JP6022493B2 - Stereolithography method, stereolithography apparatus, and generation program - Google Patents

Description

  The present invention relates to an optical modeling method, an optical modeling apparatus, and a generation program.

  An optical modeling apparatus that irradiates a photocurable material with a light beam and cures a part thereof to model a three-dimensional shape has been put into practical use (see, for example, Patent Document 1). This stereolithography apparatus can easily materialize mechanical parts designed by a CAD system. Design confirmation and direct evaluation can be performed by the shaped object.

  The optical modeling apparatus calculates the slice data in the vertical direction from the CAD data of the three-dimensional shape object, and forms the three-dimensional shape object by modeling one by one from the bottom according to the slice data.

  The optical modeling apparatus includes an elevating table that can be moved up and down in a liquid tank filled with a liquid photocurable resin as a photocurable material. The upper part of the liquid tank is open, and light is irradiated from the upper part. When modeling a three-dimensional object, the optical modeling apparatus first positions the lifting table at a height lowered from the liquid surface of the liquid photocurable resin by the thickness of the lowest layer. The stereolithography apparatus stabilizes the liquid surface by moving the recoater along the liquid surface. In this state, the optical modeling apparatus scans the light beam within a necessary range by the scanner, and photocures the lowermost layer. Next, the optical modeling apparatus lowers the lifting table by the thickness of the second layer from the lowermost layer, and similarly photocures the second layer. Thereafter, the optical modeling apparatus similarly models a three-dimensional shape by photocuring one layer at a time from the bottom.

JP 2011-218821 A

  By the way, in an optical modeling apparatus, as FIG. 5 shows, the three-dimensional shaped object which has a bridge | crosslinking structure may be modeled. The bridge structure is a structure in which the bridge girder part 121 is bridged to the abutment parts 122 and 123 stacked in the vertical direction. As shown in FIG. 6, when each layer of the three-dimensional shape having a cross-linked structure is cured, the layer may be deformed by contraction at the cross-linked portion between the abutment parts 122 and 123 and the bridge girder part 121. For this reason, the optical modeling method, the optical modeling apparatus, and production | generation program which suppress the deformation | transformation at the time of hardening of each layer of the three-dimensional shaped object which has a crosslinked structure are calculated | required.

  In addition, instead of the stippling method for curing the photocurable material by moving it while irradiating the light beam, a common problem is also present in the surface exposure method optical modeling method and the optical modeling device in which the photocurable material is cured by surface exposure. There is.

  The present invention has been made in view of such circumstances, and an object thereof is to provide an optical modeling method, an optical modeling apparatus, and a generation program that suppress deformation during curing of each layer of a three-dimensional shape having a crosslinked structure. There is to do.

Hereinafter, means for achieving the above-described problems and the effects thereof will be described.
An optical modeling method for solving the above-described problem is an optical modeling method for modeling a three-dimensional object by selectively irradiating light to a photocurable material to cure the photocurable material one by one. When forming a three-dimensional shape having a bridge structure in which the bridge girder is connected, a gap is formed in a part of the connection between the abutment and the bridge girder, and the gap is the same layer that is stacked. The gist is to form in the depth direction, which is perpendicular to the stacking direction of the bridge girder portion and along the abutment portion .

  According to the said method, when modeling the three-dimensional shaped object which has a bridge structure, a clearance gap is formed in a part of connection part of an abutment part and a bridge girder part. For this reason, even when shrinkage | contraction generate | occur | produces with hardening of each layer when modeling the three-dimensional shaped object which has a crosslinked structure, shrinkage | contraction is suppressed by a clearance gap. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed.

About the said optical modeling method, it is preferable to form the said clearance gap at intervals in the lamination direction.
According to the above method, the gap is formed at an interval in the stacking direction. For this reason, since the gap is formed at intervals while the deformation of each layer of the three-dimensional shape having a crosslinked structure is suppressed by the gap, the gap can be formed and the strength can be increased.

About the said optical modeling method, it is preferable to form the said gap over the said depth direction.

  According to the said method, a clearance gap is formed over the depth direction of the bridge girder part in the same layer laminated | stacked. The same layer of the bridge girder is deformed by contraction in the depth direction when the layers are cured. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed.

About the said optical modeling method, it is preferable to form the said clearance gap in the part on the extension line extended in the lamination direction from the angle | corner formed by the said abutment part and the said bridge girder part.
According to the above method, the gap is formed in a part on the extension line of the corner in the stacking direction of the corner formed by the abutment portion and the bridge girder portion. The extension line of the corner in the stacking direction of the corner formed by the abutment portion and the bridge girder portion is significantly deformed by the shrinkage at the time of curing of each layer. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can further be suppressed.

About the said optical modeling method, it is preferable to form the said clearance gap in at least one of the layer containing the uppermost surface of the said bridge girder part, and the layer containing the lowermost surface.
According to the above method, the gap is formed in at least one of the layer including the uppermost surface of the bridge girder and the layer including the lowermost surface. The uppermost surface and the lowermost surface, which are the connection portions between the abutment portion and the bridge girder portion, are significantly deformed by the shrinkage during curing of each layer. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can further be suppressed.

About the said optical modeling method, the said light is a light beam, Comprising: It is preferable to form the said clearance gap larger than the hardening width | variety which the said photocurable material hardens | cures by irradiation of the said light beam.
According to the said method, a clearance gap is formed larger than the hardening width | variety which a photocurable material hardens | cures by irradiation of a light ray. For this reason, it can fully suppress that contraction is transmitted when a modeling thing contracts. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed further.

The gist of a stereolithography apparatus that solves the above-described problems includes a control unit that performs the stereolithography method.
According to the said structure, when modeling the three-dimensional shaped object which has a bridge structure, a clearance gap is formed in a part of connection part of an abutment part and a bridge girder part. For this reason, even if shrinkage | contraction generate | occur | produces in a molded article at the time of hardening of each layer of the three-dimensional shape object which has a crosslinked structure, shrinkage | contraction is suppressed by a clearance gap. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed.

The generation program that solves the above-described problem is a data that is used for stereolithography for modeling a three-dimensional object by selectively irradiating light to a photocurable material and curing the photocurable material layer by layer by a control unit. A generating program for generating the control unit, based on design data of a three-dimensional shape object having a bridge structure in which the abutment part and the bridge girder part are connected to each other of the connection part between the abutment part and the bridge girder part. The gap is generated in the depth direction, which is perpendicular to the stacking direction of the bridge girder in the same layer to be stacked and is along the abutment. It is said.

  According to the said structure, in the case of the three-dimensional shaped object which has a bridge structure, a clearance gap is produced | generated in a part of connection part of an abutment part and a bridge girder part. For this reason, even if shrinkage | contraction generate | occur | produces with hardening of each layer at the time of hardening of each layer of a three-dimensional shaped object, shrinkage | contraction is suppressed by a clearance gap. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed. In addition, since a gap is generated when data is generated, processing can be simplified.

  ADVANTAGE OF THE INVENTION According to this invention, the deformation | transformation at the time of hardening of each layer of the three-dimensional shaped object which has a crosslinked structure can be suppressed.

The figure which shows schematic structure of an optical modeling apparatus. The perspective view which shows the three-dimensional shaped object which has a bridge | crosslinking structure. The figure which shows the slice data of the bridge | crosslinking part of the three-dimensional shape thing which has a bridge | crosslinking structure. The figure which shows the slice data of the bridge | crosslinking part of the three-dimensional shape thing which has a bridge | crosslinking structure. The front view which shows the three-dimensional shaped object which has a bridge | crosslinking structure. The front view which shows the deformation | transformation after modeling in the three-dimensional shaped object which has the conventional bridge | crosslinking structure.

Hereinafter, an embodiment of an optical modeling method, an optical modeling apparatus, and a generation program will be described with reference to FIGS.
As shown in FIG. 1, the stereolithography apparatus includes a liquid tank 11 filled with a liquid photocurable resin as a photocurable material, a laser 12 that emits a light beam, and a light beam emitted from the laser 12. And a scanner 13 for irradiating the tank 11. The light beam emitted from the laser 12 is incident on the scanner 13 through the optical system device. The optical modeling apparatus includes an elevating table 15 that can be moved up and down in the liquid tank 11. The lifting table 15 is moved up and down by the table driving device 16. Above the liquid tank 11, a recoater 17 for adjusting the liquid level is installed. The recoater 17 is moved in the front-rear direction (left-right direction in the figure) by the recoater driving device 18. The laser 12, the scanner 13, the table driving device 16, and the recoater driving device 18 are controlled by the control device 10.

  The stereolithography apparatus calculates slice data obtained by dividing the three-dimensional shape object in the vertical direction from CAD data (design data) of the three-dimensional shape object. And an optical modeling apparatus models the modeling thing S of a three-dimensional shaped object by modeling one by one in order from the bottom according to slice data.

  When modeling a three-dimensional object, the optical modeling apparatus first positions the lifting table 15 at a height lowered from the liquid surface of the liquid photocurable resin by the thickness of the lowermost layer. Then, the optical modeling apparatus stabilizes the liquid level by moving the recoater 17 along the liquid level. In this state, the optical modeling apparatus scans the light beam within a necessary range by the scanner 13 and photocures the lowermost layer. Next, the stereolithography apparatus lowers the lifting table 15 by the thickness of the second layer from the lowermost layer, and similarly photocures the second layer. Thereafter, the optical modeling apparatus similarly models a three-dimensional shape by photocuring one layer at a time from the bottom.

Next, with reference to FIG. 2 to FIG. 4, slice data used when modeling a three-dimensional object having a bridge structure in which an abutment part and a bridge girder part are connected will be described.
As shown in FIG. 2, a case where a three-dimensional object having an H shape in front view is modeled will be described here. The H-shaped three-dimensional object has a plate-like bridge girder part 21 and two abutment parts 22 and 23 connected to the bridge girder part 21. That is, the H-shaped three-dimensional shape has a crosslinked structure. The abutment parts 22 and 23 are plate-shaped, and are located facing each other. The bridge girder portion 21 is plate-shaped and is bridged to the opposed surfaces of the abutment portions 22 and 23. The three-dimensional shape is modeled by photocuring one layer at a time from the bottom by an optical modeling apparatus.

  When the three-dimensional object has a cross-linking structure, the control device 10 that is a control unit of the optical modeling apparatus forms a gap in the three-dimensional object when calculating slice data. The control apparatus 10 of the optical modeling apparatus stores a generation program that functions as a conversion unit that generates a gap. The control device 10 forms a gap in a part of the connection part 25 where the bridge girder part 21 and the abutment parts 22 and 23 are connected. A clearance gap is formed in the depth direction of the bridge girder part 21 in the same layer laminated | stacked. The depth direction of the bridge girder 21 is a direction perpendicular to the stacking direction and along the abutment portions 22 and 23. The gap is formed at an interval in the stacking direction. The gap is formed in a part on the extension line P extending in the stacking direction from the corner 26 formed by the bridge girder 21 and the abutment parts 22 and 23. The gap is formed in the layer including the uppermost surface and the layer including the lowermost surface of the bridge girder 21.

  As illustrated in FIG. 3, the slice data 30 a of the layer having the gap 24 is data of a shape in which the frame 31 that is the outline of the layer and the modeling portion 32 that is divided by the gap 24 are combined. The modeling part 32 includes a first modeling part 32 a that becomes the bridge girder part 21 and a second modeling part that becomes the abutment part 22 by the gap 24 positioned in the connection part 25 where the bridge girder part 21 and each abutment part 22, 23 connect. 32b and the 3rd modeling part 32c used as the abutment part 23 are provided. The width W of the gap 24 is formed to be larger than the curing width at which the curable resin is cured by the light beam (laser light) emitted from the laser 12. The gap 24 of each layer is shaped into a shape closed by a frame 31. For this reason, the designability can be maintained without irregularities appearing on the surface of the modeled object.

  As shown in FIG. 4, the slice data 30 of the bridge girder 21 includes slice data 30 a of a layer having a gap 24 and slice data 30 b of a layer having no gap 24. The slice data 30a of the layer having the gap 24 and the slice data 30b of the layer not having the gap 24 are alternately formed for each layer. The slice data 30 includes contour line data that is corrected so that the size of the three-dimensional shaped object that is formed matches the design data. The gap 24 is generated when generating the contour line data.

  A layer below the layer including the lowermost surface of the bridge girder 21 is an n layer. Since the n layer is only the abutment portions 22 and 23, the n layer is a layer including the modeling portion 34 that does not have the first modeling portion 32 a that becomes the bridge girder portion 21. The (n + 1) layer is a layer including the lowermost surface of the bridge girder 21 and has a gap 24. Each clearance gap 24 is formed in the abutment part 22 and 23 side by using the boundary line B which connected the extension line P as an edge. The (n + 2) layer is a layer composed of the modeling portion 33 that does not have the gap 24. The (n + 3) layer is a layer composed of the modeling part 32 having the gap 24. The (n + 4) layer is a layer composed of the modeling portion 33 that does not have the gap 24. The (n + 5) layer is a layer composed of the modeling part 32 having the gap 24. The (n + 6) layer is a layer composed of the modeling portion 33 that does not have the gap 24. Henceforth, the layer containing the bridge girder part 21 is formed similarly. The layer including the uppermost surface of the bridge girder 21 has a gap 24 in the same manner as the layer including the lowermost surface.

  Now, when a stereolithography apparatus models a three-dimensional shape based on the above slice data, a gap 24 is formed in the connection part 25 between the bridge girder part 21 and the abutment parts 22, 23, so that each layer can be cured. Even if contraction occurs, deformation at the cross-linked portion can be suppressed. This is because only the portion connected to the bridge girder portion 21 of the abutment portions 22 and 23 at the time of hardening of each layer has a contracting force toward the bridge girder portion 21 side. Deform. The shrinkage includes heat shrinkage due to laser light irradiation or heat of polymerization reaction, and curing shrinkage due to the fact that the density of the solid is smaller than the density of the liquid when the liquid resin changes to a solid. Therefore, the deformation in the bridge girder 21 is suppressed by dividing the shrinkage by the gap 24. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional shaped object which has a bridge | crosslinking structure can be suppressed, and it becomes a molded article without a deformation | transformation like FIG.

As described above, according to the embodiment described above, the following effects can be obtained.
(1) When forming a three-dimensional shape having a cross-linked structure, a gap 24 is formed in a part of the connection portion 25 between the abutment portions 22 and 23 and the bridge girder portion 21. For this reason, even when shrinkage occurs as each layer is cured when a three-dimensional shape having a crosslinked structure is formed, the shrinkage is suppressed by the gap 24. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed.

  (2) The gap 24 is formed at an interval in the stacking direction. For this reason, since the gap 24 is formed at an interval while suppressing the deformation of each layer of the three-dimensionally shaped article having a crosslinked structure at the time of curing, the strength can be increased.

  (3) A gap 24 is formed across the depth direction of the bridge girder portion 21 in the same layer to be laminated. The same layer of the bridge girder 21 is deformed by shrinkage in the same way when the layers are cured in the depth direction. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed.

  (4) The gap 24 is formed in a part on the extension line of the corner 26 in the stacking direction of the corner 26 formed by the abutment portions 22 and 23 and the bridge girder portion 21. The extension line of the corner 26 in the stacking direction of the corner 26 formed by the abutment portions 22 and 23 and the bridge girder portion 21 is remarkably deformed by contraction at the time of curing of each layer. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can further be suppressed.

  (5) The gap 24 is formed in at least one of the layer including the uppermost surface and the layer including the lowermost surface of the bridge girder 21. The uppermost surface and the lowermost surface, which are the connection portions between the abutment portions 22 and 23 and the bridge girder portion 21, are significantly deformed by the shrinkage at the time of curing of each layer. For this reason, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can further be suppressed.

  (6) The gap 24 is formed larger than the diameter of the irradiated laser beam. For this reason, it can fully suppress that contraction is transmitted when a modeling thing contracts. Therefore, the deformation | transformation at the time of hardening of each layer of the three-dimensional-shaped thing which has a crosslinked structure can be suppressed further.

In addition, the said embodiment can be implemented with the following forms which changed this suitably.
In the above embodiment, the slice data and the contour line data are generated using the control device 10 as the control unit, but at least one of the slice data and the contour line data may be generated using an external device different from the optical modeling apparatus as the control unit. Good.

In the above embodiment, the gap 24 is generated when generating the contour line data. However, the gap 24 may be generated when generating the slice data.
In the above embodiment, the width W of the gap 24 is made larger than the curing width at which the photocurable material is cured by the laser light irradiation. However, as long as the deformation can be suppressed, the width may be smaller than the curing width at which the photocurable material is cured by the irradiation of the laser beam.

  In the above embodiment, the gap 24 is formed in the layer including the uppermost surface and the layer including the lowermost surface of the bridge girder portion 21, but only one of them may be used. Further, the gap 24 may not be formed in any layer.

  In the above embodiment, the gaps 24 are formed on the abutment portions 22 and 23 side with the boundary line B connecting the extension line P as an edge. However, each gap 24 may be formed on the bridge girder 21 side with the boundary line B connecting the extension lines P as an edge. Further, the position of the gap 24 may be anywhere as long as it is a connection part 25 between the bridge girder part 21 and the abutment parts 22 and 23.

  In the above embodiment, the gap 24 of the connection portion 25 with respect to the abutment portions 22 and 23 is formed in the same layer. However, you may form the clearance gap 24 of the connection part 25 with respect to each abutment part 22 and 23 in a different layer.

-In the said embodiment, the clearance gap 24 was formed over the depth direction of the bridge girder part 21 in the same layer. However, the gap 24 may be divided in the same layer.
In the above embodiment, layers having gaps 24 and layers not having gaps 24 are alternately formed. However, the layer having the gap 24 and the layer having no gap 24 may be arranged for each of a plurality of layers, and the layer having the gap 24 and the layer having no gap 24 may be arranged irregularly.

  In the above embodiment, the bridge structure having the abutment portions 22 and 23 protruding from the upper surface of the bridge girder portion 21 has been described. However, the same effect can be obtained in a bridge structure having an abutment that does not protrude from the upper surface of the bridge girder 21.

  In the embodiment described above, the present invention is applied to a stippling stereolithography apparatus that cures a photocurable material with light rays. However, the present invention may be applied to a surface exposure type optical modeling apparatus that cures a photocurable material by surface exposure instead of a stippling type optical modeling apparatus. The surface exposure type stereolithography apparatus uses, as a light source, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a low pressure mercury lamp, or other lamps or LEDs that emit light other than laser light. The surface exposure type stereolithography apparatus is a liquid crystal drawing mask in which a large number of micro liquid crystal shutters capable of shielding and transmitting light in a micro dot area are arranged between a light source and a photo molding resin molding surface, or A planar drawing mask in which a plurality of digital micromirror shutters are arranged in a planar shape is arranged. The surface exposure type stereolithography apparatus irradiates light on the modeling surface of the photocurable resin through a planar drawing mask and sequentially laminates a photocurable resin layer having a predetermined cross-sectional shape pattern to form a three-dimensional object. Model.

    DESCRIPTION OF SYMBOLS 10 ... Control apparatus, 11 ... Liquid tank, 12 ... Laser, 13 ... Scanner, 15 ... Lifting table, 16 ... Table drive device, 17 ... Recoater, 18 ... Recoater drive device, 21 ... Bridge girder part, 22, 23 ... Abutment part , 24 ... gap, 25 ... connection part, 26 ... corner, 30, 30a, 30b ... slice data, 31 ... frame, 32, 33, 34 ... modeling part, 32a ... first modeling part, 32b ... second modeling part, 32c ... 3rd modeling part, B ... Boundary line, P ... Extension line, S ... Modeling thing, W ... Width.

Claims (8)

In the optical modeling method of modeling a three-dimensional shape by selectively irradiating light to the photocurable material and curing the photocurable material one by one,
When forming a three-dimensional shape having a bridge structure in which the abutment part and the bridge girder part are connected, a gap is formed in a part of the connection part between the abutment part and the bridge girder part ,
The stereolithography method , wherein the gap is formed in a depth direction which is perpendicular to the stacking direction of the bridge girder portion in the same layer to be stacked and is along the abutment portion . The stereolithography method according to claim 1,
The gap is formed with an interval in the stacking direction. In the optical modeling method according to claim 1 or 2,
The said gap is formed over the said depth direction. The optical modeling method characterized by the above-mentioned . In the optical modeling method as described in any one of Claims 1-3,
The said gap is formed in a part on the extension line extended in the lamination direction from the angle | corner formed by the said abutment part and the said bridge girder part. The optical modeling method characterized by the above-mentioned. In the optical modeling method as described in any one of Claims 1-4,
The gap is formed in at least one of a layer including the uppermost surface and a layer including the lowermost surface of the bridge girder. In the optical modeling method as described in any one of Claims 1-5,
The light is a light beam,
The said space is formed larger than the hardening width | variety which the said photocurable material hardens | cures by irradiation of the said light ray. The optical modeling method characterized by the above-mentioned. An optical modeling apparatus comprising: a control unit that performs the optical modeling method according to claim 1. A generation program that generates data to be used for optical modeling for modeling a three-dimensional shape by selectively irradiating light to a photocurable material and curing the photocurable material one layer at a time,
The control unit is a conversion unit that generates a gap in a part of a connection part between the abutment part and the bridge girder part based on design data of a three-dimensional shape object having a bridge structure in which the abutment part and the bridge girder part are connected. to function as,
The said clearance gap is produced | generated in the depth direction which is orthogonal to the lamination direction of the said bridge girder part in the same layer laminated | stacked, and is a direction along the said abutment part .

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