JPWO2017082207A1 - Manufacturing method of shaped article and shaped article - Google Patents

Abstract

In the first layer, the first material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the first layer on the upper side of the first layer is arranged. In the second layer, the first material is continuously formed in a third direction intersecting the first direction and arranged with a gap in the fourth direction intersecting the third direction. , Forming a first well beam structure. Then, a second material girder structure is formed by depositing a thin film of a second material on the wall surface of the first girder structure using an electroless plating method. Further, an electrolytic plating method is performed on the second cross beam structure to deposit the third material in the gap to form a third cross beam structure.

Description

  The present invention relates to a method for manufacturing a shaped article and a shaped article.

  A three-dimensional modeling apparatus that manufactures a model based on three-dimensional design data is known from Patent Document 1, for example. As a method of such a three-dimensional modeling apparatus, various methods such as an optical modeling method, a powder sintering method, an ink jet method, and a molten resin extrusion modeling method have been proposed and commercialized.

  In such a three-dimensional modeling apparatus, the use of a plurality of materials in one modeled object has been proposed, for example, in some documents. However, when generating a modeled object using such a plurality of materials in combination, there is a problem that bonding between different materials is weak and there is a high possibility of delamination.

JP 2002-307562 A

  An object of the present invention is to provide a method of manufacturing a modeled object that can strengthen bonding between a plurality of types of materials even when generating a modeled object using a plurality of types of materials in a composite manner. To do.

  In the method for manufacturing a shaped article according to the first aspect of the present invention, first, in the first layer, the first material is continuously formed in the first direction, and the second direction intersects the first direction. And in the second layer above the first layer, the first material is continuously formed in a third direction intersecting the first direction, and A 1st cross-girder structure is formed by arranging a gap in a fourth direction that intersects the third direction. Then, a second material girder structure is formed by depositing a thin film of a second material on the wall surface of the first girder structure using an electroless plating method. Further, an electrolytic plating method is performed on the second cross beam structure to deposit a third material in the gap to form a third cross beam structure.

  In the method for manufacturing a shaped article according to the second aspect of the present invention, first, in the first layer, the first material is continuously formed in the first direction, and the second direction intersects the first direction. And in the second layer above the first layer, the first material is continuously formed in a third direction intersecting the first direction, and A 1st cross-girder structure is formed by arranging a gap in a fourth direction that intersects the third direction. Then, a mold that covers the first cross-girder structure is formed, and then the first cross-girder structure is removed leaving the mold. Thereafter, a second material that has been melted is poured into the mold and solidified to form a second stringer structure. The mold is removed leaving the second well structure. Then, a third liquid girder structure is formed by injecting the liquid third material into the gap and solidifying the second girder structure.

It is a block diagram which shows schematic structure of the manufacturing apparatus used for manufacture of the molded article which concerns on 1st Embodiment. It is a perspective view which shows schematic structure of the three-dimensional modeling apparatus (3D printer) which concerns on 1st Embodiment. It is a front view which shows schematic structure of the three-dimensional modeling apparatus which concerns on 1st Embodiment. 2 is a perspective view showing a configuration of an XY stage 12. FIG. 3 is a plan view showing the configuration of the lifting table 14. FIG. It is process drawing explaining the manufacturing method of the molded article which concerns on 1st Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 1st Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 1st Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 1st Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 1st Embodiment. It is sectional drawing of a part of 1st cross-girder structure A1. It is sectional drawing of a part of 2nd cross-girder structure A2. It is sectional drawing of a part of 3rd cross beam structure A3. It is sectional drawing of a part of 3rd cross beam structure A3. It is sectional drawing of a part of 3rd cross beam structure A3. It is a block diagram which shows schematic structure of the manufacturing apparatus used for manufacture of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is process drawing explaining the manufacturing method of the molded article which concerns on 2nd Embodiment. It is a block diagram explaining the modification 1. FIG. It is a block diagram explaining the modification 2. FIG. FIG. 10 is a block diagram illustrating a third modification. Modification 4 will be described. Modification 4 will be described. Modification 4 will be described.

  Next, embodiments of the present invention will be described in detail with reference to the drawings.

[First Embodiment]
With reference to the block diagram of FIG. 1, the structure of the manufacturing apparatus for manufacturing the molded article which concerns on 1st Embodiment is demonstrated.
The manufacturing apparatus includes a 3D printer 100, an electroless plating apparatus 200, and an electrolytic plating apparatus 300. As will be described later, the 3D printer 100 is an apparatus for forming a modeled object made of the first material R1. As will be described later, the first material R1 is formed in the first layer at a predetermined interval with the first direction as the longitudinal direction. On the other hand, the second layer above the first layer is formed at a predetermined interval with a second direction intersecting the first direction as a longitudinal direction (so-called cross-girder structure). Below, the structure which has such a cross-girder structure is called a cross-girder structure. As the first material R1, when the 3D printer 100 uses a so-called hot melt lamination method, a thermoplastic resin such as an ABS resin, a polypropylene resin, a nylon resin, or a polycarbonate can be used.
The electroless plating apparatus 200 forms a thin film of the second material R2 as a metal material on the wall surface of the first cross beam structure A1 (first material R1) formed by the 3D printer 100 by an electroless plating method. It is a device for. As an example, the electroless plating apparatus 200 includes a seed agent container 201 that stores a seed agent and an electroless plating solution container 202 that stores an electroless plating solution. As the second material R2, various metals that can use an electroless plating method, such as copper, nickel, gold, and silver, can be used. Electroless plating is a plating method that can be performed even if the substrate is not a metal material.
The electrolytic plating apparatus 300 is an apparatus for forming the third material R3 by electrolytic plating on the second stringer structure A2 on which the thin film R2 of the second material R2 is formed. As an example, the electroplating apparatus 300 includes an electroplating solution container 301 that stores an electroplating solution. By this electrolytic plating method, the gaps of the second cross beam structure A2 are filled with the third material R3, thereby forming the third cross beam structure A3. The third material R3 may be a metal material different from the second material R2, or the same metal material.
Next, an example of the configuration of the 3D printer 100 will be described with reference to FIGS.
FIG. 2 is a perspective view showing a schematic configuration of the 3D printer 100 used in the first embodiment. The 3D printer 100 includes a frame 11, an XY stage 12, a modeling stage 13, a lifting table 14, and a guide shaft 15.

  A computer 200 is connected to the 3D printer 100 as a control device for controlling the 3D printer 100. A driver 300 for driving various mechanisms in the 3D printer 100 is also connected to the 3D printer 100.

(Frame 11)
As shown in FIG. 2, the frame 11 has, for example, a rectangular parallelepiped shape and includes a frame made of a metal material such as aluminum. For example, four guide shafts 15 are formed at four corners of the frame 11 so as to extend in the Z direction in FIG. 2, that is, in a direction perpendicular to the plane of the modeling stage 10. The guide shaft 15 is a linear member that defines a direction in which the elevating table 14 is moved in the vertical direction as will be described later. The number of guide shafts 15 is not limited to four, and is set to a number that can stably maintain and move the lifting table 14.

(Modeling stage 13)
The modeling stage 13 is a table on which the model S is placed, and is a table on which a thermoplastic resin discharged from a modeling head described later is deposited.

(Elevating table 14)
As shown in FIGS. 2 and 3, the elevating table 14 penetrates the guide shaft 15 at its four corners, and is configured to be movable along the longitudinal direction (Z direction) of the guide shaft 15. . The elevating table 14 includes rollers 34 and 35 that are in contact with the guide shaft 15. The rollers 34 and 35 are rotatably installed at arm portions 33 formed at two corners of the lifting table 14. The rollers 34 and 35 rotate while being in contact with the guide shaft 15 so that the elevating table 14 can smoothly move in the Z direction. Further, as shown in FIG. 3, the elevating table 14 transmits a driving force of the motor Mz by a power transmission mechanism including a timing belt, a wire, a pulley, and the like, so that a predetermined interval (for example, 0.1 mm pitch) in the vertical direction. Move with. As the motor Mz, for example, a servo motor or a stepping motor is suitable. It should be noted that the actual position of the lifting table 14 in the height direction is measured continuously or intermittently in real time using a position sensor (not shown), and the position accuracy of the lifting table 14 is improved by appropriately correcting the position. May be. The same applies to modeling heads 25A and 25B described later.

(XY stage 12)
The XY stage 12 is placed on the upper surface of the lifting table 14. FIG. 4 is a perspective view showing a schematic configuration of the XY stage 12. The XY stage 12 includes a frame body 21, an X guide rail 22, a Y guide rail 23, reels 24A and 24B, modeling heads 25A and 25B, and a modeling head holder H. Both ends of the X guide rail 22 are fitted into the Y guide rail 23 and are held slidable in the Y direction. The reels 24A and 24B are fixed to the modeling head holder H, and move in the XY directions following the movement of the modeling heads 25A and 25B held by the modeling head holder H. The thermoplastic resin used as the material of the shaped object S is a string-like resin (filaments 38A and 38B) having a diameter of about 3 to 1.75 mm, and is usually held in a state of being wound around the reels 24A and 24B. At the time of modeling, it is fed into the modeling heads 25A and 25B by motors (extruders) provided on the modeling heads 25A and 25B described later.

Note that the reels 24 </ b> A and 24 </ b> B may be fixed to the frame body 21 or the like without being fixed to the modeling head holder H so that the movement of the modeling head 25 is not followed. In addition, the filaments 38A and 38B are exposed to be fed into the modeling head 25. However, the filaments 38A and 38B may be fed into the modeling heads 25A and 25B with a guide (for example, a tube or a ring guide) interposed therebetween. . As will be described later, the filaments 38A and 38B are made of different materials. As an example, when one is any of ABS resin, polypropylene resin, nylon resin, and polycarbonate resin, the other can be a resin other than the one resin. Or even if it is resin of the same material, the kind and ratio of the material of the filler contained in the inside can also be made to differ. That is, it is preferable that the filaments 38A and 38B have different properties, and the characteristics (strength and the like) of the shaped article can be improved by a combination thereof.
2 to 4, the modeling head 25A is configured to melt and discharge the filament 38A, and the modeling head 25B is configured to melt and discharge the filament 38B, and independent modeling for different filaments. A head is prepared. However, the present invention is not limited to this, and there is a configuration in which only a single modeling head is prepared, and a plurality of types of filaments (resin materials) are selectively melted and discharged by the single modeling head. Can be adopted.

  The filaments 38A and 38B are fed into the modeling heads 25A and 25B from the reels 24A and 24B through the tube Tb. The modeling heads 25A and 25B are held by the modeling head holder H and configured to be movable along the X and Y guide rails 22 and 23 together with the reels 24A and 25B. Although not shown in FIGS. 3 and 4, an extruder motor for feeding the filaments 38A and 38B downward in the Z direction is disposed in the modeling heads 25A and 25B. The modeling heads 25A and 25B only need to be movable with the modeling head holder H while maintaining a certain positional relationship within the XY plane, but the mutual positional relationship can also be changed in the XY plane. It may be configured.

  Although not shown in FIGS. 3 and 4, motors Mx and My for moving the modeling heads 25 </ b> A and 25 </ b> B with respect to the XY table 12 are also provided on the XY stage 12. As the motors Mx and My, for example, a servo motor or a stepping motor is suitable.

(Driver 300)
Next, the details of the structure of the driver 300 will be described with reference to the block diagram of FIG. The driver 300 includes a CPU 301, a filament feeding device 302, a head control device 303, a current switch 304, and a motor driver 306.

  The CPU 301 receives various signals from the computer 200 via the input / output interface 307 and controls the entire driver 300. In accordance with a control signal from the CPU 301, the filament feeding device 302 instructs and controls the feeding amount (push-in amount or retracted amount) of the filaments 38A and 38B with respect to the modeling heads 25A and 25B to the extruder motor in the modeling heads 25A and 25B. To do.

  The current switch 304 is a switch circuit for switching the amount of current flowing through the heater 26. By switching the switching state of the current switch 304, the current flowing through the heater 26 is increased or decreased, thereby controlling the temperatures of the modeling heads 25A and 25B. The motor driver 306 generates drive signals for controlling the motors Mx, My, and Mz according to the control signal from the CPU 301.

  In the three-dimensional modeling apparatus according to the present embodiment, the control apparatus 200 operates such that a plurality of types of materials differ in the direction (modeling direction) in which the materials extend depending on the blending ratio of the plurality of specified materials. .

  Next, the manufacturing method of the molded article by the manufacturing apparatus of this 1st Embodiment is demonstrated with reference to FIG.1 and FIG.6-10. Note that the names of structures (A1, A1'A2, A3, etc.) and their shapes described in each figure indicate the structure (unprocessed state) immediately before the process shown in each figure is performed.

  First, as shown in FIG. 6, in the 3D printer 100, the first stringer structure A <b> 1 is formed using the first material R <b> 1. That is, in one layer (first layer), the first material R1 is melted and then discharged from the modeling head 25A or 25B. At this time, the modeling head 25A or 25B is driven so that the first material R1 is formed with the Y direction as a longitudinal direction and a predetermined interval in the X direction. On the other hand, in the second layer one layer above the first layer, unlike the first layer, the first material R1 is formed with the X direction as the longitudinal direction and a predetermined interval in the Y direction. Then, the modeling head 25A or 25B is driven. By repeating the above-described steps a predetermined number of times, the first material R1 is formed over a plurality of layers, and the first stringer structure A1 in which the longitudinal direction of the first material R1 is different between the two layers vertically adjacent to each other is completed.

Subsequently, as shown in FIG. 7, the first cross beam structure A1 is moved to the electroless plating apparatus 200, and the first cross beam structure A1 is placed in the seed agent container 201 in the apparatus for a predetermined time ( Soak (for example, 1-10 minutes). The seed agent container 201 contains an aqueous solution containing a seed agent. The seed agent is a metal atom that is attached to the surface of the first material R1 constituting the first cross beam structure A1 and becomes the core of electroless plating, and is included in the aqueous solution in the form of metal ions or metal colloids. It is. Specifically, the aqueous solution is a palladium chloride aqueous solution, a tin chloride aqueous solution, or the like, and is used at room temperature or in a heated state. Thereby, a metal atom adheres to the wall surface of 1st cross beam structure A1 as a seed agent. If necessary, as a pretreatment for facilitating adhesion of the seed agent before immersion in the aqueous seed agent solution, a degreasing step (oil component on the resin surface) is performed on the surface of the first girder structure A1. Or a roughening process (formation of fine holes on the resin surface) (not shown). Examples of the former include a degreasing process using an alternative hydrocarbon solvent such as trichlorethylene and dichloromethane, alternative chlorofluorocarbons, and various alcohols. Examples of the latter include a roughening step using a chromic acid aqueous solution, a chromium mixed acid aqueous solution, or the like.
In FIG. 7, the rectangular parallelepiped surrounding the first cross beam structure A <b> 1 illustrates the inner wall and the liquid surface of the seed agent container 201, and does not mean the shape of the structure itself. A seed agent adheres only to the wall surface of 1st cross-girder structure A1.

When the seed agent attaching step is completed, as shown in FIG. 8, the first stringer structure A1 ′ after adding the seed agent to the first stringer structure A1 is used as an electroless plating solution container of the electroless plating apparatus 200. Move to 202. Then, the first cross beam structure A1 ′ is immersed in the electroless plating solution contained in the electroless plating solution container 202 for a predetermined time. In FIG. 8, the rectangular parallelepiped surrounding the first cross beam structure A1 ′ is an illustration of the inner wall and the liquid surface of the plating solution container 202, and does not mean the shape of the structure A1 ′ itself. The electroless plating film is formed only on the surface of the first cross beam structure A1 ′.
Here, the electroless plating solution is an aqueous solution comprising a metal ion or metal complex that can be plated without using electricity, and a reducing agent. For example, when performing cobalt plating, the electroless plating solution can be a mixed aqueous solution of a cobalt complex (eg, cobalt citrate) and sodium hypophosphite, and this aqueous solution can be heated before use. (Generally 70-90 ° C).

  When performing nickel plating, the electroless plating solution can be a mixed aqueous solution of a nickel complex (eg, nickel malonate) and dimethylamine borane, and this aqueous solution can be heated and used (general) (40-70 degreeC specifically).

As another example of nickel plating, a mixed aqueous solution of nickel chloride and sodium borohydride can be used as an electroless plating solution, and this electroless plating solution can be used near room temperature (generally 10 to 40 ° C.). .
By such a method, metal atoms in the electroless plating solution are deposited and grown on the surface of the first stringer structure A1 ′ using the seed agent as a nucleus (electroless plating is applied and the second material R2 is formed on the surface). The attached first girder structure A1 ′ is hereinafter referred to as a second girder structure A2). The metal grows in proportion to the immersion time, and a metal layer of several tens of nanometers to several tens of microns can be formed.
Note that sodium hypophosphite, dimethylamine borane, and sodium borohydride used in the electroless plating solution described above are all examples of reducing agents for depositing metal. In particular, when these phosphorus compounds and / or boron compounds are used, phosphorus and / or boron elements are incorporated in the metal deposited as the second material R2 in a weight ratio of 0.1 to 15%, and the strength of the film It contributes to improvement and is preferable.

  Subsequently, the second cross beam structure A2 is moved to the electroplating apparatus 300, and the electrolytic plating method is performed on the second cross beam structure A2. That is, as shown in FIG. 9, the second well beam structure A2 is immersed in the electrolytic plating solution container 301 of the electrolytic plating apparatus 300 to perform electrolytic plating. Examples of the electrolytic plating solution include an aqueous solution in which a metal ion such as nickel sulfate or nickel sulfamate or a metal complex is mixed with a pH adjusting agent and a stabilizer. This aqueous solution is used in a heated state of about 50 ° C. to 90 ° C., for example. Although not shown, the electrolytic plating solution container 301 includes an anode (anode) and a cathode (cathode), and the anode and the cathode are spaced apart by a predetermined distance. A power source for applying a DC voltage is connected between the anode and the cathode.

  The anode can be made of a metal that is insoluble in the plating solution, such as a stainless steel plate, but the anode itself must be a metal plate made of the same material as the metal to be deposited for stable long-term plating. Is desirable. For example, when nickel plating is performed, a plate-like or spherical nickel anode can be suitably used.

  Further, the cathode has a terminal that can be connected to the second cross beam structure A2, so that a voltage can be applied to the second cross beam structure A2. For example, the cathode has a crocodile clip and is configured so that the second well beam structure A2 can be held by the holding part of the crocodile clip. The second plating beam structure A2 is subjected to electrolytic plating by applying a DC voltage to the electrolytic plating solution container 301 configured as described above and controlling the current. The second girder structure A2 includes an insulating material (first material R1) such as a resin material. As described above, the second material R2 as a metal material is adhered to the surface by electroless plating. Therefore, electrolytic plating can be performed. The second cross beam structure A2 after the electrolytic plating is performed and the gap between the second cross beam structures A2 is filled with the second material R3 is hereinafter referred to as a third cross beam structure A3.

  In the electrolytic plating method, generally, metal is deposited so as to be proportional to both the magnitude of current and the length of plating time, and thick plating can be realized by performing plating for a predetermined time. If conditions are satisfied, plating of several hundred microns to several millimeters can be performed per hour. Generally, the plating thickness can be controlled by the integrated current value (unit: Ah).

  The third well structure A3 is removed from the electrolytic plating solution container 301 and subjected to a cleaning process after the electrolytic plating method is completed. Thereby, the electrolytic plating solution adhering to the surface is removed. Then, a drying process is performed and the manufacturing process in the electroplating apparatus 300 is complete | finished (not shown).

As described above, when the electrolytic plating method is performed in this manner, the gaps of the second cross beam structure A2 are filled with the second material R3, and the third cross beam structure A3 as shown in FIG. 10 is completed. Since the gap of the first material R1 has a so-called cross-girder structure, the third material R3 embedded therein also has a cross-girder structure. That is, the third material R3 in the first layer is formed, for example, with the X direction as the longitudinal direction and at a predetermined interval in the Y direction, while the second material higher than the first layer is the second layer. The third material R3 in the layer is formed, for example, with the Y direction as the longitudinal direction and at a predetermined interval in the X direction. And the 3rd material R3 of the 1st layer and the 3rd material R3 of the 2nd layer are joined in the upper and lower surfaces, and constitute what is called a cross beam structure.
11A to 11E illustrate such a cross-girder structure using sectional views. FIG. 11A shows a partial cross-sectional view (XZ cross section) of the first cross beam structure A1, and is configured by laminating the first material R1 in the horizontal direction and the vertical direction. When electroless plating is performed on the first girder structure A1 ′ after adding the seed agent to the first girder structure A1, as shown in FIG. 11B, the second material R2 becomes the first girder structure. It is formed over the entire surface of A1 ′ and becomes the second cross beam structure A2.
Subsequently, when this second stringer structure A2 is subjected to electrolytic plating, as shown in FIG. 11C, plating is performed using the second material R2 as an electrode, and the third material R3 becomes the second stringer structure A2. Is formed over the entire surface, forming a third well structure A3.

It should be noted that the XY-direction pitch and Z-direction pitch of the first material R1 constituting the first stringer structure A1 and the conditions of electrolytic plating (liquid composition, liquid temperature, current value, current driving method, liquid flow rate, etc.) are appropriately set. If it chooses, after the end of the electroplating method, the gaps of the second stringer structure A2 can be filled with the third material R3 without gaps. In the second girder structure A2, since all the wall surfaces have electroless plating layers, the electrolytic plating proceeds in all directions, and the deposits from the two opposing wall surfaces are connected to each other near the center. Can fill the gaps in the cross-beam structure. In other words, by this method, all the voids of the cross beam structure can be replaced with the metal material, and as a result, a dense composite of the resin material and the metal material can be realized.
The second material R2 made by electroless plating and the third material R3 made by electrolytic plating have a characteristic shape in the cross-sectional structure. Specifically, when a cross-sectional sample of the third well structure A3 is prepared and observed with an optical microscope or an electron microscope, the second material R2 produced by electroless plating is a fine columnar crystal, as shown in FIG. 11D. It can be seen that the crystal growth stands perpendicular to the surface of the first material R1. On the other hand, the third material R3 produced by electroplating is a columnar crystal with coarse particles, and shows crystal growth standing perpendicular to the surface of the second material R2 as shown in FIG. A structure having a complicated crystal orientation in which crystal growths from a plurality of directions are merged is observed in the depression. In other words, the structure having the cross-sectional structure of FIG. 11D indicates that crystal growth (electroplating) was performed using the entire surface of the second material R2 as an electrode by the manufacturing method according to the present invention.

  It should be noted that non-uniform deposition with strong shape dependence is achieved by appropriately selecting the composition of the electroplating solution, solution temperature, current value, current drive method (DC continuous drive, DC pulse drive, AC bias drive, etc.), and the liquid flow rate. (Precipitation with poor step coverage) can also be selected. In such a case, a part of the plating film (third material R3) is deposited from two opposing wall surfaces and is eventually connected to each other, but another part of the plating film (third material R3) is connected. First, as shown in FIG. 11E, a metal body can be formed leaving an air gap AGx therein. In other words, by such a method, although it is a composite of a resin material and a metal material in appearance, a structure in which an air gap AGx is left inside can be realized as shown in FIG. A composite of a resin material and a metal material can be realized. The internal filling of the gap AGx varies depending on the composition, temperature, current value, and current driving method of the electrolytic plating solution described above, and is either air, hydrogen gas, electrolytic plating solution, or vacuum.

As described above, according to the present embodiment, since the resin material and the metal material each have a cross-girder structure and are closely integrated in the gap between each other, the resin material and the metal material are used in combination. In the modeled object, the bonding can be strengthened. Also, in an environment where heating and cooling are repeated such as in a heat cycle, the interface between materials is complex in the structure as described above, so there is a difference in linear expansion coefficient between multiple materials. Even if there exists, since distortion of these several materials spreads over the whole cross-beam structure and stress does not concentrate on a specific surface, the joining between several materials is maintained well, without breaking.
In particular, a modeled object using a plurality of materials composed of a resin material, a first metal material in contact with the resin material, and a second metal material in contact with the first metal material is strong. In particular, the first metal material is a columnar crystal standing perpendicular to the surface of the resin material, and the second metal material in contact with the first metal material is also a columnar crystal standing perpendicular to the first metal material surface. In this case, the strength from the outside with respect to the first and second metal materials is increased, and the stress is distributed over the entire girder structure, so that the bonding between the plurality of materials is maintained well without breaking. The In particular, a material in which the first metal material contains phosphorus and / or boron is the most preferable shaped object of the present invention.

[Second Embodiment]
Next, the manufacturing apparatus of the molded article which concerns on the 2nd Embodiment of this invention is demonstrated with reference to FIG. As shown in FIG. 12, the manufacturing apparatus of the second embodiment includes a 3D printer 100 ′, a mold forming apparatus 400, a metal or ceramic casting apparatus 500, and a resin injecting apparatus 600.

  The 3D printer 100 ′ can be the same as the 3D printer 100 of the first embodiment. The 3D printer 100 ′ is also configured to be able to form a first stringer structure A <b> 4 having the same structure as the first stringer structure A <b> 1 manufactured by the 3D printer 100 of the first embodiment. The details of the configuration may be the same as those described with reference to FIGS. However, the first cross-girder structure A4 manufactured by the 3D printer 100 'is a sacrificial material that is removed by heat treatment, etching, or the like during the manufacturing process of the modeled object.

  The mold forming apparatus 400 is an apparatus for forming a mold C1 (mold) that covers the first cross beam structure A4. The first girder structure A4 is removed by a heating process or etching after the mold C1 is cured or at the stage of curing. A cavity derived from the original shape of the first cross beam structure A4 remains in the mold C1.

  The metal or ceramic casting apparatus 500 is an apparatus for pouring molten metal or ceramic material into the cavity of the mold C1 to form the second stringer structure A5 made of the metal material or ceramic material. The mold C1 is removed by physical treatment or chemical treatment (such as etching) after the metal material of the second cross beam structure A5 is solidified.

  The resin injecting device 600 is an apparatus for manufacturing a well structure in which a liquid resin material is injected or impregnated into a gap of the second cross beam structure A5 to incorporate a metal material cross structure and a resin material cross structure. is there.

  Next, the manufacturing method of the molded article using the manufacturing apparatus of this 2nd Embodiment is demonstrated with reference to FIGS.

  First, as shown in FIG. 13, in the 3D printer 100 ′, the first cross beam structure A <b> 4 is formed using the first material R <b> 1 ′. That is, in one layer (first layer), the first material R1 'is melted and then discharged from the modeling head 25A or 25B. At this time, the modeling head 25A or 25B is driven so that the first material R1 'is formed with the Y direction as a longitudinal direction and a predetermined interval in the X direction. In the second layer, which is one layer higher than the first layer, unlike the first layer, the first material R1 ′ is formed with the X direction as the longitudinal direction and a predetermined interval in the Y direction. Thus, the modeling head 25A or 25B is driven. By repeating the above process a predetermined number of times, the first cross-girder structure A4 made of the first material R1 'is completed.

  Subsequently, as shown in FIG. 14, the first cross beam structure A4 is moved to the mold forming apparatus 400, and a mold C1 covering the periphery of the first cross beam structure A4 is formed.

  Although illustration is omitted, the mold forming apparatus 400 includes a powder container for storing the first cross beam structure A4. After placing the first stringer structure A4 in this powder container, the powder constituting the mold C1 is put into the powder container so that the first stringer structure A4 is buried. In addition, after throwing powder into a powder container, it is also possible to mount 1st cross-girder structure A4 on the upper part. In this case, it installs so that the uneven | corrugated surface of 1st cross-girder structure A4 and powder may closely_contact | adhere without gap, applying force from the upper part to such an extent that 1st cross-girder structure A4 is not damaged.

  The shape of the mold C1 to be formed may be any shape, and therefore the shape of the powder container may be arbitrary. The material of the powder container is not limited as long as it has a heat resistance equal to or higher than the curing temperature in the curing process of the mold C1, and metal or glass can be used, and plastic, wood, or cardboard can be used depending on the curing temperature conditions. it can. As the powder constituting the mold C1, silica sand (a mixture of oxides mainly composed of silicon dioxide) can be suitably used. Specifically, a caking material (clay such as bentonite) or a powder obtained by adding water glass such as an aqueous sodium silicate solution as a binder can be used and is commercially available.

  Moreover, since this powder transfers the surface shape of 1st girder structure A4, it is desirable for the particle size to be fine and uniform. As an example, a powder having a particle size of around 50 μm is commercially available. By forming the mold C1 using such a powder, a final product having an arithmetic average roughness Ra of about 10 μm can be obtained. It should be noted that the amount of powder spread in the powder container is sufficient if it is not less than the height corresponding to the thickness that can maintain the shape of the mold in the steps described later. Depending on the type of silica sand material and the setting of the temperature in the process described later, a height of about several centimeters to several tens of centimeters is sufficient in addition to the height of the first cross beam structure A4. In addition, it is desirable that the upper surface of the powder is as horizontal as possible in the container after the powder is spread.

  After the powder is spread in the powder container and the first cross-girder structure A4 is embedded in the powder, a temporary curing step of the powder is performed. The temporary curing step is performed at a temperature of about 250 ° C. to 300 ° C., for example. As a result, the silica sand and the binder in the powder are bonded and temporary curing is performed. In the heating step of the temporary curing step, it is possible to apply pressure from above the powder.

  Next, as shown in FIG. 14, a hole H1 is formed on the upper surface of the mold C1. The hole H1 can also be formed at a stage before the mold C1 is temporarily cured. For example, when the powder is charged, the hole H1 can be formed in advance before temporary hardening by mounting a hollow pipe on the surface of the first stringer structure A4.

  Thereafter, the mold C1 that has been temporarily cured is taken out from the powder container of the mold forming apparatus 400, and a heating process is performed at a temperature higher than that of the previous process. By this heating process, the main curing process is performed on the mold C1, and the mold C1 is solidified. Furthermore, the first stringer structure A4 in the mold C1 is incinerated and removed by heat treatment at a higher temperature, for example, several hundred degrees C. For example, when polyethylene is selected as the material for the first girder structure A4, when heated at 300 ° C. to 400 ° C. in the air atmosphere, the polyethylene burns and gasifies and disappears from the mold to form a cavity. Can do. After the first cross beam structure A4 is incinerated and removed, the cavity AG derived from the outer shape of the first cross beam structure A4 remains in the mold C1.

  Then, as shown in FIG. 16, the casting mold C1 is moved to the metal or ceramic casting apparatus 500, and a casting process is performed. That is, the second material R2 ', which is an inorganic substance such as a molten metal material or ceramic material, is poured into the mold C1 through the hole H1. Through the cooling process for a predetermined time, the injected material is solidified inside the mold C1 to form a second well structure A5 made of the second material R2 '. The second material R2 'can be a metal or a ceramic material. As an example of the metal, aluminum die casting can be used, and ADC1, ADC12, etc., in which silicon (Si) or copper (Cu) is added to aluminum (Al), and a trace amount of inorganic material is blended, are used. it can. Specifically, these aluminum die-cast materials are heated to around 600 to 650 ° C., melted, and poured into the mold C1 from the hole H1 with the viscosity sufficiently lowered. At this time, it is preferable to adjust the injection speed so that bubbles (voids) do not remain inside the molten metal. After the injection, the entire mold is cooled to complete the second single girder structure A5 of a single metal.

  When the second material R2 'is made of ceramic, a ceramic precursor solution is prepared. For example, when a silicon-based ceramic (main component: silicon oxide) is formed, a solution containing polycarbosilane or polyorganoborosilazane as a main component is used. This solution is poured into the mold C1 from the hole H1 at room temperature. At this time, it is preferable to inject by adjusting the injection speed so that bubbles do not remain in the solution.

  Next, the ceramic is fired. This firing process is desirably performed in multiple stages, and it is desirable to proceed with firing in a stepped temperature profile from a low temperature to a high temperature. Finally, firing is completed at 850 to 1000 ° C., and the second material R 2 ′ of the ceramic single body is solidified.

  When the second cross beam structure A5 (second material R2 ') is solidified, the mold C1 is then removed by a physical method (destruction treatment) or a chemical method (etching or the like) (see FIG. 17). The second cross beam structure A5 has substantially the same shape as the removed first cross beam structure A4.

  Thereafter, the second cross beam structure A5 is moved to the molten resin injection device 600, and the liquid third material R3 as the resin material is injected or impregnated into the gap portion. When the third material R3 is cured, a third cross-girder structure A6 in which the second material R2 '(metal or ceramic) and the third material R3 (resin) are incorporated in a cross-girder structure is completed. For example, a container containing a resin liquid (thermosetting resin) in which a certain amount of a crosslinking agent is mixed with an unsaturated material such as an epoxy resin, a silicon resin, or a phenol resin is prepared. Immerse A5. In order to prevent bubbles from forming, the second girder structure A5 is sufficiently infiltrated into the resin liquid, and then pulled up and heated to cause a crosslinking reaction, thereby forming a resin layer in the gap between the second resin materials R2. As a result, a third cross beam structure A6 in which the gap in the second cross beam structure A5 is filled with resin is completed (see FIG. 18). The ceramic described above is a silicon-based ceramic (main component: silicon oxide), but is not limited thereto, and may be a ceramic mainly composed of calcium oxide, aluminum oxide, boron oxide, or a mixture thereof. It may be.

Also according to the second embodiment, different types of materials such as inorganic materials such as metals and ceramics and resin materials are incorporated into one material with a cross-girder structure, so that bonding between a plurality of types of materials is strong. can do. In particular, in an environment where heating and cooling are repeated such as in a heat cycle, the interface between materials is complex in the structure, so even if there is a difference in linear expansion coefficient, the distortion is Since the stress is not concentrated on the whole surface and on a specific surface, the joint is maintained well without breaking.
In addition, a structure that is composited with a metal or a resin for a ceramic single body or a structure that is composited with a resin for a single metal can expand the elastic deformation area for bending, and is more flexible than a single ceramic or metal. A material rich in properties can be provided.

  As described above, the method for manufacturing a shaped article and the shaped article according to the embodiment of the present invention have been described in detail. The present invention can be variously modified and applied in accordance with the gist. In the following, some possible modifications will be described.

[Modification 1]
First, Modification 1 will be described with reference to FIG.
In FIG. 10, the first material R1 of the first cross beam structure A3 is described as being a thermoplastic resin, and the second material R2 and the third material R3 are described as being metal. In the first modification, the second material R2 is not used, and the third material R3 is replaced with metal and mica is used. Mica is a layered silicate consisting of silicon dioxide, aluminum oxide, potassium oxide and crystal water that are naturally produced as minerals. For example, chemical formulas such as KAl ₂ (Si ₃ Al) O ₁₀ (OH) ₂ and KMg ₃ (Si ₃ Al) O ₁₀ (OH) ₂ are representative examples.

  With reference to the block diagram of FIG. 19, the structure of the manufacturing apparatus for manufacturing the molded article which concerns on the modification 1 is demonstrated. This manufacturing apparatus includes a 3D printer 100, a mica slurry injection device 700, and a drying / vacuum press device 800.

  In this manufacturing apparatus, first, using the 3D printer 100, the first cross-girder structure A1 made of the first material R1 that is a resin material is created. Thereafter, liquid mica slurry (a suspension of mica) is injected into the gaps of the first well structure A1 by the slurry injection device 700. Thereby, the cross-girder structure A4 incorporating the cross-girder structure of the resin material (first material R1) and the mica cross-girder structure is manufactured.

  Subsequently, the cross-girder structure A4 is moved to the drying / vacuum press apparatus 800 and dried to remove moisture from the cross-girder structure A4. Then, vacuum pressing is performed to completely remove moisture inside. Further, the void from which water has been removed is removed by pressing. Here, the mica used for the mica slurry is particles having a distribution in the range of several microns to several tens of microns, and those dispersed in water can be used.

  Such a resin and mica well structure A4 reflects the heat resistance characteristic peculiar to mica, improves the heat resistance, and can be a structure excellent in bending characteristics. Moreover, it can be set as the structure which has a strong characteristic also with respect to delamination.

[Modification 2]
Next, Modification 2 will be described with reference to FIG.
As illustrated in FIG. 20, the manufacturing apparatus for a shaped article according to the second modification includes a 3D printer 100 ′, a mold forming apparatus 400, a ceramic casting apparatus 550, and a molten metal injection apparatus 900.

  The 3D printer 100 ′ and the mold forming apparatus 400 can be the same as those in the second embodiment (FIG. 12). However, in the second embodiment, the second material R2 ′ of the third girder structure A6 is a metal or ceramic, and the third material R3 is a thermosetting material such as an epoxy resin, a silicon resin, or a phenol resin. It is made of resin. On the other hand, in the second modification, the second material R2 'is ceramic, and the third material R3 is metal. The metal that is the third material R3 is impregnated in the gap of the second material R2 'that forms a cross-girder structure in a state of being melted in the molten metal injection apparatus 900. Here, the metal used as the third material R3 can use the above-described aluminum die casting. However, since this metal is in contact with the second material R2 ′ as the fired ceramic, a metal having a melting point higher than that of the aluminum die casting is used. It can also be used.

  The manufacturing method of this modification 2 is demonstrated referring FIG. After the first cross beam structure A4 is created by the 3D printer 100 ', a mold is formed using the mold forming apparatus 400, and then the first cross beam structure A4 formed by the 3D printer 100 is lost. The steps so far are the same as those in the second embodiment.

Then, a casting_mold | template is moved to the ceramic casting apparatus 550, and a casting process is performed. That is, the second material R2 ′, which is a molten ceramic material, is poured into the mold. By passing through the cooling process for a predetermined time, the injected material R2 is solidified inside the mold C1, and a second well structure A5 made of the second material R2 ′ is formed. Further, the second cross beam structure A5 is moved to the molten metal injection device 900, and the third material R3, which is a molten metal, is injected into the second cross beam structure A5. Such a ceramic and metal cross-girder structure reflects the property of having a high melting point, improves heat resistance, and can be a structure having both strength and flexibility.

[Modification 3]
Next, Modification 3 will be described with reference to FIG.
As shown in FIG. 21, the manufacturing apparatus for a shaped article according to Modification 3 includes a 3D printer 100 ′, a mold forming device 400, a metal casting device 560, and a molten metal injection device 910.

The 3D printer 100 ′ and the mold forming apparatus 400 can be the same as those in the second modification. However, in the modification 3, 2nd material R2 'of 3rd cross beam structure A6 is a metal, and 3rd material R3 is also a metal similarly. The melting point of the metal of the second material R2 ′ needs to be higher than the melting point of the metal of the third material R3. The second material R2 ′ is formed by the metal casting device 560, while the third material R3 is injected by the molten metal injection device 910.
The manufacturing method of this modification 3 is demonstrated referring FIG. After the first cross-girder structure A1 is created by the 3D printer 100, the process up to forming the mold using the mold forming apparatus 400 is the same as in the second embodiment and the second modification.

  Then, instead of injecting the thermosetting resin into the mold, the metal casting device 560 flows the second material R2 ', which is a molten metal, into the mold. Then, after the solidification of the metal of the second material R2 ', the mold is removed, and the molten metal as the third material R3 is injected by the molten metal injection device 910 into the remaining gap of the cross beam structure.

  Such a girder structure made of two kinds of metals can be made into a composite of two kinds of metals that cannot coexist with conventional casting methods. In addition, the unique properties of each metal can be reflected. In general, a material has two deformation regions, an elastic deformation region and a plastic deformation region, in the load-deformation amount (elongation amount, etc.) characteristic, and the ratio of the region differs depending on the material. In the cross-girder structure according to the third modified example, by combining two metal materials having different ratios, a structure having high strength and flexibility can be obtained. As an example, by using a cross-girder structure that combines a first metal having a relatively narrow elastic deformation region and a wide plastic deformation region and a second metal having a relatively large elastic deformation region and a narrow plastic deformation region. The structure can be made tough. An example of the first metal is a carbide (carbite) of iron or nickel, and an example of the second metal is aluminum.

[Modification 4]
In the above-described embodiment and the modified cross-girder structure described above, the pitches of the two kinds of materials on the XY plane are both equal and constant. However, the present invention is not limited to this.
As shown in FIG. 22, it may be a density variable cross-girder structure A7 in which the pitch and density of the constituent material (first material R1) change in the height direction (Z direction). If comprised in this way, it can be set as the cross-girder structure which has the gradation of a height direction about 2 component composition.

  As a method for manufacturing such a girder structure, it is only necessary to form a girder structure A7 in which the pitch and density of the first material R1 are variable in the 3D printers 100 and 100 ′ as shown in FIGS. . Using this pitch variable cross-girder structure A7, a material R4 different from the first material R1 is further embedded in the gap of the cross-girder structure A7. The cross-girder structure A8 manufactured using such two types of materials R1 and R4 constitutes a cross-girder structure whose overall material density is variable as shown in FIG. Since such a density variable well beam structure has gradation in the height direction, it can have different properties on the upper surface and the lower surface. For example, it can be used as a member for joining structures made of two different materials having poor adhesive strength, thereby realizing strong adhesion.

  As mentioned above, although several embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

DESCRIPTION OF SYMBOLS 100 ... 3D printer, 200 ... Computer, 300 ... Driver, 11 ... Frame, 12 ... XY stage, 13 ... Modeling stage, 14 ... Lifting table, 15 ... Guide shaft, 21 ... frame, 22 ... X guide rail, 23 ... Y guide rail, 24A, 24B ... filament holder, 25A, 25B ... modeling head, 31 ... frame 34, 35 ... Rollers, 38A, 38B ... Filaments.

Claims (17)

In the first layer, the first material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the first layer on the upper side of the first layer is arranged. In the second layer, the first material is continuously formed in a third direction intersecting the first direction and arranged with a gap in the fourth direction intersecting the third direction. Forming a first well structure;
Depositing a thin film of a second material on the wall surface of the first girder structure using an electroless plating method to form a second girder structure;
A method for producing a shaped article, comprising: performing an electrolytic plating method on the second girder structure to deposit a third material in the gap to form a third girder structure.   The method for manufacturing a shaped article according to claim 1, wherein the first material is formed by a 3D printer.   The method for manufacturing a shaped article according to claim 2, wherein the first material is a resin material having thermoplasticity. In the first layer, the first material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the first layer on the upper side of the first layer is arranged. In the second layer, the first material is continuously formed in a third direction intersecting the first direction and arranged with a gap in the fourth direction intersecting the third direction. Forming a first well structure;
Forming a mold covering the first well structure;
Removing the first girder structure leaving the mold; and
Forming a second stringer structure by pouring and solidifying a molten second material into the mold; and
Removing the mold leaving the second well structure,
Forming a third cross-girder structure by injecting and solidifying a liquid third material into the gap with respect to the second cross-girder structure.   The method according to claim 4, wherein the removal of the first cross beam structure is performed by a heat treatment.   The method for manufacturing a shaped article according to claim 4, wherein the first material is formed by a 3D printer.   The method for manufacturing a shaped article according to claim 6, wherein the first material is a resin material having thermoplasticity. In the first layer, the resin material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the second layer on the upper side of the first layer. In the layer, the resin material is continuously formed in a third direction intersecting with the first direction and arranged with a gap in a fourth direction intersecting with the third direction. The structure is composed,
A modeled object in which a metal material is configured in the gap of the first cross beam structure. The metal material is composed of a first layer in contact with the first girder structure, and a second layer located above the first layer,
The first layer is a columnar crystal having a crystal orientation perpendicular to the surface of the resin material,
The shaped article according to claim 8, wherein the second layer is a columnar crystal having a crystal orientation perpendicular to the surface of the first layer.   The model according to claim 8, wherein the second layer crystal is rougher than the first layer crystal.   The shaped object according to claim 8, wherein the second layer has crystal orientations extending in a plurality of directions in a hollow portion of the first cross beam structure.   The model according to claim 11, wherein the second layer crystal is rougher than the first layer crystal. The metal material is composed of a first layer in contact with the first girder structure and a second layer that is an upper layer of the first layer,
The shaped article according to claim 8, wherein the first layer is made of a metal material having at least phosphorus or boron. In the first layer, the metal material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the second material on the upper part of the first layer. In the layer, the metal material is continuously formed in a third direction intersecting with the first direction and arranged with a gap in a fourth direction intersecting with the third direction. The structure is composed,
A modeled object in which a metal material made of a material different from a resin material or the metal material is configured in the gap of the first cross beam structure.   The shaped article according to claim 14, wherein the resin material is a thermosetting resin. In the first layer, the ceramic material is continuously formed in the first direction and arranged with a gap in the second direction intersecting the first direction, and the second material on the top of the first layer. In the layer, the ceramic material is continuously formed in a third direction intersecting with the first direction and arranged with a gap in a fourth direction intersecting with the third direction. The structure is composed,
A molded article, wherein a resin material or a metal material is formed in the gap of the first cross beam structure.   The shaped article according to claim 16, wherein the resin material is a thermosetting resin.

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