JP6826321B2 - Modeling stage of 3D model, 3D model manufacturing device and 3D model manufacturing method - Google Patents

Description

The present invention relates to a modeling stage of a three-dimensional model, an apparatus for manufacturing a three-dimensional model, and a method for manufacturing a three-dimensional model.

Conventionally, a manufacturing apparatus for manufacturing a three-dimensional model by laminating layers has been used. In such a three-dimensional model manufacturing apparatus, a laminated body of the three-dimensional model is formed on the modeling stage.
For example, Patent Document 1 describes a manufacturing method for manufacturing a three-dimensional model using a three-dimensional model manufacturing device capable of forming a laminated body of the three-dimensional model on a modeling plate (modeling stage). It is disclosed.

Japanese Unexamined Patent Publication No. 2010-100883

It is common practice to degreas and sinter a laminate of three-dimensional objects formed on a modeling stage. When the laminated body of the three-dimensional model is degreased or sintered, the materials (removal materials) other than the final constituent materials of the three-dimensional model are decomposed and removed by volatilization or the like. The body contracts. However, when degreasing or sintering a laminated body of a three-dimensional model, the method of volatilizing the material removed from the modeling stage differs from the method of volatilizing the material removed from the modeling stage, so there is a difference in shrinkage. However, the laminate may be deformed due to degreasing or sintering. Although Patent Document 1 states that it is desirable that the material of the modeling stage has low bondability with the three-dimensional modeled object, how to volatilize the material to be removed from the modeling stage side and from the modeling stage. There is no description about the deformation of the laminate due to the difference in the volatilization method of the removal material. That is, there is no disclosure of a technique that makes it possible to suppress deformation of the laminated body due to degreasing or sintering.

Therefore, an object of the present invention is to suppress deformation of the laminated body of a three-dimensional model formed by laminating layers on a modeling stage as a result of degreasing or sintering. ..

The modeling stage of the three-dimensional modeled object according to the first aspect of the present invention for solving the above problems is an apparatus for producing a three-dimensional modeled object that manufactures a three-dimensional modeled object by laminating layers to form a laminated body. It is used and has a forming surface on which the laminate is formed, and is characterized in that it is made porous with a high melting point material having a melting point higher than that of the constituent material of the three-dimensional model.

The modeling stage of this embodiment is configured to be porous. For this reason, when degreasing or sintering a laminated body of a three-dimensional model formed by laminating layers on the modeling stage, the method of volatilizing the material to be removed from the modeling stage side (downward) and on the modeling stage ( The difference (that is, the difference in shrinkage rate) from the volatilization method of the material to be removed from the upward direction and the lateral direction can be reduced. Therefore, it is possible to prevent the laminate from being deformed as the laminate of the three-dimensional model formed by laminating the layers on the modeling stage is degreased or sintered.

The modeling stage of the three-dimensional model of the second aspect of the present invention is used in a three-dimensional model manufacturing apparatus that manufactures a three-dimensional model by laminating layers to form a laminate, and the laminate is used. It has a forming surface to be formed, and is made of a high melting point material having a melting point higher than that of the constituent material of the three-dimensional model, and is porous so as to communicate from the forming surface side to a side different from the forming surface side. It is characterized by.

The modeling stage of this embodiment is porously configured so as to communicate from the forming surface side to a side different from the forming surface side. For this reason, when degreasing or sintering a laminated body of a three-dimensional model formed by laminating layers on the modeling stage, the method of volatilizing the material to be removed from the modeling stage side (downward) and on the modeling stage ( The difference (that is, the difference in shrinkage rate) from the volatilization method of the material to be removed from the upward direction and the lateral direction can be effectively reduced. Therefore, it is possible to effectively suppress the deformation of the laminated body due to degreasing and sintering of the laminated body of the three-dimensional model formed by laminating the layers on the modeling stage.

In the first or second aspect, the modeling stage of the three-dimensional model of the third aspect of the present invention is removable from the manufacturing apparatus and has a melting point lower than that of the constituent material on the forming surface. It is characterized in that an organic film is formed.

The modeling stage of this embodiment is removable from the three-dimensional model manufacturing apparatus, and an organic film having a melting point lower than that of the constituent material of the three-dimensional model is formed on the surface of the laminate. Therefore, for example, as the laminate of the three-dimensional model is degreased or sintered at a temperature lower than the melting point of the constituent material of the three-dimensional model and higher than the melting point of the organic film, the organic film is removed. It becomes possible to remove the laminated body particularly effectively, and the laminated body can be easily separated from the molding stage. Furthermore, by making the modeling stage removable from the three-dimensional model manufacturing device, when moving the laminated body of the three-dimensional model to the device for degreasing and sintering, the entire modeling stage can be moved. It is possible to prevent the laminate from being damaged.
The "organic film having a melting point lower than that of the constituent material" means a film that covers at least a part of the forming surface and may contain an organic component having a melting point lower than that of the constituent material.

The modeling stage of the three-dimensional model of the third aspect of the present invention is characterized in that, in the third aspect, the organic film contains a component having a melting point higher than that of the constituent material.

According to this aspect, the organic film contains a component having a melting point higher than that of the constituent material of the three-dimensional model. Therefore, when the laminate of the three-dimensional model formed on the modeling stage is degreased or sintered, the component having a high melting point remains as a release material on the modeling stage after degreasing or sintering, and the laminate Can be separated from the modeling stage particularly easily.

The modeling stage of the three-dimensional model of the fifth aspect of the present invention is characterized in that, in the third or fourth aspect, the organic film contains an acrylic resin.

According to this aspect, the organic film contains an acrylic resin. Acrylic resin has a low melting point, and carbon derived from the acrylic resin does not easily remain on the molding stage after degreasing and sintering. Therefore, carbon as an impurity is mixed in the laminate of the three-dimensional model after degreasing and sintering. Can be suppressed.

In the first or second aspect, the modeling stage of the three-dimensional model of the sixth aspect of the present invention constitutes the porous pores and the average pore diameter formed on the forming surface is 1 μm or more. It is characterized in that it is 5 μm or less.

The laminated body of the three-dimensional model shrinks due to degreasing and sintering. If large pores are formed on the formation surface on which the laminated body of the three-dimensional model is formed, when degreasing or sintering is performed, the constituent materials of the three-dimensional model are restrained in the holes and three-dimensional. The laminate of the model shrinks. For this reason, there is a risk that the laminated body of the three-dimensional model will be deformed due to degreasing and sintering. However, according to this aspect, since the average pore diameter formed on the formed surface while forming the porous pores is 1 μm or more and 5 μm or less, three-dimensional modeling is performed on the pores when degreasing or sintering is performed. It is possible to prevent the constituent material of the object from entering and shrinking the laminate of the three-dimensional model while the constituent material is restrained. Therefore, it is possible to prevent the laminated body of the three-dimensional model from being deformed due to degreasing and sintering.

In the modeling stage of the three-dimensional model of the seventh aspect of the present invention, in any one of the first to sixth aspects, the refractory material comprises at least one of alumina, silicon carbide and zirconia. It is characterized by.

According to this aspect, the refractory material comprises at least one of alumina, silicon carbide and zirconia. Since these have a high melting point and are not easily deformed even at a high temperature, the deformation of the three-dimensional modeled product formed on the modeling stage is particularly effectively suppressed by degreasing or sintering. be able to.

The three-dimensional model manufacturing apparatus according to the eighth aspect of the present invention is three-dimensionally modeled by forming the laminated body on the forming surface of the modeling stage according to any one of the first to seventh aspects. It is characterized by manufacturing things.

According to this aspect, when degreasing or sintering a laminated body of a three-dimensional model formed by laminating layers on a modeling stage, the method of volatilizing the material to be removed from the modeling stage side and the method of volatilizing the material from the modeling stage. The difference from the volatilization method of the removed material can be reduced. Therefore, it is possible to prevent the laminate from being deformed as the laminate of the three-dimensional model formed by laminating the layers on the modeling stage is degreased or sintered.

The method for producing a three-dimensional model according to a ninth aspect of the present invention includes a laminate forming step of forming the laminate on the forming surface of the modeling stage according to any one of the first to seventh aspects. It is characterized by having an energy applying step of applying energy to the laminated body.

According to this aspect, when the laminate of the three-dimensional model formed by laminating layers on the modeling stage in the laminate forming step is degreased or sintered in the energy application step, the material to be removed from the modeling stage side. It is possible to reduce the difference between the method of volatilization of the material and the method of volatilization of the material to be removed from the molding stage. Therefore, it is possible to prevent the laminate from being deformed as the laminate of the three-dimensional model formed by laminating the layers on the modeling stage is degreased or sintered.

The method for producing a three-dimensional model according to a tenth aspect of the present invention is characterized in that, in the ninth aspect, a heating step of sintering or melting the constituent material is executed after the energy application step.

According to this aspect, a heating step of sintering or melting the constituent material is performed after the energy applying step. Therefore, the laminated body of the three-dimensional model obtained by degreasing in the energy application step can be sintered or melted.

FIG. 1A is a schematic configuration diagram showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention. FIG. 1B is an enlarged view of part C shown in FIG. 1A. FIG. 2A is a schematic configuration diagram showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention. FIG. 2B is an enlarged view of a portion C'shown in FIG. 2A. The schematic perspective view of the head base which concerns on one Embodiment of this invention. FIG. 4A is a plan view conceptually explaining the relationship between the arrangement of the head unit and the formation form of the three-dimensional model according to the embodiment of the present invention. FIG. 4B is a plan view conceptually explaining the relationship between the arrangement of the head unit and the formation form of the three-dimensional model according to the embodiment of the present invention. FIG. 4C is a plan view conceptually explaining the relationship between the arrangement of the head unit and the formation form of the three-dimensional model according to the embodiment of the present invention. FIG. 5A is a schematic view conceptually explaining the formation form of the three-dimensional model. FIG. 5B is a schematic view conceptually explaining the formation form of the three-dimensional model. FIG. 6A is a schematic view showing an example of other arrangements of the head unit arranged on the head base. FIG. 6B is a schematic view showing an example of other arrangements of the head unit arranged on the head base. The schematic diagram which shows the modeling stage which concerns on one Example of this invention. The flowchart of the manufacturing method of the 3D model which concerns on one Example of this invention. The schematic diagram which shows the modeling stage which concerns on one Example of this invention. The schematic diagram which shows the modeling stage which concerns on one Example of this invention.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.
1 and 2 are schematic configuration diagrams showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention.
Here, the three-dimensional model manufacturing apparatus of the present embodiment includes two types of material supply units (head bases). Of these, FIG. 1 is a diagram showing one material supply unit (a material supply unit that supplies a constituent material (a material containing a powder, a solvent, and a binder that constitutes a three-dimensional model)). Further, FIG. 2 shows another material supply unit (a material supply unit that supplies a material for forming a support portion that forms a support portion that supports the three-dimensional modeled object when forming the three-dimensional modeled object). It is a figure.
In addition, "three-dimensional modeling" in this specification indicates that a so-called three-dimensional model is formed, and for example, a flat plate shape, that is, a so-called two-dimensional shape having a thickness. It also includes forming. Further, "supporting" means supporting from the lower side, supporting from the side, and in some cases, supporting from the upper side.
Further, the three-dimensional model manufacturing apparatus of the present embodiment forms a support layer for supporting the three-dimensional model when forming the component layer of the three-dimensional model using the constituent material of the three-dimensional model. It has a possible configuration. Therefore, it is possible to form a portion (so-called overhang portion) that is convex in the direction intersecting the stacking direction without deforming it. However, the structure is not limited to such a structure, and a structure that does not form a support layer (that is, a structure that does not use a support layer forming material) may be used.

The three-dimensional model manufacturing apparatus 2000 (hereinafter referred to as the forming apparatus 2000) shown in FIGS. 1 and 2 is composed of the base 110 and the drive device 111 as a drive means provided in the base 110. The stage 120 is provided so as to be movable in the Z direction or to be driven in the rotation direction about the Z axis.
Then, as shown in FIG. 1, the head base 1100 holds a plurality of head units 1400 having one end fixed to the base 110 and having the constituent material discharging portion 1230 for discharging the constituent material to the other end. Is provided with a head base support 130 for holding and fixing.
Further, as shown in FIG. 2, one end is fixed to the base 110, and the support layer forming material discharge portion for discharging the support layer forming material for supporting the three-dimensional modeled object to the other end. It includes a head base support portion 730 for holding and fixing a head base 1600 that holds a plurality of head units 1900 including the 1730.
Here, the head base 1100 and the head base 1600 are provided in parallel on the XY plane.
The constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 have the same configuration. However, the configuration is not limited to this.

A removable modeling stage 121 is placed on the stage 120, and layers 501, 502, and 503 in the process of forming the three-dimensional modeled laminate 500 on the forming surface 121a (see FIG. 3) of the modeling stage 121. Is formed. The laminated body 500 of the three-dimensional model formed on the forming surface 121a of the modeling stage 121 is degreased (solvent and binder contained in the constituent material) by applying energy such as thermal energy after being formed by the forming device 2000. At least a part of the energy is decomposed and removed) and sintering is performed. Then, the degreasing and sintering of the laminated body 500 of the three-dimensional modeled object is performed in a constant temperature bath 650 (see FIG. 7) which can apply heat energy as an energy applying device provided separately from the forming device 2000. It is done by setting every 121. Therefore, the modeling stage 121 is required to have high heat resistance. Therefore, by using, for example, a ceramic plate as the modeling stage 121, high heat resistance can be obtained, and the reactivity with the constituent material of the three-dimensional model to be sintered (or may be melted) is also low. , It is possible to prevent deterioration of the laminated body 500 of the three-dimensional modeled object. In FIGS. 1A and 2A, three layers 501, 502, and 503 are exemplified for convenience of explanation, but up to the shape of the desired three-dimensional modeled laminate 500 (layer 50n in FIGS. 1A and 2A). Up to) are stacked.
Here, the layers 501, 502, 503, ... 50n are formed from the support layer 300 formed of the support layer forming material discharged from the support layer forming material discharge unit 1730 and the constituent material discharge unit 1230, respectively. It is composed of a constituent layer 310 formed of a constituent material to be discharged.

Further, FIG. 1B is an enlarged conceptual diagram of part C showing the head base 1100 shown in FIG. 1A. As shown in FIG. 1B, the head base 1100 holds a plurality of head units 1400. Although the details will be described later, one head unit 1400 is configured by holding the component material discharge unit 1230 provided in the component material supply device 1200 by the holding jig 1400a. The component material discharge unit 1230 includes a discharge nozzle 1230a and a discharge drive unit 1230b that discharges the component material from the discharge nozzle 1230a by the material supply controller 1500.

Further, FIG. 2B is an enlarged conceptual diagram of a C'section showing the head base 1600 shown in FIG. 2A. Here, the head base 1600 has the same configuration as the head base 1100. Specifically, as shown in FIG. 2B, the head base 1600 holds a plurality of head units 1900. The head unit 1900 is configured by holding the support layer forming material discharge unit 1730 provided in the support layer forming material supply device 1700 by the holding jig 1900a. The support layer forming material discharge unit 1730 includes a discharge nozzle 1730a and a discharge drive unit 1730b that discharges the support layer forming material from the discharge nozzle 1730a by the material supply controller 1500.

Although not provided in the forming apparatus 2000 of the present embodiment, the constituent material discharged from the constituent material discharge unit 1230 and the support layer forming material discharged from the support layer forming material discharge unit 1730 are degreased or fired. It may be provided with an energy imparting unit capable of connecting. If such an energy applying unit is provided, it is possible to eliminate the need to separately prepare an energy applying device. The configuration of the energy applying unit or the energy applying device is not particularly limited, and includes, for example, a constant temperature bath 650 capable of applying heat energy, a laser irradiation unit, and a galvanometer mirror for positioning the laser light from the laser irradiation unit. Examples include a laser irradiation device and an irradiation device for electromagnetic waves (infrared rays, ultraviolet rays, etc.).

As shown in FIG. 1, the constituent material discharge unit 1230 is connected to the constituent material supply unit 1210 and the supply tube 1220, which accommodate the constituent materials corresponding to the head units 1400 held by the head base 1100. .. Then, a predetermined constituent material is supplied from the constituent material supply unit 1210 to the constituent material discharge unit 1230. In the constituent material supply unit 1210, the constituent materials of the laminated body 500 of the three-dimensional model formed by the forming apparatus 2000 according to the present embodiment are accommodated in the constituent material accommodating portion 1210a, and the individual constituent material accommodating portions 1210a The feed tube 1220 is connected to the individual constituent material discharge portions 1230. As described above, by providing the individual constituent material accommodating portions 1210a, a plurality of different types of materials can be supplied from the head base 1100.

As shown in FIG. 2, the support layer forming material discharge unit 1730 is a support layer forming material supply unit 1710 that houses a support layer forming material corresponding to each of the head units 1900 held in the head base 1600. Is connected by a supply tube 1720. Then, a predetermined support layer forming material is supplied from the support layer forming material supply unit 1710 to the support layer forming material discharge unit 1730. In the support layer forming material supply unit 1710, the support layer forming material constituting the support layer when forming the laminated body 500 of the three-dimensional model is housed in the support layer forming material accommodating portion 1710a, and individual supports are provided. The layer-forming material accommodating portion 1710a is connected to each support layer-forming material discharging portion 1730 by a supply tube 1720. By providing the individual support layer forming material accommodating portions 1710a in this way, it is possible to supply a plurality of different types of support layer forming materials from the head base 1600.

Examples of the constituent material and the material for forming the support layer include magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), and nickel (Ni). ), Or a mixed powder such as an alloy containing one or more of these metals (malaging steel, stainless steel, cobalt-chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt-chromium alloy) as a solvent. , A slurry-like (or paste-like) mixed material containing a binder and the like can be used.
Further, general-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can be used. In addition, engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
As described above, the constituent material and the material for forming the support layer are not particularly limited, and metals other than the above metals, ceramics, resins and the like can also be used. Further, silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide and the like can be preferably used.

Examples of the solvent include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, and acetate. Acetate esters such as iso-propyl, n-butyl acetate, iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, acetyl acetone Ketones such as; alcohols such as ethanol, propanol and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine solvents such as pyridine, γ-picolin and 2,6-rutidine; tetra Examples include ionic liquids such as alkylammonium acetate (for example, tetrabutylammonium acetate, etc.), and one or a combination of two or more selected from these can be used.
Examples of the binder include acrylic resin, epoxy resin, silicone resin, cellulose resin or other synthetic resin, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide) or other thermoplastic resin. Further, an ultraviolet curable resin that polymerizes by irradiation with ultraviolet rays may be used as the binder.

The forming device 2000 includes a component material discharging unit 1230 provided in the above-mentioned stage 120 and the component material supply device 1200 based on modeling data of a three-dimensional modeled object (not shown), for example, output from a data output device such as a personal computer. In addition, a control unit 400 is provided as a control means for controlling the support layer forming material discharge unit 1730 provided in the support layer forming material supply device 1700. Although not shown, the control unit 400 is controlled so that the stage 120 and the constituent material discharge unit 1230 cooperate to drive and operate, and the stage 120 and the support layer forming material discharge unit 1730 cooperate to drive and operate. It is equipped with a control unit that controls the operation.

The stage 120 movably provided on the base 110 is a signal for controlling the movement start and stop, the movement direction, the movement amount, the movement speed, etc. of the stage 120 in the stage controller 410 based on the control signal from the control unit 400. Is generated and sent to the drive device 111 provided in the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The constituent material discharge unit 1230 provided in the head unit 1400 controls the material discharge amount from the discharge nozzle 1230a in the discharge drive unit 1230b provided in the component material discharge unit 1230 in the material supply controller 1500 based on the control signal from the control unit 400. A predetermined amount of the constituent material is discharged from the discharge nozzle 1230a by the generated signal.
Similarly, in the support layer forming material discharge unit 1730 provided in the head unit 1900, the discharge nozzle in the discharge drive unit 1730b provided in the support layer forming material discharge unit 1730 in the material supply controller 1500 based on the control signal from the control unit 400. A signal for controlling the amount of material discharged from the 1730a is generated, and a predetermined amount of the material for forming the support layer is discharged from the discharge nozzle 1730a according to the generated signal.

Next, the head unit 1400 will be described in more detail. The head unit 1900 has the same configuration as the head unit 1400. Therefore, a detailed description of the configuration of the head unit 1900 will be omitted.
3 and 4 show an example of a holding form of the head unit 1400 and the constituent material discharging unit 1230 held by the head base 1100, and FIG. 4 shows the head base 1100 from the direction of arrow D shown in FIG. 1B. It is an external view of.

As shown in FIG. 3, a plurality of head units 1400 are held on the head base 1100 by fixing means (not shown). Further, as shown in FIG. 4, in the head base 1100 of the forming apparatus 2000 according to the present embodiment, the head unit 1401 in the first row, the head unit 1402 in the second row, and the third row from the lower part of the drawing. The head unit 1403 and the head unit 1404 in the fourth row are provided with head units 1400 in which four units are arranged in a staggered manner (alternately). Then, as shown in FIG. 4A, while moving the stage 120 with respect to the head base 1100 in the X direction, the constituent materials are discharged from each head unit 1400 to form the constituent layer constituent units 50 (constituent layer constituent units 50a, 50b). , 50c and 50d) are formed. The procedure for forming the constituent layer constituent unit 50 will be described later.
Although not shown, the component material discharge unit 1230 provided in each of the head units 1401 to 1404 is configured to be connected to the component material supply unit 1210 via a discharge drive unit 1230b by a supply tube 1220.

As shown in FIG. 3, the constituent material discharge unit 1230 discharges the material M, which is a constituent material of the three-dimensional model, from the discharge nozzle 1230a toward the forming surface 121a of the modeling stage 121 mounted on the stage 120. To. The head unit 1401 exemplifies a discharge form in which the material M is discharged in the form of droplets, and the head unit 1402 exemplifies a discharge form in which the material M is supplied in the form of a continuum. The ejection form of the material M may be either a droplet form or a continuous form, but in the present embodiment, the material M will be described in the form of being ejected in the form of droplets.
The constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 are not limited to such a configuration, and may be a material supply unit of a different type such as an extruder.

The material M discharged in the form of droplets from the discharge nozzle 1230a flies in the substantially gravitational direction and lands on the modeling stage 121. The stage 120 moves, and the constituent layer constituent portion 50 is formed by the landed material M. The aggregate of the constituent layer constituent portions 50 is formed as a constituent layer 310 (see FIG. 1) of the laminated body 500 of the three-dimensional model formed on the forming surface 121a of the modeling stage 121.

Next, the procedure for forming the constituent layer constituent portion 50 will be described with reference to FIGS. 4 and 5.
FIG. 4 is a plan view conceptually explaining the relationship between the arrangement of the head unit 1400 of the present embodiment and the formation form of the constituent layer constituent unit 50. FIG. 5 is a side view conceptually showing the formation form of the constituent layer constituent portion 50.

First, when the stage 120 moves in the + X direction, the material M is discharged in the form of droplets from the plurality of discharge nozzles 1230a, the material M is arranged at a predetermined position on the forming surface 121a of the modeling stage 121, and the constituent layer constituent unit 50 Is formed.
More specifically, first, as shown in FIG. 5A, while moving the stage 120 in the + X direction, the material is placed at a predetermined position on the forming surface 121a of the modeling stage 121 from the plurality of discharge nozzles 1230a at regular intervals. Place M.

Next, as shown in FIG. 5B, while moving the stage 120 in the −X direction shown in FIG. 1, a new material M is arranged so as to fill the space between the materials M arranged at regular intervals.
However, while moving the stage 120 in the + X direction, the material M is arranged from the plurality of discharge nozzles 1230a so as to overlap the material M at a predetermined position of the modeling stage 121 (without leaving a gap) (in the X direction of the stage 120). Instead of forming the constituent layer constituent portion 50 by reciprocating movement, the constituent layer constituent portion 50 may be formed only by moving one side of the stage 120 in the X direction).

By forming the constituent layer constituent portion 50 as described above, one line of each head unit 1401, 1402, 1403 and 1404 in the X direction (the first line in the Y direction) as shown in FIG. 4A. The constituent layer constituent portions 50 (constituent layer constituent portions 50a, 50b, 50c and 50d) are formed.

Next, in order to form the second line constituent layer constituents 50'(constituent layer constituents 50a', 50b', 50c' and 50d') in the Y direction of each head unit 1401, 1402, 1403 and 1404,- The head base 1100 is moved in the Y direction. Assuming that the pitch between the nozzles is P, the amount of movement is moved in the −Y direction by the amount of P / n (n is a natural number) pitch. In this embodiment, n will be described as 3.
By performing the same operation as described above as shown in FIGS. 5A and 5B, the second line constituent layer constituent unit 50'(constituent layer constituent portion 50a) in the Y direction as shown in FIG. 4B is performed. ', 50b', 50c' and 50d') are formed.

Next, the third line constituent layer constituents 50 ″ (constituent layer constituents 50a ″, 50b ″, 50c ″ and 50d ″) of the head units 1401, 1402, 1403 and 1404 in the Y direction are formed. To form, the head base 1100 is moved in the −Y direction. The amount of movement is the P / 3 pitch in the −Y direction.
Then, by performing the same operation as described above as shown in FIGS. 5A and 5B, the third line constituent layer constituent unit 50'' in the Y direction as shown in FIG. 4C is performed.
(Constructive layer constituent parts 50a ″, 50b ″, 50c ″ and 50d ″) are formed, and the constituent layer 310 can be obtained.

Further, the material M discharged from the constituent material discharging unit 1230 can be discharged and supplied from any one unit, or two or more units of the head units 1401, 1402, 1403, and 1404, which is different from the other head units. Therefore, by using the forming apparatus 2000 according to the present embodiment, a three-dimensional model formed from different materials can be obtained.

In the first layer 501, before or after forming the constituent layer 310 as described above, the support layer forming material is discharged from the support layer forming material discharging portion 1730 and supported by the same method. Layer 300 can be formed. Then, when the layers 502, 503, ... 50n are formed by being laminated on the layer 501, the constituent layer 310 and the support layer 300 can be formed in the same manner.

The number and arrangement of the head units 1400 and 1900 included in the forming apparatus 2000 according to the above-described embodiment is not limited to the above-mentioned number and arrangement. FIG. 6 schematically shows an example of other arrangements of the head unit 1400 arranged on the head base 1100 as an example.

FIG. 6A shows a form in which a plurality of head units 1400 are arranged in parallel on the head base 1100 in the X-axis direction. FIG. 6B shows a form in which the head units 1400 are arranged in a grid pattern on the head base 1100. The number of head units arranged in each case is not limited to the illustrated example.

Next, the modeling stage 121, which is a main part of the forming apparatus 2000 according to the above-described embodiment, will be described in more detail.
FIG. 7 is a schematic view showing the modeling stage 121 of this embodiment. More specifically, it represents a state in which the modeling stage 121 on which the laminated body 500 of the three-dimensional model is formed is set in the constant temperature bath 650 as an energy applying device and degreased.

The modeling stage 121 of this embodiment is used in a forming apparatus 2000 for manufacturing a three-dimensional model by laminating layers to form a laminated body 500 of the three-dimensional model as described above, and is represented by FIG. 7. As described above, it has a forming surface 121a on which the laminated body 500 of the three-dimensional model is formed.
The modeling stage 121 is made of a high melting point material having a melting point higher than that of the constituent material of the three-dimensional model, and is made porous. Therefore, the modeling stage 121 of the present embodiment is viewed from the modeling stage 121 side (downward direction) when the laminated body 500 of the three-dimensional model formed by laminating layers on the modeling stage 121 is degreased or sintered. The difference (that is, the difference in shrinkage rate) between the volatilization method of the degreasing material (solvent, binder, etc. contained in the constituent material) and the volatilization method of the degreasing material from the modeling stage 121 (upward and lateral directions) is small. It is configured so that it can be used. Therefore, it is possible to prevent the laminated body 500 of the three-dimensional model from being deformed by degreasing or sintering the laminated body 500 of the three-dimensional model formed by laminating the layers on the modeling stage 121. It is configured so that it can be used.
The arrows in FIG. 7 conceptually represent the direction in which the removed material volatilizes. When the modeling stage 121 is not made porous, the volatilization of the material to be removed from the modeling stage 121 side (downward arrow) is almost eliminated, and the modeling stage 121 side does not shrink much as compared with other parts.

Further, the modeling stage 121 of this embodiment is removable from the forming apparatus 2000, and an organic film 600 having a melting point lower than that of the constituent material is formed on the forming surface 121a. Therefore, for example, as the laminate 500 of the three-dimensional model is degreased or sintered at a temperature lower than the melting point of the constituent material of the three-dimensional model and higher than the melting point of the organic film 600, the organic film 600 Can be removed together with the removal material, and deformation of the three-dimensional modeled product laminate 500 can be suppressed particularly effectively, and the three-dimensional modeled product laminate 500 after degreasing and sintering can be easily removed from the modeling stage 121. It has a structure that can be separated into. This is because the laminated body 500 of the three-dimensional model shrinks when it is degreased or sintered, but due to the formation of the organic film 600, the constituent material is degreased or sintered while the constituent materials are constrained by the unevenness of the formed surface 121a. This is because it is possible to suppress the shrinkage of the laminated body 500 of the three-dimensional modeled object. In particular, when the modeling stage 121 is made porous as in this embodiment, the unevenness of the forming surface 121a tends to be large, so that the effect of forming the organic film 600 is particularly large.
Furthermore, by making the modeling stage 121 removable from the forming device 2000, when moving the laminated body 500 of the three-dimensional modeled object to the energy applying device (constant temperature bath 650) for degreasing and sintering, It can be moved together with the modeling stage 121. Therefore, it is possible to prevent the laminate 500 of the three-dimensional model from being damaged when the laminate 500 of the three-dimensional model is removed from the modeling stage 121 in order to set it in the constant temperature bath 650.
Needless to say, the modeling stage 121 on which the organic film 600 is formed may be prepared in advance, and the laminated body 500 of the three-dimensional model may be formed on the modeling stage 121. However, the modeling stage 121 on which the organic film 600 is not formed is prepared in advance, and the support layer forming material is discharged from the support layer forming material discharging portion 1730 prior to the formation of the laminated body 500 of the three-dimensional modeled product. The organic film 600 may be formed on the forming surface 121a, and then the laminated body 500 of the three-dimensional model may be formed. Needless to say, the modeling stage 121 in which the organic film 600 is formed on the forming surface 121a in this way is also included in the present invention.
Further, the "organic film having a melting point lower than that of the constituent material" means a film that covers at least a part of the forming surface 121a and may contain an organic component having a melting point lower than that of the constituent material.

Here, the organic film 600 formed on the modeling stage 121 of this embodiment contains an acrylic resin. Acrylic resin has a low melting point, and carbon derived from the acrylic resin does not easily remain on the modeling stage 121 after degreasing or sintering. Therefore, carbon as an impurity is contained in the laminate 500 of the three-dimensional model after degreasing or sintering. Mixing can be suppressed.
However, the forming component of the organic film 600 is not particularly limited, and polyester resin or the like can be used in addition to acrylic resin, and a plurality of types of resins may be contained.

Further, the organic film 600 may contain a component having a melting point higher than that of the constituent material. If the organic film 600 contains a component having a melting point higher than that of the constituent material, after degreasing or sintering when the laminate 500 of the three-dimensional model formed on the modeling stage 121 is degreased or sintered. The high melting point component remains evenly on the modeling stage 121 as a release material, and the laminated body 500 of the three-dimensional model can be separated from the modeling stage 121 particularly easily (in a short time). Because.
The "component having a melting point higher than that of the constituent material" is not particularly limited, but for example, ceramics (alumina, silicon carbide, zirconia, etc.) can be used.

Further, the refractory material in the modeling stage 121 preferably contains at least one of alumina, silicon carbide and zirconia. Since these have a high melting point and are not easily deformed even at a high temperature, the laminate 500 of the three-dimensional model is deformed as the laminate 500 of the three-dimensional model formed on the modeling stage 121 is degreased or sintered. This is because this can be suppressed particularly effectively.

As described above, the forming apparatus 2000 of the present embodiment manufactures the three-dimensional modeled object by forming the laminated body 500 of the three-dimensional modeled object on the forming surface 121a of the modeling stage 121. With such a configuration, when the laminated body 500 of the three-dimensional model formed by laminating layers on the modeling stage 121 is degreased or sintered, the method of volatilizing the material to be removed from the modeling stage 121 side is determined. It is possible to reduce the difference from the method of volatilizing the material to be removed from the molding stage 121. Therefore, in the forming apparatus 2000 of the present embodiment, as the laminate 500 of the three-dimensional model formed by laminating layers on the modeling stage 121 is degreased or sintered, the laminate of the three-dimensional model is formed. The structure is such that the deformation of the 500 can be suppressed.
Further, in the forming apparatus 2000 of the present embodiment, since the organic film 600 having a melting point lower than that of the constituent material of the three-dimensional model is formed on the forming surface 121a of the modeling stage 121 that is removable from the device, By degreasing or sintering the laminated body 500 of the three-dimensional model, the organic film 600 can be removed together with the removing material, and the laminated body 500 of the three-dimensional model can be easily separated from the modeling stage. It has become.

Next, an example of a method for manufacturing a three-dimensional model formed by using the forming apparatus 2000 will be described with reference to a flowchart.
Here, FIG. 8 is a flowchart of a method for manufacturing a three-dimensional model according to the present embodiment.

As shown in FIG. 8, in the method of manufacturing the three-dimensional model of the present embodiment, first, in step S110, the data of the three-dimensional model is acquired. Specifically, for example, data representing the shape of a three-dimensional model is acquired from an application program executed on a personal computer or the like.

Next, in step S120, data for each layer is generated. Specifically, in the data representing the shape of the three-dimensional modeled object, slices are made according to the modeling resolution in the Z direction, and bitmap data (cross-section data) is generated for each cross-section.

Next, when the modeling stage 121 on which the organic film 600 is not formed is prepared, in step S130, the support layer forming material is discharged from the support layer forming material discharging portion 1730 to form the organic film 600 on the forming surface 121a. To do. However, if the modeling stage 121 on which the organic film 600 is formed is prepared in advance, this step can be omitted.

Next, in step S140, the laminated body 500 of the three-dimensional model is formed based on the data for each layer generated in step S120. Then, in step S150, step S140 and step S150 are repeated until the data for each layer is completed, and the laminated body 500 of the three-dimensional modeled object is completed on the forming surface 121a of the modeling stage 121.
In steps S140 to S150, in the method for producing a three-dimensional model of the present embodiment, the solvent is naturally volatilized without applying energy to form a laminated body 500 of the three-dimensional model (constructible layer). Although the constituent portion 50 is fixed), the constituent layer constituent portion 50 may be fixed by applying energy such as heating.

Next, in step S160, the laminated body 500 of the three-dimensional modeled object is taken out from the forming device 2000 together with the modeling stage 121, set in the constant temperature bath 650 as the energy applying device, and energy is applied (heated). In this step, the organic component of the organic film 600 is decomposed and removed.

Finally, in step S170, the energy output of the constant temperature bath 650 is increased to heat the laminated body 500 of the three-dimensional model, and the method for manufacturing the three-dimensional model of this embodiment is completed.
If step S160 is an energy applying step corresponding to degreasing, step S170 corresponds to a heating step corresponding to condensation or melting, and step S160 corresponds to an energy applying step corresponding to degreasing and coagulation. , Step S170 corresponds to the heating step corresponding to melting. Further, step S170 can be omitted when there is no need for condensation or melting, such as when the laminated body 500 of the three-dimensional model is degreased to complete or when it is condensed to complete.

As described above, the method for manufacturing the three-dimensional modeled object of the present embodiment includes the layered body forming step (step S140) of forming the laminated body 500 of the three-dimensional modeled object on the forming surface 121a using the above-mentioned modeling stage 121. It has an energy applying step (step S160) of applying energy to the laminated body 500 of the three-dimensional modeled object.
Therefore, in the laminate forming step, the laminate 500 of the three-dimensional model formed by laminating layers on the modeling stage 121 (which is porously composed of a high melting point material having a melting point higher than that of the constituent material) is formed. When degreasing or sintering in the energy application process, how to volatilize the removal material from the modeling stage 121 side (downward direction) and how to volatilize the removal material from the modeling stage 121 top (upward and lateral directions). The difference can be reduced. Therefore, it is possible to prevent the laminated body 500 of the three-dimensional model from being deformed by degreasing or sintering the laminated body 500 of the three-dimensional model formed by laminating the layers on the modeling stage 121. Can be done.
Further, the laminated body 500 of the three-dimensional model formed by laminating layers on the modeling stage 121 (in which the organic film 600 having a melting point lower than that of the constituent material is formed on the forming surface 121a) in the layered body forming step. The organic film 600 can be removed together with the removing material by degreasing and sintering in the energy applying step, and the laminated body 500 of the three-dimensional model can be easily separated from the modeling stage 121.

Further, in the method for manufacturing the three-dimensional model of the present embodiment, the organic film forming step (step S130) for forming the organic film 600 on the forming surface 121a may be executed before the laminate forming step (step S140). it can. Therefore, it is possible to use the modeling stage 121 on which the organic film 600 is not formed in advance.

Further, in the method for manufacturing a three-dimensional model of the present embodiment, after the energy application step (step S160), a heating step (step S170) for sintering or melting the constituent materials of the three-dimensional model can be executed. Therefore, the laminated body 500 of the three-dimensional model that has been degreased in the energy application step can be sintered or melted.

In the modeling stage 121 of the above embodiment, the organic film 600 having a melting point lower than that of the constituent material is formed on the forming surface 121a, but the configuration is not limited to this.
Here, FIGS. 9 and 10 are schematic views showing a modeling stage 121 having a configuration different from that of the modeling stage 121 of the above embodiment, and are views corresponding to FIG. 7 of the modeling stage 121 of the above embodiment.

The modeling stage 121 represented by FIG. 7 is formed to be porous, and is modeled when a laminated body 500 of a three-dimensional model formed by laminating layers on the modeling stage 121 is degreased or sintered. Difference between the volatilization method of the degreasing material (solvent, binder, etc. contained in the constituent material) from the stage 121 side (downward direction) and the volatilization method of the degreasing material from the modeling stage 121 top (upward and lateral direction) ( That is, the structure is such that the difference in shrinkage rate) can be reduced. This is based on the fact that the volatile component (removal material) can move to the pores associated with the porous shape of the modeling stage 121 which is configured to be porous. Further, when the holes are connected and communicate with each other from the forming surface 121a side (upper side) to a side different from the forming surface 121a side (lower side), for example, as represented by an arrow in FIG. Particularly effectively, the difference in the way of volatilization can be reduced between the modeling stage 121 side (downward direction) and the modeling stage 121 top (upward and lateral directions).
Here, the modeling stage 121 represented by FIG. 9 also communicates from the forming surface 121a side (upper side) to a side different from the forming surface 121a side (lower side), similarly to the modeling stage 121 represented by FIG. It is configured to be porous.

Here, unlike the modeling stage 121 shown in FIG. 7, the modeling stage 121 shown in FIG. 9 does not have the organic film 600 formed on the forming surface 121a. In the case of such a configuration, if the pores formed on the forming surface 121a as well as being porous are large in diameter, the constituent materials of the three-dimensional model will enter the pores when degreasing or sintering. The laminate of the three-dimensional model shrinks while the constituent materials are restrained. For this reason, there is a risk that the laminated body of the three-dimensional model will be deformed due to degreasing and sintering.
However, the modeling stage 121 represented by FIG. 9 forms porous pores and has an average pore diameter formed on the forming surface 121a of 1 μm or more and 5 μm or less. The average pore size can be determined by, for example, a mercury press-fitting method. By setting the average pore size to 1 μm or more, the solvent, binder, and the like can be sufficiently volatilized from the lower side of the modeling stage 121. Further, by setting the average pore diameter to 5 μm or less, it is possible to prevent the constituent material of the three-dimensional model from entering the pores, and when degreasing or sintering is performed, the constituent material of the three-dimensional model is formed in the pores. It is possible to suppress the shrinkage of the laminated body of the three-dimensional model while being restrained. That is, the modeling stage 121 shown in FIG. 9 can sufficiently volatilize the solvent, binder, etc. from the lower side of the modeling stage 121, and suppresses deformation of the laminated body of the three-dimensional modeled object due to degreasing and sintering. It is configured to be possible.

In addition, in order to determine whether or not the structure is porous so as to communicate from the forming surface 121a side to a side different from the forming surface 121a side, for example, a liquid such as ethanol is dripped on the forming surface 121a and the forming surface 121a is determined. It can be executed by confirming whether or not the liquid permeates the surface on the opposite side to the above.

Further, the modeling stage 121 represented by FIG. 9 is configured to communicate from the upper side to the lower side like the modeling stage 121 represented by FIG. 7, but the modeling stage 121 represented by FIG. 10 is configured. It is configured to communicate not only from the region on the upper side of the forming surface 121a where the laminate 500 is provided to the lower side but also to the region on the side surface side and the side of the forming surface 121a where the laminate 500 is not provided.
Like the modeling stage 121 represented by FIG. 10, the molding stage 121a may be made porous so as to communicate with the region where the laminated body 500 is provided on the forming surface 121a side to a side different from the forming surface 121a side. .. Here, the "different side" means that the laminated body 500 is not provided on the lower side, the side surface side, and the forming surface 121a side when the portion where the laminated body 500 is provided on the forming surface 121a side is the upper side. It is at least part of the area.
As described above, at least one of the region where the laminated body 500 is provided on the forming surface 121a side and the region where the laminated body 500 is not provided on the lower side, the side surface side, and the forming surface 121a side are communicated with each other. Is preferable.
However, if it is "porous", there are many pores, and volatile components can escape into these many pores, so that they do not communicate with each other (the laminate 500 on the forming surface 121a side is provided. The pores constituting the porous material may not be connected from the region to different sides).

The present invention is not limited to the above-described embodiment, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features in the examples corresponding to the technical features in each form described in the column of the outline of the invention may be used to solve some or all of the above-mentioned problems, or one of the above-mentioned effects. It is possible to replace or combine as appropriate to achieve a part or all. Further, if the technical feature is not described as essential in the present specification, it can be appropriately deleted.

50, 50a, 50b, 50c, 50d ... Constructible sheaf component, 110 ... Base,
111 ... Drive device, 120 ... Stage, 121 ... Modeling stage, 121a ... Forming surface,
130 ... head base support, 300 ... support layer, 310 ... constituent layer,
400 ... control unit, 410 ... stage controller,
500 ... Three-dimensional model laminate, 501, 502 and 503 ... Layers, 600 ... Organic film,
650 ... constant temperature bath, 730 ... head base support, 1100 ... head base,
1200 ... constituent material supply device, 1210 ... constituent material supply unit,
1210a ... Constituent material storage unit, 1220 ... Supply tube, 1230 ... Constituent material discharge unit,
1230a ... Discharge nozzle, 1230b ... Discharge drive unit, 1400 ... Head unit,
1400a ... Holding jig, 1401, 1402, 1403, 1404 ... Head unit,
1500 ... Material supply controller, 1600 ... Head base,
1700 ... Support layer forming material supply device, 1710 ... Support layer forming material supply unit,
1710a ... Material accommodating portion for forming a support layer, 1720 ... Supply tube,
1730 ... Material discharge part for forming support layer, 1730a ... Discharge nozzle,
1730b ... Discharge drive unit, 1900 ... Head unit, 1900a ... Holding jig,
2000 ... Forming device (manufacturing device for three-dimensional model), M ... Material (constituent material)

Claims (10)

It is used in a three-dimensional model manufacturing device that manufactures a three-dimensional model by laminating layers to form a laminate.
It has a forming surface on which the laminate is formed,
A modeling stage for a three-dimensional model, which is characterized by being porously composed of a high melting point material having a melting point higher than that of the three-dimensional model. It is used in a three-dimensional model manufacturing device that manufactures a three-dimensional model by laminating layers to form a laminate.
It has a forming surface on which the laminate is formed,
A three-dimensional model characterized by being a high melting point material having a melting point higher than that of the three-dimensional model, and being porous so as to communicate from the forming surface side to a side different from the forming surface side. Modeling stage. In the modeling stage according to claim 1 or 2.
Detachable to the manufacturing equipment
A modeling stage for a three-dimensional model, characterized in that an organic film having a melting point lower than that of the constituent material is formed on the forming surface. In the modeling stage according to claim 3.
The organic film is a modeling stage of a three-dimensional model, characterized in that it contains a component having a melting point higher than that of the constituent material. In the modeling stage according to claim 3 or 4.
The organic film is a modeling stage for a three-dimensional model, characterized in that it contains an acrylic resin. In the modeling stage according to claim 1 or 2.
A modeling stage for a three-dimensional model, characterized in that the average pore diameter formed on the forming surface while forming the porous pores is 1 μm or more and 5 μm or less. In the modeling stage according to any one of claims 1 to 6.
The molding stage of a three-dimensional model, wherein the refractory material contains at least one of alumina, silicon carbide and zirconia. An apparatus for manufacturing a three-dimensional modeled object, which comprises forming the laminated body on the forming surface of the modeling stage according to any one of claims 1 to 7, thereby producing a three-dimensional modeled object. A laminate forming step of forming the laminate on the forming surface of the modeling stage according to any one of claims 1 to 7.
An energy applying step of applying energy to the laminated body and
A method for manufacturing a three-dimensional model, which is characterized by having. In the method for manufacturing a three-dimensional model according to claim 9.
A method for producing a three-dimensional model, which comprises performing a heating step of sintering or melting the constituent material after the energy applying step.

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