JPH026877A - Optical shaping method using photosetting fluid material and heavy liquid - Google Patents

Abstract

PURPOSE:To obtain a cured product of desired shape with high precision in the dimensions and shape at a low cost by irradiating the surface of a photosetting fluid material in a vessel contg. the photsetting fluid material and a non-photosetting heavy liq. having higher sp.gr. than the material and immiscible with the material, with light. CONSTITUTION:The surface of the photosetting fluid material 7 having a depth equal to the vertical height of a cured layer to be formed is firstly irradiated by a laser beam 9 in the first stage to form a cured layer 17a having the cross section of the desired shape. The level of the heavy liq. 5 is then raised to the upper surface of the cured layer 17a in the second stage. The photo setting fluid material 7 is further supplied on the heavy liq. 5 in the vessel 1 in the third stage so that the depth of the material 7 is made equal to the vertical height of the cured layer 17b. As a result, the heavy liq. 5 or the cured layer formed in the preceding stage is always present under the cured layer, the photosetting fluid material 7 is not present under the cured layer, and hence a cured material in the form of a sagging liq. is not formed.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to an optical modeling method that uses a photocurable fluid material and a heavy liquid in combination, and in particular, the present invention relates to an optical modeling method that uses a photocurable fluid material and a heavy liquid, and in particular, it is possible to form a desired shape with high shape accuracy and dimensional accuracy. The present invention relates to an optical modeling method that uses a photocurable fluid material and a heavy liquid that can be produced.

[Prior Art] A photocurable fluid material such as a photocurable resin is irradiated with light to harden the irradiated portion, and this cured portion is continued in the horizontal direction, and a photocurable fluid material is further applied above it. An optical modeling method in which a cured body is made to continue in the vertical direction by supplying and curing in the same manner, and by repeating this process to produce a cured body with a desired shape is disclosed in Japanese Patent Application Laid-Open No. 60-24751.
No. 5, No. 62-35966, No. 62-101408, etc.

In this method, as shown in FIG. 3(a), a photocurable fluid 21 is housed in a container 20, and 11L of photocurable fluid
Using an apparatus that is equipped with an optical system so as to irradiate light 22 toward the liquid surface 21a of the container 21, and a base plate 23 that can be raised and lowered in the container 20, first, the base plate 23 is moved to the liquid surface 21a. The light 22 is scanned along the horizontal cross section of the target object. After irradiating the entire horizontal cross section of the target object (in this case, the part corresponding to the bottom surface) with light, the base plate 23 is lowered slightly and the uncured photocurable fluid material 21 is placed on top of the cured object. After flowing in, the same light irradiation as above is performed. By repeating this procedure, a cured body 24 having the desired shape is obtained as shown in FIG. 3(b).

Note that instead of scanning the light, a pattern mask may be used to irradiate the light.

[Problems to be Solved by the Invention] In the above conventional method, the light that passes through the photocurable fluid material to be cured or the refracted light causes the photocurable fluid material in the portions that should not be cured to be cured. This has the disadvantage that the shape accuracy of the resulting cured product is low. That is, for example, when manufacturing the cured body 24 by the method shown in FIGS. 3(a) and 3(b), as shown in FIG. 4, which is an enlarged view of the section ■ in FIG. The light 22a transmitted through the light 24a hardens the photocurable fluid material 21 below the cured layer 24a, and a solidified substance 25 like a droplet is formed at the bottom of the cured layer 24a. It cannot be manufactured with shape and dimensional accuracy.

In addition, it is necessary to store the photocurable fluid material 21 in the container 20 at least to the height of the cured material of the desired shape, and the cured material formed by a series of operations must be made of the same photocurable fluid material. Limited to monochromatic substances, 2F! using photocurable fluid substances of different materials and colors! It was not possible to add more than one color.

Furthermore, since it is necessary to store a large amount of photocurable fluid material in the container, the amount of photocurable fluid material required is significantly larger than the amount of cured material to be produced, resulting in lower material costs. It also had the disadvantage of being expensive.

The present invention solves the above-mentioned conventional problems, and enables the production of cured bodies in desired shapes with high dimensional and shape accuracy at low cost, as well as multicolored molded bodies and composites of two or more materials. It is an object of the present invention to provide an optical modeling method that uses a photocurable fluid material that can also produce a cured body.

[Means for Solving the Problems] The optical modeling method using the photocurable fluid material of the present invention includes:
The photocurable fluid material in a container containing a photocurable fluid material and a photonon-curable heavy liquid that has a higher specific gravity than the photocurable fluid material and is immiscible with the photocurable fluid material. A first step of irradiating the surface of the hardened layer with light to form a hardened layer having the cross-sectional shape of the target shaped object; A second step of immersing the heavy liquid in such a way that the liquid level of the heavy liquid matches the top surface of the hardened layer. and the third step of supplying the photocurable material so that the liquid depth corresponds to the thickness of the cured layer to be formed. This is a method of manufacturing a target shaped body.

[Function] In the optical modeling method of the present invention, a photocurable fluid material and a non-photocurable heavy liquid (hereinafter referred to as In the first step, the surface of the photocurable fluid material at a depth equal to the vertical height of the hardened layer to be formed is irradiated with light to form the desired shape. A hardened layer with a cross-sectional shape is formed. Then, in a second step, the liquid level of the heavy liquid is raised to match the upper surface of the cured layer. Roughly in the third step, on the heavy liquid in the container, so that the depth is equal to the vertical height of the hardened layer to be formed,
Supply photocurable fluid material.

Therefore, the heavy liquid or the cured layer formed in the previous step always exists under the cured layer, and the photocurable fluid material does not exist under the cured layer. Therefore, as shown in FIG. 4, the light transmitted through the cured layer 24a
When the photocurable fluid material 21 in the lower part of a is cured, no solidified material 25 like dripping is formed, and high dimensional accuracy is achieved.
A target shaped body can be obtained with shape accuracy.

Moreover, the liquid level of the photocurable fluid material can be raised by heavy liquid, and there is no need for a mechanism for raising and lowering the base plate as in the past.

Furthermore, it is sufficient that the amount of photocurable fluid material supplied into the container is equal to the height of the cured layer to be formed.
Only a small amount of photocurable fluid material is required, and the material cost is reduced.

Moreover, by supplying different photocurable fluid substances during the third step following the second step, it is possible to stack cured layers of different materials, colors, etc. It is possible to produce molded bodies with different characteristics.

[Example] Hereinafter, an example of the present invention will be described with reference to the drawings.

FIG. 1 is a sectional view showing an example of an optical modeling apparatus suitable for carrying out the present invention.

A base plate 2 is placed on the bottom surface of the container 1, and a frontage 1a provided on the bottom surface of the container 1 and the base plate 2.
A supply pipe 3 is connected to the heavy liquid tank 4, and the heavy liquid 5 in the heavy liquid tank 4 is configured to be supplied at a fixed amount by a metering pump P+. Reference numeral 2a indicates an opening provided in the base plate 2, and a supply pipe is connected from above the container 1 so that the photocurable fluid substance 7 is supplied in a fixed amount from the photocurable fluid substance tank 6 by a metering pump P2. 8 is installed.

In order to irradiate the liquid surface 7a of the photocurable fluid material 7 in the container 1 with the laser beam 9, a radiation part 1 at the tip of the optical fiber 10 is used.
0a is attached to the X-Y moving device 11 above the container 1. The other end of the optical fiber 10 is connected to a light source 12 via a shutter 13. Reference numeral 14 denotes a liquid level sensor and a film thickness sensor, which can be raised and lowered by a lifting device 15.

Note that the shutter 13, the X-Y i3 movement device 11, the metering pump P I % P 2 % liquid level sensor and film thickness sensor 14, and the lifting device 15 are all controlled by the computer 16.
Controlled by

17 is a cured body obtained by laminating cured layers 17a, 17b, 17c, 17d...

A method for manufacturing a desired cured body using the modeling apparatus configured as described above will be described with reference to FIGS. 2(a) to 2(f).

(2) First, as shown in FIG. 2(a), the photocurable fluid material 7 in the tank 6 is supplied onto the base plate 2 in the container i to a predetermined depth d. The depth d+ of the photocurable fluid material 7 is made equal to the vertical height of the cured N (178 in FIG. 2(b)) to be formed.

(2) Next, the radiation part 10a of the optical fiber 10 is scanned by the X-Y moving device following the horizontal cross section of the target shape to irradiate the photocurable fluid material 7 in the container 1 with light, and the bottom surface of the target shape is irradiated with light. A hardened layer 17a is obtained in a portion corresponding to (FIG. 2(b)). The hardened layer 17a is in close contact with the base plate 2.

■ Then, pour the heavy liquid 5 in the tank 4 into the container i through the opening 1a.
, 2a. At this time, the sensor 14 detects the liquid level so that the liquid level 5a of the heavy liquid 5 becomes equal to the upper surface of the hardened layer 17a (FIG. 2(C)).

■ Supply the photocurable fluid material 7 into the container 1 again, and adjust the depth d2 of the photocurable fluid material 7 to the second hardened layer (see Fig. 2).
The height should be equal to the height of 17b) in e) (Fig. 2(d)). At this time, the photocurable fluid material 7 has a lower specific gravity than the heavy liquid 5 and is immiscible with the heavy liquid 5. A photocurable fluid 'Jit7
A layer of uniform thickness is formed.

■ Similarly to (2), the photocurable fluid material 7 in the container 1 is irradiated with the light 9 to form a hardened layer 17b with a horizontal cross section corresponding to the second layer from below the object shaped object (Fig. 2(e) )).

■ Repeat the same operations as ■ to ■ to form the hardened layer 17c,
17d and 17e are formed to form a cured body 17 having the desired shape (FIG. 2(f)).

According to this modeling method, as is clear from FIGS. 2(e) and 2(f), the photocurable fluid material irradiated with light forms an extremely shallow layer, and the lateral side of the already hardened layer forms an extremely shallow layer. There is no photocurable fluid material in the area. Therefore, as shown in FIG.
is prevented from occurring as a by-product.

In addition, in the modeling method shown in FIG. 2 above, by changing the type of photocurable fluid material injected into the container, for example,
By changing the type of photocurable fluid substance between the cured layer 17a and the cured layer 17b, it is possible to easily produce a cured product composed of layers of different colors and materials.

In the present invention, various materials that harden by light irradiation can be used as the marking photocurable fluid material, such as modified polyurethane methacrylate, oligoester acrylate, urethane acrylate, epoxy acrylate, photosensitive polyimide, and amino alkyd. can be mentioned.

In the present invention, the amount of such a photocurable fluid material is only required to be approximately the same as the amount required for producing a target shaped object, which is economical. That is, for example, FIGS. 2(a) to (f)
In the example of ), the amount of photocurable fluid material excessively supplied into the container is only the photocurable fluid material in portions 7a, 7b, and 7c in FIG. 2(f), which is a very small amount.

Further, the heavy liquid may be any photo-non-curable liquid that has a specific gravity larger than the above-mentioned photo-curable fluid material and is immiscible with the photo-curable fluid material, and is not particularly limited. For example, ethylene Examples include glycol and heavy water. These heavy fluids can be reused.

As the light used in the present invention, various types of light such as visible light and ultraviolet light can be used depending on the photocurable fluid material used. Although the light may be ordinary light, using laser light has the advantages of increasing the energy level, shortening the modeling time, and improving the modeling accuracy by utilizing good light focusing. can.

In the above embodiment, the irradiation light beam is scanned by scanning the optical fiber cable, but the irradiation light beam may be scanned by converging the light with a lens and rotating this lens. Furthermore, the optical system is kept stationary and the container is
By moving the light, the light may be moved relative to the liquid level of the photocurable fluid material.

In the present invention, a pattern mask may be used instead of scanning the irradiation light beam, or other means capable of irradiating light onto a desired portion of the liquid surface may be employed.

[Effects of the Invention] As detailed above, the optical modeling method using a photocurable fluid material and a heavy liquid of the present invention has the following excellent effects, and it is possible to produce high-quality products at low cost. It can be manufactured efficiently at low cost.

■ The photocurable fluid material exists only on the surface to be cured, and there is no uncured photocurable fluid material under the cured layer, so the transmitted light or refracted light of the cured layer causes the photocurable material to be applied to unnecessary areas. No solidification of the fluid material is formed. For this reason,
A cured body having a desired shape can be easily and efficiently produced with high shape accuracy and high dimensional stability.

■ No lifting equipment is required, reducing power and equipment costs.

■ It is possible to form parts of different materials and colors on the product, making it possible to obtain products with excellent decorative properties.

■ Only a small amount of photocurable fluid material is required, reducing material costs.

■ Since the heavy liquid can also be reused, the cost of heavy liquid is also extremely low.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing an example of an apparatus suitable for implementing the present invention, FIGS. 2(a) to (f) are cross-sectional views explaining one method of implementing the present invention, and FIGS. b) is a sectional view showing the conventional method, and FIG. 4 is an enlarged view of section IV in FIG. 3(b). 1... Container, 2... Base plate, 3.8... Supply pipe, 4.6... Tank,
5... Heavy liquid, 7... Photocurable fluid substance, 10... Optical fiber, 9
...Laser light, 12...Light source, 14...
・Sensor, 16... Computer, 17.
...Cured body, 17a, 17b, 17c, 17d, 17e...Cured layer. agent

Claims (1)

[Claims] (1) Photo-curing in a container containing a photo-curable fluid material and a photo-non-curable heavy liquid that has a higher specific gravity than the photo-curable fluid material and is immiscible with the photo-curable fluid material. The first step is to irradiate the surface of the fluid material with light to form a hardened layer with the cross-sectional shape of the target object; immerse the heavy liquid in such a way that the liquid level of the heavy liquid matches the top surface of the hardened layer. By repeating the second step of supplying the photocurable fluid to a liquid depth corresponding to the thickness of the cured layer to be formed, a cured layer of the photocurable fluid is formed. An optical modeling method that uses a photocurable fluid material and a heavy liquid to produce a desired shape by laminating layers.