JPH07106602B2 - Stereolithography - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical molding method in which a fluid resin is cured by light and molded into various three-dimensional shapes.

[0002]

2. Description of the Related Art A technique for molding a three-dimensional object by irradiating a fluid resin with light to cure the resin has been known as a stereolithography method. Further, as a fluid resin that is cured by irradiation of light, an ultraviolet curable resin that is cured by ultraviolet rays, a photocurable resin that is cured by light in the visible region, and a thermosetting resin that is cured by light in the infrared region are known. There is.

On the other hand, by irradiating a fluid resin with light,
As a specific method for three-dimensionally molding a molded article, as in JP-B-63-40650, a photocurable fluid substance that is cured by light is contained in a container, and light energy is used to cure the substance. There is known a method of molding a three-dimensional structure by moving the container in the horizontal and vertical directions while irradiating light so as to concentrate the light at a required energy level.

Further, as disclosed in, for example, Japanese Patent Laid-Open No. 2-36925, a table which vertically moves up and down in the liquid tank is placed slightly below the liquid level in the liquid tank in which a resin which is cured by ultraviolet rays is stored. Provided to form a hardened layer having a constant thickness on the table by irradiating the liquid surface on the table with a laser beam of ultraviolet rays, and then submerging the position of the table slightly downward, Similarly, by irradiating the liquid surface flowing into the surface of the cured layer with light, the next cured layer is formed on the surface of the previously cured layer, and by repeating the same steps, a predetermined three-dimensional modeling is performed. A method of molding an article is also known.

[0005]

The conventional stereolithography method as described above includes the stereolithography method in which the table is lowered along with the lamination of the above-mentioned cured layers, and the resin storage container is moved in the horizontal and vertical directions. In any of the stereolithography methods, a resin in a range irradiated with light is planarly cured, and the cured cured layers are sequentially laminated to form a three-dimensional structure having a predetermined thickness over time. However, since it is not possible to change the curing depth of the resin along the light irradiation direction, there is a problem in terms of work efficiency that the processing time will inevitably become long.

Further, the above-mentioned stereolithography method has a problem in terms of working environment that an ultraviolet laser, which is harmful to the human body, must be used, and moreover, a relatively large-scaled device is required as a light source. Not only that, but a cooling device attached to this device is also required, so that there is a problem that the entire device is inevitably expensive.

[0007]

The present invention solves the problems of the conventional stereolithography method described above, and makes it possible to vary the thickness of the resin layer that is cured along the irradiation direction of laser light. Three-dimensional modeling can be easily done by observing the working state in the room by irradiating visible light with laser light, and it is cured by adjusting the moving speed of laser light or the intensity of irradiation. It is an object of the present invention to provide an excellent stereolithography method capable of appropriately adjusting the hardness of a resin to conditions such as cured, semi-cured, and non-cured.

In the stereolithography method of the present invention, as a specific means for achieving the above object, in claim 1, a monomer of an epoxy resin or an acrylic resin or a monomer of a mixture of an epoxy resin and an acrylic resin is used as a metallocene compound. 60% for a photocurable fluid substance in which a peroxide and a peroxide are mixed.
It is characterized in that the irradiated portion is cured or semi-cured by irradiating a laser beam having a wavelength of 0 to 800 nm.

In the stereolithography method of claim 2, the photocurable fluid substance is 600 to 800 nm in the first step.
After the irradiated portion is cured or semi-cured by irradiation with laser light having a wavelength of, the cured or semi-cured portion is irradiated with light having a wavelength shorter than 600 nm as a second step. Thus, it is characterized by further curing and shaping.

In the stereolithography method of the present invention, as a metallocene compound (photocuring initiator) among the materials constituting the photocurable fluid substance, Irgacure 26 manufactured by Ciba-Geigy is used.
1 [Trade name: IRGACURE261: Chemical name; (1-
6-η-cumene) (η-cyclopentadienyl) iron (1
+) Hexafluorophosphoric acid (1-)] is used. Further, as the acrylic resin monomer, a polyester acrylate monomer is used, and further, a mixture of an epoxy resin and an acrylic resin monomer is used.

Similarly, among the materials constituting the photocurable fluid substance, cumene hydroperoxide is used as the peroxide to be mixed with the metallocene compound, and preferably, it is used as a diluent in the photocurable fluid substance. Tetrahydrofurfuryl acrylate is incorporated.

In the stereolithography method of the present invention, the photocurable fluid substance is first irradiated with laser light having a wavelength of 600 to 800 nm so that the irradiated portion is cured or semi-cured. Light irradiation by a mercury lamp is preferable as a light irradiation means for irradiating light having a wavelength shorter than 600 nm in two steps to further promote curing.

[0013]

In the stereolithography method according to the present invention, as the photocurable fluid substance, a mixture of a metallocene compound and a peroxide with a monomer of an epoxy resin or an acrylic resin or a monomer of a mixture of an epoxy resin and an acrylic resin is used. By doing so, red laser light of 600 to 800 nm can be used as the irradiation light, and since it is possible to perform processing while visually observing it under room light, the processing operation can be facilitated.

Further, in the stereolithography method of the present invention, basically, the treatment as the first step by irradiation with laser light
Since the photocurable fluid substance can be cured to the depth (thickness) in the length direction along the irradiation of the laser beam, the laser irradiation device may be moved in the irradiation direction or the lens may be adjusted to adjust the laser beam. By appropriately controlling the focal position of light, the thickness of curing can be freely controlled. Furthermore,
The degree of curing, that is, the degree of curing such as curing, semi-curing, and non-curing can be freely changed by controlling the intensity of the laser beam or the moving speed.

Further, in the stereolithography method of the present invention, as described above, the photocurable fluid substance can be cured or semi-cured by irradiation with laser light of 600 to 800 nm as the first step. After the curing treatment of 1., as a second step, the object to be treated is irradiated with light having a wavelength shorter than 600 nm or visible light such as a mercury lamp containing the same to further advance the cured state to complete the treatment. Curing conditions can be provided.

The advantage of performing the treatment as the second stage after the first stage treatment is that first, by appropriately combining the conditions of light irradiation in each stage, the cured product in the course of the manufacturing work. It is possible to continuously control the hardness of. In addition, it is a cured product intended to have the same final hardness, which was not possible with the conventional curing system, by inserting a curing process by a different process, that is, an auxiliary process during the manufacturing process. However, it is possible to perform a process that causes the hardness to be different.

[0017]

EXAMPLE Next, an example of the present invention will be described. FIG. 1 is an explanatory view of a stereolithography apparatus for carrying out the present invention, in which a photocurable fluid substance is placed inside a transparent container 2 such as glass. A transparent glass plate 3 fixed to the lower surface of an elevator (not shown) is stored above the photocurable fluid substance 1 stored in the transparent container 2. The semiconductor laser irradiator 4 arranged on the lower surface of the container 2 so as to be in contact with the liquid surface, irradiates a red laser beam 7 having a wavelength of about 670 nm into the photocurable fluid substance 1 through the bottom surface of the container 2. By doing so, the photo-curable fluid substance 1 in the light-irradiated portion is cured to form a column-shaped cured portion 1a between the bottom surface of the container 2 and the glass plate 3. The semiconductor laser irradiator 4 is provided with a drive device 5 for moving the laser beam 7 in the X, Y, and Z axis directions, and the drive device 5 is operated by a computer 6.

As a specification example of the laser light irradiating means comprising the semiconductor laser irradiator 4 and the driving device 5,
The machining repeatability when reciprocating a light ray in the X, Y, and Z axis directions is 0.001 mm (1 μ), X, Y, and Z.
The minimum spot movement unit in the axial direction is 0.01 mm,
Beam spot diameter is 0.01 (X axis) x 0.02 (Y
Axis) mm, X, Y-axis moving speed during curing is 0.5 to 15 mm / sec, X, Y-axis moving speed during non-curing is 30 mm / sec,
The minimum curing spot size is 0.010 x 0.025 mm (irradiation time 0.03 sec / spot), the expansion ratio of the cured area and the exposure time are 0.10 mm / 100 sec in the X-axis direction and Y-axis direction. Is 0.25 mm / 100 seconds.

As a measure of the resolution by the laser light irradiating means, when one character is about 6 × 12 dots and the character interval is about 2 dots, a character string such as “Austrade” has a width of 0.7 mm. It can be manufactured as follows. Also, in the case of a pattern composed of straight lines parallel to the X and Y axes, the groove between each cured line is 1
It is about 0 micron.

Further, the external size of the laser beam irradiation means is about 20 cm in length, 40 cm in width and 40 cm in depth, and the weight is 20 kg including ballast for preventing vibration.
The size of the range in which the photocurable fluid substance can be cured is about 20 cm × 15 cm. The computer used was the PC-9801 series.

Many of the monomers for the photocurable fluid substance in the present invention include those containing a benzene ring, and include acrylic resins such as polyester acrylate or mixtures thereof. Further, these resin polymers having a small molecular weight may be used instead of the monomer. As the metallocene compound (iron arene complex) that is a photo-curing initiator, iron-containing Irgacure 261 [trade name: IRGAC manufactured by Ciba-Geigy Co., Ltd.]
URE261: chemical name; (1-6-η-cumene) (η-
Cyclopentadienyl) iron (1+) hexafluorophosphate (1
-)] Is typical. Cumene hydroperoxide is effective as the peroxide. Furthermore, it is preferable to add tetrahydrofurfuryl acrylate as a diluent to the photocurable fluid material.

Further, in the case of a high hardness type as the type of the photocurable fluid substance in the present invention, mainly the epoxy resin, the metallocene compound as a photocuring initiator and cumene hydrofluoride as a peroxide are used. A combination of peroxide and tetrahydrofurfuryl acrylate as a diluent is used. Next, as a type that emphasizes resolution and sensitivity, mainly in an acrylic resin, the metallocene compound as a photocuring initiator, cumene hydroperoxide as a peroxide, and tetrahydrofurfuryl acrylate as a diluent. A combination of is used. Further, as the intermediate type, those in which the compounding ratio of the acrylic resin, the epoxy resin, the metallocene compound and the cumene hydroperoxide are appropriately adjusted are used.

Next, the stereolithography method of the present invention will be described for the case of molding the cylindrical shaped article 10 as shown in FIG. 2 by the first stage curing treatment by the irradiation of laser light. First, as shown in FIGS. 3a and 4a, red laser light 7 having a wavelength of about 670 nm is emitted from the semiconductor laser irradiator 4 from the bottom surface of the transparent container 2 through the photocurable fluid material 1 to the back surface of the glass plate 3. When irradiating in the direction,
The photocurable fluid substance 1 on the lower surface of the glass plate 3 is controlled in a timed manner at the focal position of the laser light at a specific position, so that the length direction along the irradiation of the laser light, that is, the Z-axis direction. On the other hand, it is cured in a columnar shape, and a columnar cured portion 1a is attached and formed between the lower surface of the glass plate 3 and the bottom surface of the transparent container 2.

Next, as shown in FIGS. 3b and 4b, the irradiation conditions of the laser beam 7 are the same, and the laser beam 7 is sequentially moved in the X- and Y-axis directions to form the columnar hardened portion 1a. Hardened parts 1b, 1c ... 1 having the same length as
n are continuously formed so as to be successively adjacent to each other in parallel with the hardening portion 1a to form the first-stage annular hardening portion 10a.

After the annular hardened portion 10a is formed on the back surface of the glass plate 3 in this manner, the container 2 is formed as shown in FIG. 3c.
The glass plate 3 which is in contact with the liquid surface of the photocurable fluid substance 1 therein is moved upward by an elevating device so that the lower end of the annular curing portion 10a does not separate from the liquid surface of the photocurable fluid substance 1. Pulled up, and in this state, the first stage annular hardening portion 1
The lower surface of 0a is again irradiated with the laser beam 7 in the same procedure as described above to form the columnar hardened portion 1a.

Then, as shown in FIG. 3d, the columnar hardened portions 1a, 1a, 1 are formed on the lower surface of the first-stage annular hardened portion 10a in the same manner as described above.
b, 1c ... 1n are sequentially and continuously formed to form the second stage annular cured portion 10b. By repeating the same procedure as described below, the third stage annular cured portion 10c is formed on the lower surface of the second stage annular cured portion 10b, and finally the lower surface of the glass plate 3 shown in FIG. The cylindrical shaped article 10 having such a predetermined length can be molded.

Similarly, when a hollow conical shaped article 11 having different upper and lower diameters as shown in FIG. 5 is formed,
As shown in FIG. 6a, the columnar hardened portion 1a is formed on the lower surface of the glass plate 3 by the same method as in the case of the cylindrical shaped object 10.
After molding the annular curing portion 11a of the first stage by
As shown in FIG. 6b, the glass plate 3 is pulled up so that the lower end of the annular curing portion 11a does not separate from the liquid surface of the photocurable fluid substance 1, and in that state, the lower surface of the annular curing portion 11a of the first stage is slightly moved. The inner portion is irradiated with the laser beam 7 to form the columnar hardened portion 1a.

Next, as shown in FIG. 6c, on the lower surface of the first stage annular cured portion 11a, the columnar cured portions 1b, 1c. ························ n 1n is sequentially and continuously formed to form a second-stage annular hardened portion 11b having a diameter slightly smaller than that of the first-stage annular hardened portion 11a. On the lower surface of the second stage annular curing portion 11b, the third stage annular curing portion 11b is formed.
By molding c, the hollow conical shaped object 11 having a predetermined length as shown in FIG. 5 can be finally molded.

A conical shaped object 12 having a shape similar to that of the hollow conical shaped object 11 and having a solid interior as shown in FIG.
In the case of molding the glass plate 3, for example, as shown in FIGS. 9a and 10a, first, the first stage annular cured portion 12a is formed on the lower surface of the glass plate 3 by the same method as described above, and then the glass plate 3 is formed. While maintaining the same height, this annular hardening portion 12a
As the outermost peripheral hardened portion, an inner peripheral hardened portion 12b of the second circumference having a small diameter is provided adjacent to the inner peripheral surface of the outermost peripheral hardened portion 12a.

Next, as shown in FIGS. 9b and 10b, while the glass plate 3 is held at the same height, the inner ring of the third inner ring having a smaller diameter is formed on the inner peripheral surface of the inner ring hardening portion 12b. An annular cured portion 12n having a small diameter is sequentially formed toward the central portion so that the cured portion 12c is provided around, and a solid first layer cured portion 13a is formed.

In this way, the solid first layer cured portion 13
After molding a, as shown in FIG. 9c, the glass plate 3 is pulled up so that the lower end of the first layer curing portion 13a does not separate from the liquid surface of the photocurable fluid substance 1, and then the glass plate 3 of FIG. 9d and FIG. As described above, the second layer hardened portion 13b is formed on the lower surface of the first layer hardened portion 13a by the same procedure, and finally a solid conical shaped article of a predetermined length is obtained by the same method. 12
Is molded.

Further, in the case of molding the solid shaped article as described above, another method as shown in FIG. 11 is used.
The conical shaped article 14 can be formed more efficiently than the method shown in FIGS. In this method, first, as shown in FIG. 11a, the annular hardened portion 15a of the first circumference is formed on the lower surface of the glass plate 3, and then, as shown in FIG. The lower end is pulled upward so as not to separate from the liquid surface of the photocurable fluid substance 1.

In this way, when the glass plate 3 is pulled up so that the lower end of the first peripheral annular curing portion 15a does not separate from the liquid surface of the photocurable fluid substance 1, the inside of the first peripheral annular curing portion 15a is in a negative pressure state. Since it is pulled up as it is, the photocurable fluid substance 1 inside the first circumferential annular curing portion 15a in the container 2
Rises together with the glass plate 3 while being positioned inside the first peripheral annular hardening portion 15a, that is, while being attached to the lower surface of the glass plate 3.

In this state, as shown in FIG. 11c, the laser light 7 is radiated to the inner portion of the first circumferential annular curing portion 15a, and the photocurable fluid substance 1 between the bottom surface of the container 2 and the glass plate 3 is irradiated. Is cured into a columnar shape, and the same curing treatment is sequentially repeated to form a columnar second peripheral annular cured portion 15b, which is longer than the cured portion 15a, inside the first peripheral annular cured portion 15a. .

Thereafter, by the same method, as shown in FIG. 11d, the hardened portion 1 is attached to the inner portion of the second circumferential annular hardened portion 15b.
The columnar third circumference annular hardened portion 15c longer than 5b is molded, and finally the innermost annular hardened portion 1 is formed as shown in FIG. 11e.
By molding 5n, a solid conical shaped article 14 having a predetermined length is formed.

In the case of molding a modeled object having a complicated shape in plan view, for example, a modeled object 16 such as a gear shown in FIG. 12, as in the case shown in FIGS. 3a to 3d. For example, the photocurable fluid substance 1 is irradiated with a laser beam 7 to first form a columnar hardened portion 1a along the shapes of the teeth 17a and the grooves 17b on the lower surface of the glass plate 3, and then a hole 17c in the central portion. By sequentially moving the laser beam 7 in the X- and Y-axis directions so that the columnar hardened portions 1a are sequentially formed at intervals up to, the gear-shaped molding portion 16 is formed on the lower surface of the glass plate 3.
Can be adhered and molded.

Similarly, in the case of molding a modeled object 18 having partially different heights, thicknesses, etc. as shown in FIG. 13, laser light is used as in the case shown in FIGS. 6a to 6c. By moving 7 in the X-axis, Y-axis, or Z-axis direction, the position of the columnar hardened portion 1a to be molded next is displaced with respect to the previously molded columnar hardened portion 1a. It can be freely molded.

In the present invention, as described above, by the first stage curing treatment of irradiating the photocurable fluid substance with laser light,
Although the hardened shaped article can be molded, the hardness of the shaped article can be changed by adjusting the irradiation time of the laser beam only by the curing treatment in the first step. That is, the hardness can be increased by increasing the irradiation time of the laser light, and conversely, the hardness can be decreased by decreasing the irradiation time.

In addition to changing the hardness of the modeled object by adjusting the irradiation time of the laser light as described above,
Curing of the photo-curing fluid substance by changing the hardness of the modeled object by appropriately treating the focus position of the laser light with respect to the photo-curing fluid substance, or by confirming where the focus position of the light is. The progress status of can be accurately grasped. In this case, it is necessary to confirm the focus position of light by some method, but in the present invention, a spot of light that appears at a certain position when the photocurable fluid material is irradiated with laser light, that is, a far field pattern. By observing, the focus position of the laser light can be grasped.

For example, as shown in FIG. 14, laser light 7 is irradiated from the lower side of the photocurable fluid material 1 molded under the glass plate 3, and the light is slowly moved in the direction of arrow A. In this case, a certain cross section 19 above the glass plate 3 is shown in FIG.
Oval far field pattern 2 as shown in 5
1 is reflected, but the focus position 2 of this laser light 7
When 0 is under the photocurable fluid material 1, the far field pattern 21 has a shape in which a substantially triangular tail 22 having a width W is formed on the rear side in the light traveling direction.

Further, as shown in FIG. 16, when the focus position 20 of the laser light 7 is above the photocurable fluid substance 1 and the glass plate 3, the elliptical fur reflected in the upper cross section 19 of the glass plate 3 is shown. As shown in FIG. 17, the field pattern 21 has a shape in which a substantially triangular tail 22 having a width W is formed on the front side in the light traveling direction.

Further, as shown in FIG. 18, this laser beam 7
When the focal position 20 of the photocurable fluid substance 1 is at the center of the photocurable fluid substance 1, the elliptical far-field pattern 21 shown in the upper cross section 19 of the glass plate 3 is in the traveling direction of light as shown in FIG. Oval far field pattern 2 along
A curved strip 23 having the same width is formed on both sides of 1.

As mentioned above, the cross section 1 above the glass plate 3
The far field patterns 21 shown in FIG. 9 have different shapes from each other because the focus and the progress of curing of the light passing through the photo-curable fluid substance 1 are different from each other. When the focal position 20 of the laser light 7 is in the center of the photocurable fluid material 1, the hardness is properly advanced, and as shown in FIGS. 14 and 16, the focal position 20 of the laser light 7 is light. When it is out of the curable fluid substance 1, the progress of hardness is delayed.

Therefore, by monitoring the shape of the far-field pattern 21 as described above, the focus position 20 of the light can be adjusted appropriately, or if necessary, a certain portion of the molded article to be molded can be made hard. You can freely make adjustments such as softening.

According to the present invention, the hardness of the modeled object can be finally adjusted by adjusting the irradiation time of the laser light by the hardening process as the first step and adjusting the focus position. However, depending on the conditions such as the shape and the purpose of the modeled object, after the adjustment treatment as the first step as described above, after increasing the hardness of a part of the target modeled object or making it into a semi-cured state, Next, after removing the obtained shaped article from the laser light irradiation device, as a second stage treatment, near-ultraviolet rays are applied to the shaped article by a mercury lamp to finally increase the hardness of all parts. The post-cure treatment can be used together.

Depending on the working conditions, the irradiation time of the laser beam as the first step as described above may be adjusted to adjust the irradiation time of the light, the focal position, etc. By efficiently shaping the entire shape in a semi-cured state in a short time, then removing the shaped object from the laser light irradiation device, and applying near-ultraviolet irradiation by a mercury lamp, which is the second stage treatment, Finally, it is possible to perform a treatment such as increasing the hardness of all parts.

As described above, the hardening treatment is performed in the first step and the second step.
The division into stages can be used, for example, when the box body 24 as shown in FIG. That is, as shown in FIG. 20a, each wall surface 24a is hardened to a predetermined hardness by the first step by the laser light irradiation means, and the fold portion 24b connecting each wall surface 24a is in a semi-hardened or uncured state. Then, the unfolded box material is molded. Next, as shown in FIG. 20b, the box body material is taken out from the laser beam irradiation means, and the fold portion 2
After assembling the box body by bending 4b, the semi-cured or uncured crease portion 24b is cured by irradiating light with a mercury lamp as a second step, and finally a three-dimensional shape as shown in FIG. 20c is obtained. The box 24 can be obtained.

In this example of the box body 24, the folds 24b connecting the wall surfaces 24a are processed into a semi-hardened or uncured state, and finally the folds 24b are hardened in the second stage. For example, depending on the shape of the modeled object, etc., considering the convenience at the molding stage, after the cured part and the semi-cured or uncured part are molded at the same time, the cured part and the semi-cured part are finally formed. It is also possible to separate the hardened or uncured portion to form a molded article having a separate structure.

For example, as shown in FIG. 21a, a modeled object is produced in which a belt 26 that meshes with a pair of gears 25a and 25b and is movable in advance is integrally stretched between the pair of gears 25a and 25b. Case (However, this example is not necessarily an appropriate example when the part corresponding to the belt 26 is regarded as a mechanical part such as a rubber belt that can actually transmit a rotational force at high speed. But)
First, the pair of gears 25a and 25b are molded in a semi-hardened or uncured state by the laser light irradiation means as the first step by the method shown in the description of FIG. As shown in FIG. 21b, a small gap is formed outside the teeth 27 of each gear, and the portion of the belt 26 having the teeth 28 that mesh with the teeth 27 is formed into a semi-hardened or uncured state. After molding, only the gears 25a and 25b are irradiated with a mercury lamp as the second step, and the gears 25a and 25b are treated so as to have a higher cured state.

As described above, according to the present invention, it is possible to appropriately adjust the hardness of the cured molded article only by irradiating the laser beam as the first step. By combining the one-step treatment and the second-step treatment by irradiation with a mercury lamp, it is possible to give a wide variety of hardness conditions to the target shaped article at the time of completion.

As described above, in the case where the first stage treatment by laser light irradiation and the second stage treatment by mercury lamp irradiation are combined, the laser light irradiation time and the mercury lamp irradiation conditions are Depending on the combination, the hardness of the modeled object can be continuously controlled, and even if the object is to have the same hardness in the end, it has different elasticity (hardness) depending on the process during manufacturing. ), And as a result, like the box body in FIG. 20 and the gear wheel in FIG. 21, it is possible to freely add an auxiliary process that is not possible in the conventional system of this type. can do.

Further, the first by irradiation with the laser light described above
Forming a part of the molded article in a semi-cured or uncured state in the step is advantageous when molding a molded article in which a plurality of parts are combined like the above-described gear and belt relationship. There is. This is because in the process of curing the photocurable fluid substance by light energy, the volume slightly contracts depending on the degree of curing, so that the mechanical action due to the contraction can be utilized.

As a method of utilizing this volume contraction, in addition to the above-mentioned relationship between the gear and the belt,
This is advantageous when a shaped article having a complicated shape including a bridge-shaped or rope-shaped connecting portion is formed between a plurality of component-shaped shaped articles. When molding such a shaped article, the bridge-shaped or rope-shaped connecting portions are provided in a semi-cured state, and when almost the entire shape is formed, these connecting portions are laser-lighted again. When the hardness is gradually increased by the irradiation treatment of No. 3, the volume of the connecting portion contracts, and a force of attracting each other is generated between the parts. Therefore, this force is used to form a molded article of a predetermined design and It becomes possible to properly assemble the parts and to perform processing such as moving, fixing, disassembling, and correcting.

For example, as shown in FIG. 22a, after molding the shaped article 29a on the lower surface of the glass plate 3, as shown in FIG. 22b,
In the case where a connection portion 29b having a narrow cross section is formed on the lower surface of the shaped article 29a and a lower layer shaped article 29c having a large cross section is formed on the lower surface of the connection portion 29b as shown in FIG. Glass plate 3 after object 29c is molded
Is pulled up, the bottom surface of the lower layer shaped article 29c having a large area adheres to the bottom surface of the container 2, and the shaped article is attached to the container 2
It may be difficult to pull up from.

In such a case, as shown in FIG. 22a, a thin rope-shaped connecting portion 30a is preliminarily molded in a semi-cured state on the side of the shaped article 29a on the lower surface of the glass plate 3, and then, as shown in FIG. 22b, when a connecting portion 29b having a thin cross section is formed on the lower surface of the shaped article 29a, the same rope-like connecting portion 3 is formed at the lower end of the rope-like connecting portion 30a.
0b is molded in a semi-cured state.

22c, the lower layer molded article 29c is molded on the lower surfaces of the connecting portion 29b having the narrow cross section and the rope-shaped connecting portion 30b, and then the rope on the lower surface of the lower layer molded article 29c is molded. When the laser beam 7 is applied to the portion corresponding to the lower end of the semi-cured connecting portion 30b to cure the semi-cured rope-shaped connecting portions 30a and 30b, the semi-cured rope-shaped connecting portions 30a and 30b are cured.
As they harden, their volume shrinks, and this shrinking force allows the lower-layer molded article 29c to be easily peeled off from the bottom surface of the container 2 as shown in FIG. 22d.

Further, in the method of completely curing the photo-curable fluid substance 1 by the irradiation of the laser beam like the conventional stereolithography method, for example, as shown in FIG. 23a, the cylindrical body 31 is formed on the lower surface of the glass plate 3 as shown in FIG. Since the whole is molded in a rigid state from the beginning, since the lower end portion 31a of the cylindrical body 31 is closed by the photocurable fluid substance 1, a negative pressure is applied to the inside when the desired shape is formed. State, and FIG.
Like 3b, the cylindrical body 31 will be destroyed by atmospheric pressure.

In such a case, in the method of the present invention, the lower end 31a of the cylindrical body is molded in a semi-cured state so that the lower end 31a of the cylindrical body is easily separated from the bottom surface of the container 2, and When the lower end portion 31a of the cylindrical body is separated from the liquid surface of the photocurable fluid substance 1 like 23c, even if the lower end portion 31a is deformed by the pressing force from the outside, the lower end portion 31a
After is separated from the liquid surface of the photocurable fluid substance 1, the atmospheric pressure enters into the cylindrical body 31, whereby the deformation of the lower end portion 31a is recovered and the target shape can be restored. The molded article thus molded can be wholly cured by the irradiation treatment with the mercury lamp as the second step.

[0059]

As described above, according to the present invention,
Irradiation by irradiating a photocurable fluid substance obtained by mixing a metallocene compound and a peroxide with a monomer of an epoxy resin or an acrylic resin or a monomer of a mixture of an epoxy resin and an acrylic resin with a laser beam having a wavelength of 600 to 800 nm. Since the part is cured or semi-cured, the photocurable fluid substance can be efficiently cured in a columnar shape in the depth direction (thickness direction) by irradiation with laser light along the Z-axis direction. Therefore, the columnar cured state formed by the irradiation of the laser light in the Z-axis direction sequentially moves the irradiation of the laser light in the X-axis and Y-axis directions, thereby stacking thin planar cured parts as in the conventional case. Instead, it can be molded as a stack of three-dimensional layers having a predetermined thickness, and a stereolithography method with extremely high work efficiency can be expected.

Further, in the stereolithography method of the present invention, the photocurable fluid substance can be efficiently cured into a column shape in the depth direction (thickness direction) thereof by irradiation with laser light, so that the laser light By appropriately controlling the conditions such as the focal position and the moving speed of the laser light, the thickness of curing can be controlled, or the degree of curing such as curing, semi-curing or non-curing can be freely changed. A molding method having a wide range and easy to handle can be provided.

In particular, by adjusting the laser beam irradiation conditions in the first stage, it is possible to control the curing thickness and to freely change the curing degree such as curing, semi-curing or uncuring. Such curing treatment by irradiation with laser light and subsequent curing treatment by irradiation with light other than laser light as the second step can be used together as post-curing, and as a result, auxiliary treatment by a different process can be performed during manufacturing. A solid object in a wide range of fields by inserting various hardening processes or performing operations such as moving, fixing, assembling, disassembling, and correcting parts and members when molding a molded object composed of a combination of multiple parts. It has an effect that molding can be easily and efficiently performed.

In addition, the degree of curing of the photocurable fluid substance can be adjusted by monitoring the shape of the far field pattern generated by the diffraction phenomenon of the laser beam passing through the photocurable fluid substance, so that the work is always performed. Since it is possible to accurately grasp the situation and use a semiconductor laser light with a wavelength of about 670 nm, compared to the conventional method using a gas laser light, cooling equipment is not required, and power consumption is low. In addition, the entire device is compact, has good operability, and is easy to maintain and manage.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a configuration of a stereolithography apparatus used in a stereolithography method of the present invention.

FIG. 2 is a perspective view showing an example of a modeled object molded by the optical modeling method of the present invention.

FIG. 3 is a cross-sectional view showing a process of molding the modeled object of FIG.

FIG. 4 is a perspective view showing a process of molding the modeled object of FIG.

FIG. 5 is a perspective view showing another example of a modeled object formed by the optical modeling method of the present invention.

FIG. 6 is a cross-sectional view showing a process of molding the modeled object of FIG.

FIG. 7 is a perspective view showing a process of molding the modeled object of FIG.

FIG. 8 is a perspective view showing still another example of a modeled object formed by the optical modeling method of the present invention.

FIG. 9 is a cross-sectional view showing a step of molding the molded article of FIG.

FIG. 10 is a perspective view showing a process of molding the modeled object of FIG.

FIG. 11 is a cross-sectional view showing an example of a case where the molded article of FIG. 8 is molded by another process.

FIG. 12 is a perspective view showing another example of a modeled object formed by the optical modeling method of the present invention.

FIG. 13 is a perspective view showing another example of a shaped article that is similarly molded by the stereolithography method of the present invention.

FIG. 14 is a side view showing a laser light irradiation state when the focus position of the laser light is on the front side of the photocurable fluid substance.

FIG. 15 is a plan view showing the shape of a far field pattern in the irradiation state of FIG.

FIG. 16 is a side view showing an irradiation state of laser light when the focus position of the laser light is on the rear side of the photocurable fluid substance.

FIG. 17 is a plan view showing the shape of a far field pattern in the irradiation state of FIG.

FIG. 18 is a side view showing the irradiation state of laser light when the focus position of the laser light is in the photocurable fluid substance.

FIG. 19 is a plan view showing the shape of a far field pattern in the irradiation state of FIG.

FIG. 20 is a perspective view showing a molding step of the shaped article in the case where the curing treatment by irradiation with laser light and the subsequent curing treatment by other light irradiation are used together.

FIG. 21 is a curing process similarly performed by irradiation with laser light,
The perspective view which shows the shaping | molding process of the molded article of another shape in the case where it is used together with the subsequent hardening process by other light irradiation.

FIG. 22 is a cross-sectional view showing a molding step in the case of molding a molded article having a complicated shape by utilizing the shrinkage of the volume generated when the photocurable fluid substance is cured by irradiation with laser light.

FIG. 23 is a cross-sectional view showing a molding step for explaining the advantage of partially molding a shaped article in a semi-cured state as a curing treatment by irradiation with laser light.

[Explanation of symbols]

1 Photocurable fluid material, 1a, 1b, 1c ... 1
n columnar hardened part, 2 container, 3 glass plate, 4
Laser irradiator, 5 driving device, 6 computer, 7 laser light, 10 shaped object, 10a,
10b, 10c annular hardened part, 11 molded article, 11
a, 11b, 11c annular hardened part, 12 shaped article,
12a, 12b, 12c annular hardening part, 13a, 13
b, 13c 1st layer to 3rd layer cured part, 14 molded article, 15a, 15b, 15c annular cured part 16
Shaped object, 17a tooth, 17b groove, 17c
Hole, 18 model, 19 cross section on glass plate,
20 focus position, 21 far field pattern,
22 triangular tail, 23 curved strip, 24
Box, 24a wall surface, 24b fold part, 2
5a, 25b gears, 26 belts, 27 teeth,
28 teeth, 29a shaped article, 29b connection section, 29c lower layer shaped article, 30a, 30b rope-like connection section, 31 cylindrical body, 31a cylindrical body lower end portion,

Claims (18)

[Claims] 1. A laser beam having a wavelength of 600 to 800 nm for a photocurable fluid substance obtained by mixing a metallocene compound and a peroxide in a monomer of an epoxy resin or an acrylic resin or a monomer of a mixture of an epoxy resin and an acrylic resin. A stereolithography method, which comprises irradiating the irradiated part to a cured or semi-cured state. 2. A laser beam having a wavelength of 600 to 800 nm for a photocurable fluid substance obtained by mixing a metallocene compound and a peroxide in a monomer of an epoxy resin or an acrylic resin or a monomer of a mixture of an epoxy resin and an acrylic resin. To irradiate the irradiated part to a cured or semi-cured state,
After that, a stereolithography method is characterized by irradiating with light having a wavelength shorter than 600 nm to further cure and mold. 3. A metallocene compound as a photocurable fluid substance is (1-6-.eta.-cumene) (. Eta.-cyclopentadienyl).
The stereolithography method according to claim 1, which is iron (1+) hexafluorophosphate (1-). 4. The stereolithography method according to claim 1, wherein a polyester acrylate monomer is used as the acrylic resin monomer in the photocurable fluid substance. 5. The stereolithography method according to claim 1, wherein a mixture of epoxy resin and acrylic resin monomers is used as the photocurable fluid substance. 6. The stereolithography method according to claim 1, wherein the peroxide of the photocurable fluid substance is cumene hydroperoxide. 7. The stereolithography method according to claim 1, wherein tetrahydrofurfuryl acrylate is mixed as a diluent in the photocurable fluid substance. 8. The stereolithography method according to claim 2, wherein irradiation with light after irradiation with laser light is performed with a mercury lamp. 9. The stereolithography method according to claim 1, wherein laser light irradiation is performed from the bottom surface or the side surface of the transparent container containing the photocurable fluid substance toward the photocurable fluid substance inside. . 10. The irradiation of laser light is rapidly moved to a region where the photocurable fluid material is not cured, and the region to be cured is cured slowly or temporarily by irradiating the region where the photocurable fluid substance is not cured. The stereolithography method according to claim 1, wherein a region and a semi-cured region are created. 11. An assembly structure in which a plurality of members are combined using the stereolithography method according to claim 1 is cured by adjusting a moving speed or irradiation intensity of laser light irradiation. A stereolithography method in which three-dimensional molding is performed in the assembled state by creating a region to be cured, a region not to be cured, or a semi-cured region. 12. Using the stereolithography method according to claim 1, a laser-irradiated laser beam is used to create a molded article connected to each other in a semi-cured region, and then the semi-cured portion is bent. After forming another three-dimensional molded body, the above-mentioned connecting portion of the molded body is cured and connected by light irradiation or laser light irradiation so that the molded body is held, and a three-dimensional assembled molded article is produced. Molding method. 13. A glass plate is brought into contact with the surface of the photo-curable fluid material stored in the transparent container, and a laser beam is irradiated from below the transparent container, whereby the lower surface of the glass plate is photo-curable. The stereolithography method according to claim 1 or 2, wherein a cured molded article of a fluid substance is molded. 14. The glass plate which is brought into contact with the surface of the photocurable fluid material stored in the transparent container is transparent.
The stereolithography method according to item 3. 15. A laser beam is radiated from below the container in which the photo-curable fluid substance is stored to gradually pull up the cured portion of the photo-curable fluid substance while irradiating the laser beam from below the cured portion. The stereolithography method according to claim 1 or 2, wherein the cured portion is grown under the cured portion. 16. The pipe continuous molding method according to claim 1, wherein the pipe-shaped molded article is molded by sequentially shifting the irradiation section of the laser beam into an annular shape. 17. A far-field pattern, in which irradiation of laser light is moved along the photocurable fluid substance, and the transmitted light of the moving laser light is projected on a transparent plate above the photocurable fluid substance, A method for confirming the focus position of laser light, wherein the focus of the laser light is not in the photocurable flow material when a triangular tail is generated. 18. A laser irradiator having a wavelength of 600 to 800 nm is attached to a driving device which moves in three axial directions of X, Y, and Z, and a container storing a photocurable fluid substance is provided above the laser irradiator. A stereolithography method in which the transparent plate is disposed so as to contact the liquid surface of the photocurable fluid substance in the same container, and the laser irradiation device is driven by a computer.