JP7414912B1 - Laminated manufacturing device and method for manufacturing three-dimensional objects - Google Patents

Abstract

An object of the present invention is to provide a layered manufacturing apparatus and a method for manufacturing a three-dimensional object, which enable unmanned removal of a object by more appropriately removing surplus material on a modeling table. In the layered manufacturing apparatus of the present invention, the modeling table is configured to be movable up and down by a table drive mechanism, and the material layer forming device supplies material powder onto a base plate placed in a modeling area. The material layer is formed, the chuck device is configured to allow the base plate to be detachably attached and fixed within the modeling area, the material recovery device is equipped with a suction nozzle capable of suctioning excess material on the modeling table, and the moving device is configured to The robot is configured to be able to move the nozzle, the robot is configured to be able to take out the base plate and the modeled object from the chamber, and the control device is configured to control the table drive mechanism to raise the modeling table by a predetermined amount of elevation, and to move the suction nozzle. Suction of excess material powder while moving is repeated alternately. [Selection diagram] Figure 1

Description

The present invention relates to a layered manufacturing apparatus and a method for manufacturing a three-dimensional structure.

Various methods are known for additive manufacturing of three-dimensional objects. For example, in an additive manufacturing apparatus that performs powder bed fusion bonding, a base plate is placed in a printing area on a printing table placed in a chamber, material powder is supplied to the printing area to form a material layer, and a laser beam is emitted. Alternatively, a solidified layer is formed by sintering or melting the material powder by irradiating a predetermined position of the material layer with an electron beam. By repeating the formation of the material layer and the solidified layer, the solidified layer is laminated on the base plate, and if necessary, the desired three-dimensional structure is manufactured by cutting with a cutting means during or after modeling.

In additive manufacturing using powdered material, such as powder bed fusion bonding, not all of the powdered material supplied to the build region is solidified. After modeling, unsolidified material powder remains on the modeled object, base plate, and modeling table, so it is necessary to remove excess material when taking out the modeled object from the chamber.

As disclosed in Patent Document 1, it is known that a layered manufacturing apparatus is provided with a suction nozzle for suctioning and removing surplus material. Before taking out the modeled object, the surplus material is removed by the operator operating the suction nozzle to suck up the surplus material. Here, there is a demand for automatically removing the modeled object from the chamber after modeling. For example, when performing secondary processing on a modeled object, there is a demand for automating a series of steps in which the modeled object is taken out from an additive manufacturing device and automatically sent to a secondary processing device. When automatically taking out a modeled object from a chamber, it is necessary to automatically remove surplus material after modeling. Patent Document 2 discloses a configuration in which surplus material remaining after modeling is automatically removed using a suction nozzle.

Patent No. 6132962 Japanese Patent Application Publication No. 2002-205339

In a conventional layered manufacturing apparatus that automatically removes surplus material by suction, as shown in Patent Document 2, the surplus material tends to remain in the hollows of the modeled object and removal is insufficient. If surplus material remains on the modeling table, the modeled object cannot be taken out, which hinders unmanned operation.

The present invention has been made in view of these circumstances, and provides an additive manufacturing apparatus and a three-dimensional manufacturing apparatus that enables unmanned removal of a model by more appropriately removing surplus material on a model table. The purpose is to provide a method for manufacturing products.

According to the present invention, the following inventions are provided.
[1] An additive manufacturing apparatus including a modeling table, a chamber, a material layer forming device, a chuck device, a material recovery device, a movement device, a robot, and a control device, wherein the modeling table is a table The chamber is configured to be movable up and down by a drive mechanism, the chamber covers a modeling area provided on the modeling table and is an area in which a modeled object is formed, and the material layer forming device is placed in the printing area. The chuck device is arranged on the modeling table and is configured to be able to detach and fix the base plate in the modeling area, The collection device includes a suction nozzle capable of suctioning the surplus material powder on the modeling table, the moving device is configured to be able to move the suction nozzle, and the robot is configured to move the suction nozzle between the base plate and the base plate. The controller is configured to be able to take out the modeled object from the chamber, and the control device controls the table drive mechanism to raise the modeling table by a predetermined amount of elevation, and moves the suction nozzle. A layered manufacturing apparatus that alternately repeats suctioning of the excess material powder while
[2] The layered manufacturing apparatus according to [1], comprising a detection means capable of detecting the proportion of the material powder in the object to be sucked by the suction nozzle.
[3] The additive manufacturing apparatus according to [2], wherein the detection means is a flow sensor.
[4] The additive manufacturing apparatus according to [2] or [3], wherein the control device controls the modeling table to a predetermined value when a proportion of the material powder in the suction object is larger than a predetermined value. An additive manufacturing apparatus that controls the table drive mechanism to lower the table by a lowering amount.
[5] The layered manufacturing apparatus according to any one of [1] to [4], wherein the control device controls the suction nozzle at a predetermined position based on shape data of a desired three-dimensional structure. An additive manufacturing device that controls the moving device to take a predetermined posture.
[6] The additive manufacturing apparatus according to any one of [1] to [5], wherein the powder is provided to surround the modeling table and hold the material powder on the modeling table. and a material recovery bucket configured to accommodate the excess material powder discharged to the outside of the powder holding wall, and the material recovery device has a recovery mode as an operation mode. and a suction mode, the control device is configured to switch the operation mode, and the material recovery device collects the material powder in the material recovery bucket in the recovery mode, and removes impurities. is removed, the material powder is supplied to the material layer forming device, and in the suction mode, the suction nozzle is moved by the moving device, and the excess material powder on the modeling table is transferred to the suction nozzle. an additive manufacturing apparatus configured to suck by.
[7] The additive manufacturing apparatus according to any one of [1] to [6], wherein the side surface of the chuck device is covered with a chuck cover, and the chuck cover includes an outer cover and an inner side. a cover, the outer cover covers at least a part of the side surface of the inner cover, and the inner cover covers the side surface of the chuck device.
[8] The layered manufacturing apparatus according to any one of [1] to [7], wherein the chuck device fixes the base plate via a mounting plate.
[9] The additive manufacturing apparatus according to any one of [1] to [8], wherein the suction nozzle includes a suction section on the tip side, and the suction section has an end surface on the tip side as an inclined surface. A layered manufacturing apparatus having a cylindrical shape cut at a cylindrical shape and having an opening in the inclined surface.
[10] The additive manufacturing apparatus according to any one of [1] to [9], wherein the robot also serves as the moving device.
[11] The additive manufacturing apparatus according to [10], wherein the robot carries the base plate into the chamber.
[12] The layered manufacturing apparatus according to [11], wherein the robot, after taking out the object from the chamber, reverses the object.
[13] A method for manufacturing a three-dimensional object, comprising a placing step, a solidified layer forming step, a suction step, and a taking out step, and in the placing step, a chuck device placed on a modeling table is provided. By removably fixing the base plate, the base plate is placed on a printing area provided on the printing table where a modeled object is formed, and in the solidified layer forming step, the base plate is fixed on the base plate. By repeating a material layer forming step of supplying material powder to form a material layer, and a solidifying step of forming a solidified layer by irradiating a predetermined irradiation area of the material layer with a laser beam or an electron beam, The solidified layers are laminated, and in the suction step, the modeling table is raised by a predetermined amount by a table drive mechanism, and the excess material powder is suctioned while a suction nozzle is moved by a moving device. and, in the taking out step, the base plate and the three-dimensional structure formed on the base plate are taken out from a chamber covering the modeling area.

The layered manufacturing apparatus according to the present invention is provided with a suction nozzle that is movable by a moving device, and the control device controls the table drive mechanism to gradually raise the modeling table while the suction nozzle sucks and removes excess material. Therefore, vibration is applied to the modeled object, and excess material on the modeled object falls onto the base plate or the modeling table. Thereby, excess material on the modeling table can be removed more appropriately. At this time, since the removal of excess material by the suction nozzle is performed automatically, it is possible to take out the modeled object unattended.

1 is a schematic configuration diagram of a layered manufacturing apparatus 100 according to an embodiment of the present invention. FIG. 2 is a perspective view of the material layer forming device 2 of the additive manufacturing device 100. FIG. 2 is a perspective view from above of the recoater head 22 of the material layer forming apparatus 2. FIG. FIG. 2 is a perspective view from below of the recoater head 22 of the material layer forming apparatus 2. FIG. 7 is a perspective view showing a state in which a base plate 83 is fixed to the chuck device 5. FIG. 6 is a sectional view taken along line AA in FIG. 5. FIG. FIG. 8 is a perspective view showing a pallet 85, a positioning plate 86, and a shaft 87 in an exploded state. 5 is a perspective view showing a state in which a chuck cover 53 is removed from the chuck device 5. FIG. 9A and 9B are diagrams showing the tip of the suction part 79a of the suction nozzle 79. FIG. 9A is a front view, and FIG. 9B is a right side view. FIG. 7 is a diagram for explaining how the suction nozzle 79 suctions the surplus material of the surplus material layer 81a. FIG. 2 is a configuration diagram of a control device 9 of the layered manufacturing apparatus 100. It is a flowchart of the manufacturing method of the three-dimensional structure W using the laminated manufacturing apparatus 100. It is a figure for explaining the manufacturing method of the three-dimensional structure W using the layered manufacturing apparatus 100. It is a figure for explaining a solidified layer formation process. It is a figure for explaining a suction process.

Embodiments of the present invention will be described below with reference to the drawings. The features shown in the embodiments below can be combined with each other. Further, the invention is established independently for each characteristic matter.

1. Laminated manufacturing device 100
FIG. 1 is a schematic configuration diagram of a layered manufacturing apparatus 100 according to this embodiment. The additive manufacturing device 100 includes a chamber 1, a material layer forming device 2, an irradiation device 3, a modeling table 4, a chuck device 5, a robot 6, a material recovery device 7, a movement device, and a control device 9. Equipped with By repeating the formation of the material layer 81 and the solidified layer 82 in the modeling region R provided on the modeling table 4 disposed in the chamber 1, a desired three-dimensional structure W is formed.

1.1. chamber 1
The chamber 1 covers a modeling region R where a desired three-dimensional structure W is formed. The interior of the chamber 1 is filled with an inert gas of a predetermined concentration supplied from an inert gas supply device (not shown). In this specification, the inert gas is a gas that does not substantially react with the material layer 81 or the solidified layer 82, and is selected depending on the type of material. For example, nitrogen gas, argon gas, or helium gas can be used. be. Inert gas containing fumes generated during the formation of the solidified layer 82 is discharged from the chamber 1, and after the fumes are removed in a fume collector (not shown), it is supplied to the chamber 1 and reused. The fume collector is, for example, an electrostatic precipitator or a filter.

A window 1a serving as a transmission window for the laser beam B is provided on the upper surface of the chamber 1. The window 1a is made of a material through which the laser beam B can pass. Specifically, the material of the window 1a is selected from quartz glass, borosilicate glass, germanium, silicon, zinc selenium, potassium bromide crystal, etc., depending on the type of laser beam B. For example, when the laser beam B is a fiber laser or a YAG laser, the window 1a can be made of quartz glass.

Further, a contamination prevention device 17 is provided on the upper surface of the chamber 1 so as to cover the window 1a. The pollution prevention device 17 includes a cylindrical housing 17a and a cylindrical diffusion member 17b disposed within the housing 17a. The clean inert gas supplied to the space between the casing 17a and the diffusion member 17b fills the inside of the diffusion member 17b through the pores formed in the wall of the diffusion member 17b, and then flows into the bottom surface of the casing 17a. It is ejected downward through the provided opening. With this configuration, it is possible to prevent fumes from adhering to the window 1a and to exclude fumes from the irradiation path of the laser beam B.

Further, the chamber 1 is provided with a work door (not shown) that can be opened and closed under the control of the control device 9. When carrying the base plate 83 into the chamber 1 or when taking out the base plate 83 and the shaped object W from the chamber 1, the work door is opened, and the robot 6 moves in and out of the chamber 1 to perform carrying-in/out work. The work door is closed when loading/unloading work is not performed, especially during modeling.

1.2. Material layer forming device 2
The material layer forming device 2 supplies material powder onto the base plate 83 placed in the modeling region R to form the material layer 81 . As shown in FIGS. 1 to 4, the material layer forming apparatus 2 is provided inside the chamber 1 and includes a base 21 and a recoater head 22 disposed on the base 21. The recoater head 22 is configured to be able to reciprocate in one horizontal axis direction by a recoater head drive device 23.

As shown in FIGS. 3 and 4, the recoater head 22 includes a material storage section 22a, a material supply port 22b, and a material discharge port 22c. The material supply port 22b is provided on the upper surface of the material storage section 22a, has a rectangular shape extending in the longitudinal direction of the material storage section 22a, and serves as a receiving port for the material powder supplied from the material supply unit 10 to the material storage section 22a. . The material discharge port 22c is provided on the bottom surface of the material storage section 22a, and discharges the material powder in the material storage section 22a. The material discharge port 22c has a slit shape extending in the longitudinal direction of the material storage section 22a. Flat blades 22fb and 22rb are provided on both sides of the recoater head 22. The blades 22fb and 22rb flatten the material powder discharged from the material discharge port 22c to form the material layer 81.

1.3. Irradiation device 3
As shown in FIG. 1, the irradiation device 3 is provided above the chamber 1. The irradiation device 3 irradiates the irradiation region of the material layer 81 formed in the modeling region R with laser light B to melt or sinter the material powder and solidify it, thereby forming a solidified layer 82 . The laser beam B only needs to be capable of sintering or melting the material powder, and is, for example, a fiber laser, a CO2 laser, or a YAG laser. Note that the irradiation device 3 may be configured to irradiate an electron beam instead of the laser beam B to solidify the material layer 81.

1.4. Modeling table 4
The modeling table 4 is provided within the chamber 1, and a modeling area R is provided on its upper surface. The modeling table 4 is configured to be movable up and down by a table drive mechanism 41. The table drive mechanism 41 of this embodiment is configured using a motor as a drive source. Note that the configuration of the table drive mechanism 41 is not limited to the example of this embodiment, and other configurations may be used as long as the modeling table 4 can be moved in the vertical (vertical) direction.

1.5. Chuck device 5
The chuck device 5 is disposed on the modeling table 4 and is configured to allow the base plate 83 to be detachably attached and fixed within the modeling region R. The base plate 83 is placed in the modeling region R by the chuck device 5 holding and fixing the base plate 83.

The base plate 83 may be fixed directly by the chuck device 5, or may be fixed via another member such as the mounting plate 84. In this embodiment, as shown in FIGS. 1, 5, and 6, the base plate 83 is removably fixed by the chuck device 5 via a mounting plate 84 and a pallet 85. Specifically, a shaft 87 is attached to the bottom surface of the pallet 85 so as to protrude downward, and by gripping the shaft 87 with the chuck device 5, the pallet 85 is removably fixed. Furthermore, the mounting plate 84 is fixed onto the pallet 85 using fixing members such as bolts, and the base plate 83 is fixed onto the mounting plate 84 using fixing members such as bolts. That is, the chuck device 5, the pallet 85, the mounting plate 84, and the base plate 83 are arranged in this order from the bottom, and the three-dimensional structure W is formed on the upper surface of the base plate 83.

The chuck device 5 of this embodiment includes a chuck base 51 placed on the modeling table 4 and a clamp unit 52 placed on the chuck base 51, as shown in FIGS. 6 to 8.

The chuck base 51 is used to fix the chuck device 5 on the modeling table 4. In this embodiment, the four corners of the chuck base 51, which is square in plan view, are fixed to the modeling table 4 with fixing members such as bolts.

The clamp unit 52 has a substantially cylindrical shape with a bottom. On the upper surface of the clamp unit 52, a plurality of first convex portions 52a and a plurality of second convex portions 52b (four in one example) are provided concentrically in a plan view, and further radially formed from the center in a plan view. A plurality of (four in one example) contact recesses 52c are provided. Further, inside the clamp unit 52, as shown in FIG. 6, a plurality of balls 52d as locking members for locking the shaft 87 are arranged at equal intervals along the circumferential direction of the shaft 87.

As shown in FIGS. 6 and 7, the shaft 87 includes a chucking plug 87a and a locking portion 87b provided on the outside of the chucking plug 87a. A threaded portion is formed on the upper end side of the chucking plug 87a, and the threaded portion is screwed into a screw hole formed on the bottom surface of the pallet 85, so that the chucking plug 87a is attached to the pallet 85. Further, the lower end of the chucking plug 87a is inserted into the insertion hole 52e of the clamp unit 52, and the ball 52d of the clamp unit 52 is engaged with the recess 87c of the locking portion 87b, thereby locking the shaft 87. Thereby, the pallet 85 is fixed to the chuck device 5.

Furthermore, in this embodiment, a positioning plate 86 is interposed between the pallet 85 and the clamp unit 52. The positioning plate 86 is fixed to the bottom surface of the pallet 85 using a fixing member such as a bolt. The positioning plate 86 is provided with a plurality of first openings 86a and a plurality of second openings 86b (four in one example). The first opening 86a and the second opening 86b are provided at positions overlapping the first protrusion 52a and the second protrusion 52b of the clamp unit 52, respectively, in a plan view, and the first protrusion 52a is located in the first opening. The positioning plate 86 is positioned in the horizontal direction by being inserted into the portion 86a and the second convex portion 52b being inserted into the second opening 86b.

Furthermore, a plurality of (four in one example) support legs 86c are attached to the lower surface of the positioning plate 86 using attachment shafts 86d. The support leg 86c is attached to a position overlapping the contact recess 52c in plan view, and the positioning plate 86 is positioned in the vertical direction by the bottom surface of the support foot 86c coming into contact with the contact recess 52c. By attaching the positioning plate 86 to the pallet 85, when the pallet 85 is fixed by the chuck device 5, the mounting plate 84 and base plate 83 fixed on the pallet 85 can be held at predetermined positions in the horizontal and vertical directions with high precision. It can be placed in

In this embodiment, the base plate 83 is fixed to the chuck device 5 via separate members (mounting plate 84 and pallet 85). In such a configuration, the mounting parts such as screw holes for mounting the shaft 87 and the positioning plate 86 may be formed in the separate member, and the separate member may be partially or completely removed from the base plate 83 after modeling. Can be reused. Therefore, since it is not necessary to provide the base plate 83 with a mounting portion depending on the form of the chuck device 5, the base plate 83 can be manufactured at a lower cost.

As shown in FIGS. 5 and 6, in this embodiment, the side surface of the chuck device 5 is covered with a chuck cover 53. The chuck cover 53 includes an outer cover 54 and an inner cover 55. The outer cover 54 covers at least a portion of the side surface of the inner cover 55, and the inner cover 55 covers the side surface of the chuck device 5. As the material of the chuck cover 53, metal, resin, etc. can be used.

Specifically, as shown in FIGS. 6 and 8, the inner cover 55 includes a cylindrical inner covering portion 55a and a flange portion 55b extending radially outward at the lower end of the inner covering portion 55a. The inner covering portion 55a covers the side surface of the clamp unit 52 of the chuck device 5. The inner cover 55 is fixed onto the chuck base 51 at the flange portion 55b. Further, the outer cover 54 includes a cylindrical outer covering portion 54a and an upper surface portion 54b that projects radially inward at the upper end of the outer covering portion 54a. The outer covering portion 54a covers a portion of the upper side of the inner covering portion 55a. The outer cover 54 is fixed to the pallet 85 at the upper surface portion 54b with the upper surface of the upper surface portion 54b in contact with the bottom surface of the pallet 85. Moreover, the outer cover 54 and the inner cover 55 are arranged so that the outer covering part 54a and the inner covering part 55a are coaxial. With such a configuration, it is possible to prevent surplus material from entering the inside of the chuck device 5, particularly the clamp unit 52, when the fixation of the base plate 83 by the chuck device 5 is released during modeling or after the completion of modeling.

Further, as shown in FIG. 6, a gap G is provided between the outer cover 54 and the inner cover 55. Specifically, the gap G is reduced by designing the outer cover 54 and the inner cover 55 so that the condition D1>D2 is satisfied regarding the inner diameter D1 of the outer covering part 54a and the outer diameter D2 of the inner covering part 55a. provided. Note that the gap G is preferably provided such that the distance between the inner surface of the outer covering part 54a and the outer surface of the inner covering part 55a (in this embodiment, (D1-D2)/2) is 1 to 10 mm. It will be done. In such a configuration, the path for powder such as surplus material falling from the top of the base plate 83 to reach the inside of the chuck cover 53 is curved, so that intrusion of powder can be more effectively prevented.

Note that the configuration of the chuck cover 53 is not limited to the example of this embodiment. For example, the inner covering portion 55a and the outer covering portion 54a may have a rectangular tube shape. According to the chuck device 5 of the embodiment shown in FIGS. 6 to 8, the excess material powder is transferred to the clamp unit 52 regardless of the process by which the robot 6 sucks and removes the excess material powder. Since the possibility of a situation in which continuous modeling cannot be performed due to intrusion into the printer is reduced, unattended operation of continuous modeling is supported.

1.6. robot 6
The robot 6 is configured to be able to take out the base plate 83 and the modeled object W formed on the base plate 83 from the chamber 1 . In this embodiment, after completion of modeling, the pallet 85 is released from being fixed by the chuck device 5 by engaging and disengaging the ball 52d of the clamp unit 52 from the recess 87c. In this state, the robot 6 grips a predetermined part of the pallet 85 or inserts a support rod into a support hole (not shown) provided on the side surface of the pallet 85 and lifts it up, thereby attaching the base plate 83 and the modeled object W. The plate 84, pallet 85, shaft 87, and outer cover 54 are taken out from the chamber 1 via the work door.

Further, the robot 6 may be configured to take out the object W from the chamber 1, move it to a predetermined position, and then invert the object W in the vertical direction. By inverting the shaped object W, excess material adhering to the shaped object W and the base plate 83 can be dropped and removed. At this time, the inverted model W may be placed on a finishing device (not shown) provided outside the chamber 1, and the excess material may be finished and removed automatically or manually. For finishing removal, for example, the material powder is sucked by a suction nozzle, or the material powder is dropped by vibrating the object W, or the object W is transported to a suction chamber (not shown) outside the chamber 1 to remove the powder. Examples of methods include suction removal.

When performing secondary processing on the object W, the robot 6 moves the base plate 83 and the object W taken out from the chamber 1 to a secondary processing device (not shown).

Note that the robot 6 of this embodiment is also used to carry the base plate 83 into the chamber 1 before starting modeling. Specifically, a base plate set in which the base plate 83, the mounting plate 84, the pallet 85, the shaft 87, and the outer cover 54 are integrated is stored in a stocker (not shown) provided outside the chamber 1. The robot 6 carries the base plate set into the chamber 1 through the work door by grasping a predetermined part of the pallet 85 or by inserting a support rod into a support hole provided on the side of the pallet 85 and lifting it. Then, insert the lower end of the shaft 87 into the clamp unit 52. The pallet 85 is fixed by the chuck device 5 by engaging the ball 52d with the recess 87c of the inserted shaft 87.

1.7. Material powder supply/recovery system Next, a material powder supply/recovery system including the material recovery device 7 will be described. As shown in FIG. 1, a material supply unit 10 is provided near the wall surface of the chamber 1. The material supply unit 10 includes a material tank 11, a main duct 12, and an intermediate duct 13. New material powder is stored in the material tank 11 and supplied to the intermediate duct 13 through the main duct 12.

The intermediate duct 13 is movable in the vertical direction and is configured to discharge material powder from the intermediate duct outlet 13a. The intermediate duct outlet 13a of this embodiment has a rectangular shape extending in substantially the same direction as the material supply port 22b of the recoater head 22. Further, the intermediate duct outlet 13a is configured to be openable and closable by a shutter 14. The intermediate duct outlet 13a is normally closed by a shutter 14. When replenishing the material powder, the recoater head 22 moves directly below the intermediate duct 13, and the intermediate duct 13 moves so that the intermediate duct outlet 13a is at a position lower than the upper end of the material storage section 22a. In this state, the shutter 14 is opened and the material powder is replenished.

In this embodiment, a powder holding wall 42 is provided to surround the modeling table 4. The material powder is held on the modeling table 4 by the powder holding wall 42 . A material recovery bucket 70 is also provided that is configured to accommodate surplus material discharged outside the powder retaining wall 42 .

The base 21 of the material layer forming device 2 is provided with at least one powder discharge section 70b that communicates with the material recovery bucket 70. Excess material and impurities pushed out by the moving recoater head 22 are discharged from the powder discharge section 70b, guided to the shooter 70e by the shooter guide 70d, and stored in the material recovery bucket 70. Note that the powder discharge section 70b may be configured to be openable and closable by a shutter (not shown). Further, a powder discharge part 70a is provided below the powder holding wall 42 to discharge the material powder inside the powder holding wall 42, and by lowering the modeling table 4 after the completion of additive manufacturing, the material powder is unsolidified. A part of impurities such as material powder and cutting waste may be discharged from the powder discharge section 70a. In this case, the material powder discharged from the powder discharge section 70a is guided to the shooter 70e by the shooter guide 70c, and is stored in the material recovery bucket 70.

As shown in FIG. 1, the material recovery device 7 of this embodiment includes a material recovery conveyance device 71, an impurity removal device 73, a suction device 74, a material supply bucket 76, a material drying device 77, and a material supply bucket 76. A transport device 78 and a suction nozzle 79 are provided. The suction port 71b of the material recovery conveyance device 71 is connected to the material recovery bucket 70 by piping or the like via a switching valve 72, and the material powder containing impurities in the material recovery bucket 70 is transferred to the material recovery conveyance device 71. 71 and transported to an impurity removal device 73. Examples of impurities include spatter generated during irradiation and processing debris generated during cutting. The impurity removal device 73 removes impurities from the material powder conveyed from the material recovery conveyance device 71. The material powder from which impurities have been removed is stored in the material supply bucket 76. The material drying device 77 dries the material powder in the material supply bucket 76. The material powder dried by the material drying device 77 is supplied into the main duct 12 by a material supply conveying device 78 connected to the upper part of the main duct 12, and is reused.

The material recovery conveyance device 71 and the material supply conveyance device 78 have a cyclone type filter inside, and the exhaust port 71a and the exhaust port 78a of the filter are connected to the suction device 74 via a switching valve 75 by piping or the like. There is. The suction device 74 has suction power capable of suctioning gas and solid together, and is configured using, for example, a cleaner or the like. When solids such as material powder and impurities are sucked together with gas by the suction device 74, the filter uses the difference in specific gravity to separate only the solids from the airflow and cause them to fall. As a result, the solid is transported and the gas is sucked into the suction device 74 through the exhaust ports 71a and 78a. Note that even if one suction device 74 is switchably connected to the material recovery conveyance device 71 and the material supply conveyance device 78 via the switching valve 75, the material recovery conveyance device 71 and the material supply conveyance device 78 One suction device 74 may be connected to each of the suction devices 74 independently.

The suction nozzle 79 is configured to be able to suction excess material powder on the modeling table 4. Further, the suction nozzle 79 is movable by a moving device. In this embodiment, the robot 6 also serves as a moving device. Specifically, the suction nozzle 79 is stored in a storage part (not shown) outside the chamber 1, and the robot 6 grasps the suction nozzle 79, moves it into the chamber 1 from the work door, and places it at an arbitrary position. can do. Furthermore, the posture of the suction nozzle 79 relative to the object W can be changed by operating the robot 6 to tilt the suction nozzle 79 or the like.

The suction nozzle 79 of this embodiment is connected to the suction port 71b of the material recovery conveyance device 71 via a switching valve 72 and by piping or the like. For example, the suction nozzle 79 can be attached to one end of a flexible hose, and the other end of the hose can be connected to the suction port 71b via the switching valve 72. The material powder sucked from the suction nozzle 79 is supplied into the main duct 12 after being subjected to impurity removal treatment and drying treatment in the same manner as described above.

The layered manufacturing apparatus 100 of this embodiment includes a detection means (not shown) capable of detecting the proportion of material powder in the object to be sucked by the suction nozzle 79. As the ratio of the material powder in the aspirated object, for example, the volumetric flow rate or mass flow rate of the material powder in the aspirated object, or the area ratio in a predetermined detection region can be used. As the detection means, for example, a flow rate sensor or an imaging device such as a camera can be used. In this embodiment, a flow rate sensor is installed as a detection means inside the suction nozzle 79 or the hose to which the suction nozzle 79 is attached. As an example, the flow rate sensor is configured to be able to detect the volumetric flow rate of powder in the suction target. Specifically, the flow rate sensor emits microwaves and receives the reflected waves at a predetermined position inside the suction nozzle 79 or the hose. Since the frequency and amplitude of the reflected wave change depending on the amount of powder in the suction object passing through the predetermined position, the volumetric flow rate of the material powder in the suction object is detected based on the change, and the material powder The volumetric flow rate can be obtained. The detection result by the detection means is output to the control device 9. Note that the detection means may be configured to directly detect the proportion of material powder in the object to be sucked, or may be configured to indirectly detect the proportion of material powder. In the case of indirect detection, for example, the proportion of gas in the object to be aspirated may be detected, and the proportion of material powder may be obtained from the detection result.

9A and 9B are diagrams showing the tip of the suction part 79a of the suction nozzle 79. FIG. 9A is a front view, and FIG. 9B is a right side view. The suction nozzle 79 of this embodiment includes a suction part 79a on the tip side. Further, although not shown in FIGS. 9A and 9B, a gripping portion that can be gripped by the robot 6 as a moving device is provided on the base end side of the suction nozzle 79. The suction portion 79a has a cylindrical shape with the end face on the distal end side cut by an inclined surface, and an opening 79b is provided in the inclined surface. Excess material is sucked through opening 79b.

In such a configuration, as shown in FIG. 10, when the suction nozzle 79 is brought close to the layer made of surplus material (surplus material layer 81a) and a part of the opening 79b is embedded in the surplus material layer 81a, the material is removed. Powder is sucked through the opening 79b. At this time, gas is sucked from the portion of the opening 79b that is not embedded in the surplus material layer 81a. By suctioning the material powder together with the gas, it is possible to avoid situations in which the proportion of solids in the suction object becomes excessive and the suction force decreases, or clogging occurs inside the suction nozzle 79 and the hose.

The material recovery device 7 of this embodiment has a recovery mode and a suction mode as operation modes, and the operation modes are switched by a material supply/recovery control section 98 of the control device 9, which will be described later. In the recovery mode, the material recovery device 7 recovers the material powder in the material recovery bucket 70 , removes impurities, and then supplies the material powder to the material layer forming device 2 . On the other hand, in the suction mode, the material recovery device 7 moves the suction nozzle 79 using the robot 6 as a moving device, and suctions the surplus material powder on the modeling table 4 with the suction nozzle 79 . In this embodiment, the material supply/recovery control unit 98 switches the switching valve 72 to select a collection mode in which the source of the material powder by the material recovery conveyance device 71 is the material recovery bucket 70 and a mode in which the source is the suction source. The suction mode of the nozzle 79 is switched.

1.8. Control device 9
The control system of the layered manufacturing apparatus 100 includes a CAD (Computer Aided Design) device 90a, a CAM (Computer Aided Manufacturing) device 90b, and a control device 9, as shown in FIG. These devices are configured by arbitrarily combining hardware such as a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), an auxiliary storage device, an input/output interface, and software, and software. Hereinafter, among the control operations by the control system, the explanation will be limited to the controls that are strongly related to the present invention.

The CAD device 90a creates three-dimensional shape data (CAD data) that specifies the shape and dimensions of the symmetrical three-dimensional structure W. The CAM device 90b creates a project file in which instructions for the additive manufacturing device 100 are defined based on the CAD data. The CAM device 90b sends the project file to the control device 9 via a communication line or a storage medium.

The control device 9 controls the components of the additive manufacturing device 100 such as the material layer forming device 2, the irradiation device 3, the modeling table 4, the chuck device 5, the robot 6, the material recovery device 7, and the moving device according to the project file. , perform additive manufacturing. The control device 9 includes a numerical control section 91 and control sections 92, 93, 94, 95, 96, 97, and 98 that are components of the additive manufacturing apparatus 100.

The numerical control unit 91 outputs operation commands for the components of the additive manufacturing apparatus 100 to each control unit 92, 93, 94, 95, 96, 97, 98 according to the project file created by the CAM device 90b, It includes a storage section 91a, a calculation section 91b, and a memory 91c. The storage unit 91a stores the project file acquired from the CAM device 90b. The calculation unit 91b executes calculation processing for numerically controlling the components of the additive manufacturing apparatus 100 according to the project file. The memory 91c temporarily stores numerical values and data during the calculation process by the calculation unit 91b.

The control units 92 , 93 , 94 , 95 , 96 , 97 , and 98 of the constituent elements of the additive manufacturing apparatus 100 control the operation of each constituent element based on operation commands from the numerical control unit 91 . Specifically, the work door control unit 92 controls the work door to open and close the work door in a timely manner. The material layer formation control unit 93 controls the recoater head drive device 23 to reciprocate the recoater head 22 in one horizontal axis. The irradiation control unit 94 controls the irradiation device 3 so that the laser beam B is irradiated to a predetermined position within the irradiation area under predetermined conditions.

The table control unit 95 controls the table drive mechanism 41 to move the modeling table 4 in the vertical direction and arrange it at a predetermined position. The chuck control unit 96 controls the clamp unit 52 of the chuck device 5 to switch between fixing and releasing the fixation of the base plate 83.

The robot control unit 97 controls the robot 6 to carry the base plate 83 into the chamber 1 and take out the base plate 83 and the molded object W from the chamber 1, as well as to take out the base plate 83 and the molded object W from the chamber 1 as necessary. Subsequently, the shaped object W is reversed and moved to the secondary processing device. Furthermore, in this embodiment, the robot 6 also serves as a moving device for the suction nozzle 79. Therefore, the robot control unit 97 controls the robot 6 as a moving device to move the suction nozzle 79 and arrange it at a predetermined position in a predetermined posture.

The material supply/recovery control section 98 controls the material recovery device 7 and the material supply unit 10. In addition, the operation mode of the material recovery device 7 is switched.

In addition to the above-described configuration, the additive manufacturing apparatus 100 includes a machining device (not shown) in the chamber 1 for performing machining such as cutting on the solidified layer 82 and the molded object W as necessary. You can. The machining device is configured by attaching a tool (for example, an end mill) for performing machining such as cutting to a machining head, and moves the machining head appropriately in the horizontal and vertical directions to remove the solidified layer 82 or the shaped object. Perform machining on W. Further, the tool may be configured to be rotatable by being attached to the spindle of the processing head.

2. Method for Manufacturing Three-Dimensional Structure W Next, with reference to FIG. 12, a method for manufacturing a three-dimensional structure W using the layered manufacturing apparatus 100 according to the present embodiment will be described.

2.1. Mounting process S1
In the mounting step S1, the base plate 83 is placed on the modeling area R on the modeling table 4. Specifically, first, the work door control unit 92 controls and opens the work door. Furthermore, the robot control unit 97 controls the robot 6 to carry the base plate set into the chamber 1 from a stocker outside the chamber 1 . The robot 6 carries the base plate set into the chamber 1 through the opened work door, and inserts the lower end of the shaft 87 into the insertion hole 52e of the clamp unit 52. In this state, the chuck control section 96 controls the clamp unit 52 of the chuck device 5 to engage the ball 52d with the locking section 87b of the shaft 87. As a result, as shown in FIG. 13, the base plate 83 is placed in the modeling region R while being removably fixed to the chuck device 5. Further, the side surface of the chuck device 5 is covered by a chuck cover 53 consisting of an outer cover 54 and an inner cover 55.

After the base plate 83 is placed, the robot controller 97 controls the robot 6 to retreat outside the chamber 1, and the work door controller 92 closes the work door. Thereafter, an inert gas is supplied and filled into the chamber 1 from the inert gas supply device. This makes it possible to start modeling.

2.2. Material supply process S2
In the material supply step S2, material powder is supplied and stored in the material storage section 22a of the material layer forming device 2. Specifically, the material layer formation control unit 93 controls the recoater head drive device 23 to move the recoater head 22 to a position directly below the intermediate duct 13 . In this state, the material supply/recovery control section 98 controls the material supply unit 10, opens the shutter 14, and supplies the material powder into the material storage section 22a. When a sufficient amount of material powder is supplied, the material supply/recovery control section 98 closes the shutter 14 and stops supplying. Thereafter, the material layer formation control section 93 controls the recoater head drive device 23 to move the recoater head 22 to the modeling region R. Note that the material supply step S2 is performed multiple times at appropriate times from the start to the completion of modeling in order to replenish the material storage section 22a with material powder.

2.3. Solidified layer formation step S3
Next, a solidified layer forming step S3 is performed. In the solidified layer forming step S3, a material layer forming step S3-1 is performed in which material powder is supplied onto the base plate 83 to form the material layer 81, and a predetermined irradiation area of the material layer 81 is irradiated with laser light B. By repeating the solidifying step S3-2 for forming the solidified layer 82, the solidified layer 82 is laminated.

Specifically, first, the table control unit 95 controls the table drive mechanism 41 to arrange the modeling table 4 at a predetermined height. In this state, the material layer formation control unit 93 controls the recoater head drive device 23 to move the recoater head 22 from the left side to the right side in FIG. 13. As a result, a first material layer 81 is formed on the base plate 83. Next, the irradiation control unit 94 controls the irradiation device 3 to irradiate a predetermined irradiation area of the first material layer 81 with the laser beam B or the electron beam. Thereby, as shown in FIG. 14, the first material layer 81 is solidified to obtain a first solidified layer 82.

Subsequently, a second material layer forming step S3-1 is performed. After forming the first solidified layer 82, the table control unit 95 controls the table drive mechanism 41 to lower the height of the modeling table 4 by one material layer 81. In this state, the material layer formation control unit 93 controls the recoater head drive device 23 to move the recoater head 22 from the right side to the left side in FIG. 14 in the modeling region R. Thereby, the second material layer 81 is formed so as to cover the first solidified layer 82. Then, a second solidification step S3-2 is performed. In the same manner as described above, the second material layer 81 is solidified by irradiating a predetermined irradiation area of the second material layer 81 with laser light B, thereby obtaining the second solidified layer 82.

The material layer forming step S3-1 and the solidifying step S3-2 are repeated until the desired three-dimensional structure W is obtained, and a plurality of solidified layers 82 are stacked. Adjacent solidified layers 82 are strongly bonded to each other. Further, during or after modeling, cutting or the like is performed using a machining device as necessary.

2.4. Material recovery process S4
A material recovery step S4 is performed in parallel with the solidified layer forming step S3. In the material recovery step S4, the material recovery device 7 operates in a recovery mode. Specifically, the material supply/recovery control unit 98 switches the switching valve 72 so that the material collection bucket 70 is the source of the material powder being transported by the material collection transport device 71 . In addition, the material recovery conveyance device 71, the impurity removal device 73, the suction device 74, the material supply bucket 76, the material drying device 77, and the material supply conveyance device 78 are operated to remove the impurity-containing material in the material recovery bucket 70. The powder is supplied into the main duct 12 after being subjected to impurity removal processing and drying processing.

2.5. Suction process S5
After the modeling is completed, a suction step S5 is performed. In the suction step S5, the surplus material on the modeling table 4 is suctioned by the suction nozzle 79. Specifically, first, the work door control unit 92 controls and opens the work door. Next, the robot control unit 97 controls the robot 6 as a moving device to grasp the suction nozzle 79 and move it into the chamber 1 from the work door. Further, in the suction step S5, the material recovery device 7 operates in suction mode. The material supply/recovery control unit 98 switches the switching valve 72 so that the suction nozzle 79 is the source of material powder conveyed by the material recovery conveyance device 71 .

As shown in FIG. 15, from the start to the completion of modeling, the modeling table 4 is lowered by a height corresponding to the total thickness of the formed material layers 81. In this state, the robot control unit 97 controls the robot 6 to move the suction nozzle 79, and the suction nozzle 79 sucks the surplus material from the upper surface side of the surplus material layer 81a.

When suction is completed by a predetermined thickness from the upper surface of the surplus material layer 81a, the table control unit 95 controls the table drive mechanism 41 to raise the modeling table 4 by a predetermined amount. As a result, the upper surface of the surplus material layer 81a rises. In this state, the robot control unit 97 controls the robot 6 to move the suction nozzle 79 to suction the surplus material from the upper surface side.

Until all the surplus material is removed, the control device 9 controls the table drive mechanism 41 to raise the modeling table 4 by a predetermined amount, and sucks the surplus material powder while moving the suction nozzle 79. Repeat this alternately. By raising the modeling table 4, vibration is applied to the object W on the object W, and excess material remaining in the recesses of the object W falls onto the base plate 83 and the object table 4, and the material W on the object W on the object W falls onto the base plate 83 and the object W on the object W. Excess material can be removed by suction more efficiently.

The amount of rise of the modeling table 4 in one lifting operation in the suction step S5 is preferably 5 to 30 mm, more preferably 7 to 20 mm. If the amount of rise in one lifting operation is too small, not only will the vibration applied to the shaped object W be insufficient, but also the lifting operation will become frequent, which may reduce the efficiency of the suction step S5. On the other hand, if the amount of rise is too large, the height of the upper surface of the surplus material layer 81a may exceed the upper end of the powder holding wall 42, and it may become impossible to hold it on the modeling table 4.

In the suction step S5 of the present embodiment, the robot control unit 97 of the control device 9 operates as a moving device so that the suction nozzle 79 takes a predetermined posture at a predetermined position based on the shape data of the desired three-dimensional structure W. control the robot 6. Specifically, data representing the contour of the object W is read into the robot 6, and the suction nozzle 79 is prevented from coming into contact with the object W, or the excess material remaining in the depressions of the object W is efficiently sucked. The suction nozzle 79 is moved while adjusting the position of the suction nozzle 79 and its posture with respect to the object W.

Further, the table control unit 95 of the control device 9 controls the modeling table 4 when the ratio of material powder in the object to be sucked by the suction nozzle 79 is larger than a predetermined value r, based on the detection result by the flow rate sensor as a detection means. The table drive mechanism 41 is controlled to lower the table by a predetermined lowering amount. If the proportion of material powder in the suction object is too large, the suction force of the suction nozzle 79 is likely to decrease and the inside of the suction nozzle 79 and the hose are likely to become clogged. By lowering the modeling table 4, the amount of filling of the opening 79b of the suction nozzle 79 into the surplus material layer 81a can be reduced and the amount of gas suctioned can be increased, thereby avoiding the above-mentioned situation.

As an example, when a flow rate sensor is used as a detection means to obtain the volumetric flow rate of the material powder in the suction object inside the suction nozzle 79 or the hose, the volumetric flow rate of the material powder is 0.7 to 0. When it is about 8, suction can be performed efficiently and the suction nozzle 79 and the inside of the hose are less likely to be clogged. Therefore, in the configuration of such a detection means, the predetermined value r is preferably set to satisfy 0.8<r.

Further, in this embodiment, the control device 9 determines whether suction of the surplus material is completed based on the detection result of the detection means. Specifically, when the ratio of material powder in the object to be aspirated by the suction nozzle 79 becomes approximately 0, it is determined that all the surplus material on the modeling table 4 has been suctioned. After the suction is completed, the robot control unit 97 controls the robot 6 to move the suction nozzle 79 from the work door to the outside of the chamber 1 and stores it in the storage section. This completes the suction step S5.

Note that the method for determining whether suction of surplus material is complete is not limited to the above-mentioned example. For example, completion of the suction may be determined by acquiring image data of the base plate 83 and the shaped object W using an imaging device such as a camera, and checking from the image data whether there is any surplus material remaining.

2.6. Removal process S6
After the suction step S5 is completed, a take-out step S6 is performed, and the base plate 83 and the shaped object W formed on the base plate 83 are taken out from the chamber 1. Specifically, first, the chuck control unit 96 controls the clamp unit 52 of the chuck device 5 to disengage the ball 52d from the locking portion 87b, and releases the fixation of the base plate 83 by the chuck device 5. Next, the robot control unit 97 controls the robot 6 to take out the base plate 83 and the shaped object W from the chamber 1 along with the mounting plate 84, pallet 85, shaft 87, and outer cover 54.

After taking out the object W from the chamber 1, the robot control unit 97 controls the robot 6 to vertically invert the object W to drop excess material, or to transfer the inverted object W to the finishing device. It may be placed and the excess material may be removed for finishing. When performing secondary processing, the robot control unit 97 controls the robot 6 to move the object W to the secondary processing device, and then the secondary processing step S7 is performed. In that case, by introducing a fixing device having the same configuration as the chuck device 5 into the secondary processing device, the robot 6 can be controlled and the base plate 83 and The shaped object W can be fixed and placed on the fixing device via the mounting plate 84 and the pallet 85. It is possible to automate the placement of the shaped object W in the secondary processing device, and the same placement accuracy as when placed in the modeling area R is ensured, making it possible to perform highly accurate secondary processing.

After completion of the take-out step S6, the three-dimensional structures W are sequentially manufactured by repeating the above steps. In such a configuration, since the suction nozzle 79 automatically removes the surplus material after the modeling is completed, it is possible to take out the shaped object W from the chamber 1 unattended.

Although various embodiments according to the present invention have been described above, these are presented as examples and are not intended to limit the scope of the invention. The new embodiment can be implemented in various other forms, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included within the scope and gist of the invention, as well as within the scope of the invention described in the claims and its equivalents.

1: Chamber, 1a: Window, 2: Material layer forming device, 3: Irradiation device, 4: Modeling table, 5: Chuck device, 6: Robot, 7: Material recovery device, 9: Control device, 10: Material supply unit , 11: Material tank, 12: Main duct, 13: Intermediate duct, 13a: Intermediate duct outlet, 14: Shutter, 17: Contamination prevention device, 17a: Housing, 17b: Diffusion member, 21: Base, 22: Recoater Head, 22a: Material storage section, 22b: Material supply port, 22c: Material discharge port, 22fb: Blade, 22rb: Blade, 23: Recoater head drive device, 41: Table drive mechanism, 42: Powder holding wall, 51 : Chuck base, 52: Clamp unit, 52a: First protrusion, 52b: Second protrusion, 52c: Contact recess, 52d: Ball, 52e: Insertion hole, 53: Chuck cover, 54: Outer cover, 54a: Outer covering part, 54b: Top part, 55: Inner cover, 55a: Inner covering part, 55b: Flange part, 70: Material recovery bucket, 70a: Powder discharge part, 70b: Powder discharge part, 70c: Shooter guide, 70d: Shooter guide, 70e: Shooter, 71: Material recovery conveyance device, 71a: Exhaust port, 71b: Suction port, 72: Switching valve, 73: Impurity removal device, 74: Suction device, 75: Switching valve, 76: Material supply bucket, 77: Material drying device, 78: Material supply conveyance device, 78a: Exhaust port, 79: Suction nozzle, 79a: Suction part, 79b: Opening portion, 81: Material layer, 81a: Surplus material layer, 82 : solidified layer, 83: base plate, 84: mounting plate, 85: pallet, 86: positioning plate, 86a: first opening, 86b: second opening, 86c: supporting foot, 86d: mounting shaft, 87: shaft, 87a: Chucking plug, 87b: Locking part, 87c: Recess, 90a: CAD device, 90b: CAM device, 91: Numerical control section, 91a: Storage section, 91b: Arithmetic section, 91c: Memory, 92: Work door Control unit, 93: Material layer formation control unit, 94: Irradiation control unit, 95: Table control unit, 96: Chuck control unit, 97: Robot control unit, 98: Collection control unit, 100: Additive manufacturing device, B: Laser Light, G: Gap, R: Modeling area, W: Three-dimensional model

Claims (13)

An additive manufacturing device comprising a modeling table, a chamber, a material layer forming device, a chuck device, a material recovery device, a movement device, a robot, and a control device,
The modeling table is configured to be movable up and down by a table drive mechanism,
The chamber covers a modeling area provided on the modeling table and is an area where a modeled object is formed,
The material layer forming device supplies material powder onto a base plate placed in the modeling area to form a material layer,
The chuck device is arranged on the modeling table and configured to allow the base plate to be detachably attached and fixed within the modeling area,
The material recovery device includes a suction nozzle capable of suctioning the excess material powder on the modeling table,
The moving device is configured to be able to move the suction nozzle,
The robot is configured to be able to take out the base plate and the modeled object formed on the base plate from the chamber,
The control device alternately controls the table drive mechanism to raise the modeling table by a predetermined amount, and sucks the excess material powder while moving the suction nozzle. Repeat, additive manufacturing equipment. The additive manufacturing apparatus according to claim 1,
A layered manufacturing apparatus comprising a detection means capable of detecting a proportion of the material powder in an object to be sucked by the suction nozzle. The additive manufacturing apparatus according to claim 2,
In the additive manufacturing apparatus, the detection means is a flow rate sensor. The layered manufacturing apparatus according to claim 2 or 3,
The control device controls the table drive mechanism to lower the modeling table by a predetermined amount of descent when the ratio of the material powder in the suction target is larger than a predetermined value. The additive manufacturing apparatus according to any one of claims 1 to 3,
The control device is a layered manufacturing apparatus that controls the moving device so that the suction nozzle takes a predetermined attitude at a predetermined position based on shape data of a desired three-dimensional structure. The additive manufacturing apparatus according to any one of claims 1 to 3,
a powder holding wall that surrounds the modeling table and is provided to hold the material powder on the modeling table;
a material recovery bucket configured to accommodate the excess material powder discharged to the outside of the powder holding wall;
The material recovery device has a recovery mode and a suction mode as operation modes,
The control device is configured to switch the operation mode,
In the collection mode, the material recovery device collects the material powder in the material recovery bucket, removes impurities, and supplies the material powder to the material layer forming device, and in the suction mode. , a layered manufacturing apparatus configured to move the suction nozzle with the moving device and suck the surplus material powder on the modeling table with the suction nozzle. The additive manufacturing apparatus according to any one of claims 1 to 3,
A side surface of the chuck device is covered with a chuck cover,
The chuck cover includes an outer cover and an inner cover,
the outer cover covers at least a portion of a side surface of the inner cover;
The inner cover covers the side surface of the chuck device. The additive manufacturing apparatus according to any one of claims 1 to 3,
The chuck device is an additive manufacturing device that fixes the base plate via a mounting plate. The additive manufacturing apparatus according to any one of claims 1 to 3,
The suction nozzle includes a suction part on the tip side,
The suction part has a cylindrical shape with a tip end face cut with an inclined surface,
An additive manufacturing apparatus, wherein the inclined surface is provided with an opening. The layered manufacturing apparatus according to any one of claims 1 to 3, wherein the robot also serves as the moving device. The layered manufacturing apparatus according to claim 10,
The robot is an additive manufacturing apparatus that carries the base plate into the chamber. The layered manufacturing apparatus according to claim 11,
The robot is a layered manufacturing apparatus in which, after taking out the molded object from the chamber, the robot reverses the molded object. A method for manufacturing a three-dimensional object,
Comprising a mounting process, a solidified layer forming process, a material recovery process, a suction process, and a take-out process,
The material recovery step is performed in parallel with the solidified layer forming step,
The suction step is performed after the solidified layer forming step and the material recovery step,
In the placement step, the base plate is removably fixed by a chuck device placed on the modeling table, so that the base plate is attached to the printing area provided on the printing table where the modeled object is formed. Place it,
The solidified layer forming step includes a material layer forming step of supplying material powder onto the base plate to form a material layer, and a solidified layer forming step by irradiating a predetermined irradiation area of the material layer with a laser beam or an electron beam. By repeating the solidification step of forming the solidified layer, the solidified layer is laminated,
In the material recovery step, surplus material generated in the material layer forming step and impurities generated in the solidification step are recovered,
In the suction step, a table drive mechanism and a suction nozzle are controlled by a control device, and the table drive mechanism raises the modeling table by a predetermined amount, and while the suction nozzle is moved by a moving device, excess Alternately repeating suctioning the material powder,
In the manufacturing method, in the taking out step, the base plate and the three-dimensional structure formed on the base plate are taken out from a chamber covering the modeling area.