JPH09169056A - Production of three-dimensional shaped article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To properly and efficiently perform the planning of a support member and to make the mark generated on the side of a shaped article when the support member is cut off from the formed shaped article inconspicuous in a method connecting the support member, which connects a fixed structural member supporting the part required to be supported of the shaped article, to the part required to be supported of the shaped article when a photo-set layer is formed by irradiating a photo-setting resin with light and a plurality of the photo-set layers are stacked to produce the shaped article having a desired three-dimensional shape. SOLUTION: It is judged whether support is necessary for the respective photo-set layers 40 of a shaped article and the connection part 51c of a support member is formed in the same way as the shaped article so as to be connected to the photo-set layer 40d requiring support in a part of the region not overlapped with the planar shape of the photo-set layer 40c of a lower layer within the planar countour line region of the photo-set layer 40d requiring support or the whole region.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a three-dimensional shaped object, and more specifically, it uses a photocurable resin that is cured by irradiation of light to mold and produce an article having a three-dimensional shape. It is about how to do it.

[0002]

2. Description of the Related Art A method for producing a three-dimensional shaped object using a photocurable resin is to form a complicated three-dimensional shape easily and accurately without using a molding die or a special processing tool. As a method that can be used, it is considered to use it for manufacturing various product models and three-dimensional models.

For example, according to the method disclosed in Japanese Patent Laid-Open No. 63-141724, a vertically movable molding table submerged in a resin liquid is arranged immediately below the liquid surface of the resin liquid, and the liquid surface is irradiated with laser light. ,
The resin liquid layer on the molding table is photo-cured to form a photo-cured layer, and then the molding table is slightly submerged, and then the same steps as above are repeated, thereby repeating a plurality of photo-cured layers. Stack up. In addition to the above-mentioned prior art, various methods for producing a three-dimensional shaped article by stacking photocurable layers have been proposed.

In such a method for manufacturing a three-dimensional shaped object, a part of the three-dimensional shape has a canopy portion that is laterally overhanging more than the lower portion, or a hanging portion where the lower portion is not supported at all. If there is a photocurable layer that does not support the photocurable layer that forms the eaves or sags, the photocurable layer deforms or moves, and the shape of the three-dimensional shape collapses or the shape accuracy is reduced. There was a problem that it became worse.

In order to solve such a problem, it has been considered to provide a support member which is connected to the molded article and which is formed by photocuring a photocurable resin similarly to the molded article.
In Japanese Unexamined Patent Publication No. 6-8342, the planar shape of two photocuring layers stacked vertically is compared to determine whether a supporting member is required for the upper photocuring layer, and a supporting member is required. Then, a technique is disclosed in which a light irradiation area corresponding to the support member is additionally set in the light irradiation area for forming the upper photocurable layer. According to this method, the support member can be arranged at an appropriate position for supporting the modeled object based on the shape data of the modeled object, and the design of the supporting member can be easily and appropriately performed.

[0006]

In the above-mentioned prior art, the connecting portion of the support member is connected to the outer end surface of the photo-curable layer forming the modeled article so as to straddle a plurality of photo-curable layers forming the modeled article. However, the surface of the modeled article has a stepped shape because it is formed by stacking layers, and when the connecting portion of the supporting member that spans a plurality of photo-curing layers as in the above-mentioned prior art is cut off from the modeled article, there is a mark. There is a problem that remains.

It is an object of the present invention to appropriately and efficiently design a support member for supporting a modeled object in the method for molding a three-dimensional shaped object as described above, and This is to make the marks generated on the side of the modeled object inconspicuous when the support member is separated.

[0008]

According to the method for molding a three-dimensional shaped object according to the present invention, a photocurable resin is irradiated with light to form a photocurable layer, and a plurality of photocurable layers are stacked to form a desired layer. When manufacturing a modeled article having a three-dimensional shape, a method of connecting a supporting member that connects a fixed structure supporting the part to a part of the modeled object that needs to be supported with each light forming the modeled object. It is determined whether or not support is required for the curable layer, and one of the regions that do not overlap with the planar shape of the lower photocurable layer in the contour line region of the planar shape of the photocurable layer that requires the support is determined. The connection part of the support member is formed in the same manner as the modeled part so as to be connected to the photocurable layer requiring the support in part or all of the area.

As the photo-curable resin, various photo-curable resins which are also used in the conventional method for molding a three-dimensional shaped object can be used. Specific examples include urethane, urethane-acrylate, epoxy, and epoxy-acrylate-based photocurable resins. The basic technique for molding a three-dimensional shaped object such as a method for supplying a photocurable resin, a method for irradiating light, a method for forming a photocurable layer, and a method for stacking photocurable layers is known in the art. Any ordinary method or device can be applied as it is.

The planar shape of each photo-curable layer is usually produced by converting the entire outer shape of the modeled object into electronic information by a CAD device and calculating the planar shape data of each photo-curable layer from this electronic information. If the plane shape of each photocurable layer is determined, the light irradiation area for forming each photocurable layer is determined corresponding to this plane shape, and the information of the light irradiation area is used as a laser beam scanning control device. By inputting in, for example, a photo-curable layer having a required shape can be formed.

The present invention is applied to a structure of a modeled object, at least a part of which has a part requiring support. The portion that needs to be supported is the above-mentioned eaves portion or the hanging portion. The part that needs to be supported is not limited to one in one molded article, but may be in a plurality of locations. The support member is formed by irradiating the photo-curable resin with light and photo-curing it by the same means as the formation of the photo-curable layer forming the three-dimensional shape. The supporting member is usually formed by laminating a plurality of supporting layers made of a photocurable resin, but the supporting member may be composed of one supporting layer in some cases.

The support member is formed so as to connect the portion of the modeled object that needs to be supported with the fixing structure that supports the part. The fixed structure includes, for example, a surface of a molding table for molding a molded article, an inner wall surface of a resin liquid tank for storing a photocurable resin liquid, a pillar or a wall erected around a molded portion of the molded article. It is also possible to use metal, synthetic resin, or the like, or it is also possible to use, as the fixed structure, a structural part of the same shaped article that is highly rigid and difficult to deform due to its shape. Further, a photocurable resin may be photocured around the shaped article to form a peripheral wall or a pillar having sufficient rigidity, and the peripheral wall or the like may be used as a fixed structure.

As the shape of the supporting member, the structure of various supporting members which have been used in the conventional method can be adopted, and various shapes of arms or columns are formed in consideration of necessary strength and load direction of load. Any thing can be used. Each support layer constituting the support member is indirectly formed by connecting the support member connecting portion connected to the molded article, that is, the photocurable layer, and the support member connecting portion of the upper layer, which is not directly connected to the photocurable layer, to the support structure. And a support member body that supports the photocurable layer.

The support member connecting portion is connected to the lower surface of the photocurable layer to be connected and has a position and shape suitable for supporting the photocurable layer in the upper layer portion. It is preferable that the support member connecting portion is connected to the photo-curable layer with a minimum necessary area so that a mark is not noticeable when the support member connecting portion is separated from the molded article. As a specific shape of the support member connecting portion,
Besides the linear shape in plan view, various shapes such as a broken line shape, a circular shape, an elliptical shape, and a polygonal shape can be adopted.

The support member connecting portion is formed together with the photo-curing layer to be connected, that is, the photo-curing layer as a lower layer with respect to the photo-curing layer of the portion requiring the support, and the plane of the photo-curing layer requiring the support. A part or all of the contour line region of the shape that does not overlap with the planar shape of the lower photocurable layer is formed so as to be connected to the photocurable layer that requires the support. Therefore, the support member connecting portion is connected to the lower surface of the photo-curable layer that needs to be supported, but is not connected to the lower photo-curable layer. As a result, when the support member is separated from the modeled object, it is sufficient to separate it between the support member connecting portion and the photo-curing layer on the upper surface thereof, and the separation mark remains only on the lower surface side of the photo-curing layer, and the separation is performed. The scratches overlap the steps due to the stacking when forming the modeled object, making them inconspicuous.

In particular, in the case of a support member connecting portion in which relatively small unit support layers such as broken line supporting members are arranged at intervals, the contact area between the support member connecting portion and the upper photocurable layer is reduced. Therefore, the work of separating the modeled object and the support member, which is performed at the support member connecting portion, is facilitated. The support member main body is formed in a lower layer of the support member connecting portion and supports the upper support member connecting portion. Therefore, the support member main body is formed according to the arrangement shape of the support member connecting portion. The supporting member main body preferably has a size or strength sufficient to reliably support the upper photocurable layer and the supporting member connecting portion. As the specific shape of the support member main body, in addition to the same planar shape as the support member connecting portion, a cross shape, a frame shape, a honeycomb shape, or the like can be adopted.

In particular, if relatively small unit support layers such as cross-shaped support members are arranged vertically and horizontally at intervals to form the entire support member main body, the resin liquid freely flows between the unit support layers. Therefore, it is said that the time from supplying new resin liquid onto the molding table or the photo-curing layer previously formed until the liquid surface becomes smooth and the next light irradiation can be performed is shortened. There are advantages. Further, since the contact area with the support member main body formed on the molding table is reduced, the separation work becomes easy.

Since the support member main body is formed in a region which does not overlap with the planar shape of the photocurable layer requiring support and the planar shape of the lower photocurable layer, any of the photocurable layers constituting the modeled object is formed. It is not directly linked with either. Usually, the support member connecting part is arranged on the support member main body in a single layer or a plurality of layers to form a support member. However, it is also possible to configure the support member with only one layer of the support member connecting portion.

The photocurable layer connected to the support member connecting portion is
It may be all the photo-curable layers constituting the molded article, or only a part of the photo-curable layers that need to be supported. That is, the photocurable layer connected to the support member connecting portion may be vertically spaced with the photocurable layer not connected to the support member connecting portion interposed therebetween. As the proportion of the photo-curable layer connected to the support member connecting portion increases, the supporting effect is improved, but the time and effort required to manufacture the support member increase, and the time and effort to separate the support member from the modeled object also increase. Usually, the support member connecting portion may be connected only to the minimum necessary photo-curable layer.

Whether or not the support member connecting portion should be formed, that is, the layout design of the support members, can be determined by judging from the shape of the entire molded article, and among the plurality of photo-curable layers constituting the molded article. Alternatively, it can be performed based on the result of comparing the planar shapes of the two photo-curing layers stacked on top of each other. Specifically, it is possible to provide a support member connecting portion that is connected to the upper photocuring layer based on information such as the planar shape area of the upper and lower two photocuring layers, the amount of deviation of the contour line, and the angle. It can be determined whether it is necessary or not.

For example, the following method can be adopted. First,
An outline contour line is obtained when the molded article is sectioned in the stacking direction of the photo-curable layers. Microscopically, the outer shape of the modeled object formed of a laminate of a large number of photo-curing layers has stepwise steps, but the contour line is represented by an envelope that covers the steps of each photo-curing layer. For each photo-curing layer, the inclination angle between the tangent of the outline and the surface direction of the photo-curing layer at that position is determined. The support member connecting portion is connected to the photo-curable layer at a position where the tilt angle is less than a predetermined reference angle. The smaller the inclination angle, the larger the upper photocuring layer is projected to the outside with respect to the lower photocuring layer, and the necessity of the supporting member is high. Tilt angle is 90
If it is at least °, the outer edge of the upper photocurable layer is inside the outer edge of the lower photocurable layer. The reference angle varies depending on conditions such as the shape of the modeled object, the material used, and the purpose of use, but it is usually set to 15 ° or less.

The following method can also be adopted for determining the photo-curable layer connecting the supporting member connecting portions. When the area of a region that does not overlap with the planar shape of the lower photocurable layer in the planar shape of the upper photocurable layer exceeds the predetermined reference area with respect to the upper and lower two photocurable layers, The support member connecting portion is connected to the upper photocurable layer. The larger the area is, the larger the upper photo-curing layer is projected to the outside with respect to the lower photo-curing layer, and the higher the necessity of support is. The reference area varies depending on conditions such as the shape of the modeled object, the material used, and the purpose of use. The reference area can also be defined by the ratio to the area of the upper photocurable layer. For example, when the thickness of the photocurable layer is 0.2 mm, the area of 5 to 10% of the area of the upper photocurable layer can be used as the reference area.

Further, in the determination of the photo-curing layer connecting the supporting member connecting portions, the above-mentioned prior art JP-A-6-8342 is used.
The technique disclosed in the publication is also applicable. In addition, operations such as the determination of the necessity of the supporting member connecting portion and the determination of the arrangement shapes of the supporting member connecting portion and the supporting member body described above are performed based on the information about the outer shape of the modeled object input to the CAD device or the like.
It can be performed in advance by performing arithmetic processing with a computer. By simply inputting the entire shape of the modeled object into a CAD device, etc., the required arrangement shape of the support members can be obtained, and based on the result, the molding of the three-dimensional shaped object by light irradiation can be automated. It is possible.

After the shaped article composed of a plurality of photo-cured layers and the supporting member composed of the supporting member connecting portion and the supporting member main body are formed as described above, if the supporting member is separated from the shaped object, The desired shaped object is obtained. A cutting tool such as a cutter or a nipper can be used to separate the shaped article from the support member. The molded article that has been molded may be subjected to post-treatment in the usual production of a three-dimensionally shaped article, such as secondary curing by heating or surface finishing treatment that smoothes the surface.

[0025]

Embodiments of the present invention will be described below with reference to the drawings. [First Embodiment] A method of manufacturing a three-dimensional shaped object shown in FIGS. 1 to 4 in order of steps is a method of manufacturing a modeled object 4 having a cross-sectional shape shown in FIG.

As shown in FIG. 1, the elevating member 20 is submerged in the photocurable resin liquid 10. The elevating member 20 can be moved up and down by an actuator (not shown). Lifting member 20
The molding table 22 is attached to the molding table 22.
The modeled object 4 is formed on the above. By disposing the molding table 22 at a position slightly sunk from the liquid surface of the resin liquid 10 and irradiating the laser beam 30 on the liquid surface, a layer of the resin liquid 10 existing between the molding table 22 and the liquid surface. Light cure. Laser light 30
The resin liquid 10 is photo-cured according to the irradiation pattern.

On the molding table 22, a photo-curing layer 40a which is the first layer of the molded article 4 and a frame-shaped supporting member 51a which is arranged on one side of the photo-curing layer 40a are formed. The frame-shaped support member 51a has a substantially rectangular shape with the same width as the photo-curable layer 40a, and has a shape in which two U-shapes open toward the photo-curable layer 40a are arranged. The frame-shaped support member 51a is a photocurable layer 40a.
Is not connected to the side end surface of the support member and becomes a support member main body described later.

As shown in FIG. 2, while the molding table 22 is being sunk in stages, the laser beam 30 is irradiated at each stage,
A plurality of photo-curing layers 40a, 40b, 40c are sequentially stacked and formed. Simultaneously with the formation of the photocurable layers 40a, the frame-shaped support members 51a, 51b, 51c are also formed. The photo-curing layers 40a and 40b and the frame-shaped support members 51a and 51b have the same shape. A part of the photo-curing layer 40c is stacked on the top surface of the photo-curing layer 40b, and another part of the photo-curing layer 40c projects outside the photo-curing layer 40b and is connected and stacked on the top surface of the frame-shaped support member 51b. Therefore, the frame-shaped support member 51b serves as a support member connecting portion, a part of which is connected to the photo-curing layer 40c, and the rest of the supporting member main body, which is not connected to the photo-curing layer 40c. Frame-shaped support member 51b
The support member connecting part connected to the photo-curing layer 40c is
It is arranged in an area surrounded by the contour line of the planar shape of the photo-curing layer 40c and not overlapping the planar shape of the lower photo-curing layer 40b.

As shown in FIG. 3, an uppermost photocurable layer 40d is formed. A part of the photo-curing layer 40d is connected to the upper surface of the photo-curing layer 40c, and the remaining part is part of the photo-curing layer 40c.
And is connected to the upper surface of the frame-shaped support member 51b. After the molded article 4 including the four photo-cured layers 40a to 40d is formed, the molded article 4 is taken out of the photo-curable resin liquid 10 as shown in FIG.
The support member 5 composed of 51 c is separated from the modeled object 4.
Specifically, the lower surface of the photocurable layer 40d is separated from the upper surface of the frame-shaped support member 51c serving as the support member connecting portion, and the lower surface of the photocurable layer 40c and the frame-shaped support member 51 serving as the supporting member connecting portion.
If the upper surface of b is separated, the modeled article 4 and the support member 5 can be separated. Detachment mark 42 of the supporting member 5 remaining on the modeled object 4
Exists along the contour lines of the lower surfaces of the photo-cured layers 41d and 41c. Therefore, the separation mark 42 is not so noticeable in appearance.

In the above embodiment, as shown in FIGS. 2 and 3, the shape of the connecting surface between the photo-curing layer 41d and the frame-shaped supporting member 51c and the shape of the connecting surface between the photo-curing layer 41c and the frame-shaped supporting member 51b are used. Both are U-shaped. That is, the support member connecting portion having a U-shaped plane is adopted. Such a U-shaped support member connecting portion is preferable because of its excellent strength. Further, in the above-described embodiment, in a portion where the upper photocuring layer is outwardly projected than the lower photocuring layer, all the photocuring layers, that is, the lower surface of each of the photocuring layers 41c and 41d has a frame-like shape that serves as a support member connecting portion. Since the support members 51c and 51d are connected, the support effect is high.

Second Embodiment This embodiment is different from the first embodiment in the shape of the support member. As shown in FIG. 5, the first photo-curing layer 40 a and the honeycomb-shaped supporting member 52 a including a vertical and horizontal lattice are formed on the molding table 22. Next, as shown in FIG. 6, a second photo-curing layer 40b having the same shape as the photo-curing layer 40a is laminated on the photo-curing layer 40a, and has the same shape as the outer half of the honeycomb supporting member 52a. The linear support member 53b is formed on the inside of the honeycomb support member 52b and the honeycomb support member 52b.

As shown in FIG. 7, the third photo-curing layer 40 is formed.
c is connected to the photo-curing layer 40b for the most part, but one end side thereof projects outward from the photo-curing layer 40b and the linear support member 5
It is formed so as to be connected to 3b. In other words, the linear support member 53b is arranged in a region surrounded by the contour line of the planar shape of the photo-curable layer 40c and not overlapping with the planar shape of the lower photo-curable layer 40b. A linear support member 53c is formed on the honeycomb support member 52b.

As shown in FIG. 8, a fourth layer, a photo-curing layer 40.
Most of d is connected to the photo-curing layer 40c, but one end side thereof projects outward from the photo-curing layer 40c and the linear support member 5 is formed.
It is formed so as to be connected to 3c. Here, the linear support member 53c is arranged in a region surrounded by the contour line of the planar shape of the photo-curable layer 40d and not overlapping with the planar shape of the lower photo-curable layer 40c.

As a result of the above, the linear support member 53b becomes the support member connecting portion connected to the photo-curing layer 40c, the linear supporting member 53c becomes the support member connecting portion connected to the photo-curing layer 40d, and the remaining honeycomb. The support members 52a and 52b serve as a support member main body. As shown in FIG. 9, the molded product 4 including the photo-cured layers 40a to 40d manufactured in the above process is taken out from the resin liquid 10, and the linear support members 53b and 53c, which are the support member connecting portions, are separated from the molded product 4. Thus, the modeled article 4 and the support member 5 can be separated. In the molded article 4, cutting marks 42 are left only on the lower surfaces of the photo-curing layers 40d and 40c.

In the above embodiment, the linear support members 53b,
Since the modeled article 4 and the support member 5 are connected only by the narrow upper surface portion of 53d, the modeled article 4 and the support member 5 can be easily separated, and the separation trace 42 is also small. Since the honeycomb supporting members 52a and 52b are excellent in strength, they have a high supporting effect. Third Embodiment This embodiment is different from the above embodiment in the shape of the support member.

As shown in FIG. 10, on the molding table 22,
The first photo-curing layer 40a and the cross-shaped supporting member 54a are formed. The cross-shaped supporting members 54a are formed by arranging unit-shaped supporting members 54a having a planar cross shape in two rows of four rows in a row. As shown in FIG. 11, the photo-curable layer 40b of the second layer and the linear support member 53 arranged on the cross-shaped support member 54a in the row near the photo-curable layer 40b.
b and a cross-shaped support member 54b arranged on the remaining cross-shaped support member 54a are formed. In addition, in FIG.
When shifting from the state of FIG. 11 to the state of FIG.
By one step so that the resin liquid 10 flows into the photo-curing layer 40a and the cross-shaped supporting member 54a. At this time, since the resin liquid 10 freely flows between the cross-shaped support members 54a, the liquid surface of the resin liquid 10 is quickly smoothed.

As shown in FIG. 12, the third photocuring layer 4 is formed.
0c is formed over the second photocurable layer 40b and the linear support member 53b, and the linear support member 53c is formed on the cross-shaped support member 54b. The fourth photocurable layer 40d includes the third photocurable layer 40c and the linear support member 53.
It is formed over c. As a result, the linear support members 53b and 53c become the support member connecting portion, and the cross-shaped support members 54a and 54b become the support member main body.

In the above embodiment, by using the cross-shaped support members 54a and 54b as the support member main body, a sufficient support function can be achieved even with a support member having a relatively small area. [Fourth Embodiment] In this embodiment, a cross-shaped support member similar to that of the above-mentioned embodiment is adopted, but the structure of the support member is partially different.

As shown in FIG. 13, cross-shaped supporting members 54a, 54 are formed on the entire surface of the molding table 22 at intervals in the vertical and horizontal directions.
Place a '. As shown in FIG. 14, the first photo-curing layer 40b is formed on a part of the cross-shaped supporting members 54a ', and the upper part of the row of the cross-shaped supporting members 54a arranged outside the photo-curing layer 40b. On the other hand, a short linear support member, that is, a broken support member 55b as a whole is formed for each cross-shaped support member 54a.

As shown in FIG. 15, the second photo-curing layer 40c extends over the photo-curing layer 40b and the broken-line support member 55b.
And a broken line shaped support member 55c is formed on the cross shaped support member 54b. Further, a third photo-curing layer 40d is formed on the photo-curing layer 40c and the broken line-shaped support member 55c. Therefore, the broken line support members 55b and 55c serve as the support member connecting portion, and the remaining cross-shaped support members 54 are formed.
a and 54b become the support member main body. Further, some of the cross-shaped support members 54a 'have a role of supporting the entire shaped article.

In this embodiment, since the connection between the modeled article and the support member is made by the broken line-shaped support members 55b and 55c and the area of the connecting portion is small, the modeled article and the support member can be easily separated. No traces are noticeable. Further, since the cross-shaped supporting member 54a 'is present between the first-layer photo-curing layer 40b and the molding table 22, the contact area of the modeled object with the molding table 22 is reduced, and the molding from the molding table 22 is reduced. It also makes it easier to remove things.

[Fifth Embodiment] In this embodiment, the support member is connected only to a part of the photo-curing layer. FIG.
As shown in FIG. 7, the nine photocuring layers 40-1 to 40-9 are formed, and the photocuring layer 40-
3, 40-5, 40-7, and 40-9, support members 50-3, 50-5, 50-7, in which linear support members are laminated,
50-9 is formed. That is, the support member 50 supports every two layers of the photocurable layer 40.

As described above, the photo-curable layer 40 is provided for each fixed number of layers.
If the support member 50 is connected to the support member 50, it is possible to save the trouble of judging the necessity of the support member 50 one by one. [Sixth Embodiment] In this embodiment, a method for judging the necessity of supporting each photocurable layer forming a modeled object is shown.

As shown in FIG. 17, photocurable layers 40-1 to 40-1
40-9 are stacked and formed, and the support member 50-
7 to 50-9 are connected. FIG. 18 shows a method of determining a portion that needs to be supported. The vertical cross-sectional shape of the modeled object including the photo-curable layer 40, that is, the cross-sectional view taken along line XX in FIG. In this cross-sectional view, on the side where the planar shape of the upper photocurable layer 40 does not overlap with the planar shape of the lower photocurable layer 40, the reference point P at the lower corner of each photocurable layer 40 is adjusted to An envelope F is drawn by connecting the hardened layers 40. This envelope F
Represents the outline of the modeled object. At the reference point P of each photocurable layer 40, the angle formed by the tangent line of the outline F and the horizontal line H, that is, the inclination angle θ of the tangent line is obtained. The inclination angle θ becomes smaller as the length of the upper photo-curing layer 40 protruding outward than the lower photo-curing layer 40 becomes larger, and the necessity of supporting the upper photo-curing layer 40 increases.

Therefore, the preset reference angle θ ₀ is compared with the inclination angle θ of each photo-curing layer 40. If θ <θ ₀ , the photo-curing layer 40 is provided with the support member connecting portion 50. It is determined that they need to be connected and supported. The reference angle θ ₀ is set to 15 °, for example. Support member 5 as described above
The method for determining the necessity of forming 0 is to calculate the shape data of the modeled object electronically and easily and accurately.
The need for 0 can be determined.

[Seventh Embodiment] This embodiment describes another method for determining the necessity of supporting each photocurable layer forming a molded article. As shown in FIG. 19, when the photo-curing layers 40L and 40U are arranged on the upper and lower sides, the upper photo-curing layer 40 is formed.
The planar shape of U (hatched to the right is shaded) and the planar shape of the lower photocurable layer 40L (hatched to the left are shaded) overlap in the region indicated by the cross hatching. The left and right hatches do not overlap and the photo-curing layer 40U
A region 40X represented only by hatching is a region where the planar shapes of the upper and lower layers do not overlap. The support member connecting portion is connected to the region 40X.

With such an arrangement, the upper photocurable layer 40U
To determine if a support member connection is required for
The area of the region 40X is obtained and compared with whether or not the area of the region 40X is larger than the reference area. If the area of the region 40X is larger than the reference area, the support member connecting portion is connected to the photo-curing layer 40U. It can be determined that there is a need.

It is necessary to use the entire area of the photocurable layer 40U as the reference area, and to connect and support the support member connecting portion when the area of the region 40X with respect to the total area of the photocurable layer 40U exceeds a certain ratio. It can also be determined that there is. If it is determined that the supporting member connecting portion is necessary, as shown in the figure, the supporting member connecting portion 50L is an upper layer of the photo-curing layer that does not overlap with the lower layer of the photo-curing layer 40L in the contour area of the region 40X. It is formed to be connected to the layer 40U.

The necessity of support based on the area of the region 40X as described above can be easily determined by electronically calculating the CAD data of the modeled object 4. It should be noted that a combination of both the determination method based on the area and the determination method based on the tilt angle described above is used when either determination method is necessary, or when it is determined to be necessary by any one of the determination methods. The support member connecting portion may be formed.

[Other Embodiments] As the supporting member for supporting the molded article, in addition to the supporting member having the supporting member connecting portion of the present invention described above, a plurality of photocurable layers described as the prior art are spread over. A supporting member that is connected can be used together. In this case, even if a mark is left on the modeled product from which the support member is separated, there is no problem in using the modeled product. Only the supporting member having the supporting member connecting portion of the present invention may be used in a place where it is not necessary to leave a conspicuous mark on the formed object due to a problem.

[0051]

According to the method of molding a three-dimensional shaped object according to the present invention, the shaped object can be easily and properly supported by the supporting member formed by the same means as the shaped object, and the supporting member can be removed from the shaped object. It is possible to make the marks generated on the model side inconspicuous when separated. As a result, it is possible to efficiently manufacture a molded article having high shape accuracy and good appearance.

[Brief description of the drawings]

FIG. 1 is a vertical sectional view and a horizontal sectional view showing an embodiment of the present invention and showing a first stage of a molding process.

FIG. 2 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 3 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 4 is a vertical cross-sectional view showing a state in which the support member is separated from the modeled object.

FIG. 5 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing the first stage of the molding process.

FIG. 6 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 7 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 8 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 9 is a vertical cross-sectional view showing a state in which the support member is separated from the modeled object.

FIG. 10 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing the first stage of the molding process.

FIG. 11 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 12 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 13 is a vertical sectional view and a horizontal sectional view showing another embodiment and showing the first stage of the molding process.

FIG. 14 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 15 is a vertical sectional view and a horizontal sectional view showing the next stage.

FIG. 16 is a vertical cross-sectional view showing another embodiment and showing a molding process.

FIG. 17 is a vertical cross-sectional view and a plan view showing another embodiment and a molding process.

FIG. 18 is a schematic diagram illustrating a method for determining the necessity of support.

FIG. 19 is a schematic view and a plan view illustrating another embodiment and illustrating a method for determining necessity of support.

[Explanation of symbols]

 4 Modeled object 5 Supporting member 10 Photocurable resin liquid 20 Elevating member 22 Forming table 30 Laser light 40 Photocuring layer 50 Supporting member 51 Frame-like supporting member 52 Honeycomb-like supporting member 53 Linear supporting member 54 Cross-shaped supporting member 55 Broken line Shaped support member

Claims (8)

[Claims] 1. When a photocurable resin is irradiated with light to form a photocurable layer and a plurality of photocurable layers are stacked to produce a modeled product having a desired three-dimensional shape, In a method of connecting a support member that connects a fixed structure supporting this to a portion that requires support, it is determined whether support is required for each photocurable layer forming a modeled object, and In the contour line area of the planar shape of the photo-curable layer requiring support, a part or all of the area that does not overlap with the planar shape of the lower photo-curable layer is connected to the photo-curable layer requiring support. As described above, a method for manufacturing a three-dimensional shaped object, in which the connecting portion of the support member is formed in the same manner as the object. 2. The method for manufacturing a three-dimensional shaped article according to claim 1, wherein the support member main body, which is a portion of the support member other than the connecting portion, is formed by the same method as that of the modeled article so as not to contact the modeled article. . 3. The method for producing a three-dimensional shaped object according to claim 2, wherein a supporting member main body having a cross shape in a plane is formed as the supporting member main body. 4. The method for manufacturing a three-dimensional shaped article according to claim 2, wherein a supporting member main body having a planar honeycomb shape is formed as the supporting member main body. 5. The method for manufacturing a three-dimensional shaped object according to claim 1, wherein a support member connecting portion having a plane broken line shape is formed as the support member connecting portion. 6. A method for determining whether or not support is required for each photo-curable layer forming the shaped article, wherein support is determined at a predetermined stacking pitch. The method for producing a three-dimensional shaped object according to any one of claims. 7. A method for determining whether or not it is necessary to support each photocurable layer forming the modeled article, the method for determining whether or not the modeled article is cross-sectioned in the laminating direction of the photocured layer The three-dimensional shaped object according to any one of claims 1 to 5, wherein it is determined that support is required for a photocurable layer at a position where an inclination angle between a tangent line and a surface direction of the photocurable layer is less than a predetermined reference angle. Production method. 8. A method for determining whether or not it is necessary to support each photo-curing layer forming the shaped article is a plan shape of a lower photo-curing layer among the plan shapes of the photo-curing layer. The method for manufacturing a three-dimensional shaped object according to claim 1, wherein it is determined that support is required for a photocurable layer in which the area of the non-overlapping region exceeds a predetermined reference area.