JP6945470B2 - 付加造形体の製造システムおよび付加造形体の製造方法 - Google Patents
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Description
特許文献3には、3次元造形体を製造する方法であって、a)基材の表面にディスペンサを用いて粉末床を形成する工程と、b)平坦化装置によって粉末床を平坦化する工程と、c)粉末床の所定の領域において、粉末床の粉末をバインダ溶液によって結合するか、放射線を照射して粉末を溶融または焼結することによって粉末床を固化する工程と、(a)〜(c)のいずれかの間に平坦化後または固化後の粉末床の光学観察像を記録し、粉末床の平面内の欠陥サイトを評価する3次元造形体を製造する方法が開示されている(クレーム1)。
付加造形中の固化層の観察には、主に可視光画像および赤外光画像が用いられる。可視光画像からは、粉末層の塗布状態、固化層の空孔、割れおよび未溶融部の有無を評価できる。また、赤外光画像からは、溶融部の熱溜まりを検出することができる。これらの評価結果は、AM体の材料およびサイズ(厚さ)や、付加造形時の雰囲気、温度および熱源からの入熱量等の条件に依存して変化する。したがって、AM体を高い精度で評価するためには、これらの条件を考慮した上で評価する必要がある。
図1は本発明の付加造形体の製造システムの第1の例の模式図である。図1に示すように、本発明の付加造形体の製造システム1aは、大別すると、付加造形処理を行う付加造形装置10aと、付加造形装置10aで形成される粉末層および固化層の評価を行う検査装置20と、付加造形装置10aおよび検査装置20の制御を行う制御装置30とを備える。
図6は本発明の付加造形体の製造方法を示すフロー図である。以下、本発明の付加造形体の製造方法について、図1〜3および図6を参照しながら説明する。まず始めに、図1の粉末供給機13によって原料粉末保管領域110aから付加造形領域111aに原料粉末を移動し、粉末層を形成する(S1)。次に、可視光画像撮影機6によって粉末層を撮影し、可視光画像を取得する(S2)。撮影は、制御装置30の可視光画像処理部100の撮影条件データベース105に格納されている撮影条件によって実施される。そして、可視光画像処理部100によって、粉末層の状態が正常か否か(粉末層の良否)を判定する(S3)。リファレンスデータベース103に格納されている閾値データを元に観察エリアの凹凸の判定を行う。ここで不良判定が出た場合は、制御装置30は粉末層の形成をリトライするための専用動作指令を実行し、再度、粉末層形成(S1)および粉末層撮影(S2)が行われる。なお、S1〜S2の繰り返し数が指定回数に達した場合は、エラー発生として付加造形装置10aの動作を止めることができる。
Claims (6)
- 粉末を供給して粉末層を形成する工程と、熱源から前記粉末層に熱を供給し、前記粉末を溶融および凝固して固化層を形成する工程とを繰り返す付加造形処理を行う付加造形装置と、
前記粉末層または前記固化層を撮影する撮影機を有する検査装置と、
前記付加造形装置および前記検査装置の制御を行う制御装置とを備え、
前記撮影機は、可視光画像撮影機であり、繰り返し行われる前記粉末層を形成する工程ごとに前記粉末層を撮影可能であり、または繰り返し行われる前記固化層を形成する工程ごとに前記固化層を撮影可能であり、
前記制御装置は、前記付加造形処理の条件に応じて前記撮影機の撮影条件を選択し、前記可視光画像撮影機によって得られた画像を処理する可視光画像処理部を有し、
前記可視光画像処理部は、前記付加造形処理の条件に応じた前記撮影条件が保存された撮影条件データベースと、前記撮影条件を用いて前記可視光画像撮影機で撮影して得られた画像を解析する画像解析部と、前記画像解析部によって解析された画像と比較するためのリファレンスデータが格納されたリファレンスデータベースと、前記画像解析部によって解析された画像と前記リファレンスデータとを比較して前記粉末層または前記固化層の良否を判定する判定部と、前記判定部によって判定された結果を保存する記憶部とを有することを特徴とする付加造形体の製造システム。 - 前記付加造形装置は、前記付加造形処理における雰囲気を制御可能な処理室を有し、
前記制御装置は、前記処理室の雰囲気に応じて前記撮影機の撮影条件を選択することを特徴とする請求項1に記載の付加造形体の製造システム。 - 前記付加造形装置は、前記粉末層または前記固化層を加熱可能な加熱器を有し、
前記制御装置は、前記加熱器で加熱された前記粉末層または前記固化層の温度に応じて前記撮影機の撮影条件を選択することを特徴とする請求項1に記載の付加造形体の製造システム。 - 前記付加造形処理の条件は、前記粉末の材料、前記粉末層のサイズまたは前記熱源から前記粉末層または前記固化層へ供給される入熱量であることを特徴とする請求項1から3のいずれか1項に記載の付加造形体の製造システム。
- 前記撮影条件は、前記撮影のタイミング、前記撮影機の露光時間または前記撮影機の光源の照射条件であることを特徴とする請求項1から3のいずれか1項に記載の付加造形体の製造システム。
- 前記撮影機は、赤外線画像撮影機をさらに有し、前記画像解析部によって解析された画像と前記リファレンスデータとを比較して前記固化層の良否を前記判定部によって判定することを特徴とする請求項1に記載の付加造形体の製造システム。
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US16/970,185 US20210101332A1 (en) | 2018-02-23 | 2019-02-04 | Manufacturing system of additive manufacturing body and manufacturing method of additive manufacturing body |
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EP3159081B1 (en) * | 2015-10-21 | 2023-12-06 | Nikon SLM Solutions AG | Powder application arrangement comprising two cameras |
US10933468B2 (en) * | 2015-11-16 | 2021-03-02 | Renishaw Plc | Additive manufacturing method and apparatus |
JP6765666B2 (ja) * | 2016-07-12 | 2020-10-07 | 学校法人慶應義塾 | 立体物製造装置、立体物製造方法及びプログラム |
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2018
- 2018-02-23 JP JP2018030765A patent/JP6945470B2/ja active Active
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2019
- 2019-02-04 EP EP19757234.0A patent/EP3756859A4/en active Pending
- 2019-02-04 US US16/970,185 patent/US20210101332A1/en not_active Abandoned
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EP3756859A1 (en) | 2020-12-30 |
EP3756859A4 (en) | 2021-11-17 |
US20210101332A1 (en) | 2021-04-08 |
JP2019142184A (ja) | 2019-08-29 |
WO2019163495A1 (ja) | 2019-08-29 |
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