JPH02128829A - Optical molding method - Google Patents

Abstract

PURPOSE:To easily release a solid and a substrate surface by fixing a sheet like member having flexibility to a support member immersed in a fluid substance in a freely detachable manner to form the substrate surface and forming the solid on the sheet like member. CONSTITUTION:A photo-setting fluid substance A is received in a container and a base plate 2 is sunk in the fluid substance A appropriately and the selec tive irradiation with light is performed by a light converging device 4 to form the cured part (b) from the upper surface of the fluid substance A to the upper surface of a sheet like member 6. The sinking of the base plate 2 and the forma tion of the cured part by the irradiation with light are performed repeatedly to form a solid B having a desired shape and the fixing jig 7 of the base plate 2 is released and the sheet like member 6 is detached from the base plate 2 in such a state that the solid B is fixed. Thereafter, the sheet like member 6 is bent in the direction opposite to the fixing surface of the solid B to gradu ally release the member 6 from the solid B.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to an optical shaping method using light and a photocurable fluid material to form a solid body of a desired shape.

Conventional technology and its problems Traditionally, models corresponding to the product shape required during mold production, or models for tracing control in cutting or die-sinking electrical discharge machining electrodes, have been produced by hand processing or using an NC milling machine. This was done by NC cutting using, etc. However, when using manual machining, there is a problem in that it requires a lot of time and skill, and when using NC machining, it is necessary to create a complicated machining program that takes into account replacement to change the shape of the cutting edge of the blade, wear, etc. In addition, there is a problem in that additional finishing machining may be required to remove steps formed on the machined surface.

In order to deal with such problems, various methods have been proposed for selectively curing photocurable resins to obtain solids with desired shapes.

For example, as one method for forming a solid using the photocurable resin, a method has been proposed in which the photocurable resin is repeatedly selectively irradiated with light based on masking to obtain a desired three-dimensional shape. This involves first irradiating a very shallow photocurable resin with light from above or below, then placing a masking film in front of the photocurable resin with a light-transmitting part corresponding to the cross-sectional shape of the three-dimensional object to be obtained. Then, by this irradiation, a thin layer cured part with the desired cross-sectional shape is obtained, and for the continuous cross-sectional shape, the depth of the photocurable resin is gradually increased, the masking film is sequentially replaced, and the light irradiation is repeated to obtain the desired shape. This is a method to obtain a solid.

Another method is to irradiate concentrated light energy according to the cross-sectional shape of a solid of a desired shape to a layer of a photocurable fluid material having a thickness that allows a continuous hardened portion to be formed, and then to form a predetermined hardened portion. A new layer of photocurable fluid material is added to the surface of the cured part, and the cross-sectional shape that continues to the cured part is irradiated with concentrated light energy again to form a new cured part.This operation is repeated to form a desired three-dimensional shape. A method to obtain this is proposed.

In the various methods described above, the solid may be firmly fixed to a base surface that holds the solid of a desired shape, such as the bottom wall of the container or a base plate movably installed within the container, This poses a problem in that it takes time to separate the solid from the base surface, and the solid may be damaged.

An object of the present invention is to provide an optical modeling method that solves the above-mentioned problems and allows easy separation of the solid from the base surface after forming the solid in a desired shape without damaging the solid. It is in.

Means for Solving the Problems The above object of the present invention is to house a photocurable fluid material that hardens with light in a container, and while irradiating the fluid material with light, irradiating the irradiated area with respect to the container. An optical modeling method in which a solid body having a desired shape is formed on a base surface by relative movement in the horizontal and vertical directions according to the shape of the object to be modeled. The base surface is formed by removably fixing a sheet-like member having a magnetic field, the solid is formed on the sheet-like member, and after the solid is formed, the sheet-like member is bent to form the sheet from the solid. An optical modeling method characterized by peeling off a shaped member, and a photocurable fluid material that is cured by light is housed in a container, and a flexible sheet-like member is detachably attached to the bottom wall of the container. and while irradiating light into the fluid substance, move the irradiation point relative to the container in horizontal and vertical directions according to the shape of the object to be modeled, to form a solid in a desired shape on the sheet-like member. This is achieved by an optical modeling method characterized by bending the sheet-like member after forming the solid and peeling the sheet-like member from the solid.

As the photocurable fluid substance, various substances that are cured by light irradiation can be used, such as modified polyurethane methacrylate, oligoester acrylate, urethane acrylate, epoxy acrylate, photosensitive polyimide, and amino alkyd.

The photocurable fluid substance may be mixed with a modifying material such as pigment, ceramic powder, metal powder, etc. in advance.

As the light, various types of light such as visible light and ultraviolet light can be used depending on the photocurable material used.

The illumination may be regular light, but using laser light has the advantage of increasing the energy level, shortening the build time, and improving the build accuracy by taking advantage of good light focusing. .

Embodiments Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

FIG. 1 shows a step-by-step process of manufacturing a solid body of a desired shape using an apparatus for carrying out an optical modeling method according to an embodiment of the present invention. The device uses a photocurable flow material (A
), a base plate (support member) (2) supported at the lower end of a support rod (1) extending in the vertical direction, and a base plate (support member) (2) that accommodates the light source above the container. It is equipped with a light converging device (4) that focuses the light into a dot near the upper surface of the fluid material (A) in the container, so that the light irradiation position can be moved relative to the fluid material (A).

Further, in this device, a thin sheet-like member (6) having flexibility and a smooth surface is attached to the upper surface of the base plate (2) to form a base surface for solid formation. The member (6) is arranged to cover substantially the entire upper surface of the base plate (2).
) is removably attached by means of a fixture (7) on top.

The light source and light concentrator (4) are fixed outside the container,
It moves mainly horizontally with respect to the container.

The light converging device (4) may be, for example, a concave mirror instead of the convex lens as shown. In addition, the base plate (
The upper end of the support rod (1) supporting the container 2) is also fixed outside the container and moves in a direction perpendicular to the container.

Movement control of the light source and light concentrator (4), or support rod (
The movement control in 1) can be performed as appropriate, such as automatic control such as NC or manual control.

In order to perform solid modeling in a desired shape using this device, first, the photocurable fluid material (A) is placed in a container, and the base plate (2) is irradiated with light from above to form the fluid material (A).
A) Submerge and position in the fluid material (A) to a depth that provides a continuous hardened portion extending from the top surface to the top surface of the sheet-like member (6) on the base plate 4 (2). After that, a light source emits light with an energy level necessary for curing the fluid material, and the light is selectively irradiated while converging the light into a point shape with a light converging device (4), so that the sheet is sheeted from the top surface of the fluid material (A). A hardened portion (b) extending to the upper surface of the shaped member (6) is formed. (See Figure 1(a)).

After the hardened portion (b) is obtained, the depth from the upper surface of the fluid substance (A) to the upper surface of the hardened portion (b) is such that a continuous hardened portion extending between these both surfaces is obtained by light irradiation;
That is, the base plate (2) is lowered to the same depth as that at which the hardened portion was formed, and the same light concentrator (2) as described above is installed.
4) By selectively performing concentrated light irradiation via
A new hardened portion continuous to the hardened portion is obtained on the hardened portion. Furthermore, the sedimentation of the base plate (2) and the formation of a hardened portion by light irradiation are repeated to form a solid (B) of a desired shape on the upper surface of the sheet-like member (6) (first
(See figure (b)).

After the solid (B) is formed, the fixing device (7) of the base plate (2) is released, and the sheet-like member (6) is removed from the base plate (2) while the solid (B) remains fixed (the first
(See figure (c)). After that, as shown in FIG. 1(d),
The sheet-like member (6) is bent toward the side opposite to the surface to which the solid (B) is fixed, and the member (6) is gradually peeled off from the solid (B).

As a result, even if the solid (B) is firmly attached to the sheet-like member (6), the sheet-like member (6) can be easily removed from the solid (6) without damaging the solid (B). It can be peeled off from B), and the desired three-dimensional structure can be reliably obtained. Further, after forming the solid (B) in the desired shape, the solid (B) can be immediately separated from the base plate (2), so that the next solid can be formed quickly using the above apparatus. There is also an advantage.

The apparatus used in the method of the present invention can have various other forms as described below.

The apparatus shown in FIG. 2 uses a flexible net-like member (16) made of metal or synthetic resin as the sheet-like member used in the above-mentioned apparatus, and further includes a base plate (supporting member') (12). This device has a large number of through holes (18) drilled in it, and has the same configuration as the above device except for these points. The surface shape of the net-like member (16) remains on the lower surface of the solid (B) after the net-like member (16) is peeled off, but this can be removed if necessary.

In the optical modeling method using this device, a mesh member (1
The adhesion area of 6) and solid CB) is the same as the sheet-like member (6).
), which has the effect that the net-like member (16) can be more easily separated from the solid (B). In addition, the photocurable fluid substance (A) existing below the base plate (12) penetrates the through holes (18) of the base plate (12) and the mesh of the net-like member (16) due to the sedimentation of the base plate (12). It also has the advantage that it can facilitate the application of the fluid substance (A) onto the mesh (16) and onto the hardening part, as it passes through and onto the mesh (16).

In the device shown in FIG. 3, the base plate (22)
has a frame (supporting member) (23) and a flexible mesh member (26) removably stretched inside the frame (23) by means of a fixture (27). The net-like member (26) forms a base surface for forming the solid, on which the solid of the desired shape is formed. This device, except as noted above,
It has the same structure as the device used in the above example. After forming the solid CB using the apparatus in this example, the fixing device (27) for tensioning the net-like member (26) is released, and the net-like member (26) is fixed while the solid (B) remains fixed. The frame body (23
), after which the mesh member (26) is removed from the solid (B
) This is done by bending it to the side opposite to the fixed surface side.

Therefore, as described above, the net-like member (26) can be easily peeled off from the solid (B) without damaging the solid (B). Further, after forming the solid body (B) in the desired shape, the solid body (B) can be immediately removed from the frame body (23), so that other net-like members of the same shape can be removed from the frame body (23).
), the next solid formation using the above device can be performed quickly. Furthermore, the photocurable fluid material (A) existing below the net-like member (26) is caused by the sedimentation of the base plate (22).
), it also has the advantage of facilitating the application of the fluid substance (A) onto the mesh member (26) and onto the hardening part.

In addition, in the apparatus shown in FIGS. 2 and S3, a flexible sheet-like member with a plurality of through holes is used instead of the net-like members (16) and (26). Good too.

In the apparatus shown in FIG. 4(a), a support member immersed in a fluid substance (A) is supported by two horizontally extending support rods (31) supported at the lower ends of vertically extending support rods (31). Arm (3
2), two rollers (33) rotatably pivoted between the proximal ends and the distal ends of both the arms (32),
(34) and a flexible endless net-like member (36) stretched over both the rollers (33) and (34), and in other respects, the apparatus in each of the above embodiments. It has the same structure as . In this device, the upper net-like member (36) between the rollers (33) and (34) serves as a base surface for solid formation. This device consists of two rollers (
At least one of 33) and (34) is a driving roller. Based on the rotation of the drive roller, the net-like member (36) moves, and the solid (B) is conveyed to the tip side of the arm (32). The net member (36) is connected to the roller (3
4). For this reason, the roller (33), (
By adjusting the rotational speed of the net-like member (34) and making the moving speed of the net-like member (36) appropriate, the net-like member (36)
is gradually peeled off from the solid (B) without causing any damage to the solid (B) (see Fig. 4(b)).If the apparatus of this example is used, as described above, the labor is not required. The solid (B) and the base can be automatically separated from each other without causing any separation, and the photocurable fluid material (A) present below the net-like member (36) is removed by the settling of the base. )
The advantage is also obtained that it facilitates the application of the fluid substance (A) onto the mesh member (36) and onto the hardening part.

In addition, in the apparatus for the modeling method of this embodiment, the member stretched between the two rollers is made of the above-mentioned net shape, but it is not limited to this (for example, it may be made of a flexible smooth endless material). It may be a sheet-like member. Also, a plurality of through holes may be bored in the endless sheet-like member.

Furthermore, in the modeling method of the present invention, the above-mentioned member may be removably disposed on the bottom wall of a container containing a fluid substance, and a solid may be formed on the member.

As described above, the shaping method of the present invention is characterized by forming a solid body in a desired shape on the upper surface of a flexible sheet-like member that is detachably attached to a supporting member or a bottom wall of a container. As long as it has this feature, it can be applied to various modeling methods based on light irradiation. Therefore, in addition to the modeling method based on light irradiation described in the above example,
For example, a method in which the upper surface of a photocurable fluid material in a container is slightly raised and light is irradiated from above to form a solid; A method of forming a solid based on light irradiation through the transparent plate while raising the transparent plate, using a part of the side wall or bottom wall of the container as a transparent plate, and moving the transparent plate away from the transparent plate while keeping the base surface on which the cured portion is supported away from the transparent plate. It can be applied to a method of forming a solid on a substrate surface based on light irradiation through a substrate.

A release agent may be applied to the upper surface of the sheet-like member in advance. Thereby, the desired shape solid formed on the upper surface of the sheet-like member can be more easily peeled off from the sheet-like member.

In addition, light irradiation in these methods includes, for example, light irradiation using a light guide, light irradiation in which light emitted from multiple light sources intersects at one point, and light irradiation in which the portion of high light intensity in a cross section perpendicular to the optical axis is annular. It is possible to employ methods such as irradiation of light that exhibits a distribution. When using the above-mentioned light guide, if the tip of the light guide is hemispherical, there is an advantage that the light can be converged and irradiated so that the light energy is concentrated in a point shape. Furthermore, if light irradiation in which the above-mentioned plurality of lights intersect is adopted,
The light energy can be increased non-linearly at the light intersection point, and a solid having a desired shape can be quickly formed. By irradiating the light having the above-mentioned annular light intensity distribution, a relatively thick band-shaped solid can be formed with high dimensional accuracy by one scan of the light irradiation, and solids having a desired shape can be formed efficiently. .

Effects of the Invention As is clear from the above, according to the method of the present invention, the following effects can be obtained.

That is, a flexible and removable sheet-like member is used as a base for forming a solid in a desired shape, and after the solid is formed, the sheet-like member is bent and gradually peeled off from the solid. Separation of the solid from the base surface can be easily performed without damaging the solid.

[Brief explanation of drawings]

FIGS. 1(a) to (d) are explanatory diagrams showing step-by-step an optical modeling method according to an embodiment of the present invention, and FIG. 2 is an optical modeling method of the present invention using a net-like member as a sheet-like member. FIG. 3 is an explanatory diagram showing an example of the modeling method of the present invention in which the solid-forming base is a net-like member stretched over a support member,
FIG. 4(a) is an explanatory diagram showing another example of the modeling method of the present invention based on a net-like member stretched by two rollers,
Figure (b) is an explanatory diagram showing a method of separating the net-like member from the solid. (1), (31)...Support rod (2), (12), (22)...Base plate (support member) (4)...
... Light concentrator (6) ... Sheet-like member (base) (16), (
26), (36)...Net-like member (base) (32)...Arm (A)...Photocurable fluid material (B)... Desired shape solid (b)...Cured portion (and above)

Claims (1)

[Scope of Claims] [1] A photocurable fluid material that is hardened by light is placed in a container, and while irradiating light into the fluid material, the irradiated area is shaped in horizontal and vertical directions with respect to the container. An optical modeling method in which a solid body having a desired shape is formed on a base surface by relative movement according to the shape of an object, the sheet-like member having flexibility relative to a support member immersed in the fluid substance. removably fixing to form the base surface, forming the solid on the sheet-like member, and bending the sheet-like member after forming the solid to peel the sheet-like member from the solid. An optical modeling method characterized by [2] A photocurable fluid material that hardens with light is housed in a container, a flexible sheet-like member is removably installed on the bottom wall of the container, and while irradiating light into the fluid material, the fluid material is irradiated with light. , moving the irradiation point relative to the container in horizontal and vertical directions according to the shape of the object to be modeled, forming a solid of a desired shape on the sheet-like member, and bending the sheet-like member after forming the solid. and peeling off the sheet-like member from the solid body.