JP6931205B2 - Manufacturing method of 3D model - Google Patents

Description

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

Conventionally, various methods for manufacturing a three-dimensional model have been implemented. Among these, a method of forming a three-dimensional model using a fluid composition is disclosed.
For example, in Patent Document 1, a layer is formed using a metal paste as a fluid composition, and a three-dimensional model is manufactured while sintering or melting by irradiating a corresponding region of the three-dimensional model with a laser. The manufacturing method is disclosed.

Japanese Unexamined Patent Publication No. 2008-184622

However, when a three-dimensional molded product is manufactured while sintering or melting the corresponding region of the three-dimensional molded product, the heat generated during the sintering or melting causes the portion other than the corresponding region of the three-dimensional molded product to be sintered or melted. It melts, and there are cases where the load of separation work when removing the three-dimensional model and molding work after removal is heavy. That is, the conventional manufacturing method for manufacturing a three-dimensional model has not been able to sufficiently reduce the post-treatment steps of the three-dimensional model to be manufactured.

Therefore, an object of the present invention is to reduce the number of post-treatment steps after forming a three-dimensional model.

The method for producing a three-dimensional model according to the first aspect of the present invention for solving the above problems is a method for forming a fluid composition containing particles of constituent materials of the three-dimensional model and the three-dimensional model. A layer forming step of forming a layer using a fluid composition containing support part forming particles for forming a support part for supporting the three-dimensional model, and energy is applied to the constituent material particles and the support part forming particles. The energy applying step includes an energy applying step in which the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the supporting portion forming particles. It is characterized in that energy is applied so as to reach the temperature of.

According to this aspect, energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the supporting portion forming particles. Therefore, it is possible to suppress the sintering of the support portion while sintering the constituent material of the three-dimensional modeled object. Therefore, by sintering the portion other than the corresponding region of the three-dimensional modeled object, it is possible to suppress an increase in the load such as the separation work when removing the three-dimensional modeled object and the molding work after the removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

In the method for producing a three-dimensional model according to the second aspect of the present invention, in the first aspect, the layer forming step is a fluidity composition containing the constituent material particles and the fluidity including the support portion forming particles. The composition is discharged in the form of droplets to form the layer.

According to this aspect, the fluid composition containing the constituent material particles and the fluid composition containing the support portion forming particles are discharged in the form of droplets to form a layer. Therefore, by forming the layer, a three-dimensional model can be easily formed.

The method for producing a three-dimensional model according to a third aspect of the present invention is characterized in that, in the first or second aspect, there is a laminating step in which the layer forming step is repeated.

According to this aspect, it has a laminating step of repeating a layer forming step. Therefore, by repeating the layer forming step, a three-dimensional model can be easily formed.

The method for producing a three-dimensional model according to a fourth aspect of the present invention is characterized in that, in the third aspect, the energy applying step is executed after the completion of the laminating step.

According to this aspect, the energy applying step is executed after the completion of the laminating step. That is, the three-dimensional model can be sintered in one step after the shape of the three-dimensional model is formed.

The method for producing a three-dimensional model according to a fifth aspect of the present invention includes, in any one of the first to fourth aspects, a cleaning step of cleaning the three-dimensional model after the energy application step. It is a feature.

According to this aspect, it has a cleaning step of cleaning the three-dimensional modeled object after the energy applying step. Therefore, it is possible to obtain a beautiful three-dimensional model.
In addition, "cleaning" means removing impurities such as support forming particles adhering around the sintered three-dimensional model.

In the method for producing a three-dimensional model according to a sixth aspect of the present invention, in any one of the first to fifth aspects, energy weaker than the energy in the energy application step is applied prior to the energy application step. It is characterized in that the pre-energy applying step of applying the energy and the removing step of removing the support portion forming particles are performed.

According to this aspect, prior to the energy applying step, a pre-energy applying step of applying energy weaker than the energy in the energy applying step and a removing step of removing the support portion forming particles are executed. Therefore, the shape of the three-dimensional modeled object can be confirmed before the energy application process, and the shape of the three-dimensional modeled object can be suppressed from being deformed before the energy application process.
The "pre-energy applying step" means, for example, heating the three-dimensional modeled object at a heating temperature lower than that of the energy applying step, and sinterings the constituent material particles with a force weaker than that of the energy applying step. It means to (temporarily sinter).

In the method for producing a three-dimensional model according to the seventh aspect of the present invention, in the sixth aspect, the energy application step supports the three-dimensional model with particles that are not sintered by the energy application in the energy application step. It is characterized in that energy is given to the state in which it is made to run.

According to this aspect, in the energy application step, energy is applied in a state in which the three-dimensional model is supported by particles that are not sintered by the energy application in the energy application step. Therefore, it is possible to suppress the deformation of the shape of the three-dimensional modeled object before the energy application step, and to suppress the deformation of the shape of the three-dimensional modeled object during the energy application process.
The "particles that are not sintered by the energy application in the energy application step" may be the same particles as the support portion forming particles, but may be different particles, and may be different particles from the support portion forming particles. , It is preferable that the sintering temperature is higher than that of the support portion forming particles.

In the method for producing a three-dimensional model according to the eighth aspect of the present invention, in any one of the first to seventh aspects, the energy applying step is the same for the constituent material particles and the support forming particles. It is characterized by giving energy.

According to this aspect, the same energy is applied to the constituent material particles and the support forming particles. Therefore, the energy application step can be easily executed.

In the method for producing a three-dimensional model according to a ninth aspect of the present invention, in any one of the first to seventh aspects, the energy applying step has different energies for the constituent material particles and the support forming particles. Is characterized by giving.

According to this aspect, different energies are applied to the constituent material particles and the support forming particles. For this reason, by effectively preventing the portion other than the corresponding area of the three-dimensional modeled object from being excessively sintered, separation work when removing the three-dimensional modeled object, molding work after removal, and the like can be performed. It is possible to suppress an increase in load.

In the method for producing a three-dimensional model according to the tenth aspect of the present invention, in any one of the first to ninth aspects, the constituent material particles are aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel. It is a particle containing at least one component of aging steel, and the support forming particle is a particle containing at least one component of silica, alumina, titanium oxide, and zircon oxide.

According to this aspect, the sintered state in the step of applying energy to the constituent material particles and the supporting member forming particles can be easily controlled from a high sintered density to a low sintered density, a non-sintered state, and the like, and is three-dimensional. While ensuring the strength of the modeled object, it is possible to suppress an increase in load such as separation work when removing the three-dimensional modeled object and molding work after removal.

The three-dimensional model manufacturing apparatus according to the eleventh aspect of the present invention includes a discharge unit that discharges a fluid composition containing particles of constituent materials of the three-dimensional model, and the tertiary when forming the three-dimensional model. A discharge portion that discharges a fluid composition containing support portion-forming particles that form a support portion that supports the original model, a fluid composition that includes the constituent material particles, and a fluid composition that includes the support portion-forming particles. It has a control unit that controls the formation of a layer by using It is characterized in that energy is applied so that the temperature of the support portion forming particles is equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the support portion forming particles.

According to this aspect, energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the supporting portion forming particles. Therefore, it is possible to suppress the sintering of the support portion while sintering the constituent material of the three-dimensional modeled object. Therefore, by sintering the portion other than the corresponding region of the three-dimensional modeled object, it is possible to suppress an increase in the load such as the separation work when removing the three-dimensional modeled object and the molding work after the removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

(A) is a schematic configuration diagram showing a configuration of a three-dimensional model manufacturing apparatus according to an embodiment of the present invention, and (b) is an enlarged view of part C shown in (a). (A) is a schematic configuration diagram showing the configuration of a three-dimensional model manufacturing apparatus according to one embodiment of the present invention, and (b) is an enlarged view of the C'part shown in (a). The external view of the head base according to one embodiment of the present invention from the D direction shown in FIG. 1 (b). FIG. 3 is a cross-sectional view of the EE portion shown in FIG. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The plan view which conceptually explains the relationship between the arrangement of the head unit which concerns on one Embodiment of this invention, and the formation form of the landing part. The schematic diagram which shows the example of other arrangement of the head unit arranged in a head base. The schematic diagram which shows the manufacturing process of the 3D model | object 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 manufacturing process of the 3D model | object 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 manufacturing process of the 3D model | object 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), but FIGS. 1 and 2 each represent only one material supply unit. It is a figure, and the other material supply part is omitted. Further, the material supply unit of FIG. 1 is a material supply unit that supplies a fluid composition (constituent material) containing constituent material particles of a three-dimensional model. Then, the material supply unit of FIG. 2 provides a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional model when forming the three-dimensional model. It is a material supply unit to be supplied. In addition, although the fluid composition containing the constituent material particles of this example and the fluid composition containing the support portion forming particles both contain a solvent and a binder, those which do not contain these may be used. ..
In addition, "three-dimensional modeling" in this specification indicates that a so-called three-dimensional model is formed, and for example, even if it is a flat plate shape, a so-called two-dimensional shape, a shape having a thickness is formed. It also includes doing. Further, "supporting" means supporting from the lower side, supporting from the side, and in some cases, supporting from the upper side.

The three-dimensional model manufacturing apparatus 2000 (hereinafter referred to as the forming apparatus 2000) shown in FIGS. 1 and 2 includes the base 110 and the X, Y, illustrated by the driving device 111 as the driving 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, a head base 1100 holding a plurality of head units 1400 having one end fixed to the base 110 and having a constituent material discharging portion for discharging the constituent material to the other end. It includes a head base support 130 that is held and fixed.
Further, as shown in FIG. 2, a head unit 1400'having a support portion forming material discharge portion having one end fixed to the base 110 and discharging the support portion forming material to the other end portion is provided. It is provided with a head base support portion 130'in which a plurality of head bases 1100' are held and fixed.
Here, the head base 1100 and the head base 1100'are provided in parallel on the XY plane.
The constituent material discharge portion 1230 and the support portion forming material discharge portion 1230'have the same configuration except that the discharged materials (constituent material and support portion forming material) are different. However, it is not limited to such a configuration.

Layers 501, 502, and 503 are formed on the stage 120 in the process of forming the three-dimensional model 500. Further, in the region facing the stage 120, the heating unit controller 1710 connected to the control unit 400, which will be described later, controls the on / off of the irradiation of heat energy, and the heating unit 1700 capable of heating the entire region of the stage 120 is provided. It is provided.
Since the heating unit 1700 irradiates (energizes) heat energy to form the three-dimensional model 500, a heat-resistant sample plate 121 is used to protect the stage 120 from heat. A three-dimensional model 500 may be formed on the 121. By using, for example, a ceramic plate as the sample plate 121, high heat resistance can be obtained, and the reactivity with the constituent materials of the three-dimensional model to be sintered is low, so that the three-dimensional model 500 can be altered. Can be prevented. In addition, in FIG. 1A and FIG. 2A, for convenience of explanation, three layers 501, 502 and 503 are illustrated, but up to the desired shape of the three-dimensional model 500 (FIGS. 1A and 1A and FIG. (Up to the layer 50n in FIG. 2A) is laminated.
Here, the layers 501, 502, 503, ... 50n are the support layer 300 formed of the support forming material discharged from the support forming material discharge portion 1230'and the constituent material discharging portion 1230, respectively. It is composed of a constituent layer 310 (a layer corresponding to a constituent region of the three-dimensional modeled object 500) formed of the constituent materials discharged from the vehicle. Further, after forming one layer of the constituent material discharged from the constituent material discharging portion 1230 and the supporting portion forming material discharged from the supporting portion forming material discharging portion 1230', the entire layer is covered. Thermal energy can be applied from the heating unit 1700 to sinter each layer. Furthermore, the shape of the three-dimensional model is completed by forming a plurality of layers of the constituent layer 310 and the support layer 300, and this is fired in a constant temperature bath (heating part) provided separately from the forming device 2000. It is also possible to connect.

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'part showing the head base 1100'shown in FIG. 2A. As shown in FIG. 2B, the head base 1100'holds a plurality of head units 1400'. The head unit 1400'is configured by holding the support portion forming material discharge portion 1230' provided in the support portion forming material supply device 1200' by the holding jig 1400a'. The support portion forming material discharge unit 1230' includes a discharge nozzle 1230a'and a discharge drive unit 1230b' that discharges the support portion forming material from the discharge nozzle 1230a'by the material supply controller 1500.

In the present embodiment, the heating unit 1700 will be described by an energy irradiation unit that irradiates electromagnetic waves as heat energy. By using electromagnetic waves for the heat energy to be irradiated, it is possible to efficiently irradiate the target supply material with energy, and it is possible to form a high-quality three-dimensional model. Further, for example, the amount of irradiation energy (power, scanning speed) can be easily controlled according to the type of material to be discharged, and a three-dimensional model of desired quality can be obtained. However, the configuration is not limited to such a configuration, and a configuration in which heating may be performed by another method may be used. Needless to say, it is not limited to being sintered by electromagnetic waves.

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, a material (a paste-like constituent material containing metal particles (constituent material particles)) containing a raw material of the three-dimensional model 500 formed by the forming apparatus 2000 according to the present embodiment is used as a supply material. It is housed in the component material accommodating part 1210a, and each component material accommodating part 1210a is connected to each component material discharge part 1230 by a supply tube 1220. 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 portion forming material discharge portion 1230'is a support portion forming material containing a support portion forming material corresponding to each of the head units 1400' held by the head base 1100'. It is connected to the supply unit 1210'by the supply tube 1220'. Then, a predetermined support portion forming material is supplied from the support portion forming material supply unit 1210'to the support portion forming material discharge portion 1230'. The support portion forming material supply unit 1210'is a paste-like support portion forming material containing ceramic particles (support portion forming particles) constituting the support portion forming the support portion when modeling the three-dimensional model 500. ) Is housed in the support material accommodating portion 1210a'as a supply material, and the individual support portion forming material accommodating portions 1210a' are connected to the individual support portion forming material discharge portions 1230' by the supply tube 1220'. Has been done. As described above, by providing the individual support portion forming material accommodating portions 1210a', a plurality of different types of support portion forming materials can be supplied from the head base 1100'.

As the constituent material, for example, a simple powder of magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or A slurry containing a mixed powder of an alloy containing one or more of these metals (malaging steel, stainless steel, cobalt chrome molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chrome alloy), a solvent, and a binder. It can be used as a mixed material in the form (or paste).
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 materials are not particularly limited, and metals other than the above metals, ceramics, resins, and the like can also be 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 dimethylsulfoxide and diethylsulfoxide; pyridine solvents such as pyridine, γ-picolin and 2,6-rutidine; tetra Examples thereof include ionic liquids such as alkylammonium acetate (for example, tetrabutylammonium acetate), 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 (polylactic acid), PPS (polyphenylene sulfide) or other thermoplastic resin.

In the present embodiment, the material for forming the support portion contains ceramics. As the material for forming the support portion, for example, a slurry-like (or paste-like) mixture obtained by kneading a mixed powder of a metal oxide, a metal alkoxide, a metal or the like with a solvent and a thickener as a binder. It is possible to use a material or the like.
However, the material for forming the support portion is not particularly limited, and metals and resins other than ceramics as in the above example of the constituent materials can also be used.

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. , The heating unit 1700, and the control unit 400 as a control means for controlling the support unit forming material discharge unit 1230' provided in the support unit forming material supply device 1200' are provided. Although not shown, the control unit 400 includes a stage 120, a component material discharge unit 1230, and a control unit that controls the stage 120 and the support unit forming material supply device 1200'to drive and operate in cooperation with each other. ing.

The stage 120 movably provided on the base 110 is a signal that controls 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 on the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The component 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 portion forming material discharge unit 1230' provided in the head unit 1400', the discharge drive unit 1230 b provided in the support portion forming material discharge unit 1230' 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 discharge nozzle 1230a'in' is generated, and a predetermined amount of material for forming a support portion is discharged from the discharge nozzle 1230a' by the generated signal.

Further, in the heating unit 1700, a control signal is sent from the control unit 400 to the heating unit controller 1710, and an output signal for irradiating the heating unit 1700 with an electromagnetic wave is transmitted from the heating unit controller 1710.

Next, the head unit 1400 will be described in more detail. The head unit 1400'has the same configuration as the head unit 1400, in which the support portion forming material discharge portion 1230'is configured in the same arrangement instead of the constituent material discharge portion 1230. Therefore, a detailed description of the configuration of the head unit 1400'will be omitted.
3 and 4 show an example of a holding form of the head unit 1400 held by the head base 1100 and the constituent material discharging unit 1230 held by the head unit 1400, and FIG. 3 shows an arrow shown in FIG. 1 (b). The external view of the head base 1100 from the D direction, FIG. 4 is a schematic cross-sectional view of the EE portion shown in FIG.

As shown in FIG. 3, a plurality of head units 1400 are held on the head base 1100 by fixing means (not shown). In the head base 1100 of the forming apparatus 2000 according to the present embodiment, the head units 1401 and 1402 in the first row, the head units 1403 and 1404 in the second row, and the head units 1405 and 1406 in the third row from the lower part of the drawing. It also includes eight head units 1400 of the fourth row head units 1407 and 1408. Although not shown, the component material discharge unit 1230 provided in each of the head units 1401 to 1408 is connected to the component material supply unit 1210 via the discharge drive unit 1230b by a supply tube 1220 and is held by the holding jig 1400a. It is composed.

As shown in FIG. 4, the component material discharge unit 1230 discharges the material M, which is a component material of the three-dimensional model, from the discharge nozzle 1230a toward the sample plate 121 placed on the stage 120. 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 in the forming apparatus 2000 of the present embodiment is in the form of droplets. However, a discharge nozzle 1230a having a continuous shape and capable of supplying a constituent material can also be used.

The material M discharged in the form of droplets from the discharge nozzle 1230a flies in the substantially gravitational direction and lands on the sample plate 121. Then, the landed material M forms the landing portion 50. The aggregate of the landing portions 50 is formed as a constituent layer 310 (see FIG. 1) of the three-dimensional model 500 formed on the sample plate 121.

5, 6 and 7 are plan views (viewing in the D direction shown in FIG. 1) that conceptually explain the relationship between the arrangement of the head unit 1400 and the formation form of the landing portion 50. First, as shown in FIG. 5A, at the modeling starting point q1 on the sample plate 121, the material M is discharged from the discharge nozzles 1230a of the head units 1401 and 1402, and the material M landed on the sample plate 121 causes the landing portion 50a. And 50b are formed. For convenience of explanation, although it is a plan view, the impacted portion 50 is hatched, and the constituent layer 310 of the first layer 501 formed on the upper surface of the sample plate 121 will be described as an example.

First, as shown in FIG. 5A, at the modeling starting point q1 of the constituent layer 310 of the layer 501 on the sample plate 121, from the constituent material discharge unit 1230 provided in the head units 1401 and 1402 in the first row below the drawing. Material M is discharged. The landing portions 50a and 50b are formed by the discharged material M.

FIG. 5 (b) shows the sample plate 121 in the Y (+) direction relative to the head base 1100 while continuing to discharge the material M from the constituent material discharge portions 1230 of the head units 1401 and 1402. The modeling start point q1 is moved to the position corresponding to the head units 1403 and 1404 in the second row. As a result, the landing portions 50a and 50b are extended while maintaining the width t from the modeling start point q1 to the position q2 after the relative movement of the sample plate 121. Further, the material M is discharged from the head units 1403 and 1404 in the second row corresponding to the modeling starting point q1, and the landing portions 50c and 50d begin to be formed.

As shown in FIG. 5B, the landing portions 50c and 50d begin to be formed, and the sample plate 121 is attached to the head base 1100 while continuing to eject the material M from the constituent material ejection portions 1230 of the head units 1403 and 1404. On the other hand, the modeling starting point q1 shown in FIG. 5C is moved relatively in the Y (+) direction to the position corresponding to the head units 1405 and 1406 in the third row. As a result, the landing portions 50c and 50d are extended while maintaining the width t from the modeling start point q1 to the position q2 after the movement of the sample plate 121. At the same time, the landing portions 50a and 50b are extended while maintaining the width t from the modeling start point q1 to the position q3 after the relative movement of the sample plate 121. The material M is discharged from the head units 1405 and 1406 in the third row corresponding to the modeling starting point q1, and the landing portions 50e and 50f begin to be formed.

As shown in FIG. 5C, the landing portions 50e and 50f begin to be formed, and the sample plate 121 is attached to the head base 1100 while continuing to eject the material M from the constituent material ejection portions 1230 of the head units 1405 and 1406. On the other hand, the modeling starting point q1 shown in FIG. 6D is moved relatively in the Y (+) direction to the position corresponding to the head units 1407 and 1408 in the fourth row. As a result, the landing portions 50e and 50f are extended while maintaining the width t from the modeling start point q1 to the position q2 after the movement of the sample plate 121. At the same time, the landing portions 50a and 50b maintain the width t from the modeling start point q1 to the position q4 after the relative movement of the sample plate 121, and the landing portions 50c and 50d from the modeling start point q1 to the position q3 after the relative movement of the sample plate 121. Will be extended. The material M is discharged from the head units 1407 and 1408 in the fourth row corresponding to the modeling starting point q1, and the landing portions 50 g and 50 h begin to be formed.

When the position q5 is set as the modeling end position (hereinafter, the position q5 is referred to as the modeling end point q5), as shown in FIG. 6 (e), the head units 1401 and 1402 relatively reach the modeling end point q5 of the sample plate 121. By moving to, the landing portions 50g and 50h are extended. Then, at the head units 1401 and 1402 that have reached the modeling end point q5, the discharge of the material M from the constituent material discharge unit 1230 of the head units 1401 and 1402 is stopped. Further, while relatively moving the sample plate 121 in the Y (+) direction, the material M is discharged from the constituent material discharge unit 1230 until the head units 1403, 1404, 1405, 1406, 1407, and 1408 reach the modeling end point q5. Will be done. Then, as shown in FIG. 7, the landing portions 50a, 50b, 50c, 50d, 50e, 50f, 50g and 50h are formed from the modeling start point q1 to the modeling end point q5 while maintaining the width t. In this way, while moving the sample plate 121 from the modeling start point q1 to the modeling end point q5, the material M is sequentially discharged and supplied from the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408. In the example of this embodiment having a width T and a length J, a substantially rectangular landing portion 50 can be formed. Then, the constituent layer 310 of the first layer 501 can be formed and configured as an aggregate of the landing portions 50.

As described above, the forming apparatus 2000 according to the present embodiment synchronizes with the movement of the stage 120 including the sample plate 121, and discharges the constituent materials provided for the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407, and 1408. By selectively discharging and supplying the material M from the portion 1230, the constituent layer 310 having a desired shape can be formed on the sample plate 121. Further, as described above, in this example, the stage 120 is moved only in one direction along the Y-axis direction, and the landing portion having a desired shape within the region of width T × length J shown in FIG. 50, and the constituent layer 310 as an aggregate of the landing portions 50 can be obtained.

Further, the material M discharged from the constituent material discharge unit 1230 is a constituent material different from the other head units from any one unit of the head units 1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408, or two or more units. Can also be discharged and supplied. 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 material for forming the support portion is discharged from the material discharge portion 1230'for forming the support portion, and the same method as described above is performed. Therefore, the support 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 1400' provided in the forming apparatus 2000 according to the above-described embodiment is not limited to the above-mentioned number and arrangement. FIG. 8 schematically shows an example of other arrangements of the head unit 1400 arranged on the head base 1100 as an example.

FIG. 8A 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. 8B 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, an example of a method for manufacturing a three-dimensional model performed by using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 9 is a schematic view showing an example of a manufacturing process of a three-dimensional modeled object performed by using the forming apparatus 2000. In this example, using the heating unit 1700 provided in the forming apparatus 2000, the constituent material and the supporting portion forming material are discharged from the constituent material discharging portion 1230 and the supporting portion forming material discharging portion 1230'for one layer. This is an example of a method for manufacturing a three-dimensional model, in which the layer is heated each time a layer is formed to produce the three-dimensional model. Further, in the method for manufacturing a three-dimensional model of the present embodiment, a three-dimensional model in a sintered state is manufactured.
In FIG. 9, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the constituent layer 310 can be easily understood.

First, as shown in FIG. 9A, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first layer is formed. In the eye layer 501, the constituent layer 310 and the support layer 300 are formed. Here, the support layer 300 is formed in a region other than the three-dimensional model formation region (region corresponding to the constituent layer 310) in the layer.
Next, as shown in FIG. 9B, the layer 501 of the first layer is heated by the heating unit 1700 to sinter the constituent layer 310 of the layer and temporarily sinter the support layer 300. The heating temperature of the heating unit 1700 in this embodiment is the temperature at which the metal particles (constituent material particles) contained in the constituent material are sintered, and the ceramic particles (support) contained in the material for forming the supporting portion. The temperature is set so that the part-forming particles) are temporarily sintered.
In addition, "temporary sintering" means that the sintering density is lower than that of normal sintering and the constituent material particles are bonded with a weak force, and in order to sinter the raw material, the material contained in the raw material in advance is used. It includes removing a part of the material and oxidizing a part of the material contained in the raw material.

Hereinafter, the operation represented by FIG. 9A and the operation represented by FIG. 9B are repeated to complete the three-dimensional modeled object.
Specifically, as shown in FIG. 9C, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first In the second layer 502, the constituent layer 310 and the support layer 300 are formed. Then, as shown in FIG. 9D, the second layer 501 is heated by the heating unit 1700.
Further, the constituent layer 310 and the support layer 300 are formed in the third layer layer 502 as shown in FIG. 9 (e), and the third layer layer 501 is formed as shown in FIG. 9 (f). Is heated by the heating unit 1700 to form the constituent layer 310 and the support layer 300 in the fourth layer 502 as shown in FIG. 9 (g), and as shown in FIG. 9 (h), the constituent layer 310 and the support layer 300 are formed. The fourth layer 501 is heated by the heating unit 1700 to complete a three-dimensional model (constructible layer 310 in a sintered state).

Next, an embodiment of the method for manufacturing the three-dimensional model represented by FIG. 9 will be described with reference to a flowchart.
Here, FIG. 10 is a flowchart of a method for manufacturing a three-dimensional model according to the present embodiment.

As shown in FIG. 10, 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 created. 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.
At this time, the generated bitmap data is data that is distinguished by the formed region of the three-dimensional modeled object and the non-formed area of the three-dimensional modeled object.

Next, in step S130, the constituent material is discharged (supplied) from the constituent material discharge unit 1230 based on the data for forming the formation region of the three-dimensional modeled object, and the constituent layer 310 is formed.

Next, in step S140, the support portion forming material is discharged (supplied) from the support portion forming material discharge portion 1230'based on the data for forming the non-forming region of the three-dimensional modeled object, and is configured in step S130. The support layer 300 corresponding to the same layer as the constituent layer 310 is formed.
The order of steps S130 and S140 may be reversed or may be simultaneous.

Next, in step S150, the layers corresponding to the constituent layer 310 composed of step S130 and the support layer 300 composed of step S140 are irradiated with electromagnetic waves (heat energy is applied) from the heating unit 1700. The constituent layer 310 in the layer is sintered and the support layer 300 is temporarily sintered.
In this step, the constituent layer 310 is sintered and the support layer 300 is temporarily sintered, but the support layer 300 may not be temporarily sintered.

Then, in step S160, steps S130 to S160 are repeated until the modeling of the three-dimensional modeled object based on the bitmap data corresponding to each layer generated in step S120 is completed.

Then, when the modeling of the three-dimensional model is completed, in step S170, the development of the three-dimensional model (the region corresponding to the constituent layer 310, which is the region for forming the three-dimensional model, is the non-formed region of the three-dimensional model. The portion corresponding to the support layer 300 is removed, that is, the three-dimensional model is cleaned), and the method for manufacturing the three-dimensional model of this embodiment is completed.

Next, another embodiment of the method for manufacturing a three-dimensional model formed by using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 11 is a schematic view showing an example of a manufacturing process of a three-dimensional modeled object performed by using the forming apparatus 2000. In this example, the heating unit 1700 provided in the forming apparatus 2000 is not used, and in a constant temperature bath (heating portion) (not shown) provided separately from the forming apparatus 2000, the constituent material discharge portion 1230 and the support portion are formed. After the constituent material and the material for forming the support portion are discharged from the material discharge portion 1230'and the formation of the shape of the three-dimensional model is completed, the formation of the three-dimensional model is heated to manufacture the three-dimensional model. This is an example of a method for manufacturing a three-dimensional model. Further, in the method for manufacturing a three-dimensional model of the present embodiment, a three-dimensional model in a sintered state is manufactured.
In FIG. 11, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the constituent layer 310 can be easily understood.

First, as shown in FIG. 11A, the constituent material is discharged from the constituent material discharging portion 1230, and the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the first layer is formed. In the eye layer 501, the constituent layer 310 and the support layer 300 are formed. Here, the support layer 300 is formed in a region other than the three-dimensional model formation region (region corresponding to the constituent layer 310) in the layer.
Next, as shown in FIG. 11B, the constituent material is discharged from the constituent material discharging portion 1230, the supporting portion forming material is discharged from the supporting portion forming material discharging portion 1230', and the second layer is formed. In the eye layer 502, the constituent layer 310 and the support layer 300 are formed.
Then, as shown in FIGS. 11 (c) and 11 (d), the operations shown in FIGS. 11 (a) and 11 (b) are repeated to complete the shape of the three-dimensional modeled object.
Then, as shown in FIG. 11 (e), the formed product of the three-dimensional model is heated in a constant temperature bath (not shown), and the constituent layer 310 of the three-dimensional model is sintered and supported. The layer 300 is temporarily sintered to complete a three-dimensional model (constituent layer 310 in a sintered state). The heating temperature in the constant temperature bath in this embodiment is the temperature at which the metal particles (constituent material particles) contained in the constituent material are sintered, and the ceramic particles (support) contained in the material for forming the support portion. The temperature is set so that the part-forming particles) are temporarily sintered.

Next, an embodiment of the method for manufacturing the three-dimensional model represented by FIG. 11 will be described with reference to a flowchart.
Here, FIG. 12 is a flowchart of a method for manufacturing a three-dimensional model according to the present embodiment.
Since steps S110 to S140 and step S170 in FIG. 12 are the same as steps S110 to S140 and step S170 in FIG. 9, description thereof will be omitted.

As shown in FIG. 12, in the method for manufacturing a three-dimensional model of the present embodiment, after the end of step S140, the process proceeds to step S160.
Then, in step S160, steps S130 to S160 are repeated until the modeling of the three-dimensional modeled product based on the bitmap data corresponding to each layer generated in step S120 is completed, and the three-dimensional modeled product is repeated. When the molding of the formed product is completed, the process proceeds to step S165.
In step S165, the constituent layer 310 and the support layer 300 are tentatively sintered in a constant temperature bath (not shown) for the formed body of the three-dimensional model formed by repeating steps S130 to S160. In this step, the constituent layer 310 is sintered and the support layer 300 is temporarily sintered, but the support layer 300 may not be temporarily sintered. Then, after the end of this step, step S170 is executed to end the method of manufacturing the three-dimensional modeled object of this embodiment.

As represented by the above two examples, the method for manufacturing the three-dimensional model of the present embodiment forms a fluid composition (constituent material) containing the constituent material particles of the three-dimensional model and the three-dimensional model. A layer forming step (step S130 and step) of forming a layer using a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional modeled object. S140). Then, it has an energy applying step (step S150 and step S165) of applying energy to the constituent material particles and the support portion forming particles. Further, in the energy application step, energy is applied so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the supporting portion forming particles.
For this reason, it is possible to suppress the sintering of the support portion while sintering the constituent materials of the three-dimensional model, and by sintering the portion other than the corresponding region of the three-dimensional model, the three-dimensional model can be produced. It is possible to suppress an increase in load such as separation work at the time of removal and molding work after removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

In other words, the three-dimensional model manufacturing apparatus (forming apparatus 2000) of this embodiment is a discharge unit (constituting material) that discharges a fluid composition (constituting material) containing the constituent material particles of the three-dimensional modeling. Discharge unit 1230) and a discharge unit that discharges a fluid composition (material for forming a support portion) containing support portion forming particles that form a support portion that supports the three-dimensional model when forming the three-dimensional model. A control unit (control unit 400) that controls the formation of a layer by using (support portion forming material discharge portion 1230'), a fluid composition containing constituent material particles, and a fluid composition containing support portion forming particles. ), And an energy imparting portion (heating portion 1700) that imparts energy to the constituent material particles and the support portion forming particles. Then, the energy applying portion is adjusted to apply energy so that the temperatures of the constituent material particles and the support portion forming particles are equal to or higher than the sintering temperature of the constituent material particles and lower than the sintering temperature of the supporting portion forming particles. ing.
For this reason, it is possible to suppress the sintering of the support portion while sintering the constituent materials of the three-dimensional model, and by sintering the portion other than the corresponding region of the three-dimensional model, the three-dimensional model can be produced. It is possible to suppress an increase in load such as separation work at the time of removal and molding work after removal. Therefore, it is possible to reduce the number of post-treatment steps after forming the three-dimensional model.

Further, in the layer forming step (step S130 and step S140) in the method for producing the three-dimensional model of the present embodiment, the fluid composition containing the constituent material particles and the fluid composition containing the support portion forming particles are droplets. Discharge in the state to form a layer. Therefore, a three-dimensional model can be formed by a simple method of forming a layer.

Further, the method for manufacturing a three-dimensional model of the present embodiment includes a laminating step (step S130 to step S160) in which the layer forming step (step S130 and step S140) is repeated. Therefore, by repeating the layer forming step, a three-dimensional model can be easily formed.

Further, the energy application step (step S165) in the method for manufacturing the three-dimensional model of the present embodiment shown in FIG. 12 is executed after the completion of the laminating step (steps S130 to S160). Therefore, the three-dimensional model can be sintered in one step after the shape of the three-dimensional model is formed.

Further, the method for manufacturing the three-dimensional modeled object of this embodiment includes a cleaning step (step S170) for cleaning the three-dimensional modeled object after the energy application step (step S150 and step S165). Therefore, it is possible to obtain a beautiful three-dimensional model.
In addition, "cleaning" means removing impurities such as support forming particles adhering around the sintered three-dimensional model.

Prior to the energy applying step (step S150 and step S165), a pre-energy applying step of applying energy weaker than the energy in the energy applying step and a removing step of removing the support portion forming particles are executed. May be good. Specifically, in the method for manufacturing a three-dimensional model represented by FIG. 10, a pre-energy applying step and a removing step are added between steps S140 and S150. Then, in the method for manufacturing the three-dimensional model represented by FIG. 12, the pre-energy applying step and the removing step are added so as to execute the pre-energy applying step and the removing step prior to step S165. By executing the pre-energy application step in this way, the shape of the three-dimensional model can be confirmed before the energy application process, and the shape of the three-dimensional model can be suppressed from being deformed before the energy application process. ..
The "pre-energy applying step" means, for example, heating the three-dimensional modeled object at a heating temperature lower than that of the energy applying step, and sinterings the constituent material particles with a force weaker than that of the energy applying step. It means to (temporarily sinter).
Here, FIG. 13 is a schematic view showing an example of a manufacturing process of a three-dimensional modeled object when the pre-energy applying step and the removing step are executed. FIG. 13A shows a three-dimensional model 500 before sintering (before the energy application process). 13 (b) shows a state in which the pre-energy applying step is executed from the state of FIG. 13 (a) and the constituent layer 310 is temporarily sintered (the support layer 300 is neither sintered nor temporarily sintered). Represents. Then, in FIG. 13 (c), the removal step is executed from the state of FIG. 13 (b), and the support portion forming particles around the three-dimensional model 500 are removed (the shape of the three-dimensional model can be confirmed). State). Then, FIG. 13 (e) shows a state in which the energy application step is executed from the state of FIG. 13 (c) and the three-dimensional model 500 is sintered in, for example, a constant temperature bath (not shown).

Here, further, in the energy application step (step S150 and step S165), as shown in FIG. 13D, the three-dimensional modeled object was supported by particles that were not sintered by the energy application in the energy application step. Energy can be applied in a state (a state in which the three-dimensional model 500 is supported by the support layer 300). In the energy application process, by applying energy in a state where the three-dimensional model object is supported by particles that are not sintered by energy application, the shape of the three-dimensional model object is suppressed from being deformed before the energy application process. , It is possible to suppress deformation of the shape of the three-dimensional modeled object in the energy application process.
The "particles that are not sintered by the energy application in the energy application step" may be the same particles as the support portion forming particles, but may be different particles. When the particles are different from the support-forming particles, it is preferable that the sintering temperature is higher than that of the support-forming particles.

Further, in the energy application step (step S150 and step S165) in the method for manufacturing the three-dimensional model of the present embodiment, the same energy is applied to the constituent material particles and the support portion forming particles (in step S150, the constituent material particles and the support). Both the part-forming particles are irradiated with electromagnetic waves from the heating unit 1700, and in step S165, the constituent material particles and the support portion-forming particles are collectively heated in a constant temperature bath (not shown). Therefore, the energy application step can be easily executed.

However, in the energy application step, different energy may be applied to the constituent material particles and the support portion forming particles. By applying different energies, it is possible to effectively prevent the parts other than the corresponding area of the 3D model from being excessively sintered, thereby performing separation work when removing the 3D model and after removing it. This is because it is possible to suppress an increase in the load of the molding work and the like.

The constituent material particles are particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel, and the support forming particles are silica, alumina, titanium oxide, and zircon oxide. It is preferable that the particles contain at least one of the components. The sintered state in the process of applying energy to the constituent material particles and the supporting member forming particles can be easily controlled from a high sintered density to a low sintered density, a non-sintered state, etc., and the strength of the three-dimensional molded product is ensured. This is because it is possible to suppress an increase in load such as separation work when removing the three-dimensional modeled object and molding work after removal.

The present invention is not limited to the above-described embodiment, and can be realized with various configurations within a range not deviating from the gist thereof. 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 part or all. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

50, 50a, 50b, 50c, 50d, 50e, 50f, 50g and 50h landing parts,
110 bases, 111 drives, 120 stages (supports),
121 sample plate, 130, 130'head base support,
300 support layer (support part), 310 constituent layer, 400 control unit (control part),
410 stage controller, 430 laser controller,
500 three-dimensional model, 501, 502 and 503 layers,
1100, 1100'head base,
1200 component material supply device, 1200'support part forming material supply device,
1210 Constituent material supply unit, 1210'Support unit forming material supply unit,
1210a Constituent material accommodating part, 1210a'Support part forming material accommodating part,
1220, 1220'feed tube,
1230 Constituent material discharge part, 1230'Support part formation material discharge part,
1230a, 12330a'Discharge nozzle, 1230b, 1230b' Discharge drive unit,
1400, 1400'head unit,
1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408 head units,
1400a, 1400a'holding jig, 1500 material supply controller,
1600, 1600'head base, 1700 heating part (energy applying part),
1710 Heating unit controller, 2000 forming device (manufacturing device for 3D model),
L laser, M material (constituent material)

Claims (4)

A step of forming a constituent layer by ejecting a constituent material containing metal particles and a thermoplastic resin from the first nozzle opening toward the stage in a continuous shape.
A support that supports the three-dimensional model when forming a three-dimensional model by ejecting a support-forming material containing ceramic particles and a thermoplastic resin from the second nozzle opening toward the stage in a continuous shape. The process of forming layers and
A laminating step of repeating the step of forming the constituent layer and the step of forming the support layer, and
After the completion of the laminating step, the laminated layer and the supporting layer are collectively heated in a sintering furnace with the same energy, and the energy applying step is provided.
The sintering temperature of the ceramic particles is higher than the sintering temperature of the metal particles.
The energy application step is
Wherein as metallic particles sintering temperature or higher and a temperature lower than the sintering temperature of the ceramic particles, have a first energy application step of heating the structure layer and the support layer are laminated,
Prior to the first energy application step, the laminated constituent layer and the support layer are heated at a temperature lower than that of the first energy application step to temporarily sinter the constituent material particles. Has an energy application process,
A method for producing a three-dimensional modeled object, which comprises a removing step of removing the ceramic particles between the first energy applying step and the second energy applying step. In the method for manufacturing a three-dimensional model according to claim 1,
A method for manufacturing a three-dimensional model, which comprises a cleaning step of cleaning the three-dimensional model after the first energy application step.
A method for manufacturing a three-dimensional model, which is characterized in that. In the method for manufacturing a three-dimensional model according to claim 1 or 2.
The first energy applying step is characterized in that the three-dimensional model is heated while the three-dimensional model is supported by particles that are not sintered at the heating temperature in the first energy application step. Production method. In the method for manufacturing a three-dimensional model according to any one of claims 1 to 3.
The metal particles are particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel, and the ceramic particles are at least one of silica, alumina, titanium oxide, and zircon oxide. A method for producing a three-dimensional model, characterized in that it is a particle containing one component.

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