JPH0479828B2 - - Google Patents

Description

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

Conventional technology and its problems Conventionally, models corresponding to the product shape required during mold production, models for tracing control in cutting machining, or models for die-sinking electric discharge machining electrodes have been produced by hand processing or by using an NC milling machine. This was done by NC cutting using tools such as. 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 and wear to change the shape of the cutting edge. 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, and 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 increased little by little, 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 a photocurable fluid material layer with a thickness such that a continuous hardened part is formed by concentrated light energy in accordance with the cross-sectional shape of a solid having a desired shape to form a predetermined hardened part. Afterwards, a new photocurable fluid material layer is added to the surface of the cured portion, and the cross-sectional shape that continues to the cured portion is irradiated with concentrated light energy again to form a new cured portion.This operation is repeated to form a new cured portion as desired. A method has been proposed to obtain a solid.

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 base surface and the solid, 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-mentioned 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, the irradiated area is directed against 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. 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.

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 is
Container containing photocurable fluid material A (not shown)
and a base plate (supporting member) 2 supported by the lower end of the support rod 1 extending in the vertical direction, and converging the light emitted from the light source above the container into a point near the upper surface of the fluid substance A in the container. A light converging device 4 is provided to move the light irradiation position relative to the fluid material A.

Furthermore, 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 so as to cover substantially the entire upper surface of the base plate 2, and is detachably attached to the base plate 2 by a fixture 7.

The light source and the light concentrator 4 are fixed outside the container and move mainly in the horizontal direction with respect to the container. The light converging device 4 may be, for example, a concave mirror instead of the convex lens shown in the figure. Further, the upper end of the support rod 1 that supports the base plate 2 is also fixed outside the container and moves in a direction perpendicular to the container.

The movement control of the light source and light converging device 4 or the movement control of the support rod 1 can be performed as appropriate, such as automatic control such as NC, manual control, or the like.

In order to perform solid modeling in a desired shape using this device, first, the photo-curable fluid material A is placed in a container, and the base plate 2 is irradiated with light from above to form a solid object onto the base plate 2 from the top surface of the fluid material A. The sheet-like member 6 is immersed in the fluid material A and positioned to a depth that provides a continuous hardened portion that extends to the upper surface of the sheet-like member 6. Thereafter, light with an energy level necessary for curing the fluid material is emitted from a light source, and the light is selectively irradiated while converging the light into a point shape with the light concentrator 4. A hardened portion b extending to the upper surface is formed. (See Figure 1a).

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 the depth at which a continuous hardened portion extending between these surfaces is obtained by light irradiation, that is, forms the hardened portion. By lowering the base plate 2 to the same depth as the base plate 2 and selectively irradiating the base plate 2 with concentrated light through the light converging device 4 similar to that described above, a new hardened portion continuous to the hardened portion is obtained on the hardened portion. Further, the settling of the base plate 2 and the formation of a hardened portion by light irradiation are repeated to form a solid B having a desired shape on the upper surface of the sheet-like member 6 (see FIG. 1b).

After the solid B is formed, the fixture 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 (FIG. 1c).
reference). Thereafter, as shown in FIG. 1d, the sheet-like member 6 is bent toward the side opposite to the surface to which the solid B is fixed,
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 peeled off from the solid B without damaging the solid B, and as desired. It is possible to reliably obtain a solid shape. Further, after forming the solid B in the desired shape, the solid B can be immediately separated from the base plate 2, so there is an advantage that the next solid can be formed quickly using the above apparatus.

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

The device 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 device, and further includes a base plate (supporting member) 12 with a large number of through holes. 18
It 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, the adhesion area between the net-like member 16 and the solid B is smaller than that of the sheet-like member 6, and therefore the net-like member 16 can be separated from the solid B more easily. be effective. Furthermore, the photocurable fluid material A existing below the base plate 12 passes through the through holes 18 of the base plate 12 and the mesh of the net member 16 and migrates onto the net member 16 based on the sedimentation of the base plate 12. There is also the advantage that it may facilitate the application of the fluid material A onto the member 16 and onto the hardened portion.

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

Therefore, as described above, the net member 26 can be easily peeled off from the solid B without damaging the solid B. In addition, the above desired shape solid B
After forming, the solid B can be immediately removed from the frame 23, so by installing another net-like member of the same shape into the frame 23, the next solid can be formed using the above device immediately. You can also do that. Furthermore, since the photo-curable fluid substance A existing below the net member 26 passes through the mesh of the net member 26 based on the settling of the base plate 22, the fluid material A is added onto the net member 26 and the cured portion. It also has the advantage of making it easier.

In the apparatus shown in FIGS. 2 and 3, a flexible sheet-like member having a plurality of through holes may be used instead of the net-like members 16 and 26.

In the apparatus shown in FIG. 4a, a support member immersed in a fluid substance A includes two arms 32 extending in the horizontal direction supported by the lower ends of a support rod 31 extending in the vertical direction; Two rollers 3 rotatably pivoted between the proximal end and the distal end of the
3 and 34, and a flexible endless net-like member 36 stretched between the rollers 33 and 34, and in other respects has the same structure as the apparatus in each of the above-described embodiments. In this device, an upper mesh member 36 between both rollers 33 and 34 is used.
becomes the base surface for solid formation. In this device, at least one of the two rollers 33 and 34 is a driving roller. Based on the rotation of this drive roller, the net-like member 36 moves, and the solid B is transferred to the arm 3.
It is transported to the tip side of 2. The mesh member 36 flexes along the roller 34. For this reason, the rollers 33, 3
By adjusting the rotational speed of 4 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 any damage to the solid B (see Figure 4b).

By using the apparatus in this embodiment, as described above, the solid B and the base can be automatically separated without any manual effort, and furthermore, the net member 36 can be peeled off automatically.
Since the photo-curable fluid substance A present below passes through the mesh of the net-like member 36 based on the settling of the base, it also has the advantage of facilitating the addition of the fluid substance A onto the net-like member 36 and the cured portion. can get.

In addition, in the apparatus according to the modeling method of this embodiment, the member stretched between the two rollers is of the above-mentioned net shape, but it is not limited to this.
For example, it may be a flexible, smooth, endless sheet-like member. Further, the endless sheet-like member may be provided with a plurality of through holes.

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 mentioned above, in the modeling method of the present invention, on the support member,
Or, it is characterized by forming a solid in a desired shape on the upper surface of a flexible sheet-like member detachably attached to the bottom wall of the container, and as long as it has this feature, It is applied to various modeling methods. Therefore, in addition to the modeling method based on light irradiation described in the above embodiments, for example, a method in which the upper surface of a photocurable fluid material in a container is slightly raised and a solid is formed by light irradiation from above, and a method in which a solid is formed by light irradiation from above, photocuring in a container. A method in which a box body having a transparent plate is immersed in a liquid substance, the transparent plate is raised, and a solid is formed based on light irradiation through the transparent plate. It can be applied to a method of forming a solid on a substrate surface based on light irradiation through the transparent plate while moving the substrate surface on which a portion is supported away from the transparent plate.

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, by employing light irradiation in which the plurality of lights intersect, the light energy can be nonlinearly increased at the intersection of the lights, 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. The solid and the base surface can be easily separated without damaging the solid.

[Brief explanation of drawings]

Figures 1 a to d are explanatory diagrams showing step-by-step an optical modeling method according to an embodiment of the present invention, and Figure 2 shows an example of the 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 on a support member, and FIG. FIG. 4B is an explanatory diagram showing another example of the modeling method of the present invention based on a net-like member, and FIG. 4B is an explanatory diagram showing a method for separating the net-like member from a solid. 1, 31... Support rod, 2, 12, 22... Base plate (supporting member), 4... Light concentrator, 6...
...sheet-like member (base), 16, 26, 36...
Net member (base), 32...Arm, A...Photocurable fluid material, B...Solid in desired shape, b...Cured portion.

Claims (1)

[Claims] 1. A photocurable fluid material that is cured by light is placed in a container, and while irradiating light into the fluid material,
An optical modeling method in which the irradiation point is moved horizontally and vertically relative to the container according to the shape of the object to be modeled to form a solid having a desired shape on the base surface, and the solid is immersed in the fluid substance. A flexible sheet-like member is removably fixed to a supporting member to form the base surface, the solid is formed on the sheet-like member, and after the solid is formed, the sheet-like member is bent. An optical modeling method characterized by peeling the sheet-like member from the solid body. 2. A photocurable fluid material that is hardened by light is housed in a container, a flexible sheet-like member is removably installed on the bottom wall of the container, and while the fluid material is irradiated with light, 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; An optical modeling method characterized by peeling the sheet-like member from the solid.