JP4792905B2 - Manufacturing method of three-dimensional shaped object - Google Patents

Manufacturing method of three-dimensional shaped object Download PDF

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JP4792905B2
JP4792905B2 JP2005294793A JP2005294793A JP4792905B2 JP 4792905 B2 JP4792905 B2 JP 4792905B2 JP 2005294793 A JP2005294793 A JP 2005294793A JP 2005294793 A JP2005294793 A JP 2005294793A JP 4792905 B2 JP4792905 B2 JP 4792905B2
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modeling
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material supply
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JP2007100199A (en
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知実 田中
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Panasonic Corp
Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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Description

本発明は、３次元形状造形物の製造方法に関し、詳しくは光ビームを利用して金属粉末を層状に連続的に硬化させて３次元形状造形物を製造する３次元形状造形物の製造方法に関するものである。   The present invention relates to a method for manufacturing a three-dimensional shaped object, and more particularly, to a method for manufacturing a three-dimensional shaped object that uses a light beam to continuously cure a metal powder in a layer shape to produce a three-dimensional shaped object. Is.

従来の無機質粉末材料、例えば金属粉末に対して光ビーム、例えば指向性エネルギービームやレーザを照射して金属粉末を硬化させ、硬化層を積層させることにより３次元形状造形物を製造する方法について、図２を用いて説明する。   About a method for producing a three-dimensional shaped object by irradiating a conventional inorganic powder material, for example, a metal powder with a light beam, for example, a directional energy beam or a laser to cure the metal powder and laminating a cured layer, This will be described with reference to FIG.

図２は、従来の３次元形状造形物の製造方法を示す模式的断面図である。   FIG. 2 is a schematic cross-sectional view showing a conventional method for producing a three-dimensional shaped object.

図２において、１は金属粉末などの無機質粉末材料であり、２は金属粉末１に対して光ビームを照射して硬化させた硬化層である。３は金属粉末１を保持する材料保持部、４は硬化層２を形成する造形部であり、５は材料保持部３に保持されている金属粉末１を上下させる材料昇降部、６は造形部４にて造形された硬化層２を上下させる造形昇降部である。７は造形昇降部６に載置された造形台であり、造形台７の上に硬化層２を複数積層することにより３次元形状造形物が造形される。８は材料供給手段であり、材料保持部３に保持された金属粉末１を造形部４に供給する。   In FIG. 2, 1 is an inorganic powder material such as metal powder, and 2 is a cured layer obtained by irradiating the metal powder 1 with a light beam and curing it. 3 is a material holding unit that holds the metal powder 1, 4 is a modeling unit that forms the hardened layer 2, 5 is a material lifting unit that moves the metal powder 1 held up and down by the material holding unit 3, and 6 is a modeling unit 4 is a modeling lifting unit that moves up and down the hardened layer 2 modeled in 4. 7 is a modeling table placed on the modeling lifting unit 6, and a three-dimensional modeled object is modeled by laminating a plurality of hardened layers 2 on the modeling table 7. 8 is a material supply means for supplying the metal powder 1 held by the material holding unit 3 to the modeling unit 4.

従来の３次元形状造形物の製造方法は、まず、図２（ａ）に示すように、造形昇降部６を所定の高さ下げることにより硬化層２または造形台７の上面を造形部４の上端より下に位置させ、材料昇降部５を所定の高さ上げることにより金属粉末１を材料保持部３の上端より上に位置させる。   As shown in FIG. 2 (a), the conventional method for producing a three-dimensional modeled object is to lower the modeling elevating unit 6 to a predetermined height so that the upper surface of the cured layer 2 or the modeling table 7 is formed on the modeling unit 4. The metal powder 1 is positioned above the upper end of the material holding unit 3 by being positioned below the upper end and raising the material elevating unit 5 to a predetermined height.

次に、図２（ｂ）に示すように、材料供給手段８を材料保持部３の造形部４と反対側の外側から造形部４の材料保持部３と反対側の外側まで水平移動させる。材料供給手段８は材料保持部３および造形部４の内幅よりも長い板状体であり、材料供給手段８を水平移動させることにより、材料保持部３の上端より上に位置している金属粉末１を押し動かして造形部４に移送する。このとき、金属粉末１は材料供給手段８により均され、造形部４で薄い層状に堆積される。   Next, as shown in FIG. 2B, the material supply unit 8 is horizontally moved from the outside of the material holding unit 3 on the side opposite to the modeling unit 4 to the outside of the modeling unit 4 on the side opposite to the material holding unit 3. The material supply unit 8 is a plate-like body that is longer than the inner width of the material holding unit 3 and the modeling unit 4, and the metal positioned above the upper end of the material holding unit 3 by moving the material supply unit 8 horizontally. The powder 1 is pushed and moved to the modeling unit 4. At this time, the metal powder 1 is leveled by the material supply means 8 and is deposited in a thin layer shape at the modeling portion 4.

次に、図２（ｃ）に示すように、造形部４の上方から造形部４に供給された金属粉末１に対して光ビーム９を照射することにより金属粉末１を硬化させて硬化層２を形成する。この光ビーム９を照射している間または光ビーム９の照射が完了した後、材料供給手段８は、材料保持部３の造形部４と反対側の外側に移動させる。また、材料保持部３では、材料昇降部５を所定の高さ上げることにより金属粉末１を材料保持部３の上端より上に位置させる。   Next, as shown in FIG. 2 (c), the metal powder 1 is cured by irradiating the metal powder 1 supplied to the modeling unit 4 from above the modeling unit 4 by irradiating the light beam 9. Form. During the irradiation of the light beam 9 or after the irradiation of the light beam 9 is completed, the material supply unit 8 is moved to the outside of the material holding unit 3 on the side opposite to the modeling unit 4. Further, in the material holding unit 3, the metal powder 1 is positioned above the upper end of the material holding unit 3 by raising the material elevating unit 5 to a predetermined height.

以上の工程を複数回繰り返すことにより、造形部４の造形台７上に硬化層２が複数積層された３次元形状造形物を製造していた（例えば、特許文献１参照）。
特開２００１−１５０５５７号公報 By repeating the above steps a plurality of times, a three-dimensional shaped object in which a plurality of hardened layers 2 are stacked on the modeling table 7 of the modeling unit 4 has been manufactured (for example, see Patent Document 1).
JP 2001-150557 A

上記に示したような従来の方法では、金属粉末１を硬化させる際の金属粉末１の燃焼や材料の偏在、光ビーム９の照射エネルギーの時間的空間的な不均一さ等によって、硬化層２が想定よりも高く造形部４の上端より突出して形成されてしまう場合があった。その際、材料供給部８が造形部４の上を水平に移動するのみであるため、材料供給手段８と硬化層２の造形部４の上端より突出した部分とが干渉してしまい、材料供給手段８の進行方向と平行な方向の長さが短く、造形昇降部６の昇降方向と平行な方向の長さが長い３次元形状造形物は押し倒されてしまうため、３次元形状造形物が正しく形成できなくなるという課題があった。   In the conventional method as described above, the hardened layer 2 is caused by combustion of the metal powder 1 when the metal powder 1 is hardened, uneven distribution of the material, temporal and spatial nonuniformity of the irradiation energy of the light beam 9, or the like. May be formed to protrude from the upper end of the modeling part 4 higher than expected. At that time, since the material supply unit 8 only moves horizontally on the modeling unit 4, the material supply unit 8 interferes with the portion protruding from the upper end of the modeling unit 4 of the hardened layer 2, thereby supplying the material. Since the three-dimensional shaped object whose length in the direction parallel to the traveling direction of the means 8 is short and whose length in the direction parallel to the ascending / descending direction of the modeling lift 6 is long is pushed down, the three-dimensional shaped object is correct. There was a problem that it could not be formed.

上記課題を解決するために本発明は、材料保持部に保持された粉末材料の表層を材料供給手段の板状体で水平移動して造形部の上に供給し、前記供給された粉末材料に対して光ビームを照射して前記粉末材料を硬化させて硬化層を形成することを、複数回繰り返して硬化層が複数積層された３次元形状造形物を製造する方法であって、前記材料供給手段は前記板状体を回転させる回転機構を備え、前記硬化層上に突起を有する状態で前記板状体が前記粉末材料を前記造形部の上に供給する際に、前記突起に前記板状体が接触した時には前記回転機構により前記板状体が回転し一時的に退避させながら前記材料供給手段を移動させることを特徴とする。この構成により、硬化層が想定よりも高く造形部の上端より突出して形成されてしまった場合にも、材料供給手段が硬化層の造形部の上端よりも突出した部分と干渉して３次元形状造形物を押し倒してしまうことを回避することが可能となり、３次元形状造形物が正しく形成することが可能となる。 In order to solve the above-described problems, the present invention provides a method in which the surface layer of the powder material held in the material holding unit is horizontally moved by the plate-like body of the material supply unit and supplied onto the modeling unit. forming a cured layer by curing the logger powder material prior to irradiating the light beam for a method of producing a three-dimensional shaped object hardened layers are stacked by repeating a plurality of times, the The material supply means includes a rotation mechanism for rotating the plate-like body, and the plate-like body supplies the powder material onto the modeling portion in a state having the protrusion on the hardened layer. When the plate-like body comes in contact, the material supply means is moved while the plate-like body is rotated by the rotating mechanism and temporarily retracted. With this configuration , even when the hardened layer is formed higher than expected and protrudes from the upper end of the modeling part, the material supply means interferes with the part protruding from the upper end of the modeling part of the hardened layer, and the three-dimensional shape It is possible to avoid pushing down the modeled object, and a three-dimensional modeled model can be formed correctly.

本発明によれば、材料供給手段の進行方向と平行な方向の長さが短く、造形昇降部の昇降方向と平行な方向の長さが長い３次元形状造形物を製造することが可能となる。特に、造形昇降部の昇降方向と平行な方向の長さが、材料供給手段の進行方向と平行な方向の長さの３倍以上である３次元形状造形物を製造することが可能となる。   According to the present invention, it is possible to manufacture a three-dimensional shaped object having a short length in a direction parallel to the traveling direction of the material supply means and a long length in a direction parallel to the ascending / descending direction of the modeling lift unit. . In particular, it is possible to manufacture a three-dimensional shaped object in which the length in the direction parallel to the ascending / descending direction of the modeling ascending / descending unit is at least three times the length in the direction parallel to the traveling direction of the material supply means.

本発明の一実施の形態について、図１を用いて説明する。   An embodiment of the present invention will be described with reference to FIG.

図１は、本発明の一実施の形態における３次元形状造形物の製造方法を示す模式的断面図である。図１において、図２と同一物については同一番号を付して詳細な説明は省略する。   FIG. 1 is a schematic cross-sectional view showing a method for manufacturing a three-dimensional shaped object in one embodiment of the present invention. In FIG. 1, the same components as those in FIG.

図１において、１０は金属粉末１を造形部４に押し動かして移送する際に、予め設定された力以上の力を受けた時に力を受け流す機構を有する材料供給手段であり、１１は金属粉末１を硬化させる際の金属粉末１の燃焼や材料の偏在、光ビーム９の照射エネルギーの時間的空間的な不均一さ等によって、硬化層２が想定よりも高く造形部４の上端より突出して形成されてしまった突起である。   In FIG. 1, reference numeral 10 denotes a material supply means having a mechanism for receiving a force when the metal powder 1 is pushed and moved to the modeling part 4 and receives a force greater than a preset force, and 11 is a metal powder. The hardened layer 2 protrudes from the upper end of the modeling part 4 higher than expected due to the burning of the metal powder 1 when hardening 1 and the uneven distribution of the material and the temporal and spatial non-uniformity of the irradiation energy of the light beam 9. It is a protrusion that has been formed.

本発明の一実施の形態における３次元形状造形物の製造方法は、まず、図１（ａ）に示すように、造形昇降部６を所定の高さ下げることにより硬化層２または造形台７の上面を造形部４の上端より下に位置させ、材料昇降部５を所定の高さ上げることにより金属粉末１を材料保持部３の上端より上に位置させる。   In the method for manufacturing a three-dimensional shaped object in one embodiment of the present invention, first, as shown in FIG. The metal powder 1 is positioned above the upper end of the material holding unit 3 by positioning the upper surface below the upper end of the modeling unit 4 and raising the material elevating unit 5 by a predetermined height.

次に、図１（ｂ）に示すように、材料供給手段１０を材料保持部３の造形部４と反対側の外側から造形部４に向かって水平移動させる。材料供給手段１０は材料保持部３および造形部４の内幅よりも長い板状体であり、材料供給手段１０を水平移動させることにより、材料保持部３の上端より上に位置している金属粉末１を押し動かして造形部４に移送する。   Next, as shown in FIG. 1B, the material supply unit 10 is moved horizontally from the outside of the material holding unit 3 on the side opposite to the modeling unit 4 toward the modeling unit 4. The material supply unit 10 is a plate-like body that is longer than the inner width of the material holding unit 3 and the modeling unit 4, and a metal positioned above the upper end of the material holding unit 3 by horizontally moving the material supply unit 10. The powder 1 is pushed and moved to the modeling unit 4.

図１（ｃ）は、材料供給手段１０が突起１１の存在する位置にさしかかった状態を示す。図１（ｃ）に示すように、材料供給手段１０が突起１１の存在する位置にさしかかった時には、材料供給手段１０は、通常の金属粉末１を移送する際にかかる力以上の力を受けることになる。このとき、材料供給手段１０は予め設定された力以上の力を受けた時に力を受け流す機構、例えば回転機構により一時的に退避させることで、材料供給手段１０と突起１１との干渉を回避する。ここでは、材料供給手段１０の退避を回転機構により回転させて行ったが、直線移動機構を用いて、上方あるいは斜め上方に退避させてもよい。   FIG. 1C shows a state in which the material supply unit 10 is approaching the position where the protrusion 11 is present. As shown in FIG. 1 (c), when the material supply means 10 reaches the position where the projections 11 are present, the material supply means 10 receives a force greater than the force applied when the normal metal powder 1 is transferred. become. At this time, the material supply means 10 avoids the interference between the material supply means 10 and the protrusion 11 by temporarily retracting by a mechanism for receiving a force when receiving a force greater than a preset force, for example, a rotation mechanism. . Here, the material supply unit 10 is retracted by rotating the rotating mechanism. However, the material supplying unit 10 may be retracted upward or obliquely upward using a linear moving mechanism.

ここで、具体的な本発明の一実施例としは、材料保持部３の上方から見た面の大きさは、２５０ｍｍ×２５０ｍｍであり、金属粉末１を供給するために材料昇降部５が上昇する距離は０．５ｍｍ程度である。この場合、移送される金属粉末１の容積は、３１，２５０ｍｍ3となり、金属粉末１は平均粒径２０μｍの鉄粉を使用しているため、移送される金属粉末１の重量は約２５０ｇとなる。重量約２５０ｇの金属粉末１を移送する際に材料供給手段１０に通常かかる力としては、金属粉末１の重量の２〜３倍程度となるため、５〜８Ｎの力がかかることとなる。従って、本実施例では、材料供給手段１０を１０Ｎの張力で支持することにより、材料供給手段１０を通常の姿勢に保持させている。そして、予め設定された材料供給手段１０を支持する張力以上の力がかかった際には、材料供給手段１０を一時的に退避させている。 Here, as one specific embodiment of the present invention, the size of the surface of the material holding unit 3 viewed from above is 250 mm × 250 mm, and the material lifting unit 5 is raised to supply the metal powder 1. The distance is about 0.5 mm. In this case, the volume of the metal powder 1 to be transferred is 31,250 mm 3 , and the metal powder 1 uses iron powder having an average particle diameter of 20 μm, so the weight of the metal powder 1 to be transferred is about 250 g. . The force normally applied to the material supply means 10 when transferring the metal powder 1 having a weight of about 250 g is about 2 to 3 times the weight of the metal powder 1, and therefore a force of 5 to 8 N is applied. Therefore, in this embodiment, the material supply means 10 is held in a normal posture by supporting the material supply means 10 with a tension of 10N. And when the force more than the tension | tensile_strength which supports the preset material supply means 10 is applied, the material supply means 10 is temporarily retracted.

次に、図１（ｄ）に示すように、材料供給手段１０が突起１１の存在する位置を通過した後、元の姿勢に復帰し、造形部４の材料保持部３と反対側の外側まで移動して材料供給を完了する。このとき、金属粉末１は材料供給手段１０により均され、造形部４で薄い層状に堆積される。   Next, as shown in FIG. 1 (d), after the material supply means 10 passes through the position where the protrusion 11 exists, it returns to its original posture and reaches the outside of the modeling portion 4 on the side opposite to the material holding portion 3. Move to complete the material supply. At this time, the metal powder 1 is leveled by the material supply means 10 and is deposited in a thin layer shape at the modeling portion 4.

次に、従来と同様に、造形部４の上方から造形部４に供給された金属粉末１に対して光ビーム９を照射することにより金属粉末１を硬化させて硬化層２を形成する。この光ビーム９を照射している間または光ビーム９の照射が完了した後、材料供給手段１０は、材料保持部３の造形部４と反対側の外側に移動させる。また、材料保持部３では、材料昇降部５を所定の高さ上げることにより金属粉末１を材料保持部３の上端より上に位置させる。   Next, as in the prior art, the metal powder 1 is cured by irradiating the metal powder 1 supplied to the modeling unit 4 from above the modeling unit 4 to form the cured layer 2. During the irradiation of the light beam 9 or after the irradiation of the light beam 9 is completed, the material supply means 10 is moved to the outside of the material holding unit 3 on the side opposite to the modeling unit 4. Further, in the material holding unit 3, the metal powder 1 is positioned above the upper end of the material holding unit 3 by raising the material elevating unit 5 to a predetermined height.

以上の工程を複数回繰り返すことにより、造形部４の造形台７上に硬化層２が複数積層された３次元形状造形物が製造される。   By repeating the above steps a plurality of times, a three-dimensional shaped object in which a plurality of hardened layers 2 are stacked on the modeling table 7 of the modeling unit 4 is manufactured.

以上のように本発明の一実施の形態によれば、材料供給手段１０の進行方向と平行な方向の長さが短く、造形昇降部６の昇降方向と平行な方向の長さが長い３次元形状造形物を製造することが可能となる。特に、造形昇降部６の昇降方向と平行な方向の長さが、材料供給手段１０の進行方向と平行な方向の長さの３倍以上である３次元形状造形物を製造することが可能となる。   As described above, according to the embodiment of the present invention, the length in the direction parallel to the traveling direction of the material supply unit 10 is short, and the length in the direction parallel to the lifting direction of the modeling lifting unit 6 is long three-dimensional. A shaped object can be manufactured. In particular, it is possible to produce a three-dimensional shaped object in which the length in the direction parallel to the ascending / descending direction of the modeling elevator unit 6 is three times or more the length in the direction parallel to the traveling direction of the material supply means 10. Become.

なお、本発明の一実施の形態においては、材料供給手段１０が材料保持部３および造形部４の内幅よりも長い板状体を用いたが、板状体を複数に分割した構成としてもよい。また、材料供給手段１０が予め設定された力以上の力を受けた時に力を受け流す機構として回転機構を用いたが、直線移動機構でもよく、さらに材料供給手段１０が予め設定された力以上の力を受けた時に屈曲する弾性体や薄板を用いてもよい。   In the embodiment of the present invention, the material supply unit 10 uses a plate-like body that is longer than the inner width of the material holding unit 3 and the modeling unit 4, but the plate-like body may be divided into a plurality of parts. Good. In addition, the rotation mechanism is used as a mechanism for receiving a force when the material supply unit 10 receives a force greater than a preset force. However, a linear movement mechanism may be used, and the material supply unit 10 may exceed the preset force. An elastic body or a thin plate that bends when receiving a force may be used.

また、材料供給手段は複数の線状部材から構成され、予め設定された力以上の力を受けた時に力を受けた部分が造形部の水平面内で退避するようにしてもよい。   Further, the material supply means may be composed of a plurality of linear members, and the portion that receives the force when receiving a force greater than a preset force may be retracted within the horizontal plane of the modeling portion.

本発明の３次元形状造形物の製造方法および製造装置は、複雑な形状を有する射出成形金型の金型部品の製造や金属製モックアップモデルの製作等の用途にも適用できる。   The method and apparatus for producing a three-dimensional shaped object of the present invention can also be applied to uses such as the production of a mold part of an injection mold having a complicated shape and the production of a metal mockup model.

本発明の実施の形態における３次元形状造形物の製造方法を示す模式的断面図Typical sectional drawing which shows the manufacturing method of the three-dimensional shape molded article in embodiment of this invention 従来の３次元形状造形物の製造方法を示す模式的断面図Typical sectional drawing which shows the manufacturing method of the conventional three-dimensional shape molded article

符号の説明Explanation of symbols

１ 金属粉末
２ 硬化層
３ 材料保持部
４ 造形部
５ 材料昇降部
６ 造形昇降部
７ 造形台
１０ 材料供給手段
１１ 突起 DESCRIPTION OF SYMBOLS 1 Metal powder 2 Hardened layer 3 Material holding part 4 Modeling part 5 Material raising / lowering part 6 Modeling raising / lowering part 7 Modeling table 10 Material supply means 11 Protrusion

Claims (2)

材料保持部に保持された粉末材料の表層を材料供給手段の板状体で水平移動して造形部の上に供給し、前記供給された粉末材料に対して光ビームを照射して前記粉末材料を硬化させて硬化層を形成することを、複数回繰り返して硬化層が複数積層された３次元形状造形物を製造する方法であって、
前記材料供給手段は前記板状体を回転させる回転機構を備え、
前記硬化層上に突起を有する状態で前記板状体が前記粉末材料を前記造形部の上に供給する際に、前記突起に前記板状体が接触した時には前記回転機構により前記板状体が回転し一時的に退避させながら前記材料供給手段を移動させる
ことを特徴とする３次元形状造形物の製造方法。 The surface layer of the powder material held in the material holding part is horizontally moved by the plate-like body of the material supply means and supplied onto the modeling part, and the supplied powder material is irradiated with a light beam, and the powder material Is a method for producing a three-dimensional shaped object in which a plurality of cured layers are laminated by repeating a plurality of times to form a cured layer,
The material supply means includes a rotation mechanism for rotating the plate-like body,
When the plate-like body supplies the powder material onto the modeling portion with the protrusions on the hardened layer, the plate-like body is moved by the rotating mechanism when the plate-like body comes into contact with the protrusions. A method for producing a three-dimensional shaped object, wherein the material supply means is moved while rotating and temporarily retracting. 前記板状体は、複数に分割した構成であることを特徴とする請求項１記載の３次元形状造形物の製造方法。   The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the plate-like body has a structure divided into a plurality of parts.
JP2005294793A 2005-10-07 2005-10-07 Manufacturing method of three-dimensional shaped object Expired - Fee Related JP4792905B2 (en)

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