利用して切り出し基準加工を行なう場合は、造形プレート１の取り外しがなく、切り出し加工を高精度で行なうことができ、一方、造形プレート１に加工基準となるマーキングをする場合は、その後で別の装置（例えばフライス、ワイヤカット等）を用いてマーキングを基に造形プレート１を精度良く切削加工可能となる。
【００１５】
また上記硬化層３を形成するための光ビームＬの照射機構を用いて造形プレート１上へ加工基準となるマーキングを行ない、造形終了後にマーキングに沿って切削装置で造形プレートを必要形状にカットすることを特徴としており、このように構成することで、マーキング専用の装置を別途設ける必要がなくなる。
【００１６】
また本発明は、造形を行なう前に画像処理装置により造形プレート１の固定位置を計測して造形プレート１と造形物４の造形位置との位置ズレ量を求め、その位置ズレ量に応じて造形位置を移動させることを特徴としており、このように構成することで、画像処理を用いて造形プレート１の位置を認識し、位置ズレ量に応じて造形される位置を移動させることで、造形プレート１上の本来の位置に造形させることができ、しかも造形プレート１の大きさは必要形状の大きさでよく、後加工で造形プレート１を必要形状に切り出す必要がなく、加工基準を造形焼結によって形成する必要もなく、そのうえ造形物４の造形位置の方を造形プレート１の固定位置に合わせて移動させることで、造形プレート１を移動できない場合に有効である。
【００１７】
また本発明は、造形を行なう前に画像処理装置により造形プレート１の固定位置を計測して造形プレート１と造形物４の造形位置との位置ズレ量を求め、その位置ズレ量に応じて造形プレート１の位置を移動させることを特徴としており、このように構成することで、画像処理を用いて造形プレート１の位置を認識し、位置ズレ量に応じて造形プレート１の位置を修正するので、造形プレート１上の本来の位置に造形させることができ、しかも造形プレート１の大きさは必要形状の大きさでよく、後加工で造形プレート１を必要形状に切り出す必要がなく、加工基準を造形焼結によって形成する必要もなくなる。
【００１８】
また上記画像処理装置により造形プレート１の端面１ａを検出して本来あるべき造形プレート１の位置に対する位置ズレ量を計測し、位置ズレ量に応じて造形プレート１の位置を修正するのが好ましく、この場合、画像処理を用いて造形プレート１の端面１ａを検出し、位置ズレ量に応じて造形プレート１の位置修正或いは造形物４の造形位置の修正を行なうことで、造形プレート１上の本来の位置に造形させることができる。
【００１９】
また上記造形プレート１に予め画像処理検出用マーク９をつけておき、そのマーク９位置を画像処理検出することにより造形プレート１の位置ズレ量を検出するのが好ましく、この場合、画像処理検出用マーク９を造形プレート１の予め決められた位置、例えば造形プレート１の四隅につけておくことにより、画像処理による位置ズレ量の検出が容易となる。
【００２０】
また本発明は、造形タンク１０の上面において、造形途中で硬化層の表面除去加工を行なう表面除去機構６の座標系原点Ｑからの距離Ｗ１，Ｗ２がわかっている位置Ｕ，Ｖに固定基準となる位置決め構造物１１を設け、この位置決め構造物１１に合わせて造形プレート１を造形タンク１０内に固定することを特徴としており、このように構成することで、造形プレート１の位置が表面除去機構６の座標系のどこの位置にあるかわかり、造形プレート１がどこにあるかがわかれば、そこを基準に造形物４の造形位置を調整して、造形プレート１に対する造形位置を設定することができる。これにより、造形プレート１の位置決めが簡単に行なえると共に、造形タンク１０を利用して固定基準となる位置決め構造物１１を設けることにより、加工基準となる造形物４を別途造形する必要がなくなる。
【００２１】
【発明の実施の形態】
以下、本発明を添付図面に示す実施形態に基づいて説明する。
【００２２】
図１、図２は請求項１に対応する実施形態である。図３、図４は造形プレート１上に所望の三次元形状を有する造形物４を製造する造形工程の途中で硬化層３表面を所望形状に除去する表面除去工程が挿入される場合の説明図である。本発明では、造形終了後に造形プレート１を必要形状にカットして必要形状の造形物４と造形プレート１’とを一体に切り出すために、造形プレート１を必要形状にカットする際の加工基準となる基準形状部５を造形物４と同時に焼結造形する点に特徴を有している。
【００２３】
造形方法については従来と同様である。つまり図３に示す材料タンク１３内の昇降テーブル８上に金属粉末材料２を投入してその上面を平坦に均す。金属粉末材料２には例えば平均粒径がφ２０〜３０μｍ程度の鉄粉が用いられる。一方、造形タンク１０内の昇降テーブル１４を図４（ａ）に示す一層分の厚みＥだけ下げた位置にセットした状態で、平板ブレード１５を矢印Ｈに向かって材料タンク１３上から造形タンク１０上に移動させることにより、昇降テーブル１４上に固定した造形プレート１上に金属粉末材料２を供給し、その後、平板ブレード１５を材料タンク１３側に戻すと共に図４（ｂ）のように光ビームＬを金属粉末層２ａの硬化させたい箇所に照射してレーザー焼結を行ない、１層目の厚みＥを有する硬化層３を造形プレート１と一体に形成する。なお、光ビームＬには例えば炭酸ガスレーザ、ＹＡＧレーザ等が用いられる。その後、図４（ｃ）のように昇降テーブル１４を更に１層分の厚みＥだけ下降させる。つまり、初期位置から２層分の厚みＥ’だけ降下させた状態で、再び平板ブレード１５によって硬化層３の上に金属粉末層２ａを供給し、硬化させたい箇所に光ビームＬを照射して下の硬化層３と一体化された２層目の硬化層３を形成する。このような材料供給工程と光ビームＬ照射工程とを繰り返すことによって、図３のように造形プレート１上に上下複数の硬化層３が順次堆積されていき、三次元形状を有する造形物４（硬化積層物）を製造することができる。また造形工程中に、図４（ｄ）のように表面除去機構６を用いて硬化層３の表面を所望形状に除去することで、造形物４を所望の三次元形状に仕上げることができる。
【００２４】
本発明においては、上記造形プレート１上に、図１に示すように、型部となる造形物４と同時に、加工基準となる基準形状部５を焼結造形するものである。この基準形状部５は、造形プレート１を造形物４の一部として利用するために、造形プレート１を必要形状に切り出す際の加工基準として用いられるものであり、図１に示す例では、造形物４の二方向Ａ，Ｂにおいて互いに直交する２つの細長いストレート部５ａ，５ｂからなり、各ストレート部５ａ，５ｂからそれぞれ外側に所定の設計距離Ｆ，Ｇ（図２）をあけて切り出し位置（カットライン）を設定することで、造形プレート１の必要形状が残るような必要サイズＤで切り出すことができるようにしている。なお、基準形状部５は、切り出し加工後において不要であれば造形プレート１’から除去してもよい。
【００２５】
しかして、造形終了後に必要形状の造形物４と造形プレート１’とを一体に切り出す際には、造形物４と一緒に造形された基準形状部５を加工基準とする。これにより造形物４が造形プレート１のどこに造形されるのかわからない場合や、造形物４自体が加工基準となるストレート端面を持たない場合、さらに造形工程中に切削工程を持たない場合であっても、必要形状の造形物４と造形プレート１’とを後加工で一体に切り出すことが可能となり、本方法によって成形金型や部品の加工を行なうことができ、しかも造形開始前に造形プレート１の位置を造形物４の造形位置に正確に合わせる必要がないものであり、そのうえ加工基準となるストレート部５ａ，５ｂを造形物４と同時に焼結造形することで、造形時間を短縮することができる。
【００２６】
また本例では、加工基準となる基準形状部５を、図１のように型部となる造形物４とは別の位置に焼結造形するので、型部となる造形物４の形状に制約されないで、基準形状部５を任意の形状に形成できるものである。なお基準形状部５の形状は図１には限定されず、図５（ａ）のように基準形状部５が造形物４の二方向Ａ，Ｂを囲む平面視Ｌ字状の細長いストレート部５ｃ，５ｄを有する場合、或いは図５（ｂ）のように造形物４の四方Ａ，Ｂ，Ａ’，Ｂ’を囲む平面視四角形状の細長いストレート部５ｃ〜５ｆを有する場合でもよい。図１及び図５は請求項２に対応する実施形態である。また図６のように基準形状部５を複数の小さい四角形状に分散させ、各四角形状の一辺を結ぶ線Ｍ１，Ｍ２を加工基準とする場合であってもよい。この図６は請求項３に対応する実施形態である。これらいずれの場合も必要形状の切り出しが可能となり、しかも基準形状部５は型部となる造形物４とは別の位置に焼結造形されるため、型部となる造形物４の形状とは無関係に、基準形状部５を独立して任意の形状に設定できるという利点があり、特に図６の小さな複数の四角形状とした場合は、図５（ａ）或いは（ｂ）の基準形状部５と比較して焼結造形する領域を小さくでき、造形時間が一層短縮するという利点がある。
【００２７】
本発明の他の実施形態として、図７、図８に示すように、基準形状部５を造形物４と一体に形成してもよい。図７、図８は請求項４に対応する実施形態である。図７の例では、基準形状部５は造形物４の二辺に沿って互いに直角な２つのストレート端面４ａ，４ｂからなり、２つのストレート端面４ａ，４ｂを基に切り出し位置（カットライン）を決定するものであり、これにより造形物４自体が加工基準を持つようになり、余分な加工基準を造形物４とは別に別途造形する必要がなくなり、造形時間を短縮できる。
【００２８】
また図８に示すように、造形物４の外周全周を囲むように基準形状部５を配置すると共に、基準形状部５の外周の４辺にそれぞれ加工基準となるストレート端面５ｈ〜５ｋを形成するようにしてもよい。ここでは、基準形状部５の上に型部となる造形物４が配置された形状をしており、４つのストレート端面５ｈ〜５ｋは互いに直角な位置関係にあり、このストレート端面５ｈ〜５ｋを基に切り出し位置ａ１（カットライン）を決めるようにしている。これにより、造形終了後にモールドベース１７（図２０）に必要形状の造形物４と造形プレート１’を組み込んで金型を形成する場合、造形物４を型部として、基準形状部５を金型のすりあわせ面として利用できるという利点もある。
【００２９】
本発明の更に他の実施形態として、造形装置内に造形途中で硬化層３の表面除去加工を行なう表面除去機構６（図３）を備える場合において、この表面除去機構６を用いて図９に示す必要形状の切り出し基準加工或いは図１０に示す加工基準となるマーキングのいずれかを行なうようにしてもよい。図９、図１０は請求項５に対応する実施形態である。先ず図９の例では表面除去機構６（図３）として切り出し加工できる能力を有するもの、例えば回転刃物のミーリング機構によって造形プレート１を加工基準線ａ２に沿ってカットする。この場合の加工基準線ａ２のデータは表面除去機構６の駆動部に予めプログラミングされているものとする。これにより、前記実施形態のように加工基準となる基準形状部５を焼結造形により別途形成する必要がなくなるため、造形時間を短縮できるものであり、しかも、表面除去機構６を利用して造形プレート１を必要形状に切り出すので、造形プレート１の取り外しがなく、切り出し加工を高精度で行なえるものとなり、そのうえ既設の表面除去機構６を利用することで、切り出し加工のための専用の機構を別途設ける必要もなく、造形装置の構造を簡略化することができるという利点がある。これに対し、表面除去機構６が切り出し加工するだけの能力を持たない切削加工用スピンドル等の場合においては、図１０（ａ）に示すように、造形プレート１上に切削加工用スピンドルにて加工基準線７（例えばケガキ線７ａ）をマーキングし、その後、別の装置（例えばフライス加工装置、ワイヤカット装置等）で加工基準線７を基に造形プレート１を切削加工してもよい。なお加工基準線７としてはケガキ線７ａ以外に例えば十字マーク、円などの各種基準マークであってもよい。また、図１０（ｂ）に示すように、造形物４を囲む複数位置に基準穴７ｂを穴明け加工してもよい。さらに他例として、硬化層３を形成するための光ビームＬを照射する機構（図示せず）を用いて図１１に示す加工基準線７（ケガキ線、十字マーク等）を加工するようにしてもよい。なお光ビームＬには赤外線レーザ、例えば炭酸ガスレーザ、ＹＡＧレーザ等が用いられる。いずれの場合も、マーキング専用の装置を別途設ける必要がなく、造形装置の簡易化を図ることができる。
【００３０】
前記実施形態では、造形プレート１上に加工基準となる造形焼結或いはマーキングを行なう場合を説明したが、画像処理によって造形プレート１に対する造形位置の位置決めを行なう方法であってもよい。
【００３１】
図１３〜図１８は画像処理装置を造形プレート１と造形物４の造形位置とを位置決めする場合を示す。図１３は請求項７に対応し、図１４は請求項８に対応し、図１５は請求項９に対応し、図１６は請求項１０に対応し、図１７、図１８は請求項１１に対応する実施形態である。
【００３２】
まず、図１３は、画像処理装置を用いて造形プレート１の固定位置を計測し、造形プレート１と造形物４の造形位置との位置ズレ量を求め、その位置ズレ量に応じて造形させる位置を移動させる場合の一例を示している。ちなみに、図１２のように造形プレート１の固定位置と造形物４が造形位置とが既に合致している場合はよいが、実際には造形プレート１が昇降テーブル１４（図３）上に固定されるときに固定基準位置がないため、どこに固定されるのわからない。そのため、造形プレート１上のどこに造形物４が造形されるのかがわからない。そこで本例では、画像処理によって図１３（ａ）に示す造形装置内の実際の造形プレート１の固定位置を計測する。例えば撮像カメラで造形プレート１の位置を捉えて画像処理により位置を認識する。そして、設計上の造形プレート１Ａに対する平行位置ズレ量（Δｘ，Δｙ）と回転角度（Δθ）とを求め、この計測結果に応じて造形プレート１の位置をｘ，ｙ，θ方向に移動させて、図１３（ｂ）のように造形物４の造形位置を実際の造形プレート１に合致させる。しかして、画像処理にて造形プレート１の位置を認識し、位置ズレ量に応じて造形位置を決定するので、たとえ造形プレート１が傾いていても、造形プレート１上の本来の位置に造形させることができる。また本例では、造形プレート１の大きさは必要形状の大きさでよく、従って、大きめの造形プレート１に造形した後に必要形状に切り出すための後加工が不要となるため、作業の手間を大幅に削減でき、そのうえ加工基準を造形焼結によって別途形成する必要もないため、造形時間を一層短縮できるものである。そのうえ、造形位置の方を造形プレート１に合わせて移動させるので、造形プレート１を移動できない場合に有効となる。
【００３３】
図１４は、画像処理装置により造形プレート１の固定位置を計測し、造形物４の造形位置との位置ズレ量を求め、位置ズレ量に応じて造形プレート１の位置を移動させる場合の一例を示している。図１４（ａ）において、画像処理によって実際の造形プレート１の固定位置を計測して、設計上の造形プレート１Ａに対する平行位置ズレ量（Δｘ，Δｙ）と回転角度（Δθ）とを求め、計測結果に基いて図１４（ｂ）のように造形プレート１の方を移動させる。これにより、前記図１３の実施形態と同様な作用効果が得られるうえに、造形プレート１の方を造形位置に合わせて移動させるので、造形位置を移動できないときに有効である。
【００３４】
次に、上記画像処理によって造形プレート１の位置ズレ量を求める場合の具体例を説明する。図１５は、画像処理装置により実際の造形プレート１の端面１ａを検出し、本来あるべき造形プレート１の位置に対する位置ズレ量を計測する場合の一例を示している。図１５（ａ）は造形プレート１の一辺に対して最低２箇所で画像処理を行ない、端面位置を計測する場合を示す。端面位置は濃淡処理で求める。図１５（ｂ）、（ｃ）は検出ラインを境界とする明暗レベルを示している。本例では、造形プレート１の一辺において距離Ｌ１をあけた２箇所の計測座標Ｓ１（ｘ１，ｙ１）、Ｓ２（ｘ２，ｙ２）と、これと隣接する他辺において距離Ｌ２をあけた２箇所の計測座標Ｓ３（ｘ３，ｙ３）、Ｓ４（ｘ４，ｙ４）において、それぞれ端面位置を計測している。そして、図１５（ｂ）のように画像処理領域Ｓ１〜Ｓ４においてカメラで検出した検出点Ｐ１，Ｐ２とＰ３，Ｐ４とを結ぶ直線を延長し、延長線Ｎ１，Ｎ２の交点を造形プレート１の端面座標とし、この座標値と本来あるべき造形プレート１の位置との差から平行位置ズレ量（Δｘ，Δｙ）を求め、同様にして、延長線Ｎ１，Ｎ２の傾き角度と本来あるべき造形プレート１の角度の差から回転角度（Δθ）を求め、これら平行位置ズレ量（Δｘ，Δｙ）と回転角度（Δθ）とで造形プレート１の位置修正を行なう。しかして、画像処理装置により実際の造形プレート１の端面１ａを検出し、本来あるべき造形プレート１の位置に対する位置ズレ量を計測し、位置ズレ量に応じて造形プレート１の位置修正或いは造形物４の造形位置の修正を行なうことで、前記図１３の実施形態と同様な作用効果が得られるうえに、造形プレート１上の本来の位置に造形させることができるものである。
【００３５】
また他例として、図１６に示すように、造形プレート１の四隅を画像処理領域Ｓとし、各画像処理領域Ｓに画像処理検出用マーク９をつけておき、そのマーク９位置を画像処理にて検出することにより位置ズレ量を検出するようにしてもよい。画像処理検出用マーク９として例えば、小穴、十字マーク等、任意であり、これを造形プレート１の予め決められた位置、例えば造形プレート１の四隅につけておくことにより、画像処理による位置ズレ量の検出が容易となる。
【００３６】
更に他の例として、図１７に示すように、造形タンク１０の上面において、造形途中で硬化層の表面除去加工を行なう表面除去機構６（図３）の座標系原点からの距離がわかっている位置に固定基準となる位置決め構造物１１を設け、この位置決め構造物１１に合わせて造形プレート１を造形タンク１０内に固定するようにしてもよい。この位置決め構造物１１は、図１７（ａ）に示すストレート形状、或いは図１７（ｂ）に示すピン形状のいずれでもよい。いずれの場合も、位置決め構造物１１は、表面除去機構６の座標系原点Ｑからの距離Ｗ１，Ｗ２がわかっている位置Ｕ，Ｖにそれぞれ設けられ、この位置決め構造物１１に合わせて造形プレート１を固定することによって、造形プレート１の位置が表面除去機構６の座標系のどこの位置にあるかわかり、造形プレート１がどこにあるかがわかれば、そこを基準に造形物４の造形位置を調整して、造形プレート１に対する造形位置を設定することができる。従って、造形プレート１の位置決めが簡単に行なえると共に、加工基準となる造形物４を別途造形する必要がなくなり、造形時間を短縮できる。また位置決め構造物１１として、図１７（ｂ）に示す位置決めピンを用いる場合において、造形装置内に設けられる表面除去機構６を用いて位置決めピンを立てる位置の加工をすれば、位置決めピンを取り付ける際の位置合わせ調整を簡単に行なうことができるようになる。さらに図１８に示すように、造形プレート１が小さい場合は、寸法のわかっている平行ブロック５０を位置決め構造物１１と造形プレート１との間に入れ、平行ブロック５０の端面５０ａに位置決め構造物１１を位置決めする。これにより寸法がわかっている平行ブロック５０を介して、造形プレート１がどこにあるかがわかるようになり、造形プレート１が小さい場合でもその造形プレート１に対する造形位置を容易に設定できるものである。
【００３７】
【発明の効果】
上述のように請求項１記載の発明にあっては、造形プレート上に供給された金属粉末層の所定箇所に光ビームを照射して焼結させることによって硬化層を形成し、この硬化層の上に更に金属粉末層を被覆して金属粉末層の所定箇所に光ビームを照射して下の硬化層と一体となった上の硬化層を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層が一体化された三次元形状を有する造形物を製造し、造形終了後に造形プレートを必要形状にカットして必要形状の造形物と造形プレートとを一体に切り出す三次元形状造形物の製造方法であって、上記必要形状の造形物と造形プレートとを一体に切り出す際の加工基準となる基準形状部を造形物と同時に焼結造形するので、造形終了後に必要形状の造形物と造形プレートとを一体に切り出す際に、造形物と一緒に造形された基準形状部を加工基準とすることができ、従って、造形物が造形プレートのどこに造形されるのかわからない場合や、造形物自体が加工基準となるストレート端面を持たない場合、さらに造形工程中に切削工程を持たない場合であっても、必要形状の造形物と造形プレートとを後加工で一体に切り出すことが可能となり、本方法によって成形金型や部品の加工を行なうことができ、しかも造形開始前に造形プレートの位置を造形物の造形位置に正確に合わせる必要がないものであり、そのうえ加工基準となる基準形状部を造形物と一緒に焼結造形することで、造形時間を短縮できるものである。
【００３８】
また請求項２記載の発明は、請求項１記載の効果に加えて、上記基準形状部を、造形物とは別の位置に焼結造形するので、造形物の形状には制約されないで、加工基準となる基準形状部を独立して任意の形状に造形できるものである。
【００３９】
また請求項３記載の発明は、請求項２記載の効果に加えて、上記基準形状部を複数に分散させて配置するので、大きな基準形状部を焼結造形する必要がないため、造形時間を短縮できる。
【００４０】
また請求項４記載の発明は、請求項１記載の効果に加えて、上記基準形状部を、造形物と一体に形成するので、造形物自体が加工基準を持つようになり、余分な加工基準を造形物とは別に別途造形する必要がなくなり、造形時間を短縮できる。
【００４１】
また請求項５記載の発明は、造形プレート上に供給された金属粉末層の所定箇所に光ビームを照射して焼結させることによって硬化層を形成し、この硬化層の上に更に金属粉末層を被覆して金属粉末層の所定箇所に光ビームを照射して下の硬化層と一体となった上の硬化層を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層が一体化された三次元形状を有する造形物を製造する造形工程を備え、造形途中で硬化層表面を所望形状に除去する表面除去工程が挿入され、造形終了後に造形プレートを必要形状にカットして必要形状の造形物と造形プレートとを一体に切り出す三次元形状造形物の製造方法であって、上記造形途中で硬化層の表面除去加工を行なう表面除去機構に、必要形状の切り出し基準加工或いは造形プレートへの加工基準となるマーキングのいずれかを行なう機能を持たせたので、加工基準となる基準形状部を焼結造形により別途形成する必要がなくなるため、造形時間を短縮できる。さらに、造形物の表面除去加工を行なうための表面除去機構を利用して切り出し基準加工を行なう場合は、造形プレートの取り外しがなく、切り出し加工を高精度で行なうことができ、一方、造形プレートにマーキングをする場合は、その後で別の装置（例えばフライス、ワイヤカット等）を用いてマーキングを基に造形プレートを精度良く切削加工可能となる。
【００４２】
また請求項６記載の発明は、上記硬化層を形成するための光ビームの照射機構を用いて造形プレート上へ加工基準となるマーキングを行ない、造形終了後に切削装置でマーキングに沿って造形プレートを必要形状にカットするので、マーキング専用の装置を別途設ける必要がなく、造形装置の構造を簡略化することができる。
【００４３】
また請求項７記載の発明は、造形装置内に固定された造形プレート上に金属粉末層を供給し、この金属粉末層の所定箇所に光ビームを照射して焼結させることによって硬化層を形成し、この硬化層の上に更に金属粉末層を被覆して金属粉末層の所定箇所に光ビームを照射して下の硬化層と一体となった上の硬化層を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層が一体化された三次元形状を有する造形物を製造すると共に、造形途中で硬化層表面を所望形状に除去する表面除去工程を挿入する方法であって、造形を行なう前に画像処理装置により造形プレートの固定位置を計測して造形プレートと造形物の造形位置との位置ズレ量を求め、その位置ズレ量に応じて造形位置を移動させるので、画像処理を用いて造形プレートの位置を認識し、位置ズレ量に応じて造形される位置を移動させることで、造形プレート上の本来の位置に造形させることができ、しかも造形プレートの大きさは必要形状の大きさでよく、後加工で造形プレートを必要形状に切り出す必要がなく、加工基準を造形焼結によって形成する必要もないため、造形時間を一層短縮できると共に、造形位置の方を造形プレートの固定位置に合わせて移動させることで、造形プレートを移動できない場合に有効である。
【００４４】
また請求項８記載の発明は、造形装置内に固定された造形プレート上に金属粉末層を供給し、この金属粉末層の所定箇所に光ビームを照射して焼結させることによって硬化層を形成し、この硬化層の上に更に金属粉末層を被覆して金属粉末層の所定箇所に光ビームを照射して下の硬化層と一体となった上の硬化層を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層が一体化された三次元形状を有する造形物を製造すると共に、造形途中で硬化層表面を所望形状に除去する表面除去工程を挿入する方法であって、造形を行なう前に画像処理装置により造形プレートの固定位置を計測して造形プレートと造形物の造形位置との位置ズレ量を求め、その位置ズレ量に応じて造形プレートの位置を移動させるので、画像処理を用いて造形プレートの位置を認識し、位置ズレ量に応じて造形プレートの位置を修正するので、造形プレート上の本来の位置に造形させることができ、しかも造形プレートの大きさは必要形状の大きさでよく、後加工で造形プレートを必要形状に切り出す必要がなく、加工基準を造形焼結によって形成する必要もないため、造形時間を一層短縮できる。
【００４５】
また請求項９記載の発明は、請求項７又は請求項８記載の効果に加えて、画像処理装置により造形プレートの端面を検出して本来あるべき造形プレートの位置に対する位置ズレ量を計測し、位置ズレ量に応じて造形プレートの位置を修正するので、画像処理を用いて造形プレートの端面を検出し、位置ズレ量に応じて造形プレートの位置修正或いは造形物の造形位置の修正を行なうことで、造形プレート上の本来の位置に造形させることができる。
【００４６】
また請求項１０記載の発明は、請求項７又は請求項８記載の効果に加えて、造形プレートに予め画像処理検出用マークをつけておき、そのマーク位置を画像処理検出することにより造形プレートの位置ズレ量を検出するので、画像処理検出用マークを造形プレートの予め決められた位置、例えば造形プレートの四隅につけておくことにより、画像処理による位置ズレ量の検出が容易となる。
【００４７】
また請求項１１記載の発明は、造形プレート上に供給された金属粉末層の所定箇所に光ビームを照射して焼結させることによって硬化層を形成し、この硬化層の上に更に金属粉末層を被覆して金属粉末層の所定箇所に光ビームを照射して下の硬化層と一体となった上の硬化層を形成し、上記焼結と積層とを繰り返すことにより上下複数の硬化層が一体化された三次元形状を有する造形物を製造すると共に途中で硬化層表面を所望形状に除去する表面除去工程が挿入される三次元形状造形物の製造方法であって、造形タンクの上面において、造形途中で硬化層の表面除去加工を行なう表面除去機構の座標系原点からの距離がわかっている位置に固定基準となる位置決め構造物を設け、この位置決め構造物に合わせて造形プレートを造形タンク内に固定するので、造形プレートの位置が表面除去機構の座標系のどこの位置にあるかわかり、造形プレートがどこにあるかがわかれば、そこを基準に造形物の造形位置を調整して、造形プレートに対する造形位置を設定することができる。これにより、造形プレートの位置決めが簡単に行なえると共に、造形タンクを利用して固定基準となる位置決め構造物を設けることにより、加工基準となる造形物を別途造形する必要がなく、造形時間を一層短縮できる。
【図面の簡単な説明】
【図１】（ａ）は本発明の実施形態の一例を示す平面断面図、（ｂ）は側面断面図である。
【図２】同上の基準形状部を加工基準として必要形状を切り出す場合の説明図である。
【図３】同上の造形装置の概略断面図である。
【図４】（ａ）〜（ｄ）は同上の造形工程の説明図である。
【図５】（ａ）は同上の基準形状部の他例の説明図、（ｂ）は更に他例の説明図である。
【図６】同上の基準形状部の更に他例の説明図である。
【図７】同上の基準形状部を造形物と一体形成した場合の一例の平面断面図である。
【図８】（ａ）は同上の基準形状部を造形物と一体形成した場合の他例の平面断面図、（ｂ）は側面断面図である。
【図９】同上の表面除去機構を用いて必要形状を切り出し基準加工する場合の説明図である。
【図１０】（ａ）は同上の表面除去機構を用いてケガキ線をマーキングする場合の説明図、（ｂ）は加工基準穴を形成する場合の説明図である。
【図１１】同上のマーキングをレーザ照射により行なう場合の説明図である。
【図１２】同上の造形プレートの固定位置と造形物の造形位置とのズレがない場合の説明図である。
【図１３】（ａ）は同上の造形プレートの固定位置と造形物の造形位置とにズレがある場合の説明図、（ｂ）は造形位置を移動させてズレを修正した後の説明図である。
【図１４】（ａ）は同上の造形プレートの固定位置と造形物の造形位置とにズレがある場合の説明図、（ｂ）は造形プレートを移動させてズレを修正した後の説明図である。
【図１５】（ａ）（ｂ）は同上の造形プレートの固定位置と造形物の造形位置とのズレを画像処理によって検出する場合の説明図、（ｃ）は検出ラインの明暗レベルの説明図である。
【図１６】（ａ）は同上の造形プレートに画像処理検出用マークを設けた場合の説明図、（ｂ）は（ａ）の画像処理領域内の画像処理検出用マークの中心位置を検出する場合の説明図である。
【図１７】（ａ）は同上の造形タンクにおける表面除去機構の座標系に対する所定位置に位置決め構造物を設けた場合の一例の説明図、（ｂ）は他例の説明図である。
【図１８】同上の位置決め構造物の他例の説明図である。
【図１９】従来の三次元形状造形物の製造方法を説明する断面図である。
【図２０】従来の造形物及び造形プレートの必要形状の部分を型部としてモールドベースに組み込んだ状態を説明する断面図である。
【図２１】（ａ）は従来の造形プレートの位置と造形物の造形される位置とが正規の位置関係にある場合の平面図、（ｂ）は位置関係がズレている場合の平面図、（ｃ）は大きい造形プレート上に造形物を造形した場合の平面図、（ｄ）は（ｃ）の造形プレートを必要形状に切り出す場合を説明する平面図、（ｅ）は造形物に切り出しの加工基準がない場合の一例を説明する平面図である。
【図２２】従来の造形物が造形される位置と造形プレートの位置との関係を説明する平面図である。
【図２３】（ａ）は必要形状を切り出す前の断面図、（ｂ）は切り出し後の断面図である。
【符号の説明】
１，１’ 造形プレート
１ａ端面
２ａ金属粉末層
３硬化層
４造形物
５基準形状部
６表面除去機構
９画像処理検出用マーク
１０造形タンク
１１位置決め構造物
Ｌ光ビーム
Ｑ座標系原点
Ｗ１、Ｗ２座標系原点からの距離
Ｕ，Ｖ位置決め構造物の位置[0001]
BACKGROUND OF THE INVENTION
The present invention manufactures a three-dimensional shaped object by sintering and hardening a metal powder layer on a modeling plate with a light beam, and integrally cuts out a necessary-shaped object and a shaping plate by post-processing. The present invention relates to a method for manufacturing a three-dimensional shaped object.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a method is known in which a metal powder material is irradiated with a light beam to form a hardened layer, and the hardened layer is laminated to produce a three-dimensional shaped object (for example, see Patent Document 1). As another conventional example, a method of performing surface finishing of a metal powder sintered part (see, for example, Patent Document 2), or a plurality of layers in which a powder layer is selectively sintered inside a predetermined boundary and sintered to each other There is also known a method of manufacturing a component made of (see, for example, Patent Document 3).
[0003]
[Patent Document 1]
JP 2002-115004 A
[Patent Document 2]
JP 2000-73108 A
[Patent Document 3]
Japanese Patent No. 2620353
[0004]
[Problems to be solved by the invention]
By the way, conventionally, as shown in FIG. 19, the metal powder material 2 is put on the lifting table 8 in the material tank 13, and the flat blade 15 is placed on the modeling plate 1 fixed to the lifting table 14 in the modeling tank 10. By moving in the direction of arrow H, the metal powder material 2 is supplied onto the modeling plate 1, the light beam L is irradiated to the portion to be cured of the metal powder layer 2 a, laser sintering is performed, and the cured layer 3 is formed. Form. Thereafter, the lifting table 14 is lowered by a thickness E corresponding to one layer, the metal powder layer 2a is supplied, and the light beam L is irradiated to form the second hardened layer 3. By repeating such a material supply process and the light beam L irradiation process, a plurality of upper and lower cured layers 3 are sequentially deposited on the modeling plate 1 to form a three-dimensional modeled object 4 (cured laminate). To manufacture.
[0005]
Here, the modeling plate 1 is generally used as a part of the modeled object 4 rather than being separated from the modeled object 4 (cured laminate) after the modeling is completed. For example, as shown in FIG. 20, the modeled object 4 integrated on the modeling plate 1 ′ is incorporated into the mold base 17 shown in FIG. 20 and used as a mold part of a mold.
[0006]
Here, as shown in FIG. 21A, the position of the modeling plate 1 matches the position where the modeled object 4 is modeled, and the reference axis direction J (J ′) of the modeled object 4 and the reference axis of the modeled plate 1 If K (K ′) is parallel, the modeling position with respect to the modeling plate 1 is determined. However, since there is actually no reference for fixing the modeling plate 1, the reference axis of the modeled object 4 as shown in FIG. The direction J (J ′) and the reference axis K (K ′) of the modeling plate 1 are easily misaligned, and as a result, the model 4 is misaligned and shaped on the a × b size modeling plate 1 shown in FIG. It may end up. For this reason, it is difficult to match the position for modeling with the modeling plate 1 as shown in FIG.
[0007]
Therefore, in the process leading to the present invention, the present inventors form a model 4 on the modeling plate 1 larger than the required shape as shown in FIGS. 21C and 23A, and wire cut by post-processing. A method of cutting out a shaping plate 1 ′ having a required shape with a wire cutting device or the like as shown in FIGS. 21 (d) and 23 (b) using an apparatus or the like was considered.
[0008]
However, when the shaped article 4 itself has straight end faces 1m and 1n as a processing reference when cutting out as shown in FIG. 21 (d), the distance g is spaced from the straight end face 1m and the distance f from the straight end face 1n. The reference axis direction J (J ′) of the modeled object 4 is determined with respect to the position of the modeling plate 1 by cutting out with the predetermined dimensions c and d. For example, the modeled object 4 itself as shown in FIG. However, when there is no processing standard, there is a problem that it becomes impossible to cut out to a necessary shape.
[0009]
The present invention was invented in view of the problems of the above-described conventional example, and the object of the present invention is to provide a processing standard for integrally cutting out a molded object and a modeling plate of a necessary shape at the time of modeling, Providing a 3D model manufacturing method that eliminates the need to accurately match the position of the modeling plate to the modeling position of the modeled object, and allows the processing standard to be sintered together with the modeled object to shorten the modeling time. Another object is to provide a method for manufacturing a three-dimensional shaped object that can perform cutting reference processing using a surface removal mechanism or perform marking as a processing reference. The purpose of this is that it is possible to form a modeled object at the original position on the modeling plate using image processing, and there is no need to cut the modeling plate into the required shape by post-processing. There is no need to form a processing standard by modeling sintering, and it is to provide a method for manufacturing a three-dimensional modeled object that can further reduce modeling time. Another object is to use an image processing of the modeling plate. Recognizing the position, and correcting the position of the modeling plate according to the amount of positional deviation, to provide a method for manufacturing a three-dimensional shaped object that can be modeled at the original position on the modeling plate, Another object is to provide a method for producing a three-dimensional shaped object that can perform positioning and fixing of a modeling plate using a modeling tank.
[0010]
[Means for Solving the Problems]
In order to solve the above problems, the present invention forms a hardened layer 3 by irradiating a predetermined portion of the metal powder layer 2a supplied on the modeling plate 1 with a light beam L and sintering it. Further, a metal powder layer 2a is further coated thereon, and a predetermined portion of the metal powder layer 2a is irradiated with a light beam L to form an upper hardened layer 3 integrated with the lower hardened layer 3. By repeating the lamination, a model 4 having a three-dimensional shape in which a plurality of upper and lower cured layers 3 are integrated is manufactured, and after the modeling is finished, the model plate 1 is cut into a required shape and the model 4 and the model having the required shape are modeled. A manufacturing method of a three-dimensional shaped object that integrally cuts out the plate 1 ′, and the reference shape portion 5 that is a processing reference when the shaped object 4 and the shaping plate 1 ′ having the above-mentioned shape are cut out integrally is formed. 4 and sinter molding at the same time By comprising in this way, when the modeling object 4 and modeling plate 1 'of required shape are cut out integrally after completion | finish of modeling, the reference | standard shape part 5 modeled with the modeling object 4 can be made into a process reference. It is possible to cut out a necessary shape by post-processing by the reference shape portion 5, and it is possible to process a molding die or a part by this method, and further, the position of the modeling plate 1 is formed after the modeling is started. It is not necessary to accurately match the position, and in addition, the modeling time can be shortened by modeling the reference shape part 5 at the same time as the modeled object 4.
[0011]
In addition, it is preferable to sinter and shape the reference shape part 5 at a position different from the shaped object 4. In this case, the reference shape part 5 that is a processing reference is independent from the shape of the shaped object 4. Can be shaped into any shape.
[0012]
In addition, it is preferable to disperse the reference shape portion 5 in a plurality, and in this case, it is not necessary to sinter the large reference shape portion 5.
[0013]
Further, it is preferable to form the reference shape part 5 integrally with the modeled object 4. In this case, the modeled object 4 itself has a processing standard, and an extra processing standard is separately modeled separately from the modeled object 4. There is no need.
[0014]
In the present invention, the surface removal mechanism 6 that performs surface removal processing of the hardened layer 3 in the middle of modeling has a function of performing either a reference processing for cutting a required shape or a marking that is a processing reference for the modeling plate 1. With such a configuration, it is not necessary to separately form the reference shape portion 5 serving as a processing reference by sintering modeling. Furthermore, when performing the cutting reference processing using the surface removal mechanism 6 for performing the surface removal processing of the modeled article 4, there is no removal of the modeling plate 1, and the cutting processing can be performed with high accuracy, When marking as a processing reference is performed on the modeling plate 1, the modeling plate 1 can be cut with high accuracy on the basis of the marking using another apparatus (for example, a milling machine, a wire cutting, etc.).
[0015]
In addition, marking as a processing reference is performed on the modeling plate 1 using the irradiation mechanism of the light beam L for forming the hardened layer 3, and the modeling plate is cut into a necessary shape by a cutting device along the marking after the modeling is completed. With this configuration, it is not necessary to provide a dedicated marking device.
[0016]
Moreover, this invention measures the fixed position of the modeling plate 1 with an image processing apparatus before modeling, calculates | requires the positional shift amount of the modeling plate 1 and the modeling position of the molded article 4, and models according to the positional offset amount. It is characterized by moving the position, and by configuring in this way, the position of the modeling plate 1 is recognized by using image processing, and the modeling plate is moved by moving the position to be modeled according to the amount of positional deviation. 1 can be formed in the original position, and the size of the modeling plate 1 can be the size of the required shape, and it is not necessary to cut the modeling plate 1 into the required shape by post-processing, and the processing standard is shaped and sintered This is effective when the modeling plate 1 cannot be moved by moving the modeling position of the modeled object 4 in accordance with the fixed position of the modeling plate 1.
[0017]
Moreover, this invention measures the fixed position of the modeling plate 1 with an image processing apparatus before modeling, calculates | requires the positional shift amount of the modeling plate 1 and the modeling position of the molded article 4, and models according to the positional offset amount. It is characterized by moving the position of the plate 1. By configuring in this way, the position of the modeling plate 1 is recognized using image processing, and the position of the modeling plate 1 is corrected according to the amount of positional deviation. The modeling plate 1 can be formed in the original position, and the size of the modeling plate 1 can be the size of the required shape, and it is not necessary to cut the modeling plate 1 into the required shape by post-processing. There is no need to form by molding sintering.
[0018]
Further, it is preferable to detect the end face 1a of the modeling plate 1 by the image processing device, measure the positional deviation amount with respect to the position of the modeling plate 1 that should be originally, and correct the position of the modeling plate 1 according to the positional deviation amount, In this case, the end surface 1a of the modeling plate 1 is detected using image processing, and the original position on the modeling plate 1 is corrected by correcting the position of the modeling plate 1 or the modeling position of the modeled object 4 according to the amount of positional deviation. It can be shaped at the position.
[0019]
In addition, it is preferable to detect an image processing detection mark 9 by previously attaching an image processing detection mark 9 to the modeling plate 1 and detecting the position of the mark 9 by image processing. By placing the marks 9 at predetermined positions on the modeling plate 1, for example, at the four corners of the modeling plate 1, it becomes easy to detect the amount of positional deviation by image processing.
[0020]
Further, according to the present invention, on the upper surface of the modeling tank 10, the fixed reference is set at positions U and V where the distances W1 and W2 from the coordinate system origin Q of the surface removal mechanism 6 for performing the surface removal processing of the hardened layer during the modeling are known. A positioning structure 11 is provided, and the modeling plate 1 is fixed in the modeling tank 10 in accordance with the positioning structure 11. With this configuration, the position of the modeling plate 1 is a surface removal mechanism. If the position of the modeling plate 1 is known and the position of the modeling plate 1 is known, the modeling position of the modeling object 4 can be adjusted based on that position and the modeling position with respect to the modeling plate 1 can be set. it can. Thereby, while positioning of modeling plate 1 can be performed easily, by providing positioning structure 11 used as a fixed reference using modeling tank 10, it is not necessary to model modeling object 4 used as a processing standard separately.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.
[0022]
1 and 2 show an embodiment corresponding to claim 1. FIG. 3 and 4 are explanatory views in the case where a surface removal process for removing the surface of the hardened layer 3 into a desired shape is inserted in the middle of the modeling process for manufacturing the modeled article 4 having a desired three-dimensional shape on the modeling plate 1. It is. In the present invention, in order to cut the modeling plate 1 into a required shape after the modeling is completed and integrally cut out the modeling object 4 and the modeling plate 1 ′ having the required shape, It has the characteristic in the point which carries out the sintering shaping | molding of the reference | standard shape part 5 which becomes this simultaneously with the molded article 4.
[0023]
The modeling method is the same as the conventional method. That is, the metal powder material 2 is put on the lifting table 8 in the material tank 13 shown in FIG. 3 and the upper surface thereof is leveled. For the metal powder material 2, for example, iron powder having an average particle diameter of about φ20 to 30 μm is used. On the other hand, in the state where the lifting table 14 in the modeling tank 10 is set at a position where it is lowered by the thickness E of one layer shown in FIG. 4A, the flat blade 15 is directed from the material tank 13 toward the arrow H from the modeling tank 10. By moving it up, the metal powder material 2 is supplied onto the modeling plate 1 fixed on the lifting table 14, and then the flat blade 15 is returned to the material tank 13 side and the light beam as shown in FIG. 4B. The portion of the metal powder layer 2a to be cured is irradiated with L to perform laser sintering, and a cured layer 3 having a first thickness E is formed integrally with the modeling plate 1. For the light beam L, for example, a carbon dioxide laser, a YAG laser, or the like is used. Thereafter, as shown in FIG. 4C, the lifting table 14 is further lowered by a thickness E corresponding to one layer. That is, the metal powder layer 2a is again supplied onto the hardened layer 3 by the flat blade 15 in a state where the thickness E ′ is lowered by two layers from the initial position, and the light beam L is irradiated to the portion to be hardened. A second hardened layer 3 integrated with the lower hardened layer 3 is formed. By repeating such a material supply process and the light beam L irradiation process, a plurality of upper and lower cured layers 3 are sequentially deposited on the modeling plate 1 as shown in FIG. Cured laminate) can be produced. Moreover, the modeling thing 4 can be finished in a desired three-dimensional shape by removing the surface of the hardened layer 3 into a desired shape using the surface removal mechanism 6 as shown in FIG.
[0024]
In the present invention, on the modeling plate 1, as shown in FIG. 1, a reference shape portion 5 serving as a processing reference is sintered and formed simultaneously with a molded article 4 serving as a mold portion. This reference shape portion 5 is used as a processing reference when cutting the modeling plate 1 into a necessary shape in order to use the modeling plate 1 as a part of the modeled object 4, and in the example shown in FIG. The object 4 is composed of two elongated straight portions 5a and 5b orthogonal to each other in the two directions A and B, and a predetermined design distance F and G (FIG. 2) is opened outward from each of the straight portions 5a and 5b. By setting the (cut line), it is possible to cut out the required size D such that the required shape of the modeling plate 1 remains. Note that the reference shape portion 5 may be removed from the modeling plate 1 ′ if unnecessary after the cutting process.
[0025]
Therefore, when the modeled object 4 and the modeled plate 1 ′ having a required shape are cut out integrally after the modeling is completed, the reference shape part 5 modeled together with the modeled object 4 is used as a processing standard. Thereby, even when the modeling object 4 does not know where the modeling plate 1 is modeled, when the modeling object 4 itself does not have a straight end surface as a processing reference, and even when there is no cutting process during the modeling process. The molded article 4 and the modeling plate 1 ′ having the required shape can be cut out integrally by post-processing, and the molding die and parts can be processed by this method. It is not necessary to accurately match the position with the modeling position of the modeled object 4 and, further, the modeling time can be shortened by sintering the straight parts 5a and 5b serving as the processing reference simultaneously with the modeled object 4. .
[0026]
Moreover, in this example, since the reference shape part 5 that is a processing reference is sintered and formed at a position different from the shaped object 4 that is a mold part as shown in FIG. 1, the shape of the shaped object 4 that is a mold part is limited. However, the reference shape portion 5 can be formed into an arbitrary shape. The shape of the reference shape portion 5 is not limited to that in FIG. 1, and the reference shape portion 5 is an elongated straight portion 5 c having an L shape in plan view surrounding the two directions A and B of the shaped article 4 as shown in FIG. , 5d, or may have long and narrow straight portions 5c to 5f having a rectangular shape in plan view surrounding the four sides A, B, A ′, B ′ of the shaped article 4 as shown in FIG. 1 and 5 show an embodiment corresponding to claim 2. FIG. Further, as shown in FIG. 6, the reference shape portion 5 may be dispersed into a plurality of small square shapes, and the lines M1 and M2 connecting one side of each square shape may be used as the processing reference. FIG. 6 shows an embodiment corresponding to claim 3. In any of these cases, it becomes possible to cut out the necessary shape, and the reference shape portion 5 is sintered and shaped at a position different from the shaped object 4 to be the mold part, so the shape of the shaped object 4 to be the mold part is Irrespective of this, there is an advantage that the reference shape portion 5 can be independently set to an arbitrary shape, and in particular, when the plurality of small square shapes in FIG. 6 are used, the reference shape portion 5 in FIG. 5 (a) or (b). Compared to the above, there is an advantage that the area for sintering modeling can be reduced, and the modeling time is further shortened.
[0027]
As other embodiment of this invention, as shown in FIG. 7, FIG. 8, you may form the reference | standard shape part 5 integrally with the molded article 4. FIG. 7 and 8 show an embodiment corresponding to the fourth aspect. In the example of FIG. 7, the reference shape portion 5 includes two straight end surfaces 4 a and 4 b that are perpendicular to each other along two sides of the modeled object 4, and the cut-out positions (cut lines) are based on the two straight end surfaces 4 a and 4 b. As a result, the modeled object 4 itself has a processing standard, so that it is not necessary to model an extra processing standard separately from the modeled object 4, and the modeling time can be shortened.
[0028]
Further, as shown in FIG. 8, the reference shape portion 5 is arranged so as to surround the entire outer periphery of the shaped article 4, and straight end surfaces 5 h to 5 k serving as processing references are formed on the four sides of the outer periphery of the reference shape portion 5. You may make it do. Here, it has a shape in which a modeled object 4 serving as a mold part is disposed on the reference shape part 5, and the four straight end faces 5 h to 5 k are in a perpendicular relationship with each other, and the straight end faces 5 h to 5 k are Based on this, the cutout position a1 (cut line) is determined. Thus, when forming a mold by incorporating the molded object 4 and the modeling plate 1 ′ having the required shape into the mold base 17 (FIG. 20) after the modeling is completed, the molded object 4 is used as the mold part, and the reference shape part 5 is used as the mold. There is also an advantage that it can be used as a balancing surface.
[0029]
As still another embodiment of the present invention, when a surface removal mechanism 6 (FIG. 3) for performing surface removal processing of the hardened layer 3 in the middle of modeling is provided in the modeling apparatus, the surface removal mechanism 6 is used in FIG. Either the reference cutting process of the necessary shape to be shown or the marking serving as the processing reference shown in FIG. 10 may be performed. 9 and 10 show an embodiment corresponding to the fifth aspect. First, in the example of FIG. 9, the modeling plate 1 is cut along the processing reference line a2 by a surface removal mechanism 6 (FIG. 3) having an ability to be cut out, for example, by a milling mechanism of a rotary cutter. In this case, the data of the processing reference line a2 is preliminarily programmed in the driving unit of the surface removal mechanism 6. Accordingly, it is not necessary to separately form the reference shape portion 5 as a processing reference as in the above-described embodiment by sintering modeling, so that the modeling time can be shortened, and the modeling is performed using the surface removal mechanism 6. Since the plate 1 is cut into the required shape, the modeling plate 1 is not removed, and the cutting process can be performed with high accuracy. In addition, by using the existing surface removal mechanism 6, a dedicated mechanism for the cutting process can be provided. There is no need to provide it separately, and there is an advantage that the structure of the modeling apparatus can be simplified. On the other hand, in the case of a cutting spindle or the like that the surface removal mechanism 6 does not have the ability to cut out, as shown in FIG. 10A, machining is performed on the modeling plate 1 with the cutting spindle. The reference line 7 (for example, the marking line 7a) may be marked, and then the modeling plate 1 may be cut based on the processing reference line 7 with another apparatus (for example, a milling apparatus, a wire cutting apparatus, or the like). The processing reference line 7 may be various reference marks such as a cross mark and a circle other than the marking line 7a. In addition, as shown in FIG. 10B, the reference holes 7b may be drilled at a plurality of positions surrounding the shaped article 4. As another example, the processing reference line 7 (marking line, cross mark, etc.) shown in FIG. 11 is processed using a mechanism (not shown) that irradiates the light beam L for forming the hardened layer 3. Also good. For the light beam L, an infrared laser such as a carbon dioxide laser or a YAG laser is used. In any case, it is not necessary to separately provide an apparatus dedicated to marking, and the modeling apparatus can be simplified.
[0030]
In the above embodiment, the case where modeling sintering or marking as a processing reference is performed on the modeling plate 1 has been described, but a method of positioning a modeling position with respect to the modeling plate 1 by image processing may be used.
[0031]
FIGS. 13-18 shows the case where an image processing apparatus positions the modeling plate 1 and the modeling position of the molded article 4. FIG. 13 corresponds to claim 7, FIG. 14 corresponds to claim 8, FIG. 15 corresponds to claim 9, FIG. 16 corresponds to claim 10, and FIGS. 17 and 18 correspond to claim 11. It is a corresponding embodiment.
[0032]
First, FIG. 13 shows the position where the fixed position of the modeling plate 1 is measured using the image processing apparatus, the amount of positional deviation between the modeling plate 1 and the modeling position of the modeled object 4 is obtained, and modeling is performed according to the positional deviation amount. An example in the case of moving is shown. By the way, as shown in FIG. 12, it is good if the fixed position of the modeling plate 1 and the modeling position of the modeling object 4 are already matched, but the modeling plate 1 is actually fixed on the lifting table 14 (FIG. 3). Since there is no fixed reference position, it is not known where it is fixed. Therefore, it is not known where on the modeling plate 1 the modeled object 4 is modeled. Therefore, in this example, the fixed position of the actual modeling plate 1 in the modeling apparatus shown in FIG. 13A is measured by image processing. For example, the position of the modeling plate 1 is captured by an imaging camera and the position is recognized by image processing. Then, the parallel displacement amount (Δx, Δy) and the rotation angle (Δθ) with respect to the design modeling plate 1A are obtained, and the position of the modeling plate 1 is moved in the x, y, θ directions according to the measurement result. As shown in FIG. 13B, the modeling position of the modeled object 4 is matched with the actual modeling plate 1. Accordingly, the position of the modeling plate 1 is recognized by image processing, and the modeling position is determined according to the amount of positional deviation. Therefore, even if the modeling plate 1 is tilted, the modeling plate 1 is modeled at the original position. be able to. Further, in this example, the size of the modeling plate 1 may be the size of the required shape, and therefore, post-processing for cutting out to the required shape after forming on the larger modeling plate 1 is not necessary, greatly reducing the labor of the work. Furthermore, since it is not necessary to separately form the processing standard by modeling sintering, the modeling time can be further shortened. In addition, since the modeling position is moved according to the modeling plate 1, it is effective when the modeling plate 1 cannot be moved.
[0033]
FIG. 14 illustrates an example of a case where the fixed position of the modeling plate 1 is measured by the image processing apparatus, the positional deviation amount with respect to the modeling position of the modeling object 4 is obtained, and the position of the modeling plate 1 is moved according to the positional deviation amount. Show. In FIG. 14A, the actual fixed position of the modeling plate 1 is measured by image processing, and the parallel displacement (Δx, Δy) and the rotation angle (Δθ) with respect to the designed modeling plate 1A are obtained and measured. Based on the result, the modeling plate 1 is moved as shown in FIG. Thereby, the same effect as the embodiment of FIG. 13 can be obtained, and the modeling plate 1 is moved in accordance with the modeling position, which is effective when the modeling position cannot be moved.
[0034]
Next, a specific example in the case of obtaining the positional deviation amount of the modeling plate 1 by the image processing will be described. FIG. 15 shows an example in which the end face 1a of the actual modeling plate 1 is detected by the image processing apparatus and the amount of positional deviation with respect to the position of the modeling plate 1 that should be originally measured is measured. FIG. 15A shows a case where image processing is performed at least at two places on one side of the modeling plate 1 and the end face position is measured. The end face position is obtained by shading processing. FIGS. 15B and 15C show the light and dark levels with the detection line as the boundary. In this example, two measurement coordinates S1 (x1, y1) and S2 (x2, y2) having a distance L1 on one side of the modeling plate 1 and two positions having a distance L2 on the other side adjacent thereto are provided. In the measurement coordinates S3 (x3, y3) and S4 (x4, y4), the end face position is measured. Then, as shown in FIG. 15B, the straight line connecting the detection points P1, P2 and P3, P4 detected by the camera in the image processing regions S1 to S4 is extended, and the intersection of the extension lines N1, N2 is defined on the modeling plate 1. The end position coordinates are used, and the parallel position deviation amount (Δx, Δy) is obtained from the difference between the coordinate value and the position of the original modeling plate 1. Similarly, the inclination angle of the extension lines N1 and N2 and the original modeling plate should be obtained. The rotation angle (Δθ) is obtained from the difference between the angles of 1, and the position of the modeling plate 1 is corrected based on these parallel position shift amounts (Δx, Δy) and the rotation angle (Δθ). Accordingly, the end face 1a of the actual modeling plate 1 is detected by the image processing apparatus, the amount of positional deviation with respect to the position of the modeling plate 1 that should be originally measured is measured, and the position correction of the modeling plate 1 or the modeled object is performed according to the positional deviation amount. By correcting the modeling position 4, the same effect as that of the embodiment of FIG. 13 can be obtained, and the modeling position can be formed at the original position on the modeling plate 1.
[0035]
As another example, as shown in FIG. 16, four corners of the modeling plate 1 are set as image processing areas S, and image processing detection marks 9 are attached to the image processing areas S, and the positions of the marks 9 are determined by image processing. The amount of positional deviation may be detected by detection. As the image processing detection mark 9, for example, a small hole, a cross mark or the like is arbitrary, and by attaching these to predetermined positions of the modeling plate 1, for example, at the four corners of the modeling plate 1, a positional shift amount by the image processing can be reduced. Detection is easy.
[0036]
As another example, as shown in FIG. 17, the distance from the coordinate system origin of the surface removal mechanism 6 (FIG. 3) that performs the surface removal processing of the hardened layer in the middle of the modeling is known on the upper surface of the modeling tank 10. A positioning structure 11 serving as a fixing reference may be provided at the position, and the modeling plate 1 may be fixed in the modeling tank 10 according to the positioning structure 11. The positioning structure 11 may have either a straight shape shown in FIG. 17A or a pin shape shown in FIG. In any case, the positioning structure 11 is provided at positions U and V at which the distances W1 and W2 from the coordinate system origin Q of the surface removal mechanism 6 are known, and the modeling plate 1 is matched to the positioning structure 11. By fixing the position of the modeling plate 1, the position of the modeling plate 1 can be determined in the coordinate system of the surface removal mechanism 6, and if the modeling plate 1 is located, the modeling position of the modeling object 4 can be determined based on that position. The modeling position with respect to the modeling plate 1 can be set by adjusting. Therefore, positioning of the modeling plate 1 can be easily performed, and it is not necessary to separately model the modeled object 4 serving as a processing reference, and the modeling time can be shortened. When the positioning pin shown in FIG. 17B is used as the positioning structure 11, if the positioning pin is processed using the surface removing mechanism 6 provided in the modeling apparatus, the positioning pin is attached. Can be easily adjusted. Further, as shown in FIG. 18, when the modeling plate 1 is small, a parallel block 50 whose dimensions are known is placed between the positioning structure 11 and the modeling plate 1, and the positioning structure 11 is placed on the end surface 50 a of the parallel block 50. Positioning. Thereby, it becomes possible to know where the modeling plate 1 is located through the parallel block 50 whose dimensions are known, and the modeling position with respect to the modeling plate 1 can be easily set even when the modeling plate 1 is small.
[0037]
【The invention's effect】
As described above, in the first aspect of the present invention, a hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it. By further coating the metal powder layer on top and irradiating a predetermined portion of the metal powder layer with a light beam to form an upper hardened layer integrated with the lower hardened layer, and repeating the above sintering and lamination Three-dimensional shape modeling that manufactures a three-dimensional shape with a plurality of upper and lower hardened layers integrated, cuts the shaping plate into the required shape after shaping, and cuts out the required shape and the shaping plate integrally This is a manufacturing method of a product, and since a reference shape part that becomes a processing reference when cutting a molded product of the above-mentioned necessary shape and a modeling plate together is sintered simultaneously with the molded product, the molded product of the required shape after the completion of modeling And molding plate together At the time of extraction, the reference shape part formed with the modeled object can be used as the processing standard. Therefore, when the modeled object is not known where the modeled object is modeled, or the modeled object itself is the processing standard. Even if there is no straight end face, and even if there is no cutting process during the modeling process, it is possible to cut out the molded object of the required shape and the modeling plate integrally by post-processing. It is not necessary to accurately align the position of the modeling plate with the modeling position of the model before starting modeling, and the standard shape part that serves as the processing standard can be combined with the model. Sintering modeling can reduce modeling time.
[0038]
Moreover, in addition to the effect of Claim 1, since the invention of Claim 2 carries out the sintering shaping | molding of the said reference | standard shape part in the position different from a molded article, it is not restrained by the shape of a molded article, The reference shape portion serving as a reference can be independently shaped into an arbitrary shape.
[0039]
Moreover, in addition to the effect of Claim 2, since the invention of Claim 3 disperses | distributes and arrange | positions the said reference | standard shape part in multiple, since it is not necessary to carry out the sintering modeling of the big reference | standard shape part, modeling time is reduced. Can be shortened.
[0040]
In addition to the effect of claim 1, the invention according to claim 4 forms the reference shape part integrally with the modeled object, so that the modeled object itself has a processing standard, and an extra processing standard is provided. It is no longer necessary to form a model separately from the modeled object, and the modeling time can be shortened.
[0041]
In the invention of claim 5, a hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering, and a metal powder layer is further formed on the hardened layer. A plurality of upper and lower hardened layers are formed by repeating the above sintering and lamination by irradiating a predetermined portion of the metal powder layer with a light beam to form an upper hardened layer integrated with the lower hardened layer. It is equipped with a modeling process for manufacturing a modeled object having an integrated three-dimensional shape, and a surface removal process for removing the hardened layer surface into a desired shape is inserted in the middle of modeling, and the modeling plate is cut into a necessary shape after the modeling is completed. A manufacturing method of a three-dimensional shape object that cuts out a required shape object and a shape plate integrally, and the surface removal mechanism that performs the surface removal process of the hardened layer in the middle of the above shaping, the required shape cutting reference processing or modeling plate Because have a function to perform any of the processing reference marking, a reference shape portion serving as a working reference it is not necessary to separately form a sintered molding is eliminated, thereby shortening the molding time. Furthermore, when performing the cutting reference processing using the surface removal mechanism for performing the surface removal processing of the modeled object, there is no removal of the modeling plate, and the cutting process can be performed with high accuracy. In the case of marking, the shaped plate can be cut with high accuracy based on the marking using another device (for example, milling, wire cutting, etc.).
[0042]
The invention described in claim 6 performs marking as a processing reference on the modeling plate using the light beam irradiation mechanism for forming the cured layer, and after the modeling is completed, the modeling plate is moved along the marking by the cutting device. Since it cuts into a required shape, it is not necessary to separately provide an apparatus dedicated to marking, and the structure of the modeling apparatus can be simplified.
[0043]
The invention according to claim 7 forms a hardened layer by supplying a metal powder layer onto a modeling plate fixed in the modeling apparatus and irradiating a predetermined portion of the metal powder layer with a light beam to sinter. Then, a metal powder layer is further coated on the hardened layer, and a predetermined portion of the metal powder layer is irradiated with a light beam to form an upper hardened layer integrated with the lower hardened layer. It is a method of inserting a surface removal step of removing a hardened layer surface into a desired shape in the middle of modeling while manufacturing a three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating lamination. Before the modeling, the fixed position of the modeling plate is measured by the image processing apparatus to obtain the positional deviation amount between the modeling plate and the modeling position of the modeling object, and the modeling position is moved according to the positional deviation amount. Play modeling with processing By recognizing the position and moving the position to be shaped according to the amount of displacement, it can be shaped to the original position on the shaping plate, and the size of the shaping plate can be the size of the required shape Since it is not necessary to cut the modeling plate into the required shape in post-processing, and it is not necessary to form the processing standard by modeling sintering, the modeling time can be further shortened, and the modeling position can be adjusted to the fixed position of the modeling plate It is effective when the modeling plate cannot be moved by moving it.
[0044]
The invention according to claim 8 forms a hardened layer by supplying a metal powder layer onto a modeling plate fixed in the modeling apparatus and irradiating a predetermined portion of the metal powder layer with a light beam to sinter. Then, a metal powder layer is further coated on the hardened layer, and a predetermined portion of the metal powder layer is irradiated with a light beam to form an upper hardened layer integrated with the lower hardened layer. It is a method of inserting a surface removal step of removing a hardened layer surface into a desired shape in the middle of modeling while manufacturing a three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating lamination. Since the fixed position of the modeling plate is measured by the image processing apparatus before modeling, the positional deviation amount between the modeling plate and the modeling position of the modeling object is obtained, and the position of the modeling plate is moved according to the positional deviation amount. Using image processing Recognizes the position of the shaped plate and corrects the position of the shaping plate according to the amount of displacement, so it can be shaped to the original position on the shaping plate, and the size of the shaping plate is the size of the required shape Well, it is not necessary to cut the modeling plate into the required shape by post-processing, and it is not necessary to form the processing standard by modeling sintering, so the modeling time can be further shortened.
[0045]
In addition to the effect described in claim 7 or claim 8, the invention described in claim 9 detects the end face of the modeling plate by the image processing apparatus and measures the amount of positional deviation with respect to the position of the modeling plate that should be, Since the position of the modeling plate is corrected according to the positional deviation amount, the end surface of the modeling plate is detected using image processing, and the position correction of the modeling plate or the modeling position of the modeling object is performed according to the positional deviation amount. Thus, it is possible to make a model at the original position on the modeling plate.
[0046]
In addition to the effects of claim 7 or claim 8, the invention described in claim 10 is provided with a mark for image processing detection in advance on the modeling plate, and the mark position of the modeling plate is detected by image processing detection. Since the amount of positional deviation is detected, it is easy to detect the amount of positional deviation by image processing by placing image processing detection marks at predetermined positions on the modeling plate, for example, at the four corners of the modeling plate.
[0047]
According to the invention of claim 11, a hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it, and a metal powder layer is further formed on the hardened layer. A plurality of upper and lower hardened layers are formed by repeating the above sintering and lamination by irradiating a predetermined portion of the metal powder layer with a light beam to form an upper hardened layer integrated with the lower hardened layer. A manufacturing method of a three-dimensional shaped object in which a three-dimensional shaped object is manufactured, and a surface removal step for removing the surface of the cured layer into a desired shape is inserted in the middle of the object. A positioning structure serving as a fixed reference is provided at a position where the distance from the coordinate system origin of the surface removal mechanism for performing the surface removal processing of the hardened layer in the middle of the modeling is known, and the modeling plate is placed in accordance with the positioning structure Inside Since it is fixed, you can see where the modeling plate is in the coordinate system of the surface removal mechanism, and if you know where the modeling plate is, adjust the modeling position of the modeled object based on that position, and the modeling plate The modeling position with respect to can be set. As a result, positioning of the modeling plate can be easily performed, and by providing a positioning structure serving as a fixed reference using a modeling tank, there is no need to separately model a modeling object serving as a processing reference, thereby further increasing modeling time. Can be shortened.
[Brief description of the drawings]
FIG. 1A is a plan sectional view showing an example of an embodiment of the present invention, and FIG. 1B is a side sectional view.
FIG. 2 is an explanatory diagram when a necessary shape is cut out using the reference shape portion as above as a processing reference;
FIG. 3 is a schematic cross-sectional view of the modeling apparatus same as above.
FIGS. 4A to 4D are explanatory diagrams of the modeling process. FIG.
FIG. 5A is an explanatory diagram of another example of the reference shape portion, and FIG. 5B is an explanatory diagram of another example.
FIG. 6 is an explanatory diagram of still another example of the reference shape portion.
FIG. 7 is a plan cross-sectional view of an example when the reference shape portion is formed integrally with a modeled object.
8A is a cross-sectional plan view of another example in which the reference shape portion same as the above is integrally formed with a modeled object, and FIG. 8B is a side cross-sectional view.
FIG. 9 is an explanatory view when a necessary shape is cut out and subjected to reference processing using the surface removal mechanism same as above.
FIG. 10A is an explanatory view when marking a marking line using the surface removal mechanism same as the above, and FIG. 10B is an explanatory view when forming a processing reference hole.
FIG. 11 is an explanatory diagram when marking is performed by laser irradiation.
FIG. 12 is an explanatory diagram when there is no deviation between the fixed position of the modeling plate and the modeling position of the modeled object.
FIG. 13A is an explanatory diagram when there is a deviation between the fixed position of the modeling plate and the modeling position of the model, and FIG. 13B is an explanatory diagram after correcting the deviation by moving the modeling position. is there.
FIGS. 14A and 14B are explanatory diagrams in the case where there is a deviation between the fixing position of the modeling plate and the modeling position of the model, and FIG. 14B is an explanatory diagram after the deviation is corrected by moving the modeling plate. is there.
FIGS. 15A and 15B are explanatory diagrams when detecting a shift between the fixed position of the modeling plate and the modeling position of the modeling object by image processing, and FIG. 15C is an explanatory diagram of the brightness level of the detection line. It is.
FIG. 16A is an explanatory diagram when an image processing detection mark is provided on the above-described modeling plate, and FIG. 16B detects the center position of the image processing detection mark in the image processing area of FIG. It is explanatory drawing in the case.
17A is an explanatory diagram of an example when a positioning structure is provided at a predetermined position with respect to the coordinate system of the surface removal mechanism in the modeling tank, and FIG. 17B is an explanatory diagram of another example.
FIG. 18 is an explanatory diagram of another example of the positioning structure according to the embodiment.
FIG. 19 is a cross-sectional view illustrating a conventional method for producing a three-dimensional shaped object.
FIG. 20 is a cross-sectional view illustrating a state in which a part of a required shape of a conventional modeled object and a modeling plate is incorporated in a mold base as a mold part.
FIG. 21A is a plan view when the position of the conventional modeling plate and the position where the modeled object is formed are in a regular positional relationship, and FIG. 21B is a plan view when the positional relationship is shifted; (C) is a plan view in the case of modeling a modeled object on a large modeling plate, (d) is a plan view for explaining the case in which the modeled plate in (c) is cut into a required shape, and (e) is cut out in the modeled object. It is a top view explaining an example when there is no processing standard.
FIG. 22 is a plan view illustrating a relationship between a position where a conventional model is modeled and a position of a modeling plate.
23A is a cross-sectional view before cutting out a necessary shape, and FIG. 23B is a cross-sectional view after cutting out.
[Explanation of symbols]
1,1 'modeling plate
1a End face
2a Metal powder layer
3 Hardened layer
4 Modeled objects
5 Reference shape part
6 Surface removal mechanism
9 Image processing detection mark
10 Modeling tank
11 Positioning structure
L Light beam
Q origin of coordinate system
W1, W2 Distance from the coordinate system origin
U, V Position of positioning structure

Claims

A hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it, and further coating the metal powder layer on the hardened layer to form a predetermined metal powder layer. A three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating the above-described sintering and lamination by forming an upper hardened layer that is integrated with the lower hardened layer by irradiating a portion with a light beam. A manufacturing method of a three-dimensional shaped article that manufactures a shaped article, cuts the shaping plate into a necessary shape after the shaping is finished, and integrally cuts the shaped article and the shaping plate of the necessary shape, and A method for producing a three-dimensional shaped article characterized by sintering and shaping a reference shape portion as a processing reference when cutting a shaping plate integrally with a shaped article.

The method for producing a three-dimensional shaped object according to claim 1, wherein the reference shape part is formed by sintering at a position different from the shaped object.

3. The method for manufacturing a three-dimensional shaped object according to claim 2, wherein the reference shape portion is dispersed and arranged.

The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the reference shape part is formed integrally with the shaped object.

A hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it, and further coating the metal powder layer on the hardened layer to form a predetermined metal powder layer. A three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating the above-described sintering and lamination by forming an upper hardened layer that is integrated with the lower hardened layer by irradiating a portion with a light beam. A modeling process for manufacturing a modeled object is provided, and a surface removal process for removing the hardened layer surface into a desired shape is inserted in the middle of modeling, and after the modeling is completed, the modeled plate is cut into a required shape, Is a manufacturing method of a three-dimensional shaped object that is integrally cut out, and the surface removal mechanism that performs surface removal processing of the hardened layer in the middle of the modeling is a markin that serves as a reference processing for cutting a required shape or a processing reference to a modeling plate Method for producing a three-dimensionally shaped object, characterized in that have a function of performing either.

A hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it, and further coating the metal powder layer on the hardened layer to form a predetermined metal powder layer. A three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating the above-described sintering and lamination by forming an upper hardened layer that is integrated with the lower hardened layer by irradiating a portion with a light beam. A manufacturing method of a three-dimensional modeled object comprising a modeling process for manufacturing a modeled object, cutting the modeling plate into a necessary shape after the modeling is completed, and integrally cutting out the modeled object and the modeling plate of the necessary shape, A marking serving as a processing reference is performed on the modeling plate using a light beam irradiation mechanism for forming, and the modeling plate is cut into a necessary shape by a cutting device along the marking after the modeling is completed. Method of manufacturing dimensional shaped object.

A metal powder layer is supplied onto a modeling plate fixed in the modeling apparatus, and a hardened layer is formed by irradiating a predetermined portion of the metal powder layer with a light beam and sintering, and further on the hardened layer. A metal powder layer is coated, and a predetermined portion of the metal powder layer is irradiated with a light beam to form an upper hardened layer that is integrated with the lower hardened layer. An image processing apparatus that manufactures a three-dimensional shape integrated with a hardened layer and inserts a surface removal step that removes the surface of the hardened layer into a desired shape in the middle of modeling, and before image formation Manufacturing a three-dimensional shaped object characterized by measuring the fixed position of the modeling plate to determine the amount of positional deviation between the modeling plate and the modeling position of the modeled object, and moving the modeling position according to the amount of positional deviation Method.

A metal powder layer is supplied onto a modeling plate fixed in the modeling apparatus, and a hardened layer is formed by irradiating a predetermined portion of the metal powder layer with a light beam and sintering, and further on the hardened layer. A metal powder layer is coated, and a predetermined portion of the metal powder layer is irradiated with a light beam to form an upper hardened layer that is integrated with the lower hardened layer. An image processing apparatus that manufactures a three-dimensional shape integrated with a hardened layer and inserts a surface removal step that removes the surface of the hardened layer into a desired shape in the middle of modeling, and before image formation A three-dimensional shaped object characterized by measuring a fixed position of the modeling plate by calculating a positional deviation amount between the modeling plate and the modeling position of the modeling object, and moving the position of the modeling plate according to the positional deviation amount. Manufacturing method.

The position of the modeling plate is corrected according to the amount of positional deviation, by detecting an end face of the modeling plate by an image processing apparatus, measuring a positional shift amount with respect to a position of the original modeling plate. Item 9. A method for producing a three-dimensional shaped object according to Item 8.

The three-dimensional shape according to claim 7 or 8, wherein a mark for image processing detection is attached to the modeling plate in advance, and the position shift amount of the modeling plate is detected by detecting the mark processing by image processing. Manufacturing method of a model.

A hardened layer is formed by irradiating a predetermined portion of the metal powder layer supplied on the modeling plate with a light beam and sintering it, and further coating the metal powder layer on the hardened layer to form a predetermined metal powder layer. A three-dimensional shape in which a plurality of upper and lower hardened layers are integrated by repeating the above-described sintering and lamination by forming an upper hardened layer that is integrated with the lower hardened layer by irradiating a portion with a light beam. A method for producing a three-dimensional shaped object in which a surface removal step for removing the surface of the hardened layer in a desired shape is inserted in the middle of manufacturing the shaped object, and removing the surface of the hardened layer in the middle of the modeling on the upper surface of the modeling tank A positioning structure serving as a fixing reference is provided at a position where the distance from the coordinate system origin of the surface removal mechanism for processing is known, and the modeling plate is fixed in the modeling tank according to the positioning structure. three Manufacturing method of the original shaped object.