JP6707812B2 - Additive manufacturing apparatus and additive manufacturing method - Google Patents

Description

The present invention relates to a layered modeling technique for layering layers to model a three-dimensional structure.

A method for dividing a three-dimensional CAD (Computer Aided Design) data into layers and adding a material to each divided layer so that a layer is stacked on the layer to manufacture a three-dimensional structure is defined as an additive manufacturing in the international standard. ing. This manufacturing method invented in the 1980s is generally called a 3D printer (three-dimensional printer). 3D printers have been attracting attention as a new manufacturing method in recent years because they can easily manufacture complicated shapes without using a mold if they have three-dimensional CAD data.

The 3D printer can easily and accurately manufacture shapes that were once difficult to manufacture, such as mesh shapes and porous shapes, unlike the removal processing by cutting or the molding processing in which a material is poured into a mold to be solidified. Furthermore, it is also expected to enable modeling in which a plurality of types of materials are freely arranged in the same layer. This is because a three-dimensional structure having a new function that takes advantage of the characteristics of each material can be realized by modeling using a plurality of materials.

For example, a composite of a conductive material and an insulating material realizes a three-dimensional structure having a function of an electronic circuit. In addition, by combining a hard material and a flexible material, a three-dimensional structure having a function that achieves both strength and flexibility is realized. And these functions can be realized without developing a new material.

JP, 2005-131938, A JP 2007-21747 A

However, when molding multiple materials in the same layer, due to the difference in melting point of each material, when melting and solidifying the material with high melting point, the adjacent material with low melting point remelts. As a result, there is a problem that the target shape cannot be obtained accurately.

As a method for solving this problem, Patent Document 1 discloses a method of cooling a modeling portion during modeling. According to this method, a cooling gas is blown to the surface of the resin being cured to cool the resin surface during stereolithography, thereby reducing the local temperature rise due to the heat of curing generated by the photocuring reaction. As a result, it is said that the surface temperature of the cured resin surface can be kept uniform and modeling with less warpage and deformation can be achieved. However, in this method, since the entire surface of the cured resin is cooled, the material with a high melting point is heated, while the material with a low melting point is partially cooled, and the modeling is performed while actively maintaining the temperature difference in the modeling surface. You cannot do it. Therefore, a plurality of materials having different melting points cannot be formed in the same layer.

Another method of cooling a modeled portion during modeling is disclosed in Patent Document 2. According to this method, one thin layer is selectively heated and sintered, and a refrigerant is flown on the surface or cooled for each sintered one thin layer or each sintered plural thin layer. The plate is cooled by bringing it into contact with the plate or rolling a cooled roller. This makes it possible to reduce the time required for modeling and the time until the completed modeled article is taken out, while maintaining low internal stress between the thin layers. However, this method enables cooling of the entire layer, but modeling is performed while actively making a temperature difference in the modeling surface, such as heating some parts while cooling some parts in the same layer. I can't. Therefore, a plurality of materials having different melting points cannot be formed in the same layer.

The present invention has been made in view of the above problems, and an object thereof is a layered manufacturing apparatus that stacks layers to manufacture a three-dimensional structure, and a plurality of materials having different melting points can be accurately placed in the same layer. It is to be able to model well.

A layered manufacturing apparatus according to the present invention is a layered manufacturing apparatus that stacks layers to model a three-dimensional structure, wherein each of a first material, a second material, and a third material is placed at a predetermined position in the layer. And a heating unit that heats the second material when supplying the second material, the material supply unit having a melting point of the first material and the melting point of the first material. The third material having a melting point between the melting point of the second material and the melting point of the second material is supplied to a position sandwiched between the first material and the second material.

A layered manufacturing method according to the present invention is a layered manufacturing method in which layers are stacked to form a three-dimensional structure, and a first material is supplied to a predetermined position of the first material in the layer, A material is heated and supplied to a predetermined position of the second material in the layer, and a third material having a melting point between the melting point of the first material and the melting point of the second material, The material is supplied to a position sandwiched between the first material and the second material.

According to the present invention, in a layered modeling apparatus that stacks layers to manufacture a three-dimensional structure, it is possible to accurately model a plurality of materials having different melting points in the same layer.

It is a figure which shows the structure of the additive manufacturing apparatus of the 1st Embodiment of this invention. It is a figure which shows the structure of the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining the specific form which models a three-dimensional-shaped model with the additive manufacturing apparatus of the 2nd Embodiment of this invention. It is a figure explaining another concrete form which models a three-dimensional geometric model with the layered modeling device of a 2nd embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the embodiments described below have technically preferable limitations for implementing the present invention, but the scope of the invention is not limited to the following.
(First embodiment)
FIG. 1 is a diagram showing a configuration of a layered modeling apparatus according to a first embodiment of the present invention. The layered modeling apparatus 1 of the present embodiment is a layered modeling apparatus that stacks layers to model a three-dimensional structure, and uses the first material, the second material, and the third material in predetermined layers in the layer. The material supply part 2 which supplies to a position, and the heating part 3 which heats a 2nd material at the time of supplying at least a 2nd material are included. Further, the material supply unit 2 supplies a third material having a melting point between the melting point of the first material and the melting point of the second material to a position sandwiched between the first material and the second material. To do.

The additive manufacturing method of the present embodiment is the additive manufacturing method in which layers are stacked to form a three-dimensional structure, and the first material is supplied to a predetermined position of the first material in the layer, and the second material is supplied. Is heated and supplied to a predetermined position of the second material in the layer, and the third material having a melting point between the melting point of the first material and the melting point of the second material is referred to as the first material. It is supplied to a position sandwiched by the second material.

According to this embodiment, in a layered modeling apparatus that stacks layers to manufacture a three-dimensional structure, it is possible to accurately model a plurality of materials having different melting points in the same layer.
(Second embodiment)
FIG. 2 is a diagram showing a configuration of a layered modeling apparatus according to a second embodiment of the present invention. The layered modeling apparatus 10 according to the present embodiment models the first material, the second material, and the third material at predetermined positions of the respective materials within the same modeling layer, and stacks the modeling layers to form 3 layers. It has a modeling stage 50 for modeling a three-dimensional shape model (three-dimensional structure).

Further, a first material supply unit 21 that supplies the first material, a second material supply unit 22 that supplies the second material, and a third material are supplied to predetermined positions in the modeling layer. And a third material supply unit 23. Further, a first heating unit 31 that heats the first material when supplying the first material, and a second heating unit 32 that heats the second material when supplying the second material, And a third heating unit 33 that heats the third material when supplying the third material.

Further, it has a control unit 40 which is connected to the above-mentioned material supply unit and heating unit and which controls the supply amount, supply position, supply timing, heating temperature, etc. of each material regarding the modeling of the three-dimensional shape model. The control unit 40 can be realized by operating an information processing device such as a server with a program.

At the predetermined position of each material in the modeling layer, the predetermined position of the third material is sandwiched between the predetermined position of the first material and the predetermined position of the second material. The third material supply unit 23 supplies the third material to a position sandwiched between a predetermined position of the first material and a predetermined position of the second material.

The third heating unit 33 heats at a heating temperature between the heating temperature of the first heating unit 31 and the heating temperature of the second heating unit 32. The heating temperature of the second heating unit 32 is higher than the heating temperature of the first heating unit 31. The melting point of the third material has a melting point between the melting point of the first material and the melting point of the second material. The melting point of the second material is higher than the melting point of the first material.

In the additive manufacturing apparatus 10, first, the first material is supplied to a predetermined position of the first material in the modeling layer. Next, the third material is supplied to a predetermined position sandwiched between the predetermined position of the first material and the predetermined position of the second material. Next, the second material is supplied to the predetermined position of the second material.

In the layered modeling apparatus 10, the first heating unit 31 can heat the first material when supplying the first material. When the third material is supplied, the third heating unit 33 can heat the third material. When supplying the second material, the second heating unit 32 can heat the second material. In the above heating of the material, the second heating section 32 may heat the second material at least when the second material is supplied.

In addition, in the layered modeling apparatus 10, the first material supply unit 21, the second material supply unit 22, and the third material supply unit 23 are individually provided for each material, but the present invention is not limited to this. That is, for example, the first material supply unit 21 can also serve as the second material supply unit 22 or the third material supply unit 23. In this case, the 1st material supply part 21 changes the position which supplies the material in a modeling layer for every material.

In addition, in the layered modeling apparatus 10, the first heating unit 31, the second heating unit 32, and the third heating unit 33 are individually provided for each material, but the present invention is not limited to this. That is, for example, the first heating unit 31 can also serve as the second heating unit 32 or the third heating unit 33. In this case, the first heating unit 31 changes the heating temperature for each material.

In the additive manufacturing apparatus 10, when the second material having a high melting point is molded in the modeling layer, it is possible to avoid the heated second material from directly contacting the first material having a low melting point. Since the heated second material comes into contact with the third material having a higher melting point than the first material, during the shaping of the second material, the heating of the second material to the first material is prevented. The impact can be mitigated. Therefore, it is possible to suppress deformation of the shape due to heating during modeling.

Below, the concrete form of the material supply part and the heating part of the additive manufacturing apparatus 10 of this embodiment is demonstrated. In this description, it is assumed that a 3D geometric model having a function of an electronic circuit is manufactured as the 3D geometric model. Therefore, although the first material, the second material, and the third material corresponding thereto are used, the present embodiment is not limited to this.

FIG. 3 is a diagram illustrating a specific form of modeling a three-dimensional shape model by the additive manufacturing apparatus 10. In FIG. 3, a material supply pipe 201 having an opening for introducing the material and an opening for supplying the material to the modeling layer is shown as the material supply unit. Further, a heater 301 embedded in the material supply pipe 201 is shown as a heating unit. The material introduced into the material supply pipe 201 is melted by the heating of the heater 301 and supplied from the opening toward the modeling layer.

Although FIG. 3 shows one set of the material supply pipe 201 and the heater 301, a set of the material supply pipe 201 and the heater 301 can be provided for each material. Further, with a set of the material supply pipe 201 and the heater 301, the supply position in the modeling layer and the heating temperature can be changed for each material.

In FIG. 3, the three-dimensional shape model has a structure part of the first material, a structure part of the second material, and a structure part of the third material. Within the modeling layer, the structure of the third material is sandwiched between the structure of the first material and the structure of the second material. Therefore, the first material and the second material are not in direct contact with each other. Further, it is possible to prevent the first material and the second material from directly contacting each other even between adjacent modeling layers. A three-dimensional shape model can be completed by stacking modeling layers.

The first material is a dielectric, and plastic is a typical material. Specific examples thereof include, but are not limited to, ABS (Acrylonitrile Butadiene Styrene), polycarbonate, polyimide, polylactic acid, acrylic, polyetherimide, polyphenyl sulfone, nylon, polyethylene, silicone, and epoxy.

As a method of forming the first material, a method classified by ASTM (American Society for Testing and Materials) as an additive manufacturing method can be used. For example, a material that heats the material supply pipe 201 with the heater 301 and melts the first material, extrudes it from the opening of the material supply pipe 201, and deposits a predetermined amount on the modeling region of the first material in the modeling layer An extrusion method (Material extrusion) is possible. Further, as another method, a material jetting method (Material jetting) in which a droplet of the melted first material is jetted from the opening of the material supply pipe 201 and is deposited in a predetermined modeling region is possible.

The first material can be modeled by supplying a heated and melted material in a predetermined amount at a predetermined position and curing it by air cooling if it is a thermoplastic resin. Further, in the case of a thermosetting or photocurable resin, a droplet of the material is jetted and supplied, and if the thermosetting resin is heated, it is heated, and if it is a photocurable resin, it is irradiated with ultraviolet rays to be cured. Can be shaped.

The second material is a conductor. Specific examples thereof include, but are not limited to, copper, silver, and aluminum. The melting point of these second materials is higher than the melting point of the first material.

As a method of modeling the second material, the second material melted by heating the material supply pipe 201 with the heater 301 is extruded from the opening of the material supply pipe 201, and a modeling region of the second material in the modeling layer is formed. A method of depositing a predetermined amount on the substrate is possible. When the second material is supplied to the material supply pipe 201, the second material may be processed into a shape such as a powder, a filler, or a linear shape that easily melts. Alternatively, the second material may be mixed with a substance that is vaporized at the time of melting to form a paste.

Since the melting point of the second material is higher than that of the other materials, heating at a high temperature is required for shaping the second material. Therefore, as another method of forming the second material, from the method classified by ASTM as the method of Additive Manufacturing, the directed energy deposition method in which the material is melt-bonded by concentrating the heat energy while supplying the material. (Directed energy deposition) can also be used. As a method of concentrating the thermal energy, the method of FIG. 4 described later can be mentioned.

The third material can be a dielectric or a conductor. The third material is selected from materials having a melting point higher than that of the first material and lower than that of the second material. For example, when the first material is ABS and the second material is copper, the third material can be polycarbonate or polyimide. Like the first material and the second material, the third material becomes a molten state by passing through the material supply pipe 201 heated by the heater 301, and is supplied in a predetermined amount to the third modeling area and cured. It is modeled by doing.

Next, the operation of the embodiment shown in FIG. 3 will be described. In FIG. 3, it is assumed that the modeling layer is modeled in the process of forming the three-dimensional model.

First, a predetermined amount of the first material is supplied to a modeling region of the first material, which is a predetermined position in the modeling layer. The first material cures in the shaped area of the first material.

Subsequently, a predetermined amount of the third material is supplied to a modeling region of the third material, which is a predetermined position in the modeling layer. The modeling region of the third material is a region sandwiched between the modeling region of the first material and the modeling region of the second material. The third material cures in the build area of the third material.

Then, a predetermined amount of the second material is supplied to a modeling region of the second material, which is a predetermined position in the modeling layer. The second material cures in the shaped area of the second material.

When the modeling layer having the first material, the second material, and the third material is formed as described above, in order to further form the next modeling layer on the formed modeling layer, The above operation is repeated. By repeating this operation, the three-dimensional shape model is completed.

The three-dimensional shape model of FIG. 3 has a function of an electronic circuit. That is, it is possible to obtain a wiring structure in which the structure part of the first material, which is the insulating part, is penetrated by the structure part of the second material, which is the conductive part. Here, the structure part of the third material can be a conductive part or an insulating part depending on the selection of the material.

FIG. 4 is a diagram illustrating another specific mode in which a three-dimensional shape model is formed by the additive manufacturing apparatus 10 of the present embodiment. FIG. 4 shows a method of assisting modeling by irradiating laser light from the laser irradiation device 302 when each material is supplied to each modeling region. By irradiating with a laser beam, for example, melting of a material having a high melting point can be promoted, or the fluidity of the material in the modeling layer can be increased to improve the flatness of the modeling layer. As the laser irradiation device 302, a fiber laser or the like used in Additive Manufacturing can be used.

The material supply unit may be the material supply pipe 201 incorporating the heater 301 shown in FIG. The three-dimensional shape model is the same as the three-dimensional shape model shown in FIG.

Since the melting point of the second material is higher than that of the other materials, heating of the second material requires heating at a high temperature. Irradiation with laser light is effective for heating at this high temperature. That is, the second material supplied to the predetermined position is heated by the irradiation of the laser light to accelerate the melting. This improves, for example, the flatness. After that, the irradiation of the laser light is ended, and thus the second material is cured.

Next, the operation of the embodiment shown in FIG. 4 will be described. In FIG. 4, the modeling layer is modeled in the process of forming the three-dimensional model.

First, a predetermined amount of the first material is supplied to a modeling region of the first material, which is a predetermined position in the modeling layer. At this time, the supplied first material can be irradiated with laser light to promote planarization, for example. The first material is then cured in the shaped area of the first material.

Subsequently, a predetermined amount of the third material is supplied to a modeling region of the third material, which is a predetermined position in the modeling layer. The modeling region of the third material is a region sandwiched between the modeling region of the first material and the modeling region of the second material. At this time, the supplied third material can be irradiated with laser light to promote planarization, for example. The third material is then cured in the build area of the third material.

Then, a predetermined amount of the second material is supplied to a modeling region of the second material, which is a predetermined position in the modeling layer. At this time, the supplied second material can be irradiated with laser light to promote planarization, for example. Thereafter, the second material cures in the build area of the second material.

When the modeling layer having the first material, the second material, and the third material is formed as described above, in order to further form the next modeling layer on the formed modeling layer, The above operation is repeated. By repeating this operation, the three-dimensional shape model is completed.

As described above, in the layered modeling apparatus 10 of the present embodiment, when the second material having a high melting point is molded in the modeling layer, the heated second material directly contacts the first material having a low melting point. You can avoid doing. Since the heated second material comes into contact with the third material having a higher melting point than the first material, during the shaping of the second material, the heating of the second material to the first material is prevented. The impact can be mitigated. Therefore, it is possible to suppress deformation of the shape due to heating during modeling.

In the above description, the first material having a low melting point, the third material having a medium melting point, and the second material having a high melting point are sequentially formed in the same molding layer. Is not limited. That is, the fact that the second material having a high melting point is in direct contact with the first material having a low melting point is not in the same modeling layer or the adjacent modeling layers, and thus the influence of heating during modeling of the second material is caused. Are relaxed by the inclusion of the third material. Therefore, according to the present embodiment, it is possible to suppress the deformation of the shape due to the heating during modeling regardless of the order of modeling the material.

Note that the materials forming the three-dimensional shape model are not limited to the three types of the first material, the second material, and the third material, and a plurality of materials can be used. Further, it is possible to provide a material supply section and a heating section corresponding to these plural materials.

As described above, according to this embodiment, in a layered manufacturing apparatus that stacks layers to manufacture a three-dimensional structure, it is possible to accurately form a plurality of materials having different melting points in the same layer. ..

The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the invention described in the claims, and these are also included in the scope of the present invention.

The whole or part of the exemplary embodiments disclosed above can be described as, but not limited to, the following supplementary notes.

Appendix (Appendix 1)
In a layered modeling apparatus that stacks layers to model a three-dimensional structure, a material supply unit that supplies each of a first material, a second material, and a third material to a predetermined position in the layer, A heating unit that heats the second material at least when the second material is supplied, and the material supply unit has a melting point of the first material and a melting point of the second material. An additive manufacturing apparatus that supplies the third material having a melting point between them to a position sandwiched between the first material and the second material.
(Appendix 2)
The material supply unit includes a first material supply unit that supplies a first material, a second material supply unit that supplies a second material, and a third material supply unit that supplies a third material. The additive manufacturing apparatus according to appendix 1, further comprising:
(Appendix 3)
The heating unit heats the first material when supplying the first material, and the second heating unit heats the second material when supplying the second material. And a third heating unit that heats the third material when supplying the third material, wherein the third heating unit heats the first heating unit. The additive manufacturing apparatus according to appendix 1 or 2, wherein heating is performed at a heating temperature between a temperature and a heating temperature of the second heating unit.
(Appendix 4)
The additive manufacturing apparatus according to appendix 3, wherein a heating temperature of the second heating unit is higher than a heating temperature of the first heating unit.
(Appendix 5)
The additive manufacturing apparatus according to any one of appendices 1 to 4, wherein the melting point of the second material is higher than the melting point of the first material.
(Appendix 6)
The additive manufacturing apparatus according to any one of appendices 1 to 5, wherein the first material has a dielectric and the second material has a conductor.
(Appendix 7)
7. The additive manufacturing apparatus according to any one of appendices 1 to 6, wherein the material supply unit and the heating unit are integrated.
(Appendix 8)
The additive manufacturing apparatus according to any one of appendices 1 to 7, wherein the heating unit heats with a laser beam.
(Appendix 9)
In a layered manufacturing method for stacking layers to form a three-dimensional structure, a first material is supplied to a predetermined position of the first material in the layer, and a second material is supplied to the first layer in the layer. The second material is heated to a predetermined position and supplied, and a third material having a melting point between the melting point of the first material and the melting point of the second material is added to the first material and the third material. A layered manufacturing method in which the material is supplied to a position sandwiched between the two materials.
(Appendix 10)
10. The additive manufacturing method according to appendix 9, wherein the third material is heated to a temperature between the first material and the second material and supplied.
(Appendix 11)
11. The additive manufacturing method according to appendix 9 or 10, wherein the heating temperature of the second material is higher than the heating temperature of the first material.
(Appendix 12)
The additive manufacturing method according to any one of appendices 9 to 11, wherein the melting point of the second material is higher than the melting point of the first material.
(Appendix 13)
13. The additive manufacturing method according to any one of appendices 9 to 12, wherein the first material has a dielectric and the second material has a conductor.

1, 10 Additive manufacturing apparatus 2 Material supply unit 3 Heating unit 21 First material supply unit 22 Second material supply unit 23 Third material supply unit 31 First heating unit 32 Second heating unit 33 Third Heating unit 40 Control unit 50 Modeling stage 201 Material supply pipe 301 Heater 302 Laser irradiation device

Claims (6)

In a layered manufacturing method for stacking layers to form a three-dimensional structure,
Providing a first material at a predetermined location of the first material within the layer;
The second material is heated and supplied to a position in the layer that is not in direct contact with the first material,
A third material having a melting point between the melting point of the first material and the melting point of the second material,
Supplying to a position sandwiched between the first material and the second material,
Additive manufacturing method. Said third material, the first material and supplies heated to a temperature between the second material, layered manufacturing method of claim 1, wherein. The additive manufacturing method according to claim 1, wherein the heating temperature of the second material is higher than the temperature of the first material. The additive manufacturing method according to claim 1, wherein the melting point of the second material is higher than the melting point of the first material. The additive manufacturing method according to claim 1, wherein the first material has a dielectric, and the second material has a conductor. The additive manufacturing method according to claim 1, wherein at least one of the first material, the second material, and the third material is heated with a laser beam.