JP7021516B2 - Manufacturing method of 3D modeling equipment and 3D modeling - Google Patents

Description

The present invention comprises a three-dimensional modeling apparatus and a three-dimensional modeling apparatus including a layer forming portion for forming a layer of a composition containing a powder, a solvent and a binder, and a laser irradiation portion for melting or sintering the powder in the layer. It is related to the manufacturing method of the modeled object.

As an example of this type of three-dimensional modeling apparatus, the laminated modeling apparatus described in Patent Document 1 can be mentioned. This document discloses a technique of blowing off cutting powder with a gas injection device while cutting a protrusion-shaped abnormal sintered portion generated in the sintered layer.

Japanese Unexamined Patent Publication No. 2017-150048

When a layer is formed using a composition made by adding a binder for shape retention to a powder for modeling, when the layer is irradiated with laser light to melt the powder, the binder is decomposed by the energy of the laser light. Is removed from the layer. However, a part of it becomes a carbon residue like soot and adheres to the surface of the layer after the melting treatment. Most of this carbon residue is released to the outside of the layer during the melting treatment of the next layer, but a part of the carbon residue may remain as a carbonized solid solution in the modeled product.
Specifically, the carbon residue may be combined with the powder for modeling during the melting treatment to form a carbonized solid solution. This carbonized solid solution may reduce the target characteristics of the three-dimensional model to be modeled. As an example, low carbon steels such as SUS316L have an upper limit on the content of carbon components, but are defined by the carbonized solid solution produced when making a three-dimensional model made of the material of the low carbon steel. There is a risk of exceeding the upper limit of the carbon content.

Further, when the layer is melt-treated by irradiating with a laser, the sputtered particles are scattered. Some of the sputtered particles adhere to the surface of the layer after the melting treatment. Most of the sputtered particles are melted and disappeared when the laser irradiation of the next layer is performed, but some of the large sputtered particles grow and become larger when the next layer is formed. Further, when the laser irradiation of the next layer is performed, sputtered particles are newly scattered and adhere to the surface thereof. By repeating this process, the surface roughness of the final outer surface of the three-dimensional model may decrease.

An object of the present invention is to reduce the influence of carbon residue on a three-dimensional model.
Alternatively, the purpose is to suppress a decrease in the surface roughness of the final outer surface of the three-dimensional model due to the sputtered particles.

In order to achieve the above object, the three-dimensional modeling apparatus according to the first aspect of the present invention melts a layer forming portion forming a layer of a composition containing a powder, a solvent and a binder, and the powder in the layer. Alternatively, the removal unit includes a laser irradiation unit for sintering and a removal unit for removing deposits existing on the surface of the layer, and the removal unit removes deposits existing on the surface of the layer after laser irradiation by the laser irradiation unit. It is characterized by being controlled to be removed.
Here, "removal" is used in the present specification not only to completely remove the deposit, but also to include the fact that the abundance of the deposit can be reduced. ..

According to this aspect, the removing unit removes deposits existing on the surface of the layer after laser irradiation by the laser irradiation unit. As a result, the carbon residue (adhesion) generated when the layer is formed using the composition containing the binder is removed and the next layer is formed, so that the carbon residue may remain in the three-dimensional model. It is possible to reduce the risk of the carbonized solid solution remaining in the three-dimensional model.
Alternatively, the sputtered particles, which are the deposits that are scattered and adhered to the surface by the melting treatment by laser irradiation, are removed by the removing portion to form the next layer, so that the three-dimensional shaped object caused by the sputtered particles is formed. It is possible to suppress a decrease in the surface roughness of the final outer surface of the above.

In the first aspect, the three-dimensional modeling apparatus according to the second aspect of the present invention includes a solvent volatilizing unit that volatilizes the solvent in the layer, and the solvent volatilizing unit is irradiated with a laser by the laser irradiation unit. It is characterized in that it is controlled to volatilize the solvent in the layer before it is squeezed.

According to this aspect, the solvent volatilizer volatilizes the solvent in the layer before the laser irradiation is performed. As a result, the next laser irradiation can be performed with the solvent removed, and the problem of the carbon residue can be further reduced.

The three-dimensional modeling apparatus according to the third aspect of the present invention is characterized in that, in the first aspect or the second aspect, the removing portion is a wiping member that comes into contact with the surface of the layer and wipes off the deposits. And.

According to this aspect, since the removing portion is a wiping member such as a brush or a blade that comes into contact with the surface of the layer and wipes off the deposits, the structure can be simplified and the above effect can be obtained.

In the third aspect of the three-dimensional modeling apparatus of the fourth aspect of the present invention, the removing portion is a rotating brush, and the rotating brush is relative to the moving direction of the irradiation position of the layer by the laser irradiating portion. It is characterized by being movable.
Here, "relatively movable" means that the structure may be any of a structure in which the rotating brush moves, a structure in which the stage side supporting the layer moves, and a structure in which both move.

According to this aspect, since the rotating brush removes the deposits while moving, the deposits on the surface of the layer can be effectively removed.

In the three-dimensional modeling apparatus of the fifth aspect of the present invention, in the first aspect or the second aspect, the removing portion is a spraying member that blows gas onto the surface of the layer to remove the deposits. It is characterized by.

According to this aspect, since the deposit is removed by using a gas such as air, the removal process can be performed without physical contact with the surface of the layer, and the influence on the surface of the layer can be exerted. Can be reduced.

In the three-dimensional modeling apparatus of the sixth aspect of the present invention, in any one of the first to fifth aspects, the direction in which the deposit is removed from the surface of the layer by the removing portion and moves. It is characterized in that it is provided with a recovery unit for recovering the removed deposits.

According to this aspect, since the recovery portion of the removed deposit is provided, the risk of reattachment of the removed deposit can be reduced.

In the three-dimensional modeling apparatus according to the seventh aspect of the present invention, in any one of the first to sixth aspects, the layer forming portion is formed on the surface of the layer on which the deposit removal operation is performed. The next layer is formed by the above layer, and the removal operation is performed by the removing portion on the surface of the next layer, whereby a three-dimensional model composed of a plurality of layers is sequentially formed for each layer. It is characterized by that.

According to this aspect, a three-dimensional model having a multi-layer structure having the effects of each of the above aspects can be easily obtained.

In any one of the first to seventh aspects, the three-dimensional modeling apparatus according to the eighth aspect of the present invention has a layer forming portion, a laser irradiation portion and a removing portion, or the layer forming portion and a solvent volatilizing portion. The laser irradiation part and the removal part are housed in a sealed housing provided with a nitrogen gas introduction part and an exhaust part.
A stage that supports the layer of the composition is arranged in the housing, and the stage is the layer forming portion, the laser irradiation portion, and the removing portion, or the layer forming portion, the solvent volatilizing portion, the laser irradiation portion, and the removing portion. It is characterized in that it is configured so that it can be moved in order between and.

According to this aspect, a series of processes can be connected and processed in a closed housing. Further, since the housing is provided with a nitrogen gas introduction part and an exhaust part, it is possible to replace the nitrogen gas, and the influence of oxygen on the layer forming part, the solvent volatilizing part, the laser irradiation part, the removing part and the like. Can be reduced.
Further, by configuring the stage supporting the layer of the composition to be movable, it is not necessary to provide a complicated structure in which the layer forming portion, the solvent volatilizing portion, the laser irradiation portion and the removing portion are individually movable. However, the formation of each layer and the removal of deposits can be realized with a simple structure.

The method for producing a three-dimensional model according to a ninth aspect of the present invention includes a layer forming step of forming a layer of a composition containing a powder, a solvent and a binder, and a laser for melting or sintering the powder in the layer. It has an irradiation step and a removal step of removing deposits existing on the surface of the layer, and the removal step removes deposits existing on the surface of the layer after laser irradiation by the laser irradiation step. It is characterized by that.

According to this aspect, the same effect as described in the three-dimensional modeling apparatus of the first aspect can be obtained.

FIG. 6 is a device configuration diagram showing an outline of the three-dimensional modeling device according to the first embodiment of the present invention, in the case where a stage is located in a layer forming portion. The apparatus block diagram which shows the outline of the 3D modeling apparatus which concerns on Embodiment 1 of this invention, and the stage is located in the solvent volatilization part. The device block diagram which shows the outline of the 3D modeling apparatus which concerns on Embodiment 1 of this invention, when the stage is located in the laser irradiation part. The apparatus block diagram which shows the outline of the 3D modeling apparatus which concerns on Embodiment 1 of this invention, and the stage is located in the removal part. The side sectional view which shows the action of the laser irradiation part at the time of forming the 1st layer in the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The side sectional view which shows the action of the removal part at the time of forming the 1st layer in the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The side sectional view which shows the action of the layer forming part at the time of forming the 2nd layer in the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The graph which shows the effect of the improvement of the surface roughness in the 3D model formed by the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The graph which shows the effect of the improvement of the surface roughness (maximum height) in the 3D model formed by the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The graph which shows the effect of the improvement of the average surface roughness in the 3D model under formation by the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The plan view which shows the adhesion state of the carbon residue (adhesion) immediately after the laser irradiation in the 3D modeling | formation | formation | formation which concerns on Embodiment 1 of this invention. The plan view which shows the adhesion state of the carbon residue (adhesion) after removal of the deposit in the 3D model formed by the 3D modeling apparatus which concerns on Embodiment 1 of this invention. The apparatus block diagram which shows the outline of the 3D modeling apparatus which concerns on Embodiment 2 of this invention, and the stage is located in the removal part. A side sectional view schematically showing the state of scattering of carbon residue and sputtered particles generated when the formed first layer is irradiated with a laser. A side sectional view schematically showing how carbon residues and sputtered particles adhere to the surface of the formed first layer. A side sectional view schematically showing a problem in forming a second layer to be a next layer on the upper surface of the formed first layer.

Hereinafter, a three-dimensional modeling apparatus and a method for manufacturing a three-dimensional model according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
In the following description, the overall configuration of the three-dimensional modeling apparatus of the present invention will be described first, taking as an example the three-dimensional modeling apparatus according to the first embodiment shown in FIGS. 1 to 4 and 5A, 5B, and 5C. Next, the contents of the method for manufacturing a three-dimensional model of the present invention, which is executed by using the three-dimensional modeling device, will be described.

Next, FIG. 6 shows the effect of improving the surface roughness and the adhesion of carbon residue in the three-dimensional model manufactured by the three-dimensional model device and the method for manufacturing the three-dimensional model according to the first embodiment configured in this way. , 7A, 7B, 8A, 8B will be described based on the graphs.
Subsequently, FIGS. 10A, 10B, and 10C showing the conventional problems and FIGS. 5A, 5B, and 5C showing the operation of the three-dimensional modeling apparatus according to the first embodiment of the present invention are compared with each other to relate to the first embodiment. We will verify the effects of the 3D modeling device and the manufacturing method of the 3D model.
Next, the configuration of the three-dimensional modeling apparatus according to the second embodiment shown in FIG. 9, the contents of the manufacturing method of the three-dimensional modeling object executed by using the three-dimensional modeling apparatus, and their actions and effects. , The difference from the first embodiment will be mainly described.
Finally, we will refer to these two embodiments and other embodiments that differ in partial configuration.

◆◆◆ Embodiment 1 (see FIGS. 1 to 4, 5A, 5B, 5C and 10A, 10B, 10C) ◆◆
(1) Overall configuration of the three-dimensional modeling device (see FIGS. 1 to 4 and 5A, 5B, 5C)
In the three-dimensional modeling apparatus 1A according to the present embodiment, the layer 11 of the composition 9 (FIG. 5 (C)) containing the powder 3, the solvent 5, and the binder 7 is formed into a first layer 11A, a second layer 11B, and so on. It is an apparatus for manufacturing a three-dimensional model A having a multi-layer structure by sequentially forming the nth layer 11N. Here, the powder 3 is a modeling material that is melt-solidified or sintered to form a three-dimensional model. The solvent 5 is a component for forming the composition 9 into a paste. The binder 7 is a shape-retaining component for maintaining the shape of the layer 11 formed by discharging the composition 9 onto the stage 31 by the layer forming portion 13 described later.

Further, in this three-dimensional modeling apparatus 1A, the layer forming portion 13 forming the layer 11, the solvent volatilizing portion 15 for volatilizing the solvent 5 in the layer 11, and the laser irradiation for melting or sintering the powder 3 in the layer 11 are performed. It is basically composed of a portion 17 and a removing portion 19 for removing deposits 21 and 23 existing on the surface of the layer 11.
Then, in the three-dimensional modeling apparatus 1A according to the present embodiment, the removing unit 19 is a control unit (not shown) so as to remove the deposits 21 and 23 existing on the surface of the layer 11 after the laser irradiation by the laser irradiation unit 17. Controlled by.

<Powder>
Here, as the powder 3, a metal powder or a ceramic powder can be used as an example. As the metal powder, granular or powdery particles such as various metals and metal compounds can be used.
Specifically, various metals such as aluminum, titanium, iron, copper, magnesium, stainless steel, and malaging steel, silica, alumina, titanium oxide, zinc oxide, zircon oxide, tin oxide, magnesium oxide, potassium titanate, etc. Various metal oxides, various metal hydroxides such as magnesium hydroxide, aluminum hydroxide, calcium hydroxide, various metal nitrides such as silicon nitrogen, titanium nitrogen, aluminum nitride, various types of silicon carbide, titanium carbide, aluminum nitride, etc. Metal nitrides, various metal carbon residues such as silicon carbide and titanium carbide, various metal sulfides such as zinc sulfide, carbonates of various metals such as calcium carbonate and magnesium carbonate, sulfates of various metals such as calcium sulfate and magnesium sulfate. , Phostoates of various metals such as calcium silicate and magnesium silicate, phosphates of various metals such as calcium phosphate, borates of various metals such as aluminum borate and magnesium borate, and composite compounds thereof, etc. Powders such as gypsum (each hydrate of calcium sulfate, anhydride of calcium sulfate) can be used.

<Solvent>
The solvent 5 includes, for example, various types of water such as distilled water, pure water, and RO water, as well as alcohols such as methanol, ethanol, 2-propanol, 1-butanol, 2-butanol, octanol, ethylene glycol, diethylene glycol, and glycerin. Ethers (cellosolves) such as ethylene glycol monomethyl ether (methyl cellosolve), esters such as methyl acetate, ethyl acetate, butyl acetate, ethyl formate, acetone, methyl ethyl ketone, diethyl ketone, methyl isobutyl ketone, methyl isopropyl ketone, cyclohexanone, etc. Ketones, aliphatic hydrocarbons such as pentane, hexane, octane, cyclic hydrocarbons such as cyclohexane and methylcyclohexane, benzene, toluene, xylene, hexylbenzene, hebutylbenzene, octylbenzene, nonylbenzene, decylbenzene. , Undecylbenzene, Dodecylbenzene, Tridecylbenzene, Tetradecylbenzene and other long-chain alkyl groups and aromatic charcoal hydrogens having a benzene ring, methylene chloride, chloroform, carbon tetrachloride, halogenation of 1,2-dichloroethane and the like. Aromatic heterocycles containing any one of hydrocarbons, pyridine, pyrazine, furan, pyrrol, thiophene, methylpyrrolidone, nitriles such as acetonitol, propionitrile, acrylonitrile, N, N-dimethylamide, N, Examples thereof include amides such as N-dimethylacetamide, carboxylates and various other oils.

<Binder>
The binder 7 is not limited as long as it is soluble in the above-mentioned solvent 5. For example, acrylic resin, epoxy resin, silicone resin, cellulosic resin, synthetic resin and the like can be used. Further, for example, a thermoplastic resin such as PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide) can also be used.
Further, it may be dispersed in the above-mentioned solvent 5 in the state of fine particles of a resin such as the above-mentioned acrylic resin instead of the soluble state.
Incidentally, in this embodiment, SUS316L (D50 = diameter 3 μm), which is a metal powder, was used as the powder 3, propylene glycol (PG) was used as the solvent 5, and polyvinyl alcohol (PVA) was used as the binder 7 as an example. Further, as an example, the volume ratio when these were mixed to form a paste-like composition 9 was 30 vol% for the powder 3, 68 vol% for the solvent 5, and 2 vol% for the binder 7.

<Adhesion>
As the deposits 21 and 23 removed by the removing unit 19, as shown in FIG. 10A, the above-mentioned carbon residue generated by decomposing the binder 7 during melting or sintering by the laser irradiated by the laser irradiation unit 17 Examples thereof include the spatter particles 23 that scatter when the powder 3 of the modeling material is irradiated with a laser.
As shown in FIG. 10B, these carbon residues 21 and spatter particles 23 adhere to the surface of the layer 11 (for example, the first layer 11A) after laser irradiation. When the process proceeds to the laminating step of, for example, the second layer 11B, which is the next layer in this adhered state, as shown in FIG. 10C, the second layer 11B contains the carbon residue 21 and the sputtered particles 23. Layers 11B are laminated. When the treatment of irradiating the laser in this state is performed, the carbon residue 21 is decomposed together with the binder in the second layer 11B and most of it is released to the outside of the layer 11, but a part of it is in the modeled object (inside the layer). It may remain as a carbonized solid solution (not shown).
Most of the sputtered particles 23 are melted and disappeared when the next layer (second layer 11B) is irradiated with the laser, but some of the large sputtered particles 23 are irradiated with the laser when the next layer (second layer 11B) is formed. There are some that cannot be completely melted and grow as convex parts and become even larger. Further, when the next layer (second layer 11B) is formed, sputter particles are newly scattered and adhere to the surface thereof. By repeating this process, unevenness appears on the outer surface of the three-dimensional model A, which causes a decrease in surface roughness.

Further, in the present embodiment, as shown in FIGS. 1 to 4, the layer forming section 13, the solvent volatilizing section 15, the laser irradiation section 17, and the removing section 19 are the nitrogen gas _N2 introduction section 25 and the exhaust section 27. It is housed in a hermetically sealed housing 29.
Further, a stage 31 that supports the layer 11 of the composition 9 is arranged in the housing 29. The stage 31 has a forward direction X1 in a feed direction X and a return direction X2 by a transport means (not shown) so that the layer forming unit 13, the solvent volatilization unit 15, the laser irradiation unit 17, and the removal unit 19 can be sequentially moved. It is configured to be able to move freely to.

<Layer forming part>
The layer forming portion 13 is provided with a dispenser 33 provided with a drawing head 35 that can move in the scanning direction Y intersecting the feed direction X of the stage 31 and the stacking direction Z of the layers 11. Further, in the present embodiment, the layer forming portion 13 is arranged at the upstream position in the feed direction X at the left end in FIGS. 1 to 4.
A paste-like composition 9 containing the powder 3, the solvent 5, and the binder 7 described above is supplied to the layer forming portion 13, and the drawing head 35 is scanned in the scanning direction Y and the stage 31 is scanned in the feeding direction X. By moving and moving the drawing head 35 to a predetermined position and discharging the paste-like composition 9 from the discharge port 37 (FIG. 5 (C)), the layer 11 (for example, the first layer) composed of a predetermined drawing pattern is discharged. 1 layer 11A) is formed. Further, when one layer 11 is formed, the drawing head 35 is raised in the stacking direction Z by the thickness of the layer 11 to shift to the formation of the next layer 11 (for example, the second layer 11B).

<Solvent volatilization part>
The solvent volatilization unit 15 is a portion where the solvent 5 is dried and volatilized as described above. The solvent volatilization unit 15 is provided with a line-shaped lamp heater 39 as an example, and heat from the line-shaped lamp heater 39 acts on the layer 11 on the stage 31 that has moved to the solvent volatilization unit 15. Volatilize solvent 5.
In the present embodiment, as shown in FIGS. 1 to 4, the solvent volatilization section 15 is arranged at a position downstream of the feed direction X adjacent to the layer forming section 13. As a result, the solvent volatilizing unit 15 acts on the layer 11 before the laser irradiation by the laser irradiation unit 17 is performed to volatilize the solvent 5 in the layer 11.

<Laser irradiation part>
The laser irradiation unit 17 causes the powder 3 (including the binder 7) in the layer 11 to act on the laser light E irradiated based on the control signal transmitted from the control unit (not shown) to the powder 3 as described above. This is the part to be melted or sintered. As an example, the laser irradiation unit 17 is provided with a laser oscillator 41 that oscillates a laser beam E having a predetermined output on the optical path of the laser beam E oscillated from the laser oscillator 41, and the laser beam E is provided on the layer 11 on the stage 31. A laser irradiation device including a galvano mirror 43 that leads to the above is provided.
The galvano mirror 43 is configured so that the reflection angle with respect to the laser light E can be changed, and the laser light E can be freely scanned in the scanning direction Y by adjusting the reflection angle of the galvano mirror 43. It is configured.
The laser irradiation device used in the present embodiment is not particularly limited, but a fiber laser can be used as a suitable laser irradiation device because it has an advantage of high metal absorption efficiency.

<Removal part>
As described above, the removing unit 19 is a portion controlled to act on the surface of the layer 11 after laser irradiation to remove the deposits 21 and 23 existing on the surface of the layer 11.
In the present embodiment, the removing portion 19 is composed of a wiping member 45 that comes into contact with the surface of the layer 11 and wipes off the deposits 21 and 23, specifically, a rotating brush 47. The rotating brush 47 is configured to be relatively movable in the moving direction of the irradiation position of the laser beam E with respect to the layer 11 by the laser irradiation unit 17 by moving the feed direction X of the stage 31.

Further, as shown in FIG. 5B, the rotary brush 47 is configured to be rotationally driven in the direction of collecting the deposits 21 and 23 as an example, and the collection direction of the deposits 21 and 23 is shown in FIG. 5B. As described above, it is preferable to set the dispenser 33 in the direction opposite to the direction in which the dispenser 33 is arranged (downstream direction of the feed direction X).
In the present embodiment, as shown in FIG. 5B, the recovery unit 49 is provided in the direction in which the deposits 21 and 23 are removed from the surface of the layer 11 by the removal unit 19 (rotating brush 47) and move, that is, in the collection direction. There is. The collecting unit 49 is configured to collect the deposits 21 and 23 removed by the rotating brush 47. Further, in order to smoothly and surely collect the deposits 21 and 23 to the recovery unit 49, the collection unit 49 shall be provided with suction means or the like for sucking the deposits 21 and 23 and guiding them to the collection unit 49. Is desirable.

Then, in the present embodiment, as shown in FIG. 5C, the composition 9 is formed on the surface of the layer 11 (for example, the first layer 11A) on which the deposits 21 and 23 have been removed by the dispenser 33 of the layer forming portion 13. Is discharged to form the next layer (for example, the second layer 11B). At the time of forming the layer by this ejection, the removing portion 19 (rotating brush 47) is moved to the retracted position so as not to touch the next layer.
Further, although not shown, the removal unit 19 is applied to the surface of the next layer (for example, the second layer 11B) after the next layer is irradiated with the laser beam E and the laser irradiation treatment is performed. (Rotating brush 47) executes the operation of removing the deposits 21 and 23. Then, by repeating the formation of the layer 11 and the removal of the deposits 21 and 23 a predetermined number of times, the three-dimensional model A composed of the plurality of layers 11 is sequentially formed for each layer 11.

(2) Contents of the manufacturing method of the three-dimensional model (see FIGS. 1 to 4 and 5A, 5B, 5C)
The method for manufacturing a three-dimensional model according to the present embodiment is basically configured by having a layer forming step P1, a laser irradiation step P3, and a removing step P4. Further, in the present embodiment, the solvent volatilization step P2 is provided between the layer forming step P1 and the laser irradiation step P3, and the layer forming step P1, the solvent volatilization step P2, the laser irradiation step P3, and the removal step P4 are provided. A method for manufacturing a three-dimensional model is configured by having the four steps of.
Then, in the removing step P4, the deposits 21 and 23 existing on the surface of the layer 11 are removed after the laser irradiation by the laser irradiation step P3. Hereinafter, the contents of the above four steps will be specifically described along with the flow of manufacturing the three-dimensional model A.

(A) Layer forming step (see FIG. 1)
The layer forming step P1 is a step of forming the layer 11 of the composition 9 containing the powder 3, the solvent 5, and the binder 7.
That is, as shown in FIG. 1, the stage 31 is positioned at the formation start position of the layer 11 of the layer forming portion 13, the stage 31 is moved in the feed direction X, and the drawing head 35 is scanned in the scanning direction Y while the drawing head 35 is scanned. By discharging the paste-like composition 9 containing the powder 3, the solvent 5, and the binder 7 from the discharge port 37 of the above, a layer 11 (for example, the first layer 11A) composed of a predetermined drawing pattern is formed.
Prior to the formation of the layer 11, the housing 29 is sealed so that the nitrogen gas N ₂ can be replaced.

(B) Solvent volatilization step (see FIG. 2)
The solvent volatilization step P2 is a step of volatilizing the solvent 5 in the formed layer 11.
That is, as shown in FIG. 2, the stage 31 is moved to a position downstream of the feed direction X by a predetermined distance to be positioned at the solvent volatilization start position of the solvent volatilization unit 15, and the stage 31 is moved in the feed direction X while the linear lamp. The heat of the heater 39 is applied to the layer 11 on the stage 31, whereby the solvent 5 in the layer 11 is dried and volatilized.
Since the length of the line-shaped lamp heater 39 extending in the scanning direction Y is set to a length that can cover the width of the layer 11 (the length of the scanning direction Y), in the present embodiment, the scanning of the solvent volatilization unit 15 is performed. No scanning is performed in the direction Y.

(C) Laser irradiation step (see FIGS. 3 and 5A)
The laser irradiation step P3 is a step of irradiating the powder 3 in the layer 11 in which the solvent 5 has volatilized with the laser beam E to melt or sintered the powder 3.
That is, as shown in FIG. 3, the stage 31 is moved to a position downstream of the feed direction X by a predetermined distance to be positioned at the irradiation start position of the laser beam E of the laser irradiation unit 17, and the stage 31 is moved in the feed direction X. The galvano mirror 43 is swung to scan the laser beam E in the scanning direction Y, and the laser beam E is applied to the layer 11 on the stage 31 to melt or sintered the powder 3 in the layer 11.
As shown in FIG. 5A, the laser irradiation causes the carbon residue 21 and the sputtered particles 23 to adhere to the surface of the layer 11.

(D) Removal step (see FIGS. 4 and 5B and 5C)
The removal step P4 is a step of removing the deposits 21 and 23 existing on the surface of the layer 11 generated by the laser irradiation.
That is, as shown in FIG. 4, the stage 31 is moved to the upstream position of the feed direction X by a predetermined distance to be positioned at the removal start position of the deposits 21 and 23 by the removing unit 19, and the stage 31 is moved to the return direction of the feed direction X. While moving to X2, the rotating brush 47 rotating in the recovery direction is brought into contact with the surface of the layer 11 on the stage 31 to scrape off the deposits 21 and 23.
The removed deposits 21 and 23 are, for example, sucked and collected by the collection unit 49.

After the removal of the deposits 21 and 23 is completed, the stage 31 returns to the formation start position of the next layer 11. In forming the next layer (for example, the second layer 11B), the action positions of the layer forming portion 13, the solvent volatilizing portion 15, the laser irradiation portion 17 and the removing portion 19 are raised by the thickness of the layer 11. The four steps described above are performed again.
Hereinafter, the three-dimensional model A having a multi-layer structure is formed by repeating the same operation according to the number of layers 11 to be laminated.

(3) Effect of improving surface roughness and carbon residue adhesion in 3D modeled object (see FIGS. 6 and 7A-8B)
(A) Effect of improving surface roughness (see FIGS. 6, 7A, 7B)
FIG. 6 shows the formed molding with and without the removal portion 19 when the irradiation conditions of the laser beam E are 150 W for the output, 500 mm / s for the speed, and 0.04 mm for the drawing pitch. The relationship with the maximum height (Sz value) of the surface roughness of the object surface is shown.
As is clear from the figure, when the removing portion 19 is provided, the maximum height (Sz value) of the surface roughness is about half as compared with the case where the removing portion 19 is not provided, which is a significant effect of improving the surface roughness. Has been obtained.

Further, FIG. 7A compares the maximum height (Sz value) of the surface roughness when the removing portion 19 is provided and when the removing portion 19 is not provided, and FIG. 7B shows the average when the removing portion 19 is provided and when the removing portion 19 is not provided. The surface roughness (Sa value) is compared.
As is clear from the figure, by providing the removing portion 19, it was confirmed that the surface roughness was significantly improved in both the maximum height (Sz value) and the average surface roughness (Sa value) of the surface roughness.

(B) Effect of improving carbon residue adhesion (see FIGS. 8A and 8B)
8A and 8B show the case where the irradiation conditions of the laser beam E are set to an output of 75 W, a speed of 200 mm / s, a drawing pitch of 0.04 mm, and a layer 11 having a thickness of 50 μm is formed in an atmosphere in which the nitrogen gas _N2 is substituted. The state of the surface of the layer 11 is illustrated. FIG. 8A shows a state immediately after laser irradiation, and FIG. 8B shows a state in which the carbon residue 21 as an deposit is removed by the removing unit 19 after laser irradiation.
As is clear from the figure, when the carbon residue 21 is removed by using the removing portion 19, the number of carbon residues 21 present on the surface of the layer 11 is significantly reduced and the original metal surface appears more. Become.

(4) Effect of the three-dimensional modeling apparatus and the manufacturing method of the three-dimensional model according to the present embodiment (see FIGS. 5A-5C and 10A-10C).
FIG. 10C shows that the formation of the next layer 11 (for example, the second layer 11B) is started with the carbon residue 21 and the sputtered particles 23 adhering to the surface of the layer 11 (for example, the first layer 11A) after the laser irradiation. As described above, the second layer 11B is laminated with the carbon residue 21 and the sputtered particles 23 present in the second layer 11B. When the treatment of irradiating the laser in this state is performed, the above-mentioned carbonized solid solution remains in the three-dimensional model A, or spatter particles grow and appear as irregularities on the outer surface of the three-dimensional model A. The roughness is reduced.

On the other hand, in the present embodiment, after the laser irradiation shown in FIG. 5A, the carbon residue 21 and the spatter particles 23 adhering to the surface of the layer 11 (for example, the first layer 11A) are removed by the removing unit 19 as shown in FIG. 5B. It is collected and collected by the collection unit 49. As a result, as shown in FIG. 5C, when the next layer 11 (for example, the second layer 11B) is formed, the carbon residue 21 and the spatter particles 23 adhering to the surface of the layer 11 (for example, the first layer 11A) are separated. It is extremely low.
Therefore, according to the three-dimensional modeling apparatus 1A and the method for manufacturing a three-dimensional model according to the present embodiment, the carbonized solid solution resulting from the carbon residue 21 produced by laser irradiation remains in the three-dimensional model A. It is possible to reduce the risk of an increase in carbon content exceeding the specified value. Further, it is possible to reduce the decrease in the surface roughness of the final outer surface of the three-dimensional model A due to the sputtered particles 23.

◆◆◆ Embodiment 2 (see Fig. 9) ◆◆◆
The three-dimensional modeling apparatus 1B according to the second embodiment is the same as the first embodiment except that the configuration of the removing unit 19 is different from the three-dimensional modeling apparatus 1A according to the first embodiment. Therefore, the description of the same configuration as that of the first embodiment will be omitted here, and the configuration of the removal unit 19 and its operation, which are different from those of the first embodiment, will be mainly described.

That is, in the present embodiment, the removing portion 19 is composed of a spraying member 51 that blows a gas G such as air onto the surface of the layer 11 to remove the deposits 21 and 23. The spraying member 51 is provided with the mounting angle of the spraying member 51 slightly inclined so that the direction of the gas G sprayed from the spraying member 51 faces the recovery direction of the deposits 21 and 23.

Further, by providing such a removal unit 19, in the removal step P4 in the method for manufacturing a three-dimensional model, the stage 31 is fed in the feed direction X with respect to the surface of the layer 11 on the stage 31 that has reached the removal start position. While moving in the return direction X2, the gas G is sprayed from the spraying member 51 to collect the deposits 21 and 23 to the collecting unit 49.
Further, the three-dimensional modeling apparatus 1B according to the present embodiment configured in this way also exhibits the same operations and effects as the three-dimensional modeling apparatus 1A according to the first embodiment, and carbonization in the three-dimensional modeling object A is exhibited. The residual solid solution (due to the carbon residue 21) and the decrease in the surface roughness of the outer surface of the three-dimensional model A are reduced.
Further, in the case of the second embodiment, since the deposits 21 and 23 can be removed without directly contacting the surface of the layer 11, it is possible to reduce the damage to the surface of the layer 11.

[Other embodiments]
The three-dimensional modeling apparatus 1 and the method for manufacturing a three-dimensional model according to the present invention are based on having the above-described configuration, but are partially within the scope of the gist of the present invention. Of course, it is also possible to change or omit the configuration.
For example, the type of removing portion 19 that directly contacts the surface of the layer 11 and removes the deposits 21 and 23 by scraping off is a plate-shaped flat brush, a blade, or the like, in addition to the above-mentioned rotating brush 47. May be good. Further, as the type of removing unit 19 that does not contact the surface of the layer 11 or indirectly contacts via another medium, in addition to the above-mentioned gas G sprayed, sandblast or dry ice particles are sprayed onto the surface of the layer 10. The deposits 21 and 23 may be removed, or the deposits 21 and 23 may be removed by spraying a liquid such as water or oil.

In addition, it is also possible to reduce the output or the like on the surface of the layer 11 and irradiate the surface with laser light E at a level that does not affect the surface to remove the deposits 21 and 23. These different types of removing units 19 can be used individually, or a plurality of different types of removing units 19 can be used in combination.
Further, as described above, by moving the stage 31 in the feed direction X, each of the four processing units of the layer forming unit 13, the solvent volatilizing unit 15, the laser irradiation unit 17, and the removing unit 19 is sequentially executed. Not limited to this, the stage 31 side can be fixed and the four processing unit sides of the layer forming unit 13, the solvent volatilizing unit 15, the laser irradiation unit 17, and the removing unit 19 can be moved or retracted toward the stage 31. It is possible. Further, it is also possible to movably configure both the stage 31 side and the four processing units 13, 15, 17, and 19.

Further, the moving means in the stacking direction Z, which is necessary when stacking the plurality of layers 11, is provided for the four processing units 13, 15, 17, and 19, and also provided on the stage 31 side, or these four. It can be provided on both the processing units 13, 15, 17, 19 and the stage 31 side.
Further, when the solvent 5 can be volatilized at the same time by the irradiation of the laser beam E by the laser irradiation unit 17, the solvent volatilization unit 15 can be omitted from the configuration of the three-dimensional modeling apparatus 1, and the solvent described above can be omitted. The volatilization step P2 can be omitted from the configuration of the manufacturing method of the three-dimensional model.

Further, the removing unit 19 can be arranged at a position downstream of the feeding direction X of the layer forming unit 13 and can be arranged further downstream of the feeding direction X of the laser irradiation unit 17. Further, the four processing units 13, 15, 17, and 19 can be arranged in a linear shape or in a loop shape. In this case, the processing of the four processing units 13, 15, 17, and 19 can be continuously executed by moving the stage 31 in a loop shape in a certain direction without reciprocating the stage 31. ..

Further, when the drawing head 35 is a composition 9 containing the powder 3 and the thermoplastic binder 7 in addition to the dispenser 33, it is possible to use a heat melting type head that is thermally melted and ejected from a nozzle. Is.

1 ... 3D modeling device, 3 ... powder, 5 ... solvent, 7 ... binder, 9 ... composition, 11 ... layer,
13 ... layer forming part, 15 ... solvent volatilizing part, 17 ... laser irradiation part, 19 ... removing part,
21 ... carbon residue (adhesion), 23 ... sputtered particles (adhesion), 25 ... introduction part,
27 ... Exhaust section, 29 ... Housing, 31 ... Stage, 33 ... Dispenser,
35 ... drawing head, 37 ... discharge port, 39 ... line lamp heater,
41 ... laser oscillator, 43 ... galvano mirror, 45 ... wiping member, 47 ... rotating brush,
49 ... Recovery unit, 51 ... Spraying member, A ... Three-dimensional model, X ... Feeding direction, Y ... Scanning direction,
Z ... Lamination direction, N ₂ ... Nitrogen gas, E ... Laser light, P1 ... Layer formation process,
P2 ... Solvent volatilization process, P3 ... Laser irradiation process, P4 ... Removal process, G ... Gas

Claims (8)

A layer forming portion forming a layer of a composition containing a powder, a solvent and a binder, and a layer forming portion.
A laser irradiation unit that melts or sinters the powder in the layer,
A removing portion for removing deposits present on the surface of the layer is provided.
The removing unit is controlled to remove deposits existing on the surface of the layer after laser irradiation by the laser irradiation unit .
The layer forming part, the laser irradiation part, and the removing part or the layer forming part, the solvent volatilizing part, the laser irradiation part, and the removing part are housed in a sealed housing provided with a nitrogen gas introduction part and an exhaust part. Ori,
A stage that supports the layer of the composition is arranged in the housing, and the stage is the layer forming portion, the laser irradiation portion, and the removing portion, or the layer forming portion, the solvent volatilizing portion, the laser irradiation portion, and the removing portion. A three-dimensional modeling device characterized in that it is configured to be able to move in order between and . In the three-dimensional modeling apparatus according to claim 1,
The solvent volatilizing part for volatilizing the solvent in the layer is provided.
The solvent volatilizing unit is a three-dimensional modeling apparatus, characterized in that the solvent volatilizing unit is controlled to volatilize the solvent in the layer before the laser irradiation by the laser irradiation unit is performed. In the three-dimensional modeling apparatus according to claim 1 or 2.
The three-dimensional modeling apparatus, wherein the removing portion is a wiping member that comes into contact with the surface of the layer and wipes off the deposits. In the three-dimensional modeling apparatus according to claim 3,
The removing portion is a rotating brush.
The rotating brush is a three-dimensional modeling apparatus characterized in that it can move relative to the moving direction of the irradiation position to the layer by the laser irradiation unit. In the three-dimensional modeling apparatus according to claim 1 or 2.
The removing portion is a three-dimensional modeling apparatus characterized in that it is a spraying member that blows gas onto the surface of the layer to remove the deposits. In the three-dimensional modeling apparatus according to any one of claims 1 to 5.
A three-dimensional modeling apparatus comprising a recovery unit that collects the removed deposits in a direction in which the deposits are removed from the surface of the layer by the removal unit and moves. In the three-dimensional modeling apparatus according to any one of claims 1 to 6.
The next layer is formed by the layer forming portion on the surface of the layer on which the deposit removal operation is performed.
A three-dimensional object characterized in that a removal operation of the deposit is executed on the surface of the next layer by the removing portion, whereby a three-dimensional model composed of a plurality of layers is sequentially formed for each layer. Modeling equipment. A layer forming step of forming a layer of a composition containing a powder, a solvent and a binder,
A laser irradiation step of melting or sintering the powder in the layer,
It comprises a removal step of removing deposits present on the surface of the layer.
In the removing step, the deposits existing on the surface of the layer after the laser irradiation by the laser irradiation step are removed .
The layer forming part that executes the layer forming step, the laser irradiation part that executes the laser irradiation step, the removing part that executes the removing step, or the layer forming part, the solvent volatilizing part that volatilizes the solvent in the layer, and the above. The laser irradiation part and the removal part are housed in a sealed housing provided with a nitrogen gas introduction part and an exhaust part.
A stage that supports the layer of the composition is arranged in the housing, and the stage is the layer forming portion, the laser irradiation portion, and the removing portion, or the layer forming portion, the solvent volatilizing portion, the laser irradiation portion, and the removing portion. A method for manufacturing a three-dimensional model, which is characterized by moving in order between and .

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