JPWO2015151834A1 - 3D modeling equipment - Google Patents

Abstract

A three-dimensional modeling apparatus is obtained that can model a three-dimensional modeled object while arranging powder material layers of a plurality of types of powder materials in appropriate positions in one powder material layer. The three-dimensional modeling apparatus includes a first powder material supply device that forms the first powder material layer of the powder material layer, and a second powder material supply device that forms the second powder material layer. And a second powder material supply device forms a portion of the first powder material layer formed by the first powder material supply device before the first powder material is bonded, A removal device that removes the first powder material layer with the same thickness as the first powder material layer, and a first powder that forms the first powder material layer on a portion of the first powder material layer that has been removed by the removal device A filling device is provided that forms a second powder material layer by supplying and filling a second powder material different from the material.

Description

  The present invention provides a three-dimensional object to be formed by laminating a plurality of powder material layers formed by discharging a binder liquid that joins the powder material to a layered powder material supplied on a table. The present invention relates to a three-dimensional modeling apparatus that models a modeled object.

2. Description of the Related Art Conventionally, a technique called rapid prototyping, in which a three-dimensional modeled object to be modeled is modeled by stacking layers having a cross-sectional shape cut by a plurality of horizontal cross sections, is widely known.
This rapid prototyping includes laser modeling for photo-curing resin, laser lamination modeling for laminating and laminating thin film sheets, a method for extruding and laminating thermoplastic resin, and infrared laser for powder material There are various techniques such as powder sintering (melting) modeling that is sintered or melted by an electron beam, a thermal head, or the like, and modeling by powder that joins a powder material with a binder liquid.

Among these, modeling by powder has advantages that it is relatively easy to handle compared to other techniques and that a three-dimensional model can be formed at a relatively low cost.
As modeling by this powder, for example, as shown in Patent Document 1 and Patent Document 2, a powder material is supplied to the upper surface of the table as a layer of a predetermined layer thickness, and a binder is applied to the layer by an inkjet head or the like. A part of the layer of the three-dimensional structure is formed by discharging a liquid, and the three-dimensional structure is formed by sequentially stacking the layers.

In the three-dimensional modeling apparatus that performs modeling using such powder, the powder material is supplied to the table by a powder material supply apparatus (so-called recoater), while the powder material supplied on the table is supplied to the table. In general, the binder liquid is discharged by a binder liquid supply device.
When modeling a modeled object with the three-dimensional modeling apparatus having such a configuration, the following operations are generally repeated until the modeled object is completed.
First, the powder material supply device is moved linearly to form a powder material layer having a predetermined layer thickness on the table, and then the binder liquid supply device is moved. Then, by discharging the binder liquid toward the powder material on the table, the powder material is bonded and cured in a shape that matches the three-dimensional structure in the layer, and a part of the three-dimensional structure is cured. A powder material layer including a layer portion is formed.
Then, after forming one layer of the powder material layer including a part of the layer portion of the three-dimensional structure, the powder material supply device is moved again so that a new powder material is placed on the table more specifically. Is supplied onto the powder material layer formed immediately before and uniformly spread to a predetermined layer thickness, and the formation of the next powder material layer is started.

JP-A-6-218712 Special table 2004-508941 gazette

Incidentally, in recent years, attempts have been made to form a mold for forming a casting by using the three-dimensional modeling apparatus.
Here, in order to suppress the formation of internal defects such as cavities (sink nests) in the casting to be cast when the molten metal poured into the mold cools and contracts, A portion where a feeder is formed, which is a part different from the casting to be cast, is provided. This utilizes the fact that the internal defects are concentrated on the metal portion that solidifies last, solidifies the metal of the feeder part last, and as much of the internal defects as possible in the casting to be cast. This is to prevent the formation.
On the other hand, the normal mold is provided with a cooling member called a cooling metal in order to solidify the metal of the feeder part at the end, and this cooling metal is arranged at an appropriate position of the mold. By doing so, the direction in which the metal in the mold is cooled is controlled so that the portion of the feeder is cooled last.

Therefore, when the mold is formed by the three-dimensional modeling apparatus, the direction in which the metal in the mold is cooled can be appropriately controlled, and the interior of the cavity or the like formed when the metal cools and contracts It is necessary to ensure that no defects are formed in the casting to be cast.
On the other hand, since the portion of the feeder is basically a surplus portion that has nothing to do with the casting to be cast, the portion of the feeder is made as small as possible in order to reduce the amount of metal used. It is preferable to improve the casting yield. For that purpose, as described above, it is important to appropriately control the direction in which the metal in the mold proceeds to be cooled so that the internal defects are concentrated on the portion of the feeder that is smaller than before. It is.

From such a point of view, as a result of repeated researches by the inventors, when forming a mold by the three-dimensional modeling apparatus, in order to appropriately control the direction of cooling of the metal in the mold The mold is formed of a plurality of types of powder materials, and the cooling performance as a whole of the mold is controlled based on the characteristics of the material, thereby giving directivity to solidification by cooling of the metal in the mold. It was concluded that is effective.
For that purpose, it is important to form a powder material layer made of each type of powder material at an appropriate position, and a powder material made up of a plurality of types of powder material even in one powder material layer. Since a layer may have to be provided, a three-dimensional modeling apparatus capable of performing such modeling is required.

  The technical problem of the present invention is that a three-dimensional object can be formed while a powder material layer of a plurality of types of powder materials is provided in an appropriate position in one powder material layer. The object is to provide a modeling apparatus.

  In order to solve the above problems, the three-dimensional modeling apparatus of the present invention has an operation of combining the powder material in the powder material layer formed on the table in accordance with the shape of the three-dimensional modeled object to be modeled. Repeatedly, a three-dimensional modeling apparatus for modeling the three-dimensional structure by sequentially laminating the powder material layers, wherein the three-dimensional modeling apparatus includes a first powder material layer in the powder material layer. A first powder material supply device to be formed; and a second powder material supply device to form a second powder material layer in the powder material layer, and the second powder material supply device. The supply device is a part of the first powder material layer formed by the first powder material supply device before the first powder material forming the first powder material layer is bonded. Remover with the same layer thickness as the first powder material layer, and the first powder material The second powder material different from the first powder material forming the first powder material layer is supplied and filled in the portion removed by the removing device. And a filling device for forming the powder material layer.

  In the present invention, the second powder material supply device is formed to be movable in the horizontal direction on the upper side of the table on which the three-dimensional structure is formed, and the removal device is the first device. It is preferable that the direction in which a part of the powder material layer is removed and the direction in which the filling device forms the second powder material layer can be changed.

  Moreover, in this invention, the said removal apparatus shall be equipped with the suction device which attracts | sucks the 1st powder material of the part of the said 1st powder material layer of the removal object.

  In the present invention, the second powder material supply device may include an elevating mechanism that elevates or lowers one or both of the removing device and the filling device.

  According to the present invention, the second powder material supply device provided separately from the first powder material supply device includes the removal device and the filling device. A part of the first powder material layer formed by the powder material supply apparatus can be removed. Further, the filling device supplies the second powder material different from the first powder material forming the first powder material layer to the portion removed by the removing device, and fills the second powder material. Therefore, the powder material layers made of a plurality of types of powder materials can be provided at appropriate positions in one powder material layer.

FIG. 1 is a cross-sectional view schematically showing an embodiment of the three-dimensional modeling apparatus of the present invention. FIG. 2 is a main part enlarged perspective view schematically showing a state in which the first powder material layer and the second powder material layer are formed in one embodiment of the three-dimensional modeling apparatus of the present invention. . FIG. 3 is an essential part enlarged cross-sectional view schematically showing a state in which the first powder material layer and the second powder material layer are formed in the embodiment of the three-dimensional modeling apparatus. FIG. 4 schematically shows a state in which the second powder material supply device according to the embodiment of the three-dimensional modeling apparatus of the present invention forms a second powder material layer curved in plan view. It is a principal part top view.

1 to 4 show an embodiment of a three-dimensional modeling apparatus according to the present invention. A three-dimensional modeling apparatus 1 according to this embodiment includes a powder material layer 2 made of a powder material, A three-dimensional structure is formed by sequentially laminating the powder material layer 2 while supplying the binder liquid for bonding the powder material and repeating the operation of bonding the powder material of the portion to which the binder liquid is supplied. It is to be shaped.
Specifically, the three-dimensional modeling apparatus 1 includes a single table 3 on which a powder material layer 2 forming a three-dimensional modeled object (hereinafter referred to as “modeled object”) is stacked, and the table 3. For the first powder material supply device 5 that forms the first powder material layer 4 that is a part of the powder material layer 2 and the powder material layer 2 supplied on the table 3, And a binder liquid supply device 8 for discharging the binder liquid for bonding the powder material in the powder material layer 2. Further, the three-dimensional modeling apparatus 1 provides a second powder material layer 6 that is a part of the powder material layer 2 on the table 3 separately from the first powder material supply apparatus 5. A second powder material supply device 7 to be formed is provided.
Reference numeral 10 in FIG. 1 is a housing of the three-dimensional modeling apparatus 1.

  In addition, formation of the said 1st powder material layer 4 and the 2nd powder material layer 6 in which the one part layer part of the modeling object of modeling object was modeled is the modeling object input into the electronic computer which is not shown in figure. Controlled based on the data of the modeled object (for example, data in the STL (Standard Triangulated Language) file format or slice (round slice) data created based on the STL file)) Supply of the body material to the table 3 and discharge of the binder liquid are performed.

The table 3 has a flat and horizontal upper surface on which a plurality of powder material layers 2 are stacked to form the modeled object, and the upper surface is horizontal according to the layer thickness of the powder material layer 2. It is possible to move up and down in the vertical direction while maintaining a simple state.
Further, in this embodiment, the table 3 is arranged in a direction orthogonal to a moving direction (to be described later) of the first powder material supply device 5 and the binder liquid supply device 8 (in this embodiment, three-dimensional modeling). It is formed in a substantially rectangular shape in plan view that is long in the left-right direction of the device 1.

Further, the table 3 is formed in a rectangular frame shape in plan view that surrounds the front side (the front side of the 3D modeling apparatus 1), the back side (the rear side of the 3D modeling apparatus 1), and the left and right both sides of the table 3. The tubular member 9 extending in the vertical direction is housed. Each time the powder material layer 2 is formed on the table 3 and the discharge of the binder liquid to the one powder material layer 2 is completed, the table 3 is moved into the cylindrical member 9. It is the composition which descends.
Therefore, the modeling object to be modeled is finally modeled in a state where it is accommodated in the cylindrical member 9 together with the powder material not bonded by the binder liquid.

The table 3 is provided with a table elevating device (not shown) for elevating the table 3 in the vertical direction.
As this table lifting apparatus, any structure can be used as long as it can perform stable lifting and precise position control. For example, a ball screw having a screw shaft extending in the vertical direction and a nut that moves the outer peripheral surface of the screw shaft in the axial direction by rotation of the screw shaft can be used. That is, the upper end portion of the screw shaft is connected to the lower surface of the table 3, the nut is fixed to a position-immovable base, and the screw shaft is rotated by an electric motor or the like to raise and lower the screw shaft. Thus, the table 3 can be raised and lowered.
Alternatively, a structure may be provided in which a chain conveyor in which the chain moves in the vertical direction is provided, and the table 3 is moved up and down by movement of the chain of the chain conveyor.
Furthermore, using a fluid pressure cylinder in which the piston moves up and down in the vertical direction, the tip of the piston rod of the fluid pressure cylinder is connected to the lower surface of the table, and the table 3 can be moved up and down by moving the piston. .
The table 3 is preferably lifted and lowered in the state of being guided in the vertical direction by a guide rail. In this case, the table 3 has a cylindrical or spherical rolling element to smoothly lift and lower the table 3. A linear guide can be used.

The binder liquid supply device 8 includes a front-rear direction (a direction substantially parallel to a short direction on the table 3; hereinafter referred to as “Y-axis direction”) and a left-right direction (on the table 3) of the three-dimensional modeling apparatus 1. In a direction substantially parallel to the longitudinal direction (hereinafter referred to as “X-axis direction”), each of them is linearly movable.
Specifically, the binder liquid supply device 8 includes an ink jet head that discharges the binder liquid toward the powder material supplied onto the table 3 and moves in the X-axis direction. The binder liquid can be discharged from the nozzle for the entire length of the table 3 in the longitudinal direction at the maximum.

The binder liquid supply device 8 is provided with a moving device 11 for the binder liquid supply device that moves the binder liquid supply device 8 in the X-axis direction and the Y-axis direction.
The moving device 11 includes a pair of left and right guide rails 12 and 12 that are provided so as to sandwich the table 3 at both ends in the longitudinal direction of the table 3 and extend horizontally and parallel to each other in the X-axis direction. A front-rear direction moving member 13 that is spanned between the pair of guide rails 12 and 12 and is provided on the pair of guide rails 12 and 12 so as to be movable in the front-rear direction of the three-dimensional modeling apparatus 1. I have.
Furthermore, the front-rear direction moving member 13 is provided with a left-right direction moving member 14 attached to the front-rear direction moving member 13 so as to be movable in the X-axis direction. 8 is attached.
In this embodiment, the binder liquid supply device 8 uses the position of the rear side (back side) of the three-dimensional modeling apparatus 1 in the Y-axis direction as the origin position relative to the table 3.
Therefore, when the first powder material supply device 5 and the second powder material supply device 7 supply the powder material toward the table 3, the binder liquid supply device 8 basically When the first powder material supply device 5 and the second powder material supply device 7 complete the formation of the powder material layer 2 for one layer, the third order in the Y-axis direction is waited at the origin position. The binder liquid is discharged and supplied to the powder material layer 2 on the table 3 while moving in the front side (front side) and the X-axis direction of the original modeling apparatus 1. The binder liquid supply device 8 returns to the original position when the discharge of the binder liquid to the one powder material layer 2 is completed.

The amount of the binder liquid discharged from the binder liquid supply device 8 varies depending on the type of the binder liquid and the size of the powder material 2 to be solidified by one discharge. In the present invention, 1pl ˜200 pl, more preferably 10 pl to 150 pl, more preferably 30 pl to 100 pl.
Furthermore, as a discharge mechanism in the inkjet head 8a, a known mechanism such as a piezo type or a thermal type can be used.

Further, the binder liquid used in the present invention can be freely changed according to the type of the powder material. For example, when the powder material is gypsum or starch, a liquid mainly composed of water is used. It is also possible to use various binder liquids used in ordinary ink jet printers. At this time, the binder can be dyed using a dye or a pigment.
Examples of the binder liquid that can be used include organic esters, furfuryl alcohol, polyisocyanates, and mixtures of polyisocyanates and tertiary amines. Further, a mixture of furfuryl alcohol and formaldehyde, and in some cases, a mixture of these furfuryl alcohol and formaldehyde with urea can be used.

On the other hand, the first powder material supply device 5 is formed to be linearly movable back and forth in one direction (the Y-axis direction in this embodiment). Then, the first powder material 16 forming the first powder material layer 4 can be freely supplied toward the table 3 with a predetermined supply width while moving.
The first powder material supply device 5 is capable of supplying the first powder material 16 with substantially the same width as the length in the longitudinal direction (X-axis direction) on the table 3. The first powder material supply device 5 linearly moves once on the table 3 in the Y-axis direction to supply the first powder material 16 to almost the entire surface of the table 3. Is possible.
In this embodiment, when the first powder material supply device 5 moves forward (that is, when the three-dimensional modeling device 1 moves backward), the first powder material 16 is transferred to the table 3. It is the structure which supplies toward.

Specifically, the first powder material supply device 5 includes a tank unit (not shown) for storing the first powder material 16, and the first powder material 16 in the tank unit as the table. 3 and a discharge nozzle 22 that extends substantially vertically downward from the tank portion 21, which includes a discharge port 21 that discharges toward the tank 3.
Further, the first powder material supply device 5 includes a first powder material layer formed by the first powder material 16 discharged from the discharge port 21 of the discharge nozzle 22 toward the table 3. 4 is adjusted to a predetermined layer thickness and has a flattening member 23 for flattening the upper surface of the first powder material layer 4.

The first powder material supply device 5 is provided with a moving device 26 for the first powder material supply device, which moves the first powder material supply device 5 in the Y-axis direction. Yes.
The moving device 26 includes a pair of left and right guide rails 27, 27 extending in parallel with each other in the Y-axis direction, and a moving member that can move the pair of guide rails 27, 27 in the front-rear direction of the three-dimensional modeling apparatus 1. The first powder material supply device 5 is fixed to the moving members 28 and 28 at both ends in the longitudinal direction (X-axis direction).
In this embodiment, the first powder material supply device 5 sets the front side (front side) of the three-dimensional modeling apparatus 1 in the Y-axis direction as the origin position relative to the table 3. And when the said 1st powder material supply apparatus 5 moves to the back side (back side) of the said three-dimensional modeling apparatus 1 of the transversal direction of the said table 3 from the said origin position, the said for one layer When the first powder material 16 is supplied to form the first powder material layer 4 and the supply is completed, the second powder material supply device 7, which will be described in detail later, is the origin. Waiting for movement to the position, it moves to the origin position.
After that, the first powder material supply device 5 stands by at the origin position until the binder liquid supply device 8 finishes discharging and supplying the binder liquid.

  Further, the second powder material supply device 7 removes a part of the first powder material layer 4 formed by the first powder material supply device 5, and the first powder. The portion from which the material layer 4 has been removed is filled with a second powder material 30 that is different from the first powder material 16 that forms the first powder material layer 4 and the second powder material layer. 6 is formed.

In the present invention, the first powder material supplied to the table by the first powder material supply device and the second powder material supplied to the table by the second powder material supply device Examples include organic resins, metals, ceramics, starches, and glass powders.
Specifically, polystyrene resin, nylon (polyamide) resin, polycarbonate resin, acrylic (PMMA (polymethyl methacrylate)) resin, PEEK (polyether ether ketone) resin, organic resin containing glass filler, carbon fiber Use organic resin, finely divided wax, foundry sand, aluminum silicate, gypsum, starch, quartz, Ti ₆ Al ₄ V, AlSi ₁₂ , AlSi ₁₀ Mg, cobalt chromium alloy, nickel alloy, stainless alloy, iron, steel, etc. Can do.
However, the powder material used as the first powder material and the powder material used as the second powder material need to be different from each other.
The particle sizes of the first powder material and the second powder material are the thickness of the first powder material layer in the case of the first powder material, and the particle diameter in the case of the second powder material. There is no limitation as long as it is smaller than the thickness of the second powder material layer, but it can be about 1 μm to 300 μm, more preferably 10 μm to 200 μm, and more preferably 50 to 150 μm. At this time, the first powder material and the second powder material may be used in a mixture of a plurality of different particle sizes. For example, it can be used in a state where a powder material of 150 to 300 μm and a powder material of 10 to 50 μm are mixed. The particle size of the powder material used as the first powder material and the particle size of the powder material used as the second powder material may be the same or different from each other. .
Furthermore, in the present invention, regarding the layer thickness of the first powder material layer formed by the first powder material supply device and the second powder material layer formed by the second powder material supply device, It depends on the modeled object to be modeled. If the shaped object is very large such as casting or large case fixture, it can be about 0.15 to 0.5 mm, more preferably 0.2 to 0.4 mm, more preferably It is 0.25 to 0.35 mm. If the shaped article is a general industrial product, it can be about 0.05 to 0.2 mm, more preferably about 0.075 to 0.15 mm. If it is a small industrial product, for example, a small thing such as a connector, it can be about 0.01 to 0.1 mm, more preferably about 0.025 to 0.075 mm.

The second powder material supply device 7 specifically includes a removal device 31 that removes a part of the first powder material layer 4, and the removal device 31 is a first powder material layer. 4 is provided with a filling device 32 for forming the second powder material layer 6 by supplying and filling the second powder material 30 in the portion from which 4 is removed.
In this embodiment, the removal width of the first powder material layer 4 and the supply width of the second powder material 30 in the second powder material supply device 7 are the same as the first powder. The material supply device 5 is set to be smaller than the supply width for supplying the first powder material 16 toward the table 3 and the length in the longitudinal direction and the length in the short direction of the table 3.

The removing device 31 is formed on the table 3 by the first powder material supply device 5 (that is, the upper surface of the table 3 when the first layer is formed, and the table 3 when the second layer is formed). A part of the first powder material layer 4 formed on the upper surface of the existing powder material layer 4 in the lower layer and before the binder liquid is discharged by the binder liquid supply device 8. Removal is possible with the same layer thickness as the powder material layer 4.
The removal device 31 in this embodiment includes a scraping member 36 that scrapes the first powder material layer 4 with the same layer thickness as the first powder material layer 4, and the scraping member 36 scrapes the scraping member 36. And a suction device 37 for sucking the first powder material 16 of the raised first powder material layer 4.
Then, when the second powder material supply device 7 moves forward, the scraping member 36 of the removing device 31 is a portion of the first powder material layer 4 where the first powder is to be removed. The body material 16 is scraped up, and the suction device 37 sucks the scraped first powder material 16. Therefore, the portion of the first powder material layer removed by the removing device 31 is in a state where a space where the first powder material 16 does not exist is formed.

As shown in FIG. 3, the scraping member 36 is formed in a substantially triangular shape with a taper that gradually tapers toward the tip 36 a side (the advance direction of the second powder material supply device 7). The second powder material supply device 7 extends in the horizontal direction orthogonal to the forward direction.
Note that the length of the scraping member 36 in the longitudinal direction is substantially the width of removal of the first powder material layer 4 in the removal device 31, and thus the second powder material layer. 6 (the length in the direction orthogonal to the advancing direction of the second powder material supply device 7).
Further, the scraping member 36 has a substantially horizontal flat surface on the bottom surface side and an inclined surface 36b that is inclined obliquely downward toward the tip side on the top surface side. Only when the second powder material supply device 7 advances (i.e., advances) in the direction of the distal end portion 36 a of the scraping member 36, the first powder material layer 4 is formed at the distal end portion 36 a. The first powder material 16 can be scraped up toward the inclined surface 36b.

Further, the suction device 37 includes a suction nozzle 38 for sucking the first powder material 16 scraped up by the scraping member 36, and various suction means such as a compressor such as a compressor for generating suction force and a vacuum pump. (Not shown) and the suction nozzle 38 and the suction means are communicated with each other, and the first powder material 16 sucked by the suction nozzle 38 is conveyed by the suction force generated by the suction means. A pipe 39 is provided.
In this embodiment, as shown in FIG. 3, the suction nozzle 38 is arranged on the inclined surface 36b of the scraping member 36 with the suction port 38a facing the tip end 36a side of the scraping member 36. It is arranged. The suction nozzle 38 can mainly suck the first powder material 16 placed on the inclined surface 36b of the scraping member 36.
Therefore, the removal portion of the first powder material layer 4 removed by the removal device 31 is because the suction device 37 sucks the first powder material 16 that has been scraped up by the scraping member 36. A space in which the first powder material 16 does not exist is formed.

On the other hand, the filling device 32 has a portion where the first powder material 16 is removed by the removal device 31 in the first powder material layer 4 formed by the first powder material supply device 5. The second powder material layer 6 is formed by supplying and filling a second powder material 30 different from the first powder material 16 forming the first powder material layer 4. is there.
The filling device 32 has a tank section for storing the second powder material 30 and the second powder material 30 in the tank section facing the table 3, more specifically, the first powder material 30. The powder material layer 4 includes a discharge nozzle 42 that extends substantially vertically downward and includes a discharge port 41 that discharges toward the space of the portion where the first powder material 16 has been removed by the removing device 31. ing.
Further, the filling device 32 adjusts the second powder material layer 6 formed of the second powder material 30 to the same layer thickness as the first powder material layer 4 and the first powder material layer 4. 2 has a flattening member 43 for flattening the upper surface of the powder material layer 6.

The discharge port 41 of the discharge nozzle 42 has the same supply width as the length of the scraping member 36 of the removal device 31 in the longitudinal direction, that is, the removal width of the first powder material layer 4 of the removal device 31. The second powder material 30 can be discharged toward the table 3 (more specifically, toward the space where the first powder material 16 has been removed by the removing device 31). Yes. Accordingly, the supply width of the second powder material 30 from the discharge port 41 is substantially the supply width of the second powder material 30 in the filling device 32.
Further, the flattening member 43 scrapes the upper surface of the second powder material layer 6 formed by the second powder material 30 discharged from the discharge port 41 of the discharge nozzle 42, The layer thickness is made the same as that of the first powder material layer 4 and the upper surface is flattened. In this embodiment, the discharge nozzle 42 is interconnected.

Here, the second powder material supply device 7 includes an elevating mechanism 45 that elevates or lowers one or both of the removing device 31 and the filling device 32 in the vertical direction.
The second powder material supply device 7 can adjust the heights of the removal device 31 and the filling device 32 by the lifting mechanism 45. For example, the thickness of the first powder material layer 4 is as follows. The height of the removing device 31 and the filling device 32 can be adjusted so as to conform to the above.
In addition, the second powder material supply device 7 is to be removed from the first powder material layer 4 by the removal device 31 when the second powder material layer 6 is formed by the lifting mechanism 45. When removing the portion, only the removal device 31 is lowered at the start of removal, while the filling device 32 can be raised to a position where it does not contact the first powder material layer 4. Furthermore, when the removal device 31 removes the first powder material 16 from the first powder material layer 4, a space for the filling device 32 is formed in the first powder material layer 4. In addition, the filling device 32 can be lowered to form the second powder material layer 6.
In addition, when the removal device 31 completes the removal of the portion to be removed from the first powder material layer 4 and only the operation relating to the supply of the second powder material 30 by the filling device 32 is left. Only the removal device 31 is raised so as not to come into contact with the first powder material layer 4, while the height of the filling device 32 is maintained and the supply of the second powder material is continued. You can also
As described above, the lifting mechanism 45 allows the removal device 31 and the filling device 32 to freely move up and down, so that the second powder material supply device 7 as a whole can be operated in various ways.

As the elevating mechanism 45, any one can be used as long as one or both of the removing device 31 and the filling device 32 can be stably moved up and down and precise position control can be performed. A configuration can be used.
For example, a ball screw having a screw shaft extending in the vertical direction and a nut that moves the outer peripheral surface of the screw shaft in the axial direction by rotation of the screw shaft can be used. That is, the lower end portion of the screw shaft is attached to the removing device 31, the nut is fixed to a rotating device 52 to be described later, and the screw shaft is rotated by an electric motor or the like, so that the screw shaft is moved up and down to remove the screw shaft. It can be set as the structure which raises / lowers the apparatus 31. FIG. Further, the filling device 32 can also be moved up and down by using a ball screw having the same configuration. Therefore, the ball screw used in the filling device 32 and the screw shaft of the ball screw used in the removal device 31 are used. It is possible to control the positions of the removing device 31 and the filling device 32 by controlling the number of rotations and the rotation angle.
In addition, an electric slide table or the like can be used.

Meanwhile, the second powder material supply device 7 is formed so as to be movable in the horizontal direction above the table 3, and the removal device 31 is a part of the first powder material layer 4. And the direction in which the filling device 32 forms the second powder material layer 6, that is, the direction in which the second powder material supply device 7 advances can be freely changed.
Specifically, the second powder material supply device 7 includes a movement for the second powder material supply device 7 that moves the second powder material supply device 7 in the X-axis direction and the Y-axis direction. A device 51 and a rotating device 52 that rotates the second powder material supply device 7 around an axis extending in the vertical direction to change the direction (forward direction) of the second powder material supply device 7 are attached. ing.
As a result, the second powder material supply device 7 can freely set its forward direction in an arbitrary direction, and moves to draw an arbitrary locus in plan view as shown in FIG. 4, for example. Therefore, the planar view shape of the second powder material layer 6 can be formed in an arbitrary shape.

The moving device 51 for the second powder material supply device 7 spans between a pair of left and right guide rails 53, 53 extending in parallel with each other in the Y-axis direction, and the pair of guide rails 53, 53. And a front-rear direction moving member 54 for a second powder material supply device provided on the pair of guide rails 53, 53 so as to be movable in the Y-axis direction.
Further, the front-rear direction moving member 54 for the second powder material supply device is attached to the front-rear direction movement member 54 so as to be movable in the X-axis direction. A moving member 55 is provided, and the second powder material supply device 7 is attached to the left / right moving member 55 via the rotating device 52.

The rotating device 52 rotates the second powder material supply device 7 around an axis extending in the vertical direction with respect to the left and right moving member 55 for the second powder material supply device. It is interposed between the second powder material supply device 7 and the left-right moving member 55.
As the rotating device 52, the second powder material supply device 7 can be rotated around an axis extending in the vertical direction, and the direction of the second powder material supply device 7 can be accurately and stably. If it can be controlled, an arbitrary configuration is used. For example, a stepping motor, a servo motor or the like, or a rotary table using these motors can be used.

Further, in this embodiment, the second powder material supply device 7 is located on the front side of the three-dimensional modeling apparatus 1 in the Y-axis direction from the origin position of the first powder material supply device 5 ( The position on the front side) is the origin position.
Therefore, the second powder material supply device 7 stands by at the origin position when the first powder material supply device 5 supplies the first powder material 16 toward the table 3. Or the first powder material layer formed by the first powder material supply device 5 by moving forward so as to follow the first powder material supply device 5 while maintaining a certain distance. 4, the first powder material 16 is removed from the portion to be removed and the second powder material 30 is supplied to form the second powder material layer 6.
Then, when the second powder material supply device 7 has completed the formation of the second powder material layer 6, the second powder material supply device 7 before the movement of the first powder material supply device 5 to the origin position. Returning to the origin position of the second powder material supply apparatus 7, the apparatus waits at the origin position until the binder liquid supply apparatus 8 finishes discharging and supplying the binder liquid.
Note that when the rotating device 52 is used to form the second powder material layer 6 having a substantially curved shape in plan view when creating a modeled object, the suction nozzle 38 and the discharge port 41 of the discharge nozzle 42 are used. Do not draw the same locus, it is preferable that the start and end of the formation of the second powder material layer 6 be a relaxation curve. Although the same curve is not drawn as the relaxation curve, it is sufficient that the second powder material 30 spreads due to gravity or force from the second powder material supply device 7. Further, in order to weaken the influence caused by the mismatch between the locus of the suction nozzle 38 and the discharge port 41 of the discharge nozzle 42, the positions of the suction nozzle 38 and the discharge port 41 can be as much as possible. Closer is preferable. The relaxation curve may be a curve that reduces curvature, such as a clothoid curve, a cubic curve, or a sine half-wavelength decreasing curve.

When forming the modeled object with the three-dimensional modeling apparatus 1 having the above-described configuration, the first powder material supply apparatus 5 is first advanced to supply the first powder material 16 onto the table 3. A first powder material layer 4 is formed.
Next, the second powder material supply device 7 is advanced after the first powder material layer 4 is formed or so as to follow the advance of the first powder material supply device 5. Then, the first powder of the portion to be removed in the first powder material layer 4 formed by the first powder material supply device 5 and before the binder liquid is discharged by the binder liquid supply device 8. The material 16 is removed by the removing device 31, and the second powder material layer 6 is filled by supplying the second powder material 30 to the portion removed by the removing device 31 by the filling device 32 and filling it. Form.
As a result, the first powder material layer 4 and the second powder material layer 6 are formed in one powder material layer 2.

Then, the said binder liquid supply apparatus 8 is moved, and the modeling object used as modeling object with respect to the one powder material layer 2 which consists of the 1st powder material layer 4 and the 2nd powder material layer 6 The binder liquid is discharged in accordance with the shape of the first powder material 16 and the second powder material 30 are combined.
Thereby, the one layer powder material layer 2 containing the one part layer part of the modeling object used as modeling object, and the powder material which is not couple | bonded is formed.
Thereafter, while the table 3 is lowered one layer at a time, the above operation is repeated to form the powder material layer 2 one layer at a time, and by sequentially laminating, the shaped object in the powder material layer 2 A part of the layer portions are laminated, and a modeled object to be modeled is finally completed.

  Thus, according to the three-dimensional modeling apparatus 1 having the above-described configuration, the second powder material supply apparatus 7 provided separately from the first powder material supply apparatus 5 includes the removal apparatus 31 and the second powder material supply apparatus 7. And a plurality of powder material layers made of a plurality of types of powder materials in one layer of the powder material layer 2 by the removal device 31 and the filling device 32, respectively. It becomes possible to install it stably and reliably.

Therefore, for example, in the case where a mold is formed by the three-dimensional modeling apparatus, since a powder material layer of each type of powder material can be formed at an appropriate position, functions resulting from those powder materials Thus, the direction in which the metal in the mold is cooled can be appropriately controlled, the cooling performance of the entire mold can be controlled, and the solidification due to the cooling of the metal in the mold can be given directivity.
As a result, internal defects such as cavities formed when the metal in the mold cools and contracts can be concentrated on the feeder, so that it is stably suppressed from being formed in the casting to be cast. be able to. In addition, since it is possible to give directionality to the solidification by cooling of the metal in the mold, it is possible to minimize the portion of the feeder that has nothing to do with the casting to be cast. The yield of casting can be improved by reducing the amount of metal used.

  In the embodiment, the second powder material supply device 7 is formed so as to be movable in the horizontal direction above the table 3, and the removal device 31 is the first powder material. The direction in which a part of the layer 4 is removed and the direction in which the filling device 32 forms the second powder material layer 6 can be changed. However, the second powder material supply device does not necessarily have such a configuration. For example, the second powder material supply device may be configured to move only in the X-axis direction and the Y-axis direction without changing the orientation.

In the embodiment, the removing device 31 of the second powder material supply device 7 sucks the first powder material 16 in the portion to be removed in the first powder material layer 4. 37.
However, the removing device ensures that the removed first powder material can be temporarily held and discarded after the formation of the second powder material layer, and the like. If it can be removed, the suction device is not necessarily provided.

  In the embodiment, the removal device 31 of the second powder material supply device 7 scrapes the first powder material layer 4 with the same layer thickness as the first powder material layer 4. Although the scraping member 36 is provided, if the portion to be removed of the first powder material layer 4 can be removed with the same layer thickness as the first powder material layer 4, the scraping member is Can be omitted. At this time, for example, when the suction device is provided, the first powder material of the portion to be removed in the first powder material layer is transferred to the tip of the suction nozzle of the suction device (more specifically, Alternatively, suction may be performed while being scraped up at the opening edge portion of the suction port) or directly by only the suction force of the suction device.

  In the embodiment, the second powder material supply device 7 includes the lifting mechanism 45 that moves up or down one or both of the removal device 31 and the filling device 32 in the vertical direction. In the case where it is not necessary to change the height of the filling device, the second powder material supply device may not necessarily include the lifting mechanism.

Furthermore, in the said embodiment, although the said filling apparatus 32 is provided with the discharge nozzle 42 which discharges | emits the 2nd powder material 30 in a tank part toward the table 3, a filling apparatus is 2nd powder. If the body material can be reliably supplied and filled in the part from which the first powder material has been removed, it is not always necessary to provide a discharge nozzle, such as providing a discharge port directly at the bottom of the tank unit.
Moreover, in the said embodiment, although the 1st powder material supply apparatus 5 is provided with the discharge nozzle 22 which discharges | emits the 1st powder material 16 in a tank part toward the table 3, 1st powder If the body material supply device can reliably supply the first powder material toward the table, the discharge nozzle is not necessarily required.

  In the embodiment, the second powder material supply device 7 is configured by the removal device 31 and the filling device 32 integrally, but the second powder material supply device is a removal device. It may be a configuration in which a certain amount of space is formed between the container and the filling device and arranged in a state separated from each other.

In the embodiment, the powder material is bonded to the powder material layer 2 supplied from the first powder material supply device 5 onto the table 3 by the binder liquid discharged from the binder liquid supply device 8. Then, it was related to a so-called ink jet type three-dimensional modeling apparatus that forms a modeled object.
However, as a three-dimensional modeling apparatus, for example, a powder that sinters or melts a powder material with an infrared laser, an electron beam beam, a thermal head, or the like as long as the powder material is combined by any means to perform modeling. It may be related to sintering (melting) modeling. At this time, when powdered metal is used as the powder material, the molten powdered metal is continuously changed to a solid, so that the physical properties change continuously, Bonding does not weaken.
Alternatively, the powder material is supplied onto the table by the powder material supply device, and after the curing inhibitor is discharged to the powder material in accordance with the shape of the modeled object by the inkjet head or the like, the curing agent or the It may be a three-dimensional modeling apparatus for implementing means for forming a part of the modeled object by discharging an additive used together with the curing agent to the powder material.
In addition, when forming a casting mold (sand mold) with the three-dimensional modeling apparatus of the present invention, the first powder material and the second powder material may include fine particles of metal such as iron sand, alumina, Silicon nitride, boron nitride, zinc oxide, graphite, and other artificial heat-conductive sand such as chromite sand and zircon sand may be mixed. It becomes possible to give directivity to the cooling of the metal.

DESCRIPTION OF SYMBOLS 1 3D modeling apparatus 2 Powder material layer 3 Table 4 1st powder material layer 5 1st powder material supply apparatus 6 2nd powder material layer 7 2nd powder material supply apparatus 16 1st Powder material 30 Second powder material 31 Removal device 32 Filling device 37 Suction device 45 Lifting mechanism

Claims (4)

By repeating the operation of combining the powder material in the powder material layer formed on the table in accordance with the shape of the three-dimensional structure to be modeled, the three-dimensional structure is formed by sequentially laminating the powder material layers. A three-dimensional modeling apparatus for modeling a model,
The three-dimensional modeling apparatus includes: a first powder material supply device that forms a first powder material layer in the powder material layer; and a second powder material layer that forms a second powder material layer in the powder material layer. Two powder material supply devices, and the second powder material supply device comprises:
A part of the first powder material layer formed by the first powder material supply device before the first powder material forming the first powder material layer is bonded is added to the first powder material layer. A removal device for removing with the same layer thickness as the powder material layer of 1;
A second powder material different from the first powder material that forms the first powder material layer is supplied to a portion of the first powder material layer that has been removed by the removing device. And a filling device for forming the second powder material layer by filling in a three-dimensional modeling apparatus.   The second powder material supply device is formed so as to be movable in the horizontal direction on the upper side of the table on which the three-dimensional structure is formed, and the removal device is formed of the first powder material layer. The three-dimensional modeling apparatus according to claim 1, wherein a direction in which a part is removed and a direction in which the filling device forms the second powder material layer can be changed.   The said removal apparatus is equipped with the suction device which attracts | sucks the 1st powder material of the part of the removal object in the said 1st powder material layer, The Claim 1 or Claim 2 characterized by the above-mentioned. 3D modeling equipment.   The said 2nd powder material supply apparatus is equipped with the raising / lowering mechanism which raises / lowers one or both of the said removal apparatus and a filling apparatus to an up-down direction, The any one of Claims 1-3 characterized by the above-mentioned. The three-dimensional modeling apparatus described in 1.

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