JPH05305673A - Optical shaping apparatus - Google Patents

Abstract

PURPOSE:To prevent the lowering of the accuracy of a three-dimensional model by providing a smoothing means scraping off the necessary buildup of the level of the photo-setting resin solution covering a photo-set layer above a molding stand in an optical shaping apparatus forming a three-dimensional resin model by the irradiation of the photo-setting resin solution with laser beam. CONSTITUTION:An optical shaping apparatus 11 is constituted of a resin solution storage means 21 containing a storage tank 22 having a photo-setting resin solution 15 received therein, a light means 31 raising and lowering a molding stand 32 within the storage tank 22 and a laser irradiation means 41. After a photo-set layer is formed by irradiating the surface of the resin solution 15 with laser beam, operation allowing the molding stand 32 to fall by definite quantity is repeated to stack photo-set layers to produce a three-dimensional resin model. In this apparatus, a smoothing means 61 horizontally moving a smoothing plate 62 through a feed screw part 64 by the operation of a motor 65 is arranged above the molding stand 32. By this smoothing means 6, the surface S of the resin solution 15 is smoothed prior to a beam irradiation process and the photo-set layer can be accurately formed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical modeling apparatus for forming a three-dimensional resin model by irradiating a photocurable resin liquid with light, and more particularly, to a liquid surface of the photocurable resin liquid during light irradiation. The present invention relates to a device capable of smoothing.

[0002]

2. Description of the Related Art An optical molding method is known as a means for easily manufacturing a complicated three-dimensional shape without using a molding die or a special processing tool. As prior arts related to this, Japanese Patent Laid-Open No. 64-8021 and Japanese Patent Laid-Open No. 1-228-128.
Japanese Unexamined Patent Publication No. 827 and Japanese Unexamined Patent Publication No. 2-103128 are known.

FIG. 7 shows a manufacturing process of a three-dimensional model by an optical modeling method. In FIG. 7, reference numeral 1 denotes a storage tank in which the photocurable resin liquid 2 is stored. Inside the storage tank 1, a molding table 3 that can move up and down is arranged. A light irradiation unit 5 that irradiates the laser light L is arranged above the molding table 3. The light irradiation unit 5 scans the laser light L based on the three-dimensional cross-sectional shape.

In the optical modeling apparatus of FIG. 7, as shown in FIG. 7A, the photocurable resin liquid 2 located above the molding table 3 is irradiated with the laser beam L. When the laser light L is irradiated, as shown in FIG.
Is formed. When the photocurable layer 2a is formed, the molding table 3 is formed.
Is lowered and the photocurable layer 2a joined to the molding table is buried by a distance ΔH from the liquid surface of the photocurable resin liquid 2. In this state, as shown in FIG. 7C, the photocurable resin liquid 2 covering the photocurable layer 2a is irradiated with the laser light L.

In FIGS. 7D and 7E, the irradiation of the photocurable resin liquid 2 with the laser light L and the burying of the photocurable layer 2a in the photocurable resin liquid 1 are repeated, and The hardened layers 2a are stacked. As a result, the three-dimensional resin model 9 that is the three-dimensional model shown in FIG. 7F is formed.

However, in the conventional optical modeling method shown in FIG. 7, since the following phenomenon exists, the method shown in FIG. 8A is actually used. This will be described below. In the case of FIG. 7, the photocurable layer 2a is formed by irradiating the photocurable resin liquid 2 with the laser beam L.
Is formed, a distance ΔH (for example, 0.1
(About .about.0.2 mm) to cover the surface of the photo-curing layer 2a with the photo-curing resin liquid 2, but in reality, the distance ΔH
However, the photo-curable resin liquid 2 cannot be embedded in the photo-curable resin liquid 2 due to the surface tension of the photo-curable resin liquid 2.

In order to deal with this, as shown in FIG. 8A, the molding table 3 is once lowered largely and the photocurable layer 2a is formed.
Is completely immersed in the photocurable resin liquid 2 and then the molding table 3 is raised to keep the distance between the liquid surface of the photocurable resin liquid 2 and the surface of the photocurable layer 2a at ΔH.

[0008]

However, as shown in FIG. 8A, the photo-curable layer 2a is completely covered with the photo-curable resin liquid 2.
When the molding table 3 is raised after being dipped in the photocurable resin liquid 2 due to surface tension, as shown in FIG.
The liquid surface S of the above-mentioned rises in a convex shape, and it becomes impossible to accurately maintain the distance ΔH between the liquid surface of the photocurable resin liquid 2 and the surface of the photocurable layer 2a. If the rise of the photocurable resin liquid 2 is large, as shown in FIG.
It becomes difficult to sufficiently cure the portion of the photocurable resin liquid 2 covering a by irradiation with the laser light L, and sufficient bonding with the already-cured photocurable layer 2a cannot be achieved. Therefore, as shown in FIG. 12B, the photo-curable layer 2a corresponding to the raised portion may be separated from the photo-curable layer 2a already formed, and the accuracy of the three-dimensional model deteriorates.

In view of the above problems, it is an object of the present invention to provide an optical modeling apparatus capable of smoothing the surface of the photocurable resin liquid covering the photocurable layer.

[0010]

An optical modeling apparatus according to the present invention which meets the above-mentioned object, irradiates the liquid surface of a photocurable resin liquid with light to form a photocurable layer, and the photocurable layer is mounted thereon. The photocurable layer is embedded in the photocurable resin liquid by lowering the molding table by a certain amount, and the photocurable resin liquid covering the photocurable layer is irradiated with light and the photocurable resin liquid of the photocurable layer is applied. In the optical modeling apparatus that stacks the photo-curing layers by repeating the step of burying the photo-curing layer in the optical modeling apparatus to manufacture a three-dimensional resin model, the photo-curing resin liquid is moved along the liquid surface above the molding table. It is provided with a smoothing means for scraping off unnecessary bulges on the surface of the photocurable resin liquid covering the cured layer.

[0011]

In the optical modeling apparatus configured as described above, the unnecessary rising of the liquid surface of the photocurable resin liquid is scraped off by the smoothing means which moves along the liquid surface of the photocurable resin liquid. It Therefore, the liquid surface of the photocurable resin liquid becomes flat, and the distance between the surface of the photocurable layer and the liquid surface of the photocurable resin liquid is kept constant. Therefore, the photocurable resin liquid covering the photocurable layer is cured over the entire area, and the existing photocurable layer and the new photocurable layer are reliably bonded.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of an optical modeling apparatus according to the present invention will be described below with reference to the drawings.

First Embodiment FIGS. 1 to 4 show a first embodiment of the present invention.
As shown in FIGS. 1 and 2, the optical modeling apparatus 11 includes
It is composed of a resin liquid storage means 21, an elevating means 31, a laser light irradiation means 41, a control means 51, and a smoothing means 61.

The resin liquid storage means 21 comprises a storage tank 22,
It has an overflow tank 23 and a circulation pump 24. The storage tank 22 stores a photocurable resin liquid 15 which is cured by irradiation with laser light. An overflow tank 23 is arranged outside the storage tank 22. The storage tank 22 and the overflow tank 23 can communicate with each other via a passage 25 in which a circulation pump 24 is arranged.

The circulation pump 24 has the photocurable resin liquid 1 overflowing from the storage tank 22 to the overflow tank 23 side.
5 has a function of returning to the storage tank 22. The photocurable resin liquid 15 always overflows from the storage tank 22 during the operation of the circulation pump 24, whereby the position of the liquid surface S of the photocurable resin liquid 15 is kept constant.
The operation of the circulation pump 24 is controlled by the control means 51 described later.

Inside the storage tank 22, a molding table 32 of the elevating means 31 is arranged. The elevating means 31 is the molding table 3
2, the feed screw portion 33, and the motor 34.
The molding table 32 is made of a plate-shaped member and has a plurality of holes 32a penetrating in the vertical direction. A feed screw portion 33 is attached to one side of the molding table 32. One end of the feed screw portion 33 is connected to the motor 34. The motor 34 is rotationally driven based on a signal from the control means 51, and the rotational driving of the motor 34 causes the feed screw portion 33 to rotate and the molding table 32 to move in the vertical direction.

A laser light irradiation means 41 is provided above the molding table 32. The laser light irradiation means 41 has a scanning control unit 42 and a laser light irradiation unit 43. The laser light irradiation unit 43 is configured to scan the laser light L within a predetermined range based on a signal from the scan control unit 42. The scanning control unit 42 is controlled by a command from the control means 51.

Above the molding table 32, smoothing means 61 is arranged. The smoothing means 61 has a smoothing plate 62, a guide mechanism portion 63, a feed screw portion 64, and a motor 65.
The smooth plate 62 is composed of a plate-shaped member extending along the liquid surface S of the photocurable resin liquid 15. Both ends of the smooth plate 62 are slidably held by guide mechanism portions 63 extending parallel to the liquid surface S of the photocurable resin liquid 15. A feed screw portion 64 is connected to the smooth plate 62. One end of the feed screw portion 64 is connected to the motor 65. The motor 65 is rotationally driven based on the signal from the control means 51, and the feed screw portion 64 is rotated. When the feed screw portion 64 rotates, the smooth plate 62 moves to the photocurable resin liquid 1
5 along the liquid surface S of the photocurable resin liquid 15
Is smoothed.

In this embodiment, the smoothing plate 62 is driven by the rotation of the feed screw portion 64, but a feed mechanism using an actuator utilizing air pressure may be used. Further, the smoothing plate 62 of the smoothing means 61 is 1
Although it may be composed of a single plate member, the smooth plate 62 is divided into a plurality of parts in this embodiment. The reason why the smooth plate 62 is divided in this way is as follows.

As shown in FIG. 9, the photocurable resin liquid is cured.
Of the possible regions, depending on the type of cubic model
Part K where the photo-cured layer is formed₁And a photo-cured layer is formed
Part not to be K₂And occur. Therefore, the photocurable layer
The part that is formed and the part that is not formed are
The surface tension of the liquid surface S of 15 is different, and as shown in FIG.
Due to this, the rise of the liquid level of the photocurable resin liquid 15
Degree H₁, H₂, H ₃The phenomenon that
It Therefore, if the smooth plate 62 is an integrated type, the laser light
At the time of irradiating
The liquid 15 is removed too much, and the resin liquid cannot be removed in some areas.
The phenomenon that becomes sufficient occurs.

Therefore, in this embodiment, the photocurable resin liquid 15 that covers the photocurable layer 15a at the time of irradiating the laser light L is used.
The smooth plate 62 is divided so that the level of the liquid surface S is constant, and the vertical movement control of each of the divided smooth plates 62a is performed. FIG. 4 shows a control system for moving the smooth plates 62a in the horizontal direction and the vertical direction.

In FIG. 4, above the molding table 32, a plurality of smooth plates 62a are provided along the liquid surface S of the photocurable resin liquid 15.
Are arranged. Each smooth plate 62a has a feed screw portion 6
7 are connected. The upper end of the feed screw portion 67 is connected to the motor 68. Each motor 68 has a control means 5
It is controlled by the command from 1. When each motor 61 rotates, each smooth plate 62a moves up and down by the rotation of the feed screw portion 67. The control means 51 controls the amount of elevation of each smooth plate 62a according to the surface shape of the photocurable layer 15a.

Each smooth plate 62a is slidably held by a guide mechanism 69. The guide mechanism portion 69 that holds each smooth plate 62a is connected to the motor 65 via the feed screw portion 64 as in the first embodiment. Motor 6
When 5 is rotationally driven by the control means 51, the feed screw portion 64 rotates and each smoothing plate 62a simultaneously moves in the horizontal direction.

The control means 51 is composed of a computer and is capable of inputting production information of the three-dimensional model via the input section 52. As shown in FIG. 3, the control means 51 has a function of changing the three-dimensional model information M into image data D ₁ and creating cut data D ₂ of the three-dimensional model M from the image data D ₁ . The cut data D ₂ is the cross-sectional shape data of the three-dimensional model for each constant distance, and the scanning range of the laser light is controlled based on the cut data. The control means 51 is adapted to display processing information such as cut data via the output section 53.

The control means 51 has the function of controlling the circulation pump 24, the motor 34 of the elevating means 31, and the motor 65 of the smoothing means 61, in addition to the scanning control of the laser light L. As a result, the photocurable resin liquid 15 is irradiated with the laser light L, and the photocurable layer 15a is irradiated with the laser light L.
And the raising and lowering operation of the molding table 32 on which the photo-curable layer 15a is placed are sequentially and repeatedly performed to stack the photo-curable layers 15a. When the control of each part by the control means 51 is completed, the three-dimensional resin model 1 shown in FIG.
6 is formed.

Next, the operation of the first embodiment will be described. In the first step of the manufacturing process of the three-dimensional model 16, the molding table 32 is lowered by the rotation of the motor 34 of the elevating means 31, and the molding table 32 is embedded in the photocurable resin liquid 15. When the molding table 32 is deeply embedded in the photo-curable resin liquid 15, the motor 34 rotates in the reverse direction so that the molding table 32 is
Rises and the molding table 32 is stopped at a predetermined position.

When the positioning of the molding table 32 is completed, the smoothing plate 62 is moved by the rotation of the motor 65 of the smoothing means 61, and the unnecessary rising portion of the photocurable resin liquid 15 due to the surface tension is scraped off. That is, the movement of the smooth plate 62 makes the liquid surface S of the convex photocurable resin liquid 15 flat. As a result, the distance ΔH between the upper surface of the molding table 32 and the liquid surface of the photocurable resin liquid 15 is constant over the entire range.

By the movement of the smooth plate 3, the photocurable resin liquid 1
When the liquid surface S of 5 is flattened, the laser light L is irradiated from the laser light irradiation unit 43 toward the photocurable resin liquid 15.
Since the laser light L is scanned based on the cut data, a certain range of the photocurable resin liquid 15 is cured, and as a result, the photocurable layer 15a is formed.

When the photo-curable layer 15a is formed, the molding table 32 on which the photo-curable layer 15a is placed descends again, and the photo-curable layer 15a is formed.
a is deeply buried in the photocurable resin liquid 15. Forming table 3
When 2 is deeply buried in the photocurable resin liquid 15, the motor 3
The molding table 32 is raised by the reverse rotation of 4, and the molding table 32 is stopped at a predetermined position.

When the positioning of the molding table 32 is completed, the smoothing plate 62 is moved by the rotation of the motor 65 of the smoothing means 61, and the rising of the liquid surface S of the photocurable resin liquid 15 due to the surface tension is scraped off. This ensures that the distance between the surface of the photocurable layer 15a and the liquid surface S of the photocurable resin liquid 15 is maintained at ΔH. Therefore, the entire portion of the photocurable resin liquid 15 that covers the photocurable layer 15a is reliably cured by the irradiation of the laser light L, and the photocurable layer 15a that has already been formed is formed.
Joining with is secure.

Further, in this embodiment, since the smooth plate 62 is divided into a plurality of parts, each smooth plate 62a is formed in accordance with the surface shape of the photo-cured layer 15a formed before the laser beam L is irradiated. It is possible to control the amount of ascent and descent by scraping off according to various rises of the resin liquid. As a result, the laser light L
At the time of irradiating with, the distance ΔH between the photocurable layer 15a and the liquid surface S of the photocurable resin liquid 15 covering the photocurable layer 15a can be made constant. Therefore, the entire portion of the photocurable resin liquid 15 covering the photocurable layer 15a can be surely cured, and the peeling phenomenon of the photocurable layer 15a is prevented.

Second Embodiment FIG. 5 shows a second embodiment of the present invention. The only difference between this embodiment and the first embodiment is the control of the circulation pump for the photocurable resin liquid, and the other portions are the same as those of the first embodiment. The description of the corresponding parts is omitted by assigning the reference numerals, and only different parts will be described. The same applies to other embodiments described later.

In the case of the first embodiment, the photocurable resin liquid 15 overflowing from the storage tank 22 is circulated by the circulation pump 24.
I always return it to the storage tank 22 by
In this case, the following phenomenon occurs. As shown in (A) to (C) of FIG. 11, even after the rising liquid level of the photocurable resin liquid 15 is flattened by the movement of the smooth plate 62 due to the surface tension, the circulation pump 24 stores the liquid. Since it is returned to the tank 22, the liquid level S rises again due to the surface tension.

Therefore, in the present embodiment, as shown in FIG. 5, the circulation is performed by a command from the control means 51 from the completion of the smoothing of the liquid surface S by the smooth plate 62 to the completion of the scanning of the laser light L. The operation of the pump 24 is stopped. Therefore, during this period, the supply of the photocurable resin liquid 15 to the storage tank 22 is blocked, and the photocurable resin liquid 15 is blocked.
The liquid surface S of is maintained flat.

Third Embodiment FIG. 6 shows a third embodiment of the present invention. In FIG.
Although the operation of the circulation pump 24 is stopped until the scanning of the laser beam L is completed after the smoothing of the liquid surface S by the smoothing plate 62 is completed, in the present embodiment, it is supplied to the storage tank 22 side. The resin liquid 15 is returned to the upstream side of the circulation pump 24.

As shown in FIG. 6, the upstream side and the downstream side of the circulation pump 24 can communicate with each other via a bypass passage 26. The bypass passage 26 is provided with an electromagnetic valve 27 that is switched and controlled by a command from the control means 51. In the third embodiment having such a configuration, the laser beam L is supplied after the smoothing of the liquid surface S by the smoothing plate 62 is completed.
Until the scanning of is completed, the electromagnetic valve 27 is switched by the command from the control means 51, the photocurable resin liquid 15 discharged from the circulation pump 24 is returned to the upstream side of the circulation pump 24, and is transferred to the storage tank 22. Inflow of resin liquid is blocked.

[0037]

According to the present invention, the liquid of the photocurable resin liquid that moves along the liquid surface of the photocurable resin liquid and covers the photocurable layer above the molding table on which the photocurable layer is formed. Since the smoothing means for scraping off unnecessary swelling of the surface is provided, the distance between the surface of the photocurable layer and the liquid surface of the photocurable resin liquid can be made constant.

As a result, the photocurable resin liquid in the portion covering the photocurable layer can be reliably cured by irradiation of light, and the bondability between the photocurable layer already formed and the new photocurable layer is improved. Can be made Therefore, peeling of a new photocurable layer can be reliably prevented, and a highly accurate three-dimensional model can be obtained.

[Brief description of drawings]

FIG. 1 is a perspective view of an optical modeling apparatus according to a first embodiment of the present invention.

2 is a cross-sectional view of the device of FIG.

FIG. 3 is a process diagram showing a procedure for creating cut data in the control means of the apparatus of FIG.

FIG. 4 is a control system diagram of the apparatus of FIG.

FIG. 5 is a process sectional view of an optical modeling apparatus according to a second embodiment of the present invention.

FIG. 6 is a sectional view of an optical modeling apparatus according to a third embodiment of the present invention.

FIG. 7 is a manufacturing process diagram of a tertiary model by a conventional optical modeling method.

FIG. 8 is a process diagram showing a rising state of a photocurable resin liquid in the production of a three-dimensional model by a conventional optical modeling method.

FIG. 9 is a perspective view of a case where an unmolded region is formed in the cross-sectional shape of the photo-curable layer in the optical modeling method.

10 is a cross-sectional view of FIG.

FIG. 11 is a cross-sectional view showing a liquid level state of the storage tank when the photocurable resin liquid overflowing from the storage tank is constantly returned to the storage tank by a circulation pump.

FIG. 12 is a process diagram showing the occurrence of a defect when the liquid surface of the photo-curable resin liquid rising due to surface tension is irradiated with laser light.

[Explanation of symbols]

 11 Optical Modeling Device 15 Photocurable Resin Liquid 15a Photocurable Layer 21 Reservoir Means 24 Circulation Pump 31 Elevating Means 32 Molding Platform 41 Laser Light Irradiating Means 51 Control Means 61 Smoothing Means L Laser Light

Claims (1)

[Claims] 1. A light-curable resin liquid is irradiated with light to form a photo-curable layer, and a molding table on which the photo-curable layer is placed is lowered by a predetermined amount to form the photo-curable layer. The photocurable layer is embedded in a resin liquid, the photocurable resin liquid covering the photocurable layer is repeatedly irradiated with light, and the photocurable layer is immersed in the photocurable resin liquid to stack the photocurable layers, thereby forming a three-dimensional resin. In an optical modeling apparatus for producing a model, an unnecessary rise of the liquid level of the photocurable resin liquid that moves along the liquid level of the photocurable resin liquid and covers the photocurable layer above the molding table. An optical modeling apparatus comprising a smoothing means for scraping off.