JPH09277384A - Manufacture of three dimensional structure and apparatus therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mold rapidly and accurately a three dimensional structure to be molded by combining photo-setting layers of different thicknesses by a method wherein a means supporting the photo-setting layer is arranged in a means housing a photo-setting fluid resin, and an exposure value is automatically set according to thickness information of the supported photo-setting layer. SOLUTION: In an optically molding device 1, and elevator 104 fixing resin 103 hardened by irradiation with light is provided above a tank 102 housing photo-setting fluid resin 101, and an actuator 105 determining a position of the elevator 104 is connected thereto. A tape 107 making the hardened resin 103 separable from a surface of glass is provided to a tank inner surface side of light permeable glass 106 of a bottom surface of the tank 102. A shutter 112 is controlled from thickness information of the hardened layer between the elevator 104 and the high wettable tape 107 and information on the photo- setting fluid resin 101 to be used, and a suitable exposure value for obtaining the aimed hardened layer is automatically set with a controller 113 and a computer 115.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stereolithography technique using a photocurable fluid resin. Particularly, in the present invention, a two-dimensional image is irradiated onto the photocurable fluidized resin layer by a light image irradiation means to form a photocurable layer, and the photocurable layers are sequentially stacked to manufacture a desired three-dimensional structure. And a method for manufacturing the three-dimensional structure.

[0002]

2. Description of the Related Art In recent years, micromachines have been actively researched, and there is a great need for three-dimensional component processing and assembling techniques, and various fine processing techniques have been studied. One of these microfabrication technologies is the stereolithography technology, which has recently attracted attention as a technology for manufacturing a three-dimensional structure that does not require a cutting process (the point of producing a three-dimensional model from CAD data, labor saving and automation, 1992. September issue, P38-63;
Shigeru Nagamori, Micromachine design and manufacturing by processing method using UV curable resin, mechanical design, 1992, P50-
55; Satoshi Ikuta, 3D microfabrication by Koso, 5th Micromachine Symposium Material, P
79, P78). A specific manufacturing method for molding a three-dimensional structure by the optical molding method is shown in the process flow chart of FIG. Each step is as described below. 1) Input the drawing of the three-dimensional structure in the three-dimensional CAD. 2) A horizontal slice graphic data group is created for each certain thickness from the three-dimensional structure. 3) A photocurable fluid resin, for example, a photocurable fluid resin composed of three elements: an oligomer (epoxy acrylate, urethane acrylate, etc.), a reactive diluent (monomer), and a photopolymerization initiator (benzoin-based, acetophenone-based, etc.) An elevator that moves in the vertical direction is installed at the position, and the photocurable liquid resin is positioned so that the laminated thickness is constant. 4) Laser beam, for example, excimer laser (308 nm) having a wavelength range of ultraviolet rays, He-Cd laser (325 nm), Ar laser (351 to 346n)
m) is scanned along the horizontal cross section of the target shape to cure the photocurable fluid resin. 5) The elevator is again positioned so that the laminated thickness is constant, and the uncured photocurable fluid resin is introduced. 6) Repeat steps 4) and 5) until the desired three-dimensional structure is completed. 7) The three-dimensional structure is taken out and the uncured photocurable fluid resin adhering to the surface is washed. 8) Perform post exposure.

The details of these stereolithography steps are shown in FIG. This figure is a schematic view of stereolithography by the regulated liquid level method in which light is irradiated from the lower surface of the photocurable fluid resin to fabricate. As shown in this figure, in the regulated liquid level method, the elevator 20
1. A glass plate 202 that transmits light (for example, quartz glass is preferable when ultraviolet rays are used), a tank 200 containing a photocurable fluid resin, and a focused laser beam 2.
04 (for example, an Ar laser having a wavelength of 330 to 364 nm or a He-Cd laser having a wavelength of 325 nm can be used), a photocurable fluid resin that is cured by light (for example, X-rays, ultraviolet rays, or visible light). Photocurable fluid resin that is cured by, for example, from three elements: oligomer (epoxy acrylate, urethane acrylate, etc.), reactive diluent (monomer), photopolymerization initiator (benzoin-based, acetophenone-based compound, etc.) No. 205, cured photocurable fluid resin 20
6, the cured photocurable fluid resin 206 to the glass plate 202
A low wettability material 203 (eg,
Teflon tape) is used.

In FIG. 2A, the elevator 201 is raised so that the distance between the elevator 201 and the glass plate 202 corresponds to one layer of the above CAD data, and the laser beam 2 is moved.
04 shows the state where the glass plate 202 and the material 203 having low wettability are transmitted and irradiated to cure the photocurable fluid resin 205 and form the photocurable layer 206. FIG.
FIG. 6B is a diagram showing a state where the curing of the first layer of the photocurable fluid resin has been completed. FIG. 2C is a diagram in which the irradiation of the laser beam 204 for curing the photocurable fluid resin is stopped in order to obtain the second photocured layer, and the elevator 201 is raised by the thickness of the second layer. Is. FIG. 2D is a diagram in which the second photo-curing layer 206 is cured by the laser beam 204. The procedure of FIG. 2A to FIG. 2D is repeated to form the three-dimensional structure while curing and stacking the photocurable fluid resin 205.

Further, details of the stereolithography process by another method are shown in FIG. This figure is a schematic diagram of stereolithography by the free liquid surface method in which light is irradiated from the upper surface of the photocurable fluidized resin to fabricate a three-dimensional structure. 3A and 3B, the photocurable liquid resin contained in the tank 210 is cured on the elevator 211 by irradiating the laser beam 212 from the upper surface direction of the photocurable liquid resin. Hardened layer 215
It is a figure showing the place where the 1st layer of is hardened. FIG.
(C) is a diagram in which the irradiation of the laser beam 212 is stopped to cure the second photo-cured layer and the elevator 211 is lowered by the thickness of the second layer. FIG. 3D is a diagram in which the second photo-curing layer is cured by the laser beam 212. The procedure of FIGS. 3A to 3D is repeated to form a three-dimensional structure while curing and laminating the photocurable fluid resin.

By such a method, a three-dimensional structure can be manufactured without cutting. However, in the above-mentioned method, although it is slightly different depending on the photocurable fluid resin, it is not possible to manufacture a three-dimensional structure by the above method when heat resistance is required because the resin generally has a low glass transition point. Appropriate. In addition, although the tensile strength of the three-dimensional structure obtained from them is generally small, it may be slightly different depending on the photocurable fluid resin used, and therefore the above-mentioned method is required for producing a three-dimensional structure requiring mechanical strength. The method is inappropriate.

[0007] Further, a proposal regarding molding of a metal or ceramic structure to which a stereolithography method is applied is disclosed in Japanese Patent Publication No. 7-24248.
2 is shown. This is the content described below.
In a liquid photo-curable liquid resin, a mixed material of a metal or a ceramic material is mixed by changing the composition ratio of each component for each coating layer, and the mixed material is irradiated with light to cure the resin,
Stereolithography a three-dimensional structure. After that, the resin component in the resin molded body is burned and removed, and the powder contained is sintered to form a functionally gradient material having a desired shape, which is a stereolithography method.

However, in this method, the light exposure amount required for curing is different depending on the photocurable fluid resin used, the powder material mixed with the photocurable fluid resin, the powder diameter, and the blending amount of the powder material. The use of the exposure amount causes a problem that a certain layer does not undergo curing due to an insufficient exposure amount, and a certain layer has too much exposure amount to obtain a cured layer having a desired thickness. Further, in these documents, there is no description relating to the automatic adjustment of the exposure amount appropriately in accordance with the powder-mixed photocurable fluid resin to be used, and a complicated operation of resetting the exposure amount for each layer is required. However, there is also a problem that it takes time to form the structure. Therefore, it is difficult to rapidly and accurately form a fine three-dimensional structure by the method described above.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and its object is to quickly and accurately form a three-dimensional structure formed by combining photo-curing layers having different thicknesses. An object of the present invention is to provide a three-dimensional structure manufacturing apparatus and a three-dimensional structure manufacturing method capable of forming a three-dimensional structure.

[0010]

The above-mentioned object is achieved by the following (1) to (5). (1) A photo-curing layer is formed by irradiating the photo-curable fluidized resin layer with light by a light irradiating unit that scans and irradiates light or irradiates a light image, and a plurality of the photo-curable layers are combined. In a stereolithography device that molds a three-dimensional structure with
An accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in the accommodating means for supporting the photocurable layer, and an exposure of the light irradiation means according to thickness information of the photocurable layer. A stereolithography apparatus, comprising: an exposure amount setting means for automatically setting the amount.

(2) The photocurable fluidized resin layer is irradiated with light by a light irradiation means for scanning and irradiating light or irradiating a light image to form a photocurable layer. In a stereolithography apparatus for constructing a three-dimensional structure by combining a plurality of layers, a plurality of accommodating means for accommodating the photocurable fluid resin and arranged in any of the accommodating means to support the photocurable layer. Support means for moving the moving means, the moving means for moving the supporting means in any one of the plurality of housing means and arranging the supporting means, and which of the plurality of housing means the supporting means is arranged. An optical modeling apparatus, comprising: an exposure amount setting unit that automatically sets the exposure amount of the light irradiation unit according to the accommodation unit information and the thickness information of the photocurable layer.

(3) The photocurable fluidized resin layer is irradiated with light by a light irradiation means for scanning and irradiating light or irradiating a light image to form a photocurable layer. In a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of layers, a plurality of accommodating means for accommodating the photocurable fluid resin and arranged in any of the accommodating means and supporting the photocurable layer. A supporting means for moving the moving means, a moving means for relatively moving the supporting means in any of the plurality of housing means, and a light irradiating means in which of the plurality of housing means. And a light exposure amount setting means for automatically setting the light exposure amount of the light irradiation means in accordance with the light irradiation means information.

(4) A stereolithography method for molding a three-dimensional structure using a plurality of photocurable fluid resins having different characteristics, wherein the photocurable fluid resin is formed on a layer of the photocurable fluid resin. Of a structure forming step of forming a structure comprising at least one layer by irradiating light with an exposure amount according to the characteristics of the above, and a photocurable material having different characteristics from the structure forming step. The structure forming step is performed by irradiating light with a fluid resin at an exposure dose different from that of the structure forming step to form at least one layer of a photocurable fluid resin having different characteristics from the structure. A three-dimensional structure forming step of joining and forming the structure obtained in the step to a three-dimensional structure forming step.

(5) A laminated portion obtained by stacking a plurality of photocurable layers and at least one side surface perpendicular to the laminated surface of the laminated portion has a thickness equal to or larger than the thickness of the photocured layer of the laminated portion. A three-dimensional structure comprising a photo-cured portion coated with a photo-curable layer.

The present invention will be described in more detail below. In the present invention, the photocurable fluid resin means a fluid photocurable resin mixed with a reactive diluent, a photopolymerization initiator and the like as necessary.

Further, in the present invention, the powder-mixed photocurable fluid resin refers to a mixture of the photocurable fluid resin and powder which can be processed into a ceramic by sintering. First, the first invention will be described. According to the first aspect of the invention, the photocurable fluidized resin layer is irradiated with light by a light irradiation unit that scans and irradiates light or irradiates a light image to form a photocured layer. In a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of layers, a housing means for housing the photocurable fluid resin, and a support means arranged in the housing means for supporting the photocurable layer. And an exposure amount setting unit for automatically setting the exposure amount of the light irradiation unit according to the thickness information of the photo-cured layer.

The apparatus of the present invention comprises a housing means for housing the photocurable fluid resin. The storage means is not particularly limited as long as it can store the photocurable fluid resin. Specifically, a plastic tank made of Teflon, ABS, styrene resin, polycarbonate, or the like, or a metal tank made of a material that does not easily rust such as stainless steel (SUS303, 304, 430) or aluminum is preferable. In addition, as the shape of the tank, a cylindrical shape that facilitates cleaning of the tank is preferable. The accommodating means may be further provided with a vibrating means such as an ultrasonic vibrating machine or a defoaming machine depending on the photocurable fluid resin used.

Further, the apparatus of the present invention is provided in the above-mentioned accommodating means and is provided with a supporting means on which a photo-cured product is formed. An example of the supporting means is an elevator. The supporting means is provided with a device for positioning it, which raises and lowers the supporting means. In the device of the present invention, the thickness of the photocured product is determined by the position of the supporting means in the container, that is, the position information from the positioning device. In the present invention, the photo-cured product is formed by scanning the photo-curable fluid resin with light to form a photo-cured layer or by stacking a plurality of the photo-cured layers.

Further, the apparatus of the present invention comprises light irradiation means for curing the photocurable fluid resin. Specifically, the light irradiating means may be an X-ray light source, an ultraviolet light source, a visible light source or the like, though it depends on the photocurable fluid resin used. For example, an Ar laser having a wavelength of 330 to 364 nm,
For example, a He-Cd laser with a wavelength of 325 nm and a wavelength of 20
A mercury lamp of 0 nm to 400 nm or the like can be used. The light from the light source is applied to the photocurable fluid resin in the housing means by an appropriate optical path such as a mirror or an optical fiber. For example, when the light source is a laser beam, the photocurable fluid resin in the housing means is irradiated with a mirror or an optical fiber, and when the light source is a lamp, an optical fiber is used.

The apparatus of the present invention further comprises exposure amount setting means for automatically adjusting the exposure amount of the light from the light source according to the thickness information of the cured layer. Here, the thickness information of the cured layer means the thickness of the photocurable fluid resin to be cured,
It can be determined from the information on whether or not the supporting means is present at the position within the container. Specifically, for example,
In the regulated liquid level method, it is information about how much the containing means is located above, for example, a glass plate provided on the bottom surface of the containing container.

As the exposure amount setting means, means for adjusting the exposure amount by adjusting the output of the light source by changing the voltage and current of the light source consisting of an ultraviolet lamp, and a control device for shifting the focal position are attached to the lens. To adjust the amount of exposure,
A mask provided at the light irradiation port of the light source or a means for adjusting the exposure amount by scanning by changing the slit diameter, a means for adjusting the exposure amount by changing the scanning speed of the light, and a light transmission amount in the optical path. A means for adjusting the exposure amount by inserting and exchanging different slits and optical filters can be mentioned. Furthermore, when a shutter is used, the exposure amount can be adjusted by changing the opening / closing speed of a shutter including an electromagnetic shutter, a liquid crystal shutter, an acousto-optical element, and the like. Specifically, for example,
There is a method in which a shutter is provided in the optical path of light from a light source, and a computer appropriately adjusts the opening / closing speed of the shutter based on the thickness information of the cured layer, material data of the photocurable fluid resin, and the like. In the present invention, in particular, the exposure amount is automatically set from the information on the thickness of the cured layer and the information on the photocurable fluid resin to be used.

By using the apparatus of the present invention, a three-dimensional structure composed of a plurality of cured products having different layer thicknesses can be formed. As a specific example of the apparatus of the present invention, there is an apparatus (schematic diagram) for forming a three-dimensional structure by the restricted liquid level method shown in FIG.

Further, as another specific example of the first invention,
There is an apparatus (schematic diagram) for forming a three-dimensional structure by the free liquid level method shown in FIG. Next, the second invention will be described. According to the second aspect of the invention, the photocurable fluidized resin layer is irradiated with light by a light irradiation unit that scans and irradiates light or irradiates a light image to form a photocurable layer. In a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of layers, a plurality of accommodating means for accommodating the photocurable liquid resin, and arranged in any of the accommodating means, the photocurable layer A supporting means for supporting, a moving means for relatively moving and arranging the supporting means in any of the plurality of accommodating means, and a supporting means arranged in any of the plurality of accommodating means. An optical modeling apparatus is provided, which is provided with an exposure amount setting unit that automatically sets an exposure amount of the light irradiation unit in accordance with information on the housing unit and information on the thickness of the photocurable layer.

The present invention is an apparatus capable of forming a three-dimensional structure composed of a plurality of hardened products having different compositions, each of which has a plurality of containing means, each containing a photocurable fluid resin having a different composition. Is. Each of the accommodating means and the light irradiating means are the same as those in the first invention.

The moving means for disposing the supporting means in any of the plurality of housing means includes a table to which the plurality of housing means are fixed and an actuator for moving the table. The table includes a cleaning tank, if necessary,
A post-exposure tank or a drying tank may be further provided.

In the apparatus of the present invention, the exposure amount for automatically adjusting the exposure amount of the light from the light source is based on the thickness information of the above-mentioned hardened layer, the containing means information indicating in which containing means the supporting means is located, and the like. A setting means is provided. The exposure amount setting means may be the same as the exposure amount setting means of the first invention. In the present invention, in particular, the exposure amount is automatically set based on the thickness information of the cured layer, the containing means information regarding which containing means is to be irradiated with light, and the information about the photocurable fluid resin to be used.

An embodiment of the second invention is shown in FIG. 6 (schematic diagram). FIG. 6 shows an example of an optical modeling apparatus for modeling a three-dimensional structure by the regulated liquid surface method. Another aspect of the second invention is shown in FIG. 7 (schematic diagram). FIG. 7 shows an optical modeling apparatus for modeling a three-dimensional structure by the free liquid surface method.

In the present invention, the same resin, light source, etc. as the photocurable fluid resin described in the first invention can be used. Next, the third invention will be described.

According to the third invention, the light irradiation means for scanning and irradiating light, or irradiating a light image,
The photocurable fluid resin layer is irradiated with light to form a photocurable layer,
In a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of photocurable layers, a plurality of accommodating means for accommodating the photocurable fluid resin and one of the accommodating means are provided. Supporting means for supporting the cured layer,
Moving means for relatively moving and arranging the supporting means in any of the plurality of accommodating means, and light irradiating means information indicating in which of the plurality of accommodating means the light irradiating means is arranged. And an exposure amount setting unit for automatically setting the exposure amount of the light irradiation unit according to the thickness information of the photocurable layer.

The device of the present invention has the same structure as the device of the second invention. In the third invention, the exposure amount of the light from the light source is determined by the thickness information of the cured layer, the light irradiation means information indicating in which housing means the light irradiation means is located, and the information of the photocurable fluid resin to be used. Is automatically adjusted. As the means for automatically setting the exposure amount, the same means as the exposure amount setting means of the first invention can be mentioned.

By using this apparatus, a three-dimensional structure composed of a plurality of cured products having different compositions can be formed. Next, the fourth invention will be described. A fourth invention is a stereolithography method for molding a three-dimensional structure using a plurality of photocurable fluid resins having different characteristics, wherein a layer of the photocurable fluid resin is a layer of the photocurable fluid resin. A photocurable flow having different characteristics from the structure forming step of forming a photocurable layer by irradiating light with an exposure amount according to the characteristics and the structure forming step. The resin is irradiated with light at an exposure dose different from that of the structure forming step to form at least one layer of a structure of a photocurable fluid resin having different characteristics from the structure, And a three-dimensional structure forming step of forming a joint with the structure obtained in (3). That is, it is a method for producing a three-dimensional structure, in which a three-dimensional structure having a plurality of compositions is formed using the apparatus of the present invention. In the manufacturing method of the present invention, the structure forming step and / or the three-dimensional structure forming step may be performed a plurality of times to form a three-dimensional structure made of a plurality of different photocurable flow resins.

FIG. 8 shows an example of a three-dimensional structure forming process according to the optical forming method of the present invention. This example is a modeling example of a three-dimensional structure made of a photocured product having different characteristics by using different types of powder-mixed photocurable flow resins. First, the photocurable fluid resin described in the first invention and the inorganic powder material a are kneaded. The kneading is performed by stirring using a stirring defoaming machine or the like because it is necessary to prevent bubbles from entering when the photocurable fluid resin and the powder are mixed. This is introduced, for example, into a plurality of first accommodating means of the device of the second invention. On the other hand, similarly, the photocurable fluid resin having different characteristics and the inorganic powder material b are mixed and introduced into the second container. The structure A is stereolithographically formed in the first accommodating means. In the formation of the structure A, the amount of exposure is variably controlled and light is pattern-irradiated. The structure A thus obtained is subjected to post-treatment steps of washing and post-exposure. Next, the structure A after the post-treatment is subjected to the step of forming the structure B. The structure B is additionally formed on the structure A obtained previously. Even in the modeling of the structure B, the amount of exposure is variably controlled and light is pattern-irradiated.
The above structure A and structure B until the desired structure is obtained.
Repeat the stereolithography. The obtained three-dimensional structure having a desired shape is taken out, subjected to washing and post-exposure steps to obtain a desired three-dimensional structure.

Next, the fifth invention will be described. A fifth aspect of the present invention is a laminated portion obtained by stacking a plurality of photocurable layers, and at least one side surface perpendicular to the laminated surface of the laminated portion has a thickness equal to or larger than the thickness of the photocurable layer of the laminated portion. A three-dimensional structure comprising a photo-cured portion coated with a photo-curable layer.

The three-dimensional structure has the structure shown in FIG. That is, the three-dimensional structure 5 of the present invention is the second cured product 18 obtained by curing the second photocurable fluid resin.
3 is bonded to the first cured product 182, which is obtained by curing the first photocurable fluid resin, by laminating a plurality of layers so as to be adjacent to each other over at least a part of the laminating side surface perpendicular to the laminating surface. Characterize. The thickness of the cured product 182 is the cured product 1
It may be thicker than 81.

Such a three-dimensional structure 5 is a photocured product 1.
Since the photo-cured product 183 is formed by adjoining at least a part of the laminated side surface perpendicular to the laminated surface of the cured product 82, the discontinuous portion of the laminated surface can be reduced, and the stress due to the fine uneven portion can be reduced. The concentration can be reduced, and the three-dimensional structure has improved strength and durability of the joint. This three-dimensional structure can be manufactured by the above-described three-dimensional structure modeling apparatus and three-dimensional structure manufacturing method of the present invention.

[0036]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 A stereolithography apparatus (FIG. 4) of the present invention will be described. This device is a device for forming a three-dimensional structure by a regulated liquid level method.

The stereolithography apparatus 1 of the present invention is provided with a tank 102 containing a photocurable fluid resin 101. An elevator 104 for fixing the resin 103 cured by light irradiation is provided above the tank, and an actuator 105 for determining the position of the elevator is further connected to the elevator. In addition, the tank (10
A glass 106 that transmits light is provided on the bottom surface of 2),
A tape 107 is provided on the inner surface side of the glass tank to facilitate the separation of the cured resin (103) from the glass surface. On the other hand, below the bottom surface of the tank (102), an actuator 110 for moving the light 109 from the light source 108 is provided.
0) is provided with a light condensing unit 111 for condensing light from the light source toward the bottom surface of the tank (102). Between the light source (108) and the condensing unit (111), means 112 for adjusting the exposure amount of the light from the light source is provided. Examples of the means include a shutter. Further, the apparatus of the present invention is provided with a control device 113 for controlling each of the actuators (105, 110), the light condensing unit (111) and the exposure amount adjusting means (112), and the control device (113). The actuators (105, 110), the mirror (111), and the exposure amount adjusting means (112) are connected by a cable 114.

The light-transmissive glass (1
No. 06) depends on the light used to cure the photocurable fluid resin, but when irradiating with ultraviolet rays or visible light, quartz glass or the like is used.

The light source (108) that can be used in this embodiment is X
It is a line light source, an ultraviolet light source, a visible light source, or the like. In particular,
The light source is a mercury lamp or a laser. Specifically, it varies depending on the photocurable fluid resin, but the wavelength is, for example, 330 to 364.
nm Ar laser, eg wavelength 325 nm or 442n
m He-Cd laser, or a wavelength of 200 nm to 400
A nm mercury lamp or the like can be used.

The tape for facilitating the separation of the cured photocurable fluid resin from the glass surface is preferably Teflon tape or the like which transmits light and has low wettability. The actuator (110) for moving the light (109) from the light source (108) may be specifically an XY stage. The member for directing the light of the light condensing part (111) to the bottom surface of the tank (102) is not particularly limited as long as it appropriately reflects the light (109) from the light source. For example, a mirror can be mentioned. Also,
Examples of the member for condensing light in the condensing unit include a combination of a slit such as a pinhole and a lens. Further, the exposure amount adjusting means (112) is not particularly limited as long as it can appropriately adjust the exposure amount of the light from the light source. For example, a shutter etc. can be mentioned. In this apparatus, an optical fiber may be used instead of the mirror to irradiate the photocurable fluid resin with light.

The actuator (110) and the light collecting section (1
11) and the shutter (112) are connected to the control device (11
3) is controlled. That is, the actuator, the condenser, the shutter, and the like are controlled by the control device connected to the computer 115 based on the material information of the photocurable fluid resin in the computer.

In the present invention, the elevator (1
04) and the tape (107) with high wettability, the thickness information of the hardened layer (this is obtained from the position information of the actuator (105) for positioning the elevator) and the photocurable fluid resin to be used ( The shutter is controlled based on the information of 101), and an appropriate exposure amount for obtaining the target cured layer is automatically set by the control device (113) and the computer (115).

This device is used as follows. First, the elevator (104) is moved to the tank (102) by the actuator (105) so that a certain clearance is generated between the elevator (105) and the highly wettable release material.
Position within. This positioning is performed by the computer (1
15) and the control device (113), and the position information is stored as data in the computer. By this positioning, the layer thickness of the three-dimensional cured product or the first layer thereof is determined. Next, the optimum exposure dose for pattern irradiation is calculated based on the photocurable fluid resin used and the previously obtained position information. This exposure amount is a means for adjusting the output of the light source, a means for shifting the focal position of the emitted light, a means for changing the diameter or size of a mask or a slit attached to the light emission port, a means for changing the light scanning speed. When a shutter is used, it can be adjusted and set by changing the amount of light energy incident on a unit area by means of changing the opening / closing speed of the shutter. Further, the energy amount of incident light per unit area can be adjusted and set by changing the irradiation time. Next, light irradiation is performed using slice data obtained from CAD data of a desired three-dimensional structure. The light irradiation allows the light emitted from the light source (108) to pass through, for example, the shutter (112), guides it to the mirror on the XY stage while adjusting the exposure amount, and causes the photocurable flow from the bottom surface of the tank (102). This is done by irradiating the resin. The XY stage (110) and the shutter (112) are the controller (113) and the computer (1
15). When the desired structure is a single layer, after the irradiation of the desired pattern is completed, the elevator (10
4) is taken out from the tank, washed, and post-exposed. Also, if the desired structure is to be modeled from multiple stiffening layers, the elevator (104) may be replaced by an actuator (105).
And a predetermined clearance is provided between the hardened layer and the release material, and the above procedure is repeated again to form a desired three-dimensional structure. In the second and subsequent stereolithography, the stereolithography is performed by adjusting the exposure amount suitable for shaping the desired cured product. After that, the elevator (104) is taken out from the tank, washed, and post-exposed.

In the above-mentioned apparatus, the shutter is used as the exposure amount setting means, and the thickness information of the photo-curing layer (this is obtained from the position information of the elevator (104)) and the photo-curing fluid resin to be used ( Although the method of controlling from the information of 101) is used, other various means as described above can be used. For example, the exposure amount can be set by directly controlling the output of the light source for light irradiation.
Also in this case, the control device (113) and the computer (115) control based on the above information.

By using this apparatus, it is possible to form a three-dimensional structure composed of cured products of various thicknesses. Embodiment 2 In this embodiment, an optical modeling apparatus of the present invention for modeling a three-dimensional structure by the free liquid surface method will be described. The stereolithography apparatus using the free liquid level method has a configuration as shown in the schematic view of FIG. That is, the stereolithography apparatus 2 of the present invention
Comprises a tank 102 containing a photocurable fluid resin 101. An elevator 104 for fixing the resin 103 cured by light irradiation is provided above the tank, and an actuator 105 for determining the position of the elevator is further connected to the elevator. An actuator 116 for scanning the light 109 from the light source 108 is provided above the tank (102), and a condensing light for condensing light from the light source is adjacent to the actuator (116). The section 117 is installed. An exposure amount adjusting means 112 for adjusting the exposure amount of the light from the light source is provided between the light source (108) and the actuator (116). Furthermore, in the device of the present invention, each of the above-mentioned actuators (105, 116) and the condensing unit (11).
7) and the exposure amount adjusting means (112) are provided with a control device 113. The control device (113), the actuators (105, 116), and the exposure amount adjusting means (112) are connected to a cable 114. Are connected by. The exposure amount adjusting means (112) may be a shutter or the like.

The light source (108) that can be used in this apparatus is the same as in the first embodiment. An actuator (1) for scanning the light (109) from the light source (108)
A specific example of 16) is a galvanometer mirror. In addition, a shutter (11
2) is not particularly limited as long as it can appropriately adjust the exposure amount of light from the light source.

Each actuator (105, 116), shutter (112) and the like are controlled by a control device (113). That is, the respective actuators, mirrors, shutters, etc. are controlled by the control device (113) connected to the computer 115 based on the material information of the photocurable fluid resin in the computer.

In the present invention, the elevator (1
04) and the liquid level of the photocurable fluid resin (101), the thickness information of the cured layer (this is obtained from the position information of the actuator (105) for positioning the elevator) and the photocurable fluid to be used. The shutter is controlled from the information of the resin (101), and an appropriate exposure amount for obtaining the target cured layer is automatically set by the control device (113) and the computer (115).

This device is used as follows. First, the actuator (105) moves the elevator (104) to the tank (10) so that a certain clearance is generated between the elevator (105) and the liquid surface of the photocurable fluid resin.
2) Position inside. This positioning is performed by the computer (115) and the control device (113), and the position information is stored in the computer as data. By this positioning, the layer thickness of the three-dimensional cured product or the first layer thereof is determined. Next, with the photocurable fluid resin used,
The optimum exposure amount for pattern irradiation is calculated based on the position information obtained previously. This exposure amount can be adjusted by using the same means as the setting means described in the regulated liquid level method. Next, light irradiation is performed using slice data obtained from CAD data of a desired three-dimensional structure. For the light irradiation, the light emitted from the light source (108) is guided to the condensing unit 117 while adjusting the exposure amount, for example, through the shutter (112), and the photocurable fluid resin is introduced from above the tank (102). By irradiating the The light irradiation can be performed, for example, by pattern irradiation with a galvano mirror (117). The galvano mirror (11
7), the shutter (112) is controlled by the control device (113) and the computer (115). When the desired structure has a single layer, after the irradiation of the desired pattern is completed, the elevator (104) is taken out from the tank, washed, and post-exposed. Further, when a desired structure is formed by a plurality of cured layers, the elevator (104) is lowered by the actuator (105) and a predetermined space is provided between the cured layer and the liquid surface of the photocurable fluid resin. A clearance is provided, and the above procedure is repeated again to form a desired three-dimensional structure.
In the second and subsequent stereolithography, the stereolithography is performed by adjusting the exposure amount suitable for shaping the desired cured product. After that, the elevator (104) is taken out from the tank, washed, and post-exposed.

In the above-mentioned apparatus, a shutter is used as the exposure amount setting means, the thickness information of the photo-curing layer (this is obtained from the position information of the elevator (104)) and the photo-curing fluid resin to be used ( Although the method of controlling from the information of 101) is used, other various means as described above can be used. For example, the exposure amount can be set by directly controlling the output of the light source for light irradiation.
Also in this case, the control device (113) and the computer (115) control based on the above information.

By using this apparatus, it is possible to form a three-dimensional structure composed of cured products of various thicknesses. Embodiment 3 This mode is an apparatus for forming a three-dimensional structure composed of a plurality of cured products having different characteristics by using different photocurable fluid resins.

This aspect will be described with reference to FIG. FIG. 6 is a schematic view of an optical modeling apparatus that models a three-dimensional structure by the regulated liquid surface method. The stereolithography apparatus according to this aspect includes a tank 53 containing a photocurable fluid resin A60, a photocurable fluid resin B6.
A second tank 54 for accommodating 1), a cleaning tank 55 for cleaning the photocured product 52, and a post-exposure tank 56 are provided. Each tank has a table 6 for fixing these
Fixed by 2. An elevator 51 and an actuator 50 for moving the elevator 51 are installed above these tanks. Also, below the bottom of the tank,
An actuator 68 for scanning the light from the light source 63 is provided so that desired light scanning can be performed. On the actuator (68), a condensing unit 67 that condenses light on the bottom surface of each tank is provided, and the light exposure amount is controlled in an optical path 65 between the light source (63) and the condensing unit (67). The shutter 64 is provided. The table (62) is installed on an actuator 74 for moving the table, and the actuator (74) scans an elevator, a light source (63), a shutter (64), a condensing unit (67), and light. It is moved to the light irradiating section including the actuator (68). Examples of the actuator (74) as a table moving unit include a pulse motor and a servo motor.

The cleaning tank (55) is preferably provided with means 59 for increasing the cleaning efficiency. The means (59) may be, for example, an ultrasonic transducer. The cleaning tank (55) contains a cleaning solvent 75.
The solvent (75) may be, for example, acetone, alcohol or the like, though it depends on the photocurable fluid resin used.

In the device of this embodiment, each actuator (5
0, 68, 74), shutter (64), condensing part (6
7) etc. are controlled by a controller 72, a computer 71 that incorporates software for converting a three-dimensional structure into slice data, and further adjusts an exposure amount based on design values, material information, and cured layer thickness information, and a monitor 70. These are connected by the wiring 73.

The actuators (50, 68) and the light collecting section (67) are as described in the first embodiment.
Furthermore, the apparatus of this embodiment may be provided with a drying tank for drying the cured product with warm air or cold air. The drying tank is
Since it is used for drying the cured product after washing, it is not necessarily installed. For example, in the case of washing with highly volatile ethyl alcohol, it is dried by leaving it in the air for several tens of minutes after washing. For example, a 1 mm cube-shaped cured product is dried in 8 to 10 minutes. Therefore, when highly volatile ethyl alcohol is used as the cleaning liquid, it is not necessary to provide a drying tank in this apparatus, and the modeled object is held at a position where it does not come into contact with the cleaning liquid and left for about 8 to 10 minutes. A drying process may be provided. The cleaning tank may be installed only when a cleaning liquid with low volatility is used.

The tank (53, 54) for containing the above-mentioned photocurable liquid resin is provided with a glass 57 coated with a material having low wettability so that the bottom surface thereof transmits light and a photocured product does not adhere thereto. Set up. In addition, the cleaning tank (55)
It is preferable to provide means 59 for increasing the cleaning efficiency. The means (59) may be, for example, an ultrasonic transducer. Further, the post-exposure tank (55) is provided with a lamp 69 for performing post-exposure. As the lamp, for example, a light source such as a mercury lamp, a halogen lamp or an ultraviolet lamp can be used.

FIG. 6 shows an example in which two tanks contain the photocurable fluid resin, but the device of the present invention is not limited to this, and two or more tanks can be provided. Further, a plurality of washing tanks, post-exposure tanks, drying tanks and the like can be provided.

This device is used as follows. First, the elevator (51) is moved by the actuator (50) so that a certain clearance is generated between the elevator (51) and the glass plate (58) covered with the highly wettable release material.
Is positioned in the first tank (53). This positioning is performed by the computer (71) and the control device (72), and the position information is stored in the computer as data. This positioning determines the layer thickness of the first layer of the three-dimensional cured product. Next, the optimum exposure dose for pattern irradiation is calculated based on the photocurable fluid resin used and the previously obtained position information. This exposure amount can be set by the exposure amount setting means described in the first embodiment. Next, light irradiation is performed using slice data obtained from CAD data of a desired three-dimensional structure. The light irradiation guides the light emitted from the light source (63) to, for example, the condenser (67) on the XY stage while passing the shutter (64) to adjust the exposure amount, and from the bottom surface of the tank (53). It is performed by irradiating the photocurable fluid resin. The XY stage (68) and the shutter (64) are the control device (7
2) and the computer (71). When the irradiation of the desired pattern is completed and the desired hardened layer is obtained, the elevator (51) is raised by the actuator (50) to provide a predetermined clearance between the hardened layer and the peeling material, and again the above-mentioned The above procedure is repeated to form a desired structure (when the desired structure is composed of one layer, the next step may be performed without repeating the above procedure).
Next, the elevator (5) to which the first cured product (52) is adhered
1) is taken out from the tank (53) by the actuator (50). Then, the cleaning tank (5) containing the cleaning solvent (75) at the position of the elevator is moved by the moving means (62).
5) is moved, the elevator (51) and the first cured product (52) are immersed in a cleaning solvent by an actuator (50), and cleaning is performed by using a means (59) for improving cleaning efficiency as needed. I do. After cleaning, the elevator (51) to which the first cured product is adhered is moved to the actuator (50).
To remove from the tank (53). Next, the post-exposure tank (56) is moved by the moving means as described above, and post-exposure is performed in the post-exposure tank. After the post-exposure is completed, the tank (54) containing the second photocurable fluid resin is moved to the position of the elevator (51) to which the first photocured product (52) is adhered by the moving means as described above. Then, the second cured product is formed by the same procedure as the formation of the first photo-cured product described above.
FIG. 13 shows a diagram in which the tank containing the second photocurable fluid resin is moved to the position of the elevator (51) to which the first photocurable product (52) is bonded. If necessary, the above procedure is repeated to form a photo-cured product composed of different photo-curable fluid resins. Here, in the second and subsequent stereolithography, the stereolithography is performed by adjusting the exposure amount suitable for shaping the desired cured product.

In the above-mentioned apparatus, a method of controlling the shutter as the exposure amount setting means based on the information on the thickness of the cured layer and the information on the photocurable fluid resin to be used is used.
In addition to this, various means as described above can be used. For example, the exposure amount can be set by directly controlling the output of the light source for light irradiation. Also in this case, the control device and the computer control based on the above information.

Embodiment 4 This embodiment will be described with reference to FIG. FIG. 7 is a schematic view of an optical modeling apparatus for modeling a three-dimensional structure by the free liquid surface method.

In the stereolithography apparatus 4 of this embodiment, a tank 53 for accommodating the photocurable fluid resin A60, a second tank 54 for accommodating the photocurable fluid resin B61, and a photocured product 52 are provided. A cleaning tank 55 for cleaning and a post-exposure tank 56 are provided. Each tank is fixed by a table 62 for fixing them. Above the tank, a light irradiation unit including an elevator 51, an actuator 50 for moving the elevator 51, a light source 63, a shutter 64 for controlling the amount of light exposure, a condenser unit 67, and an actuator 80 for scanning the light is installed. To do. Further, the shutter (64) includes a light source (63) and a light condensing unit (67).
It is provided in the optical path 65 between them. The table (62) is installed on an actuator 74 for moving the table (62), and the table (62) is moved to the elevator and the light irradiation unit by the actuator (74). The actuator (74) as a means for moving the table includes, for example, a pulse motor,
There is something like a servo motor.

In the apparatus of this embodiment, each actuator (5
0, 68, 74), a shutter (64), etc., incorporates a control device 72 and software for converting a three-dimensional structure into slice data, and further sets the exposure amount from design values, material information, and hardening layer thickness information. It is controlled by a computer 71 for adjustment and a monitor 70, and these are connected by a wire 73.

The actuators (50, 68) and the light collecting section (67) are as described in the first embodiment.
Furthermore, the apparatus of this embodiment may be provided with a drying tank for drying the cured product with warm air or cold air. The drying tank is
Since it is used for drying the cured product after washing, it is not necessarily installed. For example, in the case of washing with highly volatile ethyl alcohol, it is dried by leaving it in the air for several tens of minutes after washing. For example, a 1 mm cube-shaped cured product is dried in 8 to 10 minutes. Therefore, it is not necessary to provide a drying tank in this device. The drying tank may be installed only when using a cleaning liquid having low volatility.

The washing tank (55) is preferably provided with a means 59 for enhancing the washing efficiency. The means (59) may be, for example, an ultrasonic transducer. The cleaning tank contains a cleaning solvent 75. The solvent (75) may be, for example, acetone, alcohol, water or the like, though it depends on the photocurable fluid resin used.

Further, the post-exposure tank (55) is provided with a lamp 69 for performing post-exposure. As the lamp, for example, a light source such as a mercury lamp, a halogen lamp or an ultraviolet lamp can be used.

FIG. 7 shows an example in which there are two tanks containing the photocurable fluid resin, but the apparatus of the present invention is not limited to this, and two or more tanks can be provided. Further, a plurality of washing tanks, post-exposure tanks, drying tanks and the like can be provided.

This device is used as follows. First, the elevator (51) and the first photocurable fluid resin (6
The elevator (51) is positioned in the first tank (53) by the actuator (50) so that a certain clearance is generated between the elevator (51) and the liquid surface of (0). This positioning is performed by the computer (71) and the control device (72), and the position information is stored in the computer as data. This positioning determines the layer thickness of the first layer of the three-dimensional cured product. Next, with the photocurable fluid resin used,
The optimum exposure amount for pattern irradiation is calculated based on the position information obtained previously. This exposure amount can be set by the exposure amount setting means described in the first embodiment.
Next, light irradiation is performed using slice data obtained from CAD data of a desired three-dimensional structure. Light irradiation is performed by the light source (6
The light emitted from 3) is emitted, for example, from the shutter (6
4) is passed to adjust the exposure amount, the light is guided to a condensing unit (67) attached to the galvanometer mirror (80), and the photocurable fluid resin is irradiated from the bottom surface of the tank (53). Galvo mirror (80), shutter (6
4) is controlled by the controller (72) and the computer (71). When the irradiation of the desired pattern is completed and the desired hardened layer is obtained, the elevator (51) is lowered by the actuator (50), a predetermined clearance is provided between the hardened layer and the release material, and the above-mentioned process is performed again. The above procedure is repeated to form a desired structure (when the desired structure is composed of one layer, the next step may be performed without repeating the above procedure). Next, the elevator (51) to which the first cured product (52) is adhered is taken out from the tank (53) by the actuator (50). Then, the transportation means (6
2) The cleaning tank (55) containing the cleaning solvent (75) is moved to the position of the elevator by the 2), and the actuator (5
0) elevator (51) and first cured product (52)
Means for improving the cleaning efficiency by immersing the
Wash using 9) as required. After washing, the elevator (51) to which the first cured product is adhered is taken out from the tank (53) by the actuator (50). Next, as described above, the post-exposure tank (5
6) is moved to perform post-exposure in the post-exposure tank. After the post-exposure is completed, the tank (54) containing the second photocurable fluid resin is moved to the position of the elevator (51) to which the first photocured product (52) is bonded by the moving means as described above. Then, the second cured product is formed by the same procedure as the formation of the first photo-cured product described above. If necessary, the above procedure is repeated to form a photo-cured product composed of different photo-curable fluid resins. Here, in the second and subsequent stereolithography, the stereolithography is performed by adjusting the exposure amount suitable for shaping the desired cured product.

The device of the present invention according to the above-mentioned first and second aspects is based on the thickness information of the photo-curing layer (this is equal to the position information of the elevator), and in which tank the elevator is located. Automatically adjust the exposure of light from the light source. In the present invention, in particular, the exposure amount is automatically set by the computer from the thickness information of the photocurable layer, the containing means information regarding which containing means is to be irradiated with light, and the information about the photocurable fluid resin to be used. To do.

Embodiment 5 A three-dimensional structure forming method of the present invention will be described. First, the production of a photocurable fluid resin that can be used will be described.

The photocurable fluid resin that can be used in the present production method is as described in the first invention. A three-dimensional structure is formed by using two or more kinds of these photocurable fluid resins. Specific examples of the photocurable fluid resin that can be used in the present production method include photocurable photocurable fluid resins having different Young's moduli, for example, UV curable resin 3042 (Young's modulus: 590 MPa) or UV curable resin 3052C (Young's modulus: 290MP)
a) etc. In addition, a water-soluble UV curable resin 3046D manufactured by ThreeBond Co., Ltd. can be used in combination with a water-insoluble UV curable resin 3042. When a three-dimensional structure is formed by using such a water-soluble resin and a water-insoluble resin in combination, the water-soluble resin portion can be partially dissolved and removed, which is more complicated. It becomes possible to form a three-dimensional structure. Furthermore,
Powder-mixed photo-curable fluid resin [eg, from three elements: fluid and photo-curable oligomer (epoxy acrylate, urethane acrylate, etc.), reactive diluent (monomer), photo-polymerization initiator (benzoin-based, acetophenone-based, etc.) A mixture of an inorganic powder capable of being sintered with the photo-curable fluidized resin described below] can also be used. Examples of the sinterable inorganic powder include alumina, gold, platinum, palladium, stainless steel, copper, nickel, silver, piezoelectric PZT, and P.
There are fine powders and fibers of LZT, magnetic substances such as samarium, cerium, and neodymium.

Powder Preparation To prepare a photocurable fluid resin, the above powder is mixed with the photocurable fluid resin. Since it is necessary to prevent bubbles from entering when the powder and the photocurable fluid resin are mixed, stirring is performed using a stirring defoaming machine or the like. For example, when using UV curable resin 3042 manufactured by ThreeBond Co., Ltd., in the case of alumina, 30 vol% of a powder having an average powder particle size of 1 μm is mixed, and then defoamed for 30 minutes by a stirring defoaming machine. Stirring is performed to produce a powder-mixed photocurable fluid resin.

Further, the surface of the powder can be surface-treated with a silane coupling agent, and such a treatment can increase the powder mixing ratio. For example, in the above example, the mixing ratio of the powder can be increased to 45 vol%.

The first embodiment of the method for manufacturing a three-dimensional structure according to the present invention will be described with reference to FIG. FIG. 9 is an example of a method for manufacturing a three-dimensional structure made of different materials by the regulated liquid level method. The stereolithography apparatus used in this method is as described in the third embodiment. In this embodiment, for the sake of simplicity, only the accommodating means, the supporting means, the light to be irradiated, and the powder-mixed photocurable fluid resin among the above devices are shown. The accommodating means is the same as the tank described in the first embodiment.
As shown in FIG. 9 (A), the tank A (130) is provided with glass 132, for example, quartz glass that easily transmits ultraviolet rays, on the bottom surface thereof, and the glass (13
2) A release material such as Teflon tape with good release properties 1
33 is installed. A plurality of such tanks are prepared, and powder-mixed photocurable fluid resins of different types prepared as described above are introduced into each tank.

First, the elevator 131 is dipped and inserted into the powder-mixed photocurable fluid resin A136, and the elevator 13
After a certain clearance is set between 1 and the peeling material 133 for peeling the cured product, light 134 is irradiated to form the first layer of a desired three-dimensional structure. The light source of the light 134 used for photocuring is, for example, 10 vol% of an alumina powder having an average particle diameter of 1 μm in an ultraviolet curable resin manufactured by ThreeBond.
When the mixed powder-mixed photocurable fluid resin is used, an Ar laser having a wavelength of 330 to 364 nm, for example, a wavelength of 32 is used.
A 5 nm He-Cd laser, an SHG laser having a wavelength of 437 nm, or the like can be used. The irradiation of light from the light source is performed by setting an exposure amount suitable for the powder-mixed photocurable fluid resin used and the desired shape of the structure. The exposure amount is set by the automatic exposure amount setting means described in the first embodiment. That is, the exposure amount is set by a means for adjusting the output of the light source, a means for shifting the focal position of the emitted light, a means for changing the diameter or size of a mask or a slit attached to the light exit port, a light scanning speed. The exposure amount can be set by a means for changing the shutter speed, or a means for changing the opening / closing speed of the shutter when a shutter is used. As described in the first embodiment, these exposure amount setting means are automatically controlled by the control device based on the data such as the thickness information of the photo-cured layer to determine the exposure amount. The curing of the powder-mixed photocurable fluid resin can be considered to occur at a constant exposure dose. Here, the exposure amount refers to the amount of radiation applied to the surface to be irradiated per unit area, or the irradiance of the exposed light integrated over time (unit: joule per square meter (J / m ² )). .

The light from the light source is condensed by a quartz lens or the like and applied to the powder-mixed photocurable fluid resin. The irradiation is performed by pattern-irradiating the light from the light source with a scanning means such as an XY stage. FIG. 9A shows a state where a cured product 135 is formed by such pattern irradiation.

Next, the elevator 131 is taken out of the tank A, and the cured product is washed, dried and post-exposed (each step is not shown) to manufacture a desired first cured product 135. Next, to the position of the elevator (131), another tank B141 into which the powder-mixed photo-curable fluid resin B different from the powder-mixed photo-curable fluid resin A is introduced is moved, and the second cured product is stereo-molded. . The process of forming the second cured product 139 will be described below with reference to FIG. First, the elevator 131
Is immersed in the powder-mixed photocurable fluid resin B138 to set a constant clearance between the powder-mixed photocurable resin B138 and the release material 142. After that, the light-cured layer is formed by pattern-irradiating the light 137 having an appropriate exposure amount for curing the powder-mixed photocurable fluid resin B138. Next, elevator 1
31 is raised by a certain lamination thickness and light 137 is pattern-irradiated to form the second layer of the second cured product 139. This operation is repeated to obtain the desired cured product. FIG. 9B shows an example in which a cured product having three layers is formed. The photocured product does not necessarily have to have three layers, and may have one layer or plural layers. The cured product may have a planar shape and dimensions different from those of the first cured product 135. Light used for photocuring (13
7) is set to an exposure amount suitable for the shapes of the powder-mixed photocurable fluid resin B (138) and the desired structure (139). This means uses the above means. The light irradiation is condensed light having an appropriate exposure amount, and the wavelength is, for example, a powder-mixed photocurable mixture of 3 vol% alumina powder having an average particle size of 0.5 μm mixed with UV curable resin manufactured by ThreeBond. When a fluid resin is used, 330 to 364n of Ar laser is used.
m or 325 nm light of a He-Cd laser can be used. Next, the elevator 131 is connected to the tank B (1
The second cured product 139 is obtained by taking it out from 41), washing, drying and post-exposure (each process is not shown). As a result, a structure composed of the photo-cured product 135 and the photo-cured product 139 is formed.

Next, the tank A (130) is moved to the position of the elevator (131) again to form a third cured product. This is shown in FIG. 9 (C). The elevator (131) is immersed in the powder-mixed photocurable fluid resin A (136) to set the clearance for the thickness of the photocured product 140 from the release material (133), and then the light 144 is irradiated with a pattern to perform photocuring. The object (140) is molded. FIG. 9C shows that the photocurable fluid resin (136) is cured on the side surface of the laminated surface of the cured three-layer photocured product (139) to a thickness of three layers. The light (144) is adjusted by the exposure amount setting means to an exposure amount suitable for performing such modeling. As the light source, the one used for forming the first cured product (135) can be used as it is, but the exposure amount needs to be appropriately adjusted so that the third cured product can be formed.

Subsequently, washing, drying and post-exposure can be performed to obtain a desired three-dimensional structure. In this example, the powder-cured photocurable fluid resin A is used to form the third cured product.
However, the third powder-mixed photocurable fluid resin C can also be used. In this case, the light source, the exposure amount adjusting means, etc. are appropriately selected according to the powder-mixed photocurable fluid resin C.

The exposure dose of the light irradiation in each step is determined by the supporting means information, the characteristic information of the powder-mixed photocurable fluid resin used, and the light source used. By using the above method, it is possible to form a three-dimensional photo-curing structure having a composite structure including photo-curing layers having different material properties.

In the above example, the powder-mixed photocurable fluid resin is used, but a photocurable fluid resin can be used instead. Further, in the above example, the three-dimensional structure was formed by using the powder-mixed photo-curable fluid resin having different characteristics, but the same photo-curable fluid resin was used, and the three-dimensional structure was composed of cured products having different laminated thicknesses. Three-dimensional structures may be manufactured.
In this case, the device according to the first or second embodiment can be used. Further, the device of the above-mentioned Embodiment 3 or Embodiment 4 can also be used, but in this case,
Light irradiation may be performed without moving the tank. Further, when using the same photo-curable fluid resin or powder-mixed photo-curable fluid resin as described above, it is necessary to obtain a cured product having a different laminated thickness by adjusting the exposure amount of the light for pattern irradiation to the thickness information of the cured layer and the light. This is possible by automatic adjustment based on the characteristic information of the curable fluid resin.

In the three-dimensional structure manufactured by the manufacturing method of the present invention, the photocured product 140 is adjoined and bonded to the entire side surface of the photocured product 139 perpendicular to the laminated surface of the cured product, so that the discontinuity is reduced. It is possible to reduce the stress concentration due to the fine irregularities, and it is possible to improve the strength and durability of the joint. Further, peeling of the laminated surface of the cured product 139 composed of a plurality of layers is less likely to occur, resulting in a three-dimensional structure having high strength.

Generally, when a three-dimensional structure is formed by using two different types of photocurable fluid resins, as shown in FIG. 11, a cured product obtained by curing the first photocurable fluid resin. 180 is adjacently joined to the cured product 181 obtained by curing the second photocurable fluid resin with the same thickness, and this modeling step is repeated a plurality of times. In such a method, every time the photocurable fluid resin is changed, it is necessary to remove the excess photocurable fluid resin in the uncured portion, perform washing, drying and post-exposure. In addition, this must be repeated the number of times of lamination. I have to. Therefore, in order to model the three-dimensional structure as shown in FIG. 11, washing, drying and post-exposure must be performed six times, respectively, and the operation is complicated and the modeling takes a very long time. Further, since the joining area is increased, a discontinuous portion is formed on the joining surface, and the strength of the joining portion is weakened. On the other hand, as shown in FIG. 10, a resin that is difficult to cure in consideration of the curing characteristics of the resin (a resin that requires a large amount of exposure for curing)
If multiple layers are pre-molded and then a resin that is easily cured (a resin that has a small amount of exposure during curing) is molded with a thickness of the multiple layers so that adjacent layers are joined, cleaning, drying and post-exposure are performed twice. Therefore, the operation is simple and the processing time can be shortened. Also, the scanning time is shortened because it is convenient to scan four times to form the three-dimensional structure. The exposure amount of light irradiation in this case is determined by the characteristics of each photocurable fluid resin, the supporting means information, and the type of light source.

It is also possible to form a three-dimensional structure in the same manner as described above using the same photocurable fluid resin.
In this case, the layer thickness of the first cured product and the second cured product is changed by automatically adjusting the exposure amount of the irradiation light according to the supporting means information. When the same photocurable fluid resin is used, the washing, drying and post-exposure can be performed only once, so the molding time can be further shortened. As a three-dimensional structure forming apparatus using such one type of photocurable fluid resin, the apparatus shown in FIG. 4, that is, the apparatus including one tank can be used.

As described above, by using the apparatus and the manufacturing method of the present invention, a functional three-dimensional structure having a plurality of compositions can be formed efficiently in a short time. The production method of the present invention is characterized in that the exposure amount of light for pattern irradiation is changed depending on the photocurable fluid resin or the like used.
As a method of changing the exposure amount of this light, as described above, means for adjusting the output of the light source, means for shifting the focal position of the irradiated light, diameter and size of the mask or slit attached to the light exit port, etc. Change the amount of light energy incident on the unit area by changing the scanning speed of the light, changing the scanning speed of the light, and changing the opening / closing speed of the shutter when a shutter is used. Can be changed by changing the irradiation time. As an effect of adjusting this exposure amount, data of the curing dimension with respect to the scanning speed were taken and compared.

The photo-curable resins used are UV-curable resin 3042 and UV-curable resin 3052C manufactured by ThreeBond Co., Ltd. In addition, the light source has a wavelength of 250 to 45
A 0 nm mercury lamp was used, and the light of this lamp was focused by a quartz lens for irradiation. This irradiation light had an energy of 1.2 mW / cm ² at the exit end. Also,
Curing was performed by changing the scanning speed from 10 to 300 μm / sec to adjust the exposure amount. Under such conditions, whether the photocurable fluid resin is cured or not is confirmed, and the curing dimension when cured is compared.
The results are shown in Table 1.

[0086]

[Table 1]

As shown in Table 1, UV curable resin 3
042 cures up to a scan speed of 250 μm / sec, but UV curable resin 3052C 40 μm / s.
Only cures up to ec scan speed. From this result, when stereolithography using different photo-curable fluid resins,
If an optical modeling machine that does not have the function of adjusting the exposure amount for each photocurable fluid resin is used, the UV curable resin 304
2 and the condition for curing the ultraviolet curable resin 3052C is a scan speed of 40 μm / sec. At this scanning speed, the curing width of the ultraviolet curable resin 3042 is 3
The thickness is as thick as 80 μm, and it is impossible to form a fine cured body.

On the other hand, the ultraviolet curable resin 3042 is 180 μm when the scanning speed is 250 μm / sec.
It is a resin material that can form a structure with a narrow curing width,
When a three-dimensional structure is formed in combination with the UV curable resin 3052C, the scan speed is set to 40 μm / sec and curing is performed, so the scan speed is 1/6.
become.

On the other hand, the manufacturing method according to the present invention having means for changing the exposure amount (scan speed in the above example) for each photocurable fluid resin to be used, and the apparatus according to the first to fourth embodiments described above. According to this, the above-mentioned problems do not occur, and it becomes possible to manufacture a fine molded body accurately and in a short time.

Next, with reference to FIG. 12, a second embodiment of the method for manufacturing a three-dimensional structure will be described below. FIG. 12 is an example of a method of manufacturing a three-dimensional structure made of different materials by the regulated liquid level method. The stereolithography apparatus used in this method is as described in the third embodiment. In this embodiment, for the sake of simplicity, only the accommodating means, the supporting means, the light to be irradiated, and the powder-mixed photocurable fluid resin among the above devices are shown. The accommodating means is the same as the tank described in the first embodiment, and the configuration is also as described in the first embodiment.

As shown in FIG. 12 (A), first, the elevator 151 is dipped in the powder-mixed photo-curable fluid resin A156 and inserted, and the space between the elevator 151 and the peeling material 153 for peeling off the cured product. After a certain clearance is set, the light 154 is irradiated to form the first layer of the desired three-dimensional structure. The light source of the light 154 used for photocuring is, for example, an ultraviolet curable resin made by ThreeBond, and an average particle size of 1 μm.
When using a powder-mixed photocurable fluidized resin in which 10 vol% of alumina powder of m is mixed, the wavelength is 330 to 364n.
m Ar laser, for example, a He—Cd laser having a wavelength of 325 nm can be used. The irradiation of light from the light source is
This is performed by setting an exposure amount suitable for the powder-mixed photocurable fluid resin used and the desired shape of the structure. The exposure setting is
This is performed by the automatic exposure amount setting means described in the first aspect.
The curing of the powder-mixed photocurable fluid resin can be considered to occur at a constant exposure dose.

The light from the light source is condensed by a quartz lens or the like and applied to the powder-mixed photocurable fluid resin. The irradiation is performed by pattern-irradiating the light from the light source with a scanning means such as an XY stage. FIG. 12 (A) shows
The shape of the cured product 155 is shown by such pattern irradiation.

Next, the elevator 151 is taken out of the tank A, and the cured product is washed, dried and post-exposed (each step is not shown) to manufacture a desired first cured product 155. Next, to the position of the elevator (151), another tank B145 into which the powder-mixed photo-curable fluid resin B different from the powder-mixed photo-curable fluid resin A is introduced is moved, and the second cured product is stereo-molded. . The process of forming the second cured product 159 will be described below with reference to FIG. First, elevator 15
1 into the powder-mixed photocurable fluid resin B158,
A certain clearance is set between the release material 153 and the release material 153.
After that, the light-cured layer is formed by pattern-irradiating the light 157 having an appropriate exposure amount for curing the powder-mixed photocurable fluid resin B158. Next, the elevator 151 is raised by a certain layer thickness and the light 157 is pattern-irradiated to form the second layer of the second cured product 159. This operation is repeated to obtain the desired cured product. FIG. 12B shows an example in which two cured products (159) each having three layers are formed. The photocured product does not necessarily have to have three layers, and may have one layer or plural layers. Further, the number of cured products (159) may be two or more. Furthermore, the cured product (159) may have a planar shape and dimensions different from those of the first cured product 155. The light (157) used for photocuring is set to an exposure amount suitable for the shape of the powder-mixed photocurable fluid resin B (158) and the desired structure (159). This means uses the above-mentioned exposure amount setting means. The light irradiation is condensed light having an appropriate exposure amount, and the wavelength is, for example, a powder-mixed photocurable mixture of 3 vol% alumina powder having an average particle size of 0.5 μm mixed with UV curable resin manufactured by ThreeBond. When a fluid resin is used, 325 nm light of a He-Cd laser can be used. Next, the elevator 151 is taken out from the tank B (145), washed, dried, and post-exposed (each step is not shown) to obtain a second cured product (15).
9) is obtained. As a result, a structure composed of the photo-cured product (155) and the photo-cured product (159) is formed.

Next, the tank A (150) is moved again to the position of the elevator (151), and the third cured product is formed. This is shown in FIG. Elevator (151)
Is immersed in the powder-mixed photocurable fluid resin A (156),
After setting the clearance for the thickness of the photocured product 169 from the release material (153), the light 160 is irradiated with a pattern to form the photocured product (169). In FIG. 12C, between the two cured three-layer photo-cured products (159), the photo-curable fluid resin (1
56) is cured. Light (160)
Is adjusted by the exposure amount setting means to an exposure amount suitable for performing such modeling. As the light source, the light source used for forming the first cured product (155) can be used as it is, but the exposure amount must be appropriately adjusted so that the third cured product can be formed.

In this way, a structure in which the cured product (155), the cured product (159) and the cured product (169) are joined is formed. Next, the elevator (151) is moved upward by a desired amount of the photo-curing layer to provide a clearance between the structure and the peeling material. The light 168 is pattern-irradiated to cure the powder-mixed photocurable fluid resin A158 to form a cured product. FIG. 12D shows that the structure 165 is formed by pattern irradiation of light. Light (168)
Is adjusted by the exposure amount setting means to an exposure amount suitable for performing such modeling. As the light source, the one used in the formation of the first cured product (155) can be used as it is, but the exposure amount needs to be appropriately adjusted so that the fourth cured product can be formed. Further, in the present example, the powder-mixed photocurable fluid resin A is used to form the third and fourth cured products.
Was used, but the third powder-mixed photocurable fluid resin C,
Various powder-mixed photocurable flow resins can also be used. In this case, the light source, the exposure amount adjusting means and the like are appropriately selected depending on the photocurable fluid resin C and the like of the powder.

The exposure dose of light irradiation in each step is determined by the supporting means information, the characteristic information of the powder-mixed photocurable fluid resin used, and the light source used. Further, in the above example, the powder-mixed photocurable fluid resin is used, but instead of this, a photocurable fluid resin may be used.

By using the above method, it is possible to form a three-dimensional photo-curing structure having a composite structure composed of photo-curing layers having different material characteristics without assembling. According to the production method of the present invention, by changing the exposure dose according to the type of photocurable fluid resin used and the shape to be cured, a new cured product can be formed in a direction parallel to or perpendicular to a specific photocured product. It can be additionally shaped, and three-dimensional structures of various complex compositions or structures can be shaped. Therefore, the method of the present invention is a method of manufacturing a three-dimensional structure having a very high degree of freedom. Further, by using the manufacturing method of the present invention, it is possible to form a three-dimensional structure having a composite structure composed of photo-cured products having different material characteristics without assembling. In addition, the manufacturing method of the present invention not only partially bonds two materials, but also cures a structure having a complicated groove or the like like the three-dimensional structure manufacturing method described in FIG. Objects can be joined and shaped.

The present invention includes the following inventions in addition to the above first to fifth inventions. In the following, in order to clarify the relationship between the first invention to the fifth invention, these are also described below. The first invention is the following (1), the second invention is the following (3), the third invention is the following (6), the fourth invention is the following (11), and the fifth invention is the following. Invention corresponds to the following (14). (1) A photo-curing layer is formed by irradiating the photo-curable fluidized resin layer with light by a light irradiating unit that scans and irradiates light or irradiates a light image, and a plurality of the photo-curable layers are combined. In a stereolithography device that molds a three-dimensional structure with
An accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in the accommodating means for supporting the photocurable layer, and an exposure of the light irradiation means according to thickness information of the photocurable layer. A stereolithography apparatus, comprising: an exposure amount setting means for automatically setting the amount. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) Since the photocurable layer can be stably obtained even if the thickness of the photocurable fluidized resin layer is changed by the exposure amount setting means that automatically sets the exposure amount according to the thickness information of the cured layer, the target By changing the thickness of the photocurable fluid resin layer according to the shape of the three-dimensional structure and the required accuracy, it is possible to reduce the number of laminated photocurable layers and shorten the time of the forming process. (2) In a stereolithography apparatus for shaping a three-dimensional structure by irradiating a photocurable fluid resin with light while scanning the light to form a photocured product, a housing for accommodating the photocurable fluid resin Means, supporting means disposed in the housing means, on which the photocurable layer is formed, and the photocurable fluid resin in the housing means for curing the photocurable fluid resin is irradiated with light. An optical modeling apparatus comprising: a light irradiation unit and an exposure amount setting unit that automatically sets an exposure amount of the light irradiation unit according to thickness information of the cured layer and material information of the photocurable fluid resin. . (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Function / effect) The photocurable layer is stable even if the material characteristics and thickness of the photocurable fluidized resin layer are changed by means of automatically setting an appropriate exposure amount according to the thickness information and material information of the cured layer. Since it can be obtained, it is possible to change the thickness of the photocurable fluid resin layer according to the target shape of the three-dimensional structure and the required accuracy, and to adjust the thickness of the photocurable fluid resin layer according to the material characteristics. By optimizing the photo-curing layer according to the dimensional accuracy and material characteristics, it is possible to reduce the number of laminated layers and shorten the time of the forming process. (3) A photo-curing layer is formed by irradiating the photo-curable fluidized resin layer with light by a light-irradiating means that scans and irradiates light or irradiates a light image, and a plurality of photo-curable layers are combined. In a stereolithography device that molds a three-dimensional structure with
A plurality of accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in any of the accommodating means for supporting the photocurable layer, and a accommodating means in any of the plurality of accommodating means Depending on the moving means for relatively moving and arranging the supporting means, the accommodating means information of which of the plurality of accommodating means the supporting means is arranged, and the thickness information of the photocurable layer. An optical modeling apparatus comprising: an exposure amount setting unit that automatically sets the exposure amount of the light irradiation unit. (Structure) The third and fourth embodiments are applicable. (Function / effect) When the exposure time varies depending on the characteristics of the photocurable fluid resin that is cured by light, it is necessary to set an appropriate exposure amount for each material. The photocurable liquid resin material characteristics and the photocurable liquid resin layer thickness information are automatically set appropriately according to the thickness information. The thickness of the layer can be appropriately set according to the shape of the body and the required dimensional accuracy, and the time of the forming process can be shortened. (4) In the three-dimensional structure manufacturing apparatus described in (1) to (3) above, the thickness information of the hardened layer is given according to the position information of the supporting means. Body manufacturing equipment. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) By setting the thickness information from the position information of the supporting means, it is possible to easily estimate the thickness information of the modeled object without measuring the modeled object. (5) In the manufacturing apparatus for a three-dimensional structure described in (1) to (3) above, the thickness information of the photocurable fluid resin is the position information of the supporting means and the photocuring formed on the supporting means. An apparatus for manufacturing a three-dimensional structure characterized by being provided as an output from a photocurable fluidized resin layer thickness calculating means calculated based on position information of an object. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) By setting the thickness information from the positional information of the supporting means and the positional information of the photo-curing layer formed on the supporting means, the thickness information of the molded article and the supporting means can be easily obtained without measuring the molded article. Since the position information can be estimated, the exposure amount can be adjusted with respect to the supporting means, and a more complicated modeled object can be modeled. (6) A photo-curing layer is formed by irradiating the photocurable fluidized resin layer with light by a light irradiating unit that scans and irradiates light or irradiates a light image, and a plurality of photocurable layers are combined. In a stereolithography device that molds a three-dimensional structure with
A plurality of accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in any of the accommodating means for supporting the photocurable layer, and a accommodating means in any of the plurality of accommodating means The moving means for relatively moving and arranging the supporting means, the light irradiating means information on which of the plurality of accommodating means the light irradiating means is arranged, and the thickness information of the photo-curable layer. And an exposure amount setting unit for automatically setting the exposure amount of the light irradiating unit. (Structure) The third and fourth embodiments are applicable. (Operation / Effect) By setting the exposure amount for each of a plurality of accommodating means in which a photocurable liquid resin having different material characteristics is placed, the exposure amount for each photocurable liquid resin can be adjusted only by operating the accommodating means. Since it can be done, there is an effect that it becomes a simple operation. (7) A manufacturing apparatus for a three-dimensional structure, wherein the exposure amount setting means described in (1) to (3) above is for automatically setting the output of the light source of the light image irradiation means. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) Since the exposure amount setting means is controlled by the output value of the light source of the light image irradiation means, the exposure amount can be adjusted by electrical control. Therefore, there is an effect that the device can be easily systematized. (8) An apparatus for manufacturing a three-dimensional structure, wherein the exposure amount setting means described in (1) to (3) above is for automatically setting the scanning speed of the light beam of the light image irradiation means. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) Since the exposure amount setting means is controlled by the scanning speed of the light beam of the light image irradiation means, the exposure amount can be adjusted by electrical control. Therefore, there is an effect that the system of the present invention can be easily systematized. (9) The third aspect, wherein the exposure amount setting means described in (1) to (3) above is a means for setting the opening / closing speed of the shutter by making the light beam of the light irradiation means into a pulse shape by a shutter. Original structure manufacturing equipment. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) Since the exposure amount setting means is controlled by the opening / closing speed of the shutter, the exposure amount can be adjusted by electrical control. Therefore, there is an effect that the device of the present invention can be easily systemized. (10) The exposure amount setting means described in (1) to (3) above is a means for setting an irradiation area of a light beam by a means capable of setting an aperture diameter in an optical path of the light beam of the light irradiation means. 3D structure manufacturing equipment. (Structure) Embodiments 1, 2, 3 and 4 are applicable. (Operation / Effect) Since the exposure amount setting means is controlled by means capable of setting the aperture diameter in the optical path of the light beam, the exposure amount can be adjusted by electrical control. Therefore, there is an effect that the device of the present invention can be easily systematized. (11) A stereolithography method for molding a three-dimensional structure using a plurality of photocurable fluid resins having different properties, wherein a layer of the photocurable fluid resin has a characteristic of the photocurable fluid resin. Forming a photo-curing layer by irradiating light with an appropriate exposure amount,
A structure forming step of forming a structure composed of at least one layer and a photocurable fluid resin having different characteristics from the structure forming step are used, and light is irradiated with an exposure amount different from that of the structure forming step. And a three-dimensional structure forming step of joining and molding at least one layer of a structure made of a photocurable fluid resin having different characteristics from the structure to the structure obtained in the structure forming step. The stereolithography method characterized in that (Structure) The fifth embodiment is applicable. (Operation / Effect) When a photocurable fluid resin having different properties is cured to form a three-dimensional structure made of a cured product having different properties, the exposure amount of the modeling apparatus is adjusted according to the properties of the cured product. Thus, the thickness of each cured product layer can be the same or different. When the thickness of each cured product is the same, modeling can be performed with an exposure amount suitable for each photocurable fluid resin, so that the modeling accuracy is improved and it is suitable for microfabrication such as micromachines. Further, when the thickness of each photo-cured product is changed, the number of laminations during molding of the cured product can be reduced, and the number of cleanings and post-exposures can be reduced. The formation time can be shortened. (12) In the photofabrication method described in (11) above, the material information of the photocurable fluid resin used by the exposure amount of the light pattern irradiation in the structure modeling step and the three-dimensional structure forming step and the photocuring. The method is characterized in that it is set on the basis of thickness information of a cured product layer of a volatile resin. (Structure) The fifth embodiment is applicable. (Function / effect) When molding a three-dimensional structure composed of multiple materials, the exposure time may differ depending on the characteristics of the photocurable fluid resin that is cured by light, or exposure may be performed by adding powder to the photocurable fluid resin. When time changes,
It is necessary to set an appropriate exposure amount for each material. In the present invention, since the exposure amount can be adjusted according to the characteristics of the material used, the exposure amount suitable for the material can be set, and a fine three-dimensional structure can be formed. In addition, it is possible to reduce the number of laminations during molding of the cured product by appropriately adjusting the exposure amount, and since it is possible to reduce the number of washings and post-exposures, it is possible to reduce the time for forming the three-dimensional structure. Can be shortened. Furthermore, by changing the thickness of the layer of each cured product of the three-dimensional structure, it is possible to improve the bonding strength of each cured layer by reducing the irregularities generated on the surface perpendicular to the lamination direction of the cured layer of the cured product. The effect is that you can do it. (13) In the stereolithography method described in (11) above, the thickness of the photocurable layer of the structure formed in the structure forming step is different from that of the structure formed in the three-dimensional structure forming step. A method characterized by. (Structure) The fifth embodiment is applicable. (Operation / Effect) When a photocurable fluid resin having different properties is cured to form a three-dimensional structure made of a cured product having different properties, the exposure amount of the modeling apparatus is adjusted according to the properties of the cured product. Thus, the thickness of each cured product layer can be the same or different. When the thickness of each cured product is the same, modeling can be performed with an exposure amount suitable for each photocurable fluid resin, so that the modeling accuracy is improved and it is suitable for microfabrication such as micromachines. Further, when the thickness of each photo-cured product is changed, the number of laminations during molding of the cured product can be reduced, and the number of cleanings and post-exposures can be reduced. The formation time can be shortened. Furthermore, by changing the thickness of the layer of each cured product of the three-dimensional structure, it is possible to improve the bonding strength of each cured layer by reducing the irregularities generated on the surface perpendicular to the lamination direction of the cured layer of the cured product. The effect is that you can do it. (14) A laminated portion obtained by stacking a plurality of photocured layers, and a photocured layer having at least one side surface perpendicular to the laminated surface of the laminated portion with a thickness equal to or larger than the thickness of the photocured layer of the laminated portion. A three-dimensional structure comprising a photo-cured portion coated with. (Structure) The fifth embodiment is applicable. (Operation / effect) By bonding and molding a cured product having different characteristics so as to cover the side surface of the cured product that is perpendicular to the stacking direction, the bonding strength of the cured product stack is improved, and a three-dimensional structure with high strength is obtained. Can be manufactured. Further, there is an effect that the bonding force of each cured layer can be improved by reducing the irregularities generated in the direction perpendicular to the laminated surface. (15) A stereolithography method for molding a three-dimensional structure using a plurality of photocurable fluid resins having different characteristics, the method comprising: A light having different characteristics from the structure forming step of forming a structure by laminating a plurality of photocurable layers by pattern-irradiating light of an exposure amount and the structure forming step. Using a curable fluid resin, pattern irradiation with light at an exposure dose different from that of the structure forming step, at least one layer of a structure comprising a photocurable fluid resin having different properties from the structure, A three-dimensional structure forming step in which at least one side face perpendicular to the laminated surface of the structure obtained in the structure forming step is joined and molded with a single layer having a thickness equal to or larger than the thickness of the laminated portion. . (Structure) The fifth embodiment is applicable. (Function / effect) When molding a three-dimensional structure composed of multiple materials, the exposure time may differ depending on the characteristics of the photocurable fluid resin that is cured by light, or exposure may be performed by adding powder to the photocurable fluid resin. When time changes,
It is necessary to set an appropriate exposure amount for each material. In the present invention, since the exposure amount can be adjusted according to the characteristics of the material used, the exposure amount suitable for the material can be set, and a fine three-dimensional structure can be formed. In addition, it is possible to reduce the number of laminations during molding of the cured product by appropriately adjusting the exposure amount, and since it is possible to reduce the number of washings and post-exposures, it is possible to reduce the time for forming the three-dimensional structure. Can be shortened. Further, by bonding and molding a cured product having different characteristics so as to cover the side surface of the cured product that is perpendicular to the stacking direction, the bonding force of the cured product is improved.
It is possible to manufacture a strong three-dimensional structure. Further, there is an effect that the bonding force of each cured layer can be improved by reducing the irregularities generated in the direction perpendicular to the laminated surface. (16) The above (11), (12), (13) or (1)
5) The stereolithography method according to 5), wherein the structure forming step and / or the three-dimensional structure forming step is provided a plurality of times. (Structure) The fifth embodiment is applicable. (Function / effect) When molding a three-dimensional structure composed of multiple materials, the exposure time may differ depending on the characteristics of the photocurable fluid resin that is cured by light, or exposure may be performed by adding powder to the photocurable fluid resin. When time changes,
It is necessary to set an appropriate exposure amount for each material. In the present invention, since the exposure amount can be adjusted according to the characteristics of the material used, the exposure amount suitable for the material can be set, and a fine three-dimensional structure can be formed. In addition, it is possible to reduce the number of laminations during molding of the cured product by appropriately adjusting the exposure amount, and since it is possible to reduce the number of washings and post-exposures, it is possible to reduce the time for forming the three-dimensional structure. Can be shortened. Further, by bonding and molding a cured product having different characteristics so as to cover the side surface of the cured product that is perpendicular to the stacking direction, the bonding force of the cured product is improved.
It is possible to manufacture a strong three-dimensional structure. Further, there is an effect that the bonding force of each cured layer can be improved by reducing the irregularities generated in the direction perpendicular to the laminated surface.

Further, since the structure forming step and / or the three-dimensional structure forming step are performed a plurality of times, it is possible to easily form a complex functional three-dimensional structure made of a plurality of different materials.

[0100]

According to the stereolithography apparatus of the present invention, even if the thickness of the photocurable fluid resin layer is changed by the exposure amount setting means for automatically setting the exposure amount according to the thickness information of the photocurable fluid resin layer. Since the photo-cured layer can be obtained stably, the number of photo-cured layers can be reduced by changing the thickness of the photo-curable fluidized resin layer according to the shape of the target three-dimensional structure and the required accuracy. It is possible to shorten the process time. Moreover, a more complicated three-dimensional structure can be formed.
Further, the device of the present invention can electrically control the light irradiation means, and the device can be easily systemized.

In the stereolithography method of the present invention, when a photocurable fluid resin having different characteristics is cured to form a three-dimensional structure made of a cured product having different characteristics, the three-dimensional structure may be formed depending on the characteristics of the cured product. By adjusting the exposure dose of the modeling apparatus, the thickness of each cured product layer can be made the same or different. When the thickness of each cured product is the same, modeling can be performed with an exposure amount suitable for each photocurable fluid resin, so that the modeling accuracy is improved and it is suitable for microfabrication such as micromachines. Further, when the thickness of each photo-cured product is changed, the number of laminations during molding of the cured product can be reduced, and the number of cleanings and post-exposures can be reduced. The formation time can be shortened. Furthermore, by changing the thickness of the layer of each cured product of the three-dimensional structure, it is possible to improve the bonding strength of each cured layer by reducing the irregularities generated on the surface perpendicular to the lamination direction of the cured layer of the cured product. it can.

By using the stereolithography method of the present invention, it is possible to form a three-dimensional photo-curing structure having a composite structure composed of photo-curing layers having different material characteristics without assembling.

According to the manufacturing method of the present invention, the exposure amount is changed according to the type of the photocurable fluid resin used and the shape to be cured, so that a new photocurable product can be provided with a new direction in a direction parallel to or perpendicular to the photocured product. The cured product can be additionally modeled,
Three-dimensional structures of various complex compositions or structures can be shaped. In addition, the manufacturing method of the present invention can not only partially bond two materials, but also bond-mold a cured product to a structure having a complicated shape such as a groove.

Further, in the three-dimensional structure of the present invention, a cured product having different characteristics is joined and molded so as to cover the side surface of the cured layer of the cured product which is perpendicular to the laminating direction. Therefore, the bonding strength of the cured product is improved, and a three-dimensional structure having high strength can be manufactured. Further, there is an effect that the bonding force of each cured layer can be improved by reducing the irregularities generated in the direction perpendicular to the laminated surface.

[Brief description of drawings]

FIG. 1 is a flow chart showing a conventional three-dimensional structure forming process.

FIG. 2 is a schematic view showing a conventional stereolithography method by a regulated liquid level method.

FIG. 3 is a schematic view showing a conventional stereolithography method by a free liquid surface method.

FIG. 4 is a schematic view of a stereolithography apparatus of the present invention for shaping a three-dimensional structure by a regulated liquid level method.

FIG. 5 is a schematic view of an optical modeling apparatus of the present invention for modeling a three-dimensional structure by a free liquid surface method.

FIG. 6 is a schematic view of a stereolithography apparatus of the present invention for shaping a three-dimensional structure by a regulated liquid level method, in which a plurality of accommodating means are provided.

FIG. 7 is a schematic diagram of an optical modeling apparatus of the present invention for modeling a three-dimensional structure by the free liquid level method, in which a plurality of accommodating means are provided.

FIG. 8 is a diagram schematically showing a step of forming a three-dimensional structure by the manufacturing method of the present invention.

FIG. 9 is a schematic view of a three-dimensional structure formed by a conventional method using different photo-curable fluid resins.

FIG. 10 is a three-dimensional structure of the present invention formed by using different photo-curable flow resins.

FIG. 11 is a flowchart showing steps of stereolithography of a three-dimensional structure by the stereolithography method of the present invention.

FIG. 12 is a diagram schematically showing a step of forming a three-dimensional structure by the manufacturing method of the present invention.

FIG. 13 is a schematic view of a stereolithography apparatus of the present invention for shaping a three-dimensional structure by a regulated liquid level method,
A plurality of accommodating means are provided.

[Explanation of symbols]

Tanks ... 53, 54, 55, 56, 102, 130, 1
41, 145, 150, 200, 210; photocurable fluid resin ... 60, 61, 101, 136, 138, 156,
158, 205, 213; elevators, 51, 104,
131, 151, 201, 211; glass plate ... 108,
132, 143, 147, 152, 202; material having high wettability ... 107, 133, 142, 146, 153, 2
03; photocured product ... 52, 103, 135, 139, 14
0, 155, 159, 165, 169, 180, 18
1, 183, 206, 215; irradiation light ... 66, 109,
134, 137, 144, 154, 157, 160, 1
68, 204, 212; actuators ... 50, 68,
74, 80, 105, 110, 116; shutters ... 6
4, 112; light source ... 63, 108; wiring ... 73, 11
4; control device ... 72, 113; computer ... 70, 1
15; monitor ... 70; condensing unit ... 67, 111, 117;
Glass plate coated with highly wettable material ... 57, 58;
Optical path ... 65; Table ... 62; Ultrasonic transducer ... 59; Post-exposure lamp ... 69.

Claims (5)

[Claims] 1. Scanning and irradiating light, or
By a light irradiation means for irradiating a light image, a photocurable fluidized resin layer is irradiated with light to form a photocurable layer, and in a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of the photocurable layers, An accommodating means for accommodating the photocurable liquid resin, a supporting means arranged in the accommodating means for supporting the photocurable layer, and an exposure of the light irradiation means according to thickness information of the photocurable layer. A stereolithography apparatus, comprising: an exposure amount setting means for automatically setting the amount. 2. Scanning and irradiating light, or
By a light irradiating means for irradiating a light image, a light curable fluidized resin layer is irradiated with light to form a photocurable layer, and in a stereolithography device for molding a three-dimensional structure by combining a plurality of the photocurable layers, A plurality of accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in any of the accommodating means for supporting the photocurable layer, and a accommodating means in any of the plurality of accommodating means Depending on the moving means for relatively moving and arranging the supporting means, the accommodating means information of which of the plurality of accommodating means the supporting means is arranged, and the thickness information of the photocurable layer. An optical modeling apparatus comprising: an exposure amount setting unit that automatically sets the exposure amount of the light irradiation unit. 3. Scanning and irradiating light, or
By a light irradiation means for irradiating a light image, a photocurable fluidized resin layer is irradiated with light to form a photocurable layer, and in a stereolithography apparatus for molding a three-dimensional structure by combining a plurality of the photocurable layers, A plurality of accommodating means for accommodating the photocurable fluid resin, a supporting means arranged in any of the accommodating means for supporting the photocurable layer, and in any of the plurality of accommodating means The moving means for relatively moving and arranging the supporting means, the light irradiating means information on which of the plurality of accommodating means the light irradiating means is arranged, and the thickness information of the photocurable layer. And an exposure amount setting unit for automatically setting the exposure amount of the light irradiating unit. 4. A stereolithography method for molding a three-dimensional structure using a plurality of photocurable fluid resins having different characteristics, wherein a layer of the photocurable fluid resin comprises a layer of the photocurable fluid resin. A structure forming step of forming a photocurable layer by irradiating light with an exposure amount according to characteristics and forming a structure consisting of at least one layer, and a photocurable flow having different characteristics from the structure forming step. The resin is irradiated with light at an exposure dose different from that of the structure forming step to form at least one layer of a structure of a photocurable fluid resin having different characteristics from the structure, A three-dimensional structure forming step of joining and forming the structure obtained in step 3). 5. A laminated portion obtained by laminating a plurality of photo-curing layers, and at least one perpendicular to a laminated surface of the laminated portion.
A three-dimensional structure comprising a photo-cured portion having one side surface covered with a photo-cured layer having a thickness equal to or greater than the thickness of the photo-cured layer of the laminated portion.