JPWO2018199041A1 - Manufacturing method of three-dimensionally shaped object and three-dimensionally shaped object - Google Patents

Abstract

Provided is a method for manufacturing a three-dimensionally shaped object in which powder layer formation and solidified layer formation are alternately repeated. In the manufacturing method of the present invention, the density change region where the density of the three-dimensionally shaped object is locally different is provided on the surface portion including the inclined surface of the three-dimensionally shaped object, and the density change region includes the surface in the surface portion including the inclined surface. Varies the density according to the angle formed by the solidified layer and the stacking direction.

Description

  The present disclosure relates to a method for manufacturing a three-dimensionally shaped object and a three-dimensionally shaped object. More specifically, the present disclosure relates to a method of manufacturing a three-dimensionally shaped object that forms a solidified layer by irradiating a powder layer with a light beam, and also relates to a three-dimensionally shaped object obtained thereby.

A method of manufacturing a three-dimensionally shaped object by irradiating a powder material with a light beam (generally referred to as a “powder bed fusion bonding method”) is conventionally known. Such a method produces a three-dimensional shaped object by alternately and repeatedly performing the formation of a powder layer and the formation of a solidified layer based on the following steps (i) and (ii) (see Patent Document 1 or Patent Document 2). .
(I) a step of irradiating a predetermined portion of the powder layer with a light beam and sintering or melting and solidifying the powder at the predetermined portion to form a solidified layer;
(Ii) a step of forming a new powder layer on the obtained solidified layer and similarly irradiating a light beam to form a further solidified layer;

  According to such a manufacturing technique, it is possible to manufacture a complex three-dimensionally shaped object in a short time. When an inorganic metal powder is used as the powder material, the obtained three-dimensionally shaped object can be used as a mold. On the other hand, when an organic resin powder is used as the powder material, the resulting three-dimensionally shaped object can be used as various models.

  A case where a metal powder is used as a powder material and a three-dimensionally shaped object obtained thereby is used as a mold will be described as an example. As shown in FIG. 12, first, the powder 19 is transferred by moving the squeezing blade 23 to form a powder layer 22 having a predetermined thickness on the modeling plate 21 (see FIG. 12A). Next, the solidified layer 24 is formed from the powder layer by irradiating a predetermined portion of the powder layer with the light beam L (see FIG. 12B). Subsequently, a new powder layer is formed on the obtained solidified layer, and the light beam is irradiated again to form a new solidified layer. When the formation of the powder layer and the formation of the solidified layer are alternately repeated in this manner, the solidified layers 24 are stacked (see FIG. 12C), and finally, the three-dimensional shape of the stacked solidified layers is formed. A shaped object can be obtained. Since the solidified layer 24 formed as the lowermost layer is bonded to the modeling plate 21, the three-dimensionally shaped object and the modeling plate form an integrated body, and the integrated body can be used as a mold. it can.

Japanese Patent Publication No. Hei 1-502890 JP-A-2000-73108

  When a three-dimensionally shaped object is used as a mold, a molding material in a molten state (hereinafter, referred to as “mold side”) is formed in a mold cavity space formed by combining a so-called “core side” and “cavity side” mold. (Also referred to as "molten raw material"). Specifically, a molded product is obtained by pouring a molten raw material into a mold cavity space and cooling the poured molten raw material. In other words, a molded article is obtained by the molten raw material flowing and filling the mold cavity space while the molten raw material changes to a solidified state.

  In the obtained molded product, linear marks may be generated due to the flow of the molten raw material in the mold cavity space. That is, a so-called "weld line" occurs in the molded product. Weld lines are undesirable in terms of the appearance of the molded article. Also, the weld line is not desirable in terms of the strength of the molded product. Therefore, in order to reduce the number of weld lines, for example, a gas existing in the mold cavity space or a gas generated from the molten raw material when the molten raw material is filled is discharged to the outside (hereinafter, also referred to as “gas release”).

  The inventor of the present application has noticed that there is a problem to be overcome in the conventional gas venting, and has found that it is necessary to take measures for that. Specifically, the present inventor has found that there are the following problems.

  When a mold made of a three-dimensionally shaped object is used, it is conceivable to provide fine holes on the surface of the three-dimensionally shaped object and to perform degassing using the region of the fine holes as a ventilation region. In such a ventilation region, the fine holes themselves function as gas passages. Therefore, it is preferable in terms of degassing. However, there is a possibility that the surface of the molded article becomes rough due to the fine holes. In other words, when the ventilation area is provided on the surface of the mold, the ventilation area itself may have an adverse effect on the surface of the molded product, and high-quality molding transfer may be difficult. This means that in the case of a mold provided with a ventilation area on the surface, there is a trade-off between "gas release characteristics" and "high-quality transfer characteristics". In particular, the inventor of the present application has found that when a mold surface having a ventilation area includes an “inclined surface”, a unique transfer characteristic is exhibited, and the surface roughness of the molded product may not be negligible.

  The present invention has been made in view of such circumstances. That is, a main object of the present invention is to provide a three-dimensionally shaped object that is more suitable as a mold having a ventilation area.

In order to solve the above problem, in one embodiment of the present invention,
(I) a step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) a new powder on the obtained solidified layer. Forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer, wherein the powder layer formation and the solidified layer formation are alternately repeated to produce a three-dimensionally shaped object manufacturing method. And
A density change region where the density of the three-dimensional shaped object is locally different is provided on the surface portion including the inclined surface of the three-dimensional shaped object,
In the density change region, there is provided a method for manufacturing a three-dimensionally shaped object, in which the density locally varies according to the angle formed by the surface of the object including the inclined surface and the direction in which the solidified layer is formed.

In one embodiment of the present invention, a three-dimensional structure obtained by the above manufacturing method is also provided. One embodiment of the present invention is a three-dimensional structure including a solidified layer stacked, and having a slope.
A density change region where the density of the three-dimensional shaped object is locally different is provided on the surface portion including the inclined surface,
In the density change region, the density is locally different depending on the angle between the surface of the modeled object including the inclined surface and the direction in which the solidified layer is formed.

  According to one embodiment of the present invention, it is possible to more suitably obtain a three-dimensionally shaped object having a ventilation region. More specifically, in one embodiment of the present invention, a three-dimensional shaped object can be obtained as a mold that suitably exhibits both “gas release characteristics” and “high-quality transfer characteristics”.

  In particular, in a mold including a three-dimensionally shaped object according to one embodiment of the present invention, high-quality transfer characteristics can be ensured even in a ventilation region having an “inclined surface”, while ensuring favorable “gas release characteristics”. Can be obtained. That is, it is possible to reduce the roughness of the surface of the molded product while securing suitable degassing characteristics.

  In addition, for example, when a cylindrical molded product is molded by a mold, a weld line is usually easily generated at the tip of the cylindrical molded product. According to one aspect of the present invention, it is possible to provide a mold with a wider ventilation area for effectively reducing such a weld line.

FIG. 2 is a cross-sectional view schematically illustrating a three-dimensional structure (a three-dimensional structure having an inclined surface as a “non-smooth surface”) according to one embodiment of the present invention. FIG. 2 is a cross-sectional view schematically illustrating a three-dimensional structure (a three-dimensional structure having an inclined surface as a “smooth surface”) according to one embodiment of the present invention. Schematic diagram for explaining “roughness of molded product surface due to surface opening” Sectional view of a three-dimensionally shaped object for explaining the micropore structure in the density change region Sectional view of a three-dimensionally shaped object for explaining an embodiment in which a hollow path is provided Sectional view of a three-dimensionally shaped object for explaining an embodiment in which a “solidified portion of random micropores” is provided in a hollow passage Perspective view partially showing a cylindrical molded product Perspective perspective view partially showing a mold for obtaining a cylindrical molded product Sectional view of a three-dimensionally shaped object for explaining an embodiment having two hollow paths Sectional view of a three-dimensionally shaped object for explaining an aspect in which the density changes inward. Sectional view of a three-dimensionally shaped object for explaining an aspect in which an outer peripheral portion is a region of random micropores or a high density region FIG. 12A is a cross-sectional view schematically showing a process of stereolithography combined processing in which a powder bed fusion bonding method is performed (FIG. 12A: powder layer formation, FIG. 12B: solidified layer formation, FIG. 12C) : Lamination of solidified layer) Perspective view schematically showing the configuration of an optical molding multi-tasking machine Flow chart showing the general operation of the stereolithography multitasking machine

  Hereinafter, an embodiment of the present invention will be described in more detail with reference to the drawings. The shapes and dimensions of various elements in the drawings are merely examples, and do not reflect actual shapes and dimensions.

  In the present specification, the “powder layer” means, for example, a “metal powder layer made of metal powder” or a “resin powder layer made of resin powder”. The “predetermined portion of the powder layer” substantially indicates a region of the three-dimensionally shaped object to be manufactured. Therefore, by irradiating the light beam on the powder present at such a predetermined location, the powder is sintered or melt-solidified to form a three-dimensionally shaped object. Further, the “solidified layer” means a “sintered layer” when the powder layer is a metal powder layer and a “hardened layer” when the powder layer is a resin powder layer. Note that the metal powder used in one embodiment of the present invention is a powder mainly containing an iron-based powder, and in some cases, a group including a nickel powder, a nickel-based alloy powder, a copper powder, a copper-based alloy powder, and a graphite powder. The powder may further comprise at least one selected from the group consisting of:

  The “up and down” directions described directly or indirectly in this specification are based on the positional relationship between the modeling plate and the three-dimensional shaped object at the time of manufacturing the three-dimensional shaped object. Specifically, the side on which the three-dimensionally shaped object is manufactured is referred to as “upward” with respect to the modeling plate, and the opposite side is referred to as “downward”. For convenience, it can be considered that a vertically downward direction (that is, a direction in which gravity acts) corresponds to “downward”, and the opposite direction corresponds to “upward”.

  Further, the `` cross-sectional view '' used directly or indirectly in the present specification is equivalent to a side view when the powder bed fusion bonding method is viewed from the side or viewed along the horizontal direction, For simplicity, it may be regarded as a cross-sectional view of a three-dimensionally shaped object obtained when the three-dimensionally shaped object is virtually cut off on a plane parallel to the lamination direction of the solidified layer.

[Powder bed fusion bonding method]
First, a powder bed fusion method which is a premise of the production method according to one embodiment of the present invention will be described. In particular, a stereolithography combined machining in which a cutting process is additionally performed on a three-dimensionally shaped object in the powder bed fusion bonding method will be described as an example. FIG. 12 schematically shows a process mode of the optical molding combined processing. FIG. 13 and FIG. 14 respectively show a main configuration and a flowchart of an operation of the laser beam multi-tasking machine capable of performing the powder bed fusion bonding method and the cutting process.

  As shown in FIG. 13, the stereolithography machine 1 includes a powder layer forming unit 2, a light beam irradiation unit 3, and a cutting unit 4.

  The powder layer forming means 2 is a means for forming a powder layer by laying a powder such as a metal powder or a resin powder at a predetermined thickness. The light beam irradiation means 3 is a means for irradiating a predetermined portion of the powder layer with the light beam L. The cutting means 4 is a means for cutting the side surface of the stacked solidified layer, that is, the surface of the three-dimensionally shaped object.

  As shown in FIG. 12, the powder layer forming means 2 mainly has a powder table 25, a squeezing blade 23, a support table 20, and a shaping plate 21. The powder table 25 is a table that can move up and down in a powder material tank 28 whose outer periphery is surrounded by a wall 26. The squeezing blade 23 is a blade that can move the powder 19 on the powder table 25 in the horizontal direction so as to provide the powder layer 22 on the support table 20. The support table 20 is a table that can move up and down in a modeling tank 29 whose outer periphery is surrounded by a wall 27. The modeling plate 21 is a plate that is disposed on the support table 20 and serves as a base for a three-dimensionally shaped object.

  The light beam irradiation means 3 mainly includes a light beam oscillator 30 and a galvanomirror 31, as shown in FIG. The light beam oscillator 30 is a device that emits a light beam L. The galvanomirror 31 is a unit for scanning the emitted light beam L on the powder layer 22, that is, a scanning unit for the light beam L.

  The cutting means 4 mainly has an end mill 40 and a drive mechanism 41 as shown in FIG. The end mill 40 is a cutting tool for shaving the side surface of the solidified layer, that is, the surface of the three-dimensionally shaped object. The drive mechanism 41 is means for moving the end mill 40 to a desired cutting position.

  The operation of the stereolithography machine 1 will be described in detail. As shown in the flowchart of FIG. 14, the operation of the stereolithography machine 1 includes a powder layer forming step (S1), a solidified layer forming step (S2), and a cutting step (S3). The powder layer forming step (S1) is a step for forming the powder layer 22. In the powder layer forming step (S1), first, the support table 20 is lowered by Δt (S11) so that the level difference between the upper surface of the modeling plate 21 and the upper end surface of the modeling tank 29 becomes Δt. Next, after raising the powder table 25 by Δt, the squeegee blade 23 is moved in the horizontal direction from the powder material tank 28 toward the modeling tank 29 as shown in FIG. Thereby, the powder 19 arranged on the powder table 25 can be transferred onto the modeling plate 21 (S12), and the powder layer 22 is formed (S13). Examples of the powder material for forming the powder layer 22 include “metal powder having an average particle size of about 5 μm to 100 μm” and “resin powder such as nylon, polypropylene, or ABS having an average particle size of about 30 μm to 100 μm”. it can. After the powder layer 22 is formed, the process proceeds to a solidified layer forming step (S2). The solidified layer forming step (S2) is a step of forming the solidified layer 24 by light beam irradiation. In the solidified layer forming step (S2), the light beam L is emitted from the light beam oscillator 30 (S21), and the light beam L is scanned to a predetermined position on the powder layer 22 by the galvanomirror 31 (S22). As a result, the powder at a predetermined portion of the powder layer 22 is sintered or melt-solidified to form a solidified layer 24 as shown in FIG. 12B (S23). As the light beam L, a carbon dioxide laser, a Nd: YAG laser, a fiber laser, an ultraviolet ray, or the like may be used.

  The powder layer forming step (S1) and the solidified layer forming step (S2) are performed alternately and repeatedly. As a result, a plurality of solidified layers 24 are stacked as shown in FIG.

  When the laminated solidified layer 24 reaches a predetermined thickness (S24), the process proceeds to a cutting step (S3). The cutting step (S3) is a step for cutting the side surface of the stacked solidified layer 24, that is, the surface of the three-dimensionally shaped object. The cutting step is started by driving the end mill 40 (see FIGS. 12C and 13) (S31). For example, when the end mill 40 has an effective blade length of 3 mm, a cutting process of 3 mm can be performed along the height direction of the three-dimensional molded object. When the solidified layer 24 is laminated, the end mill 40 is driven. Specifically, while the end mill 40 is moved by the drive mechanism 41, a cutting process is performed on the side surface of the stacked solidified layer 24 (S32). At the end of such a cutting step (S3), it is determined whether or not a desired three-dimensionally shaped object has been obtained (S33). If the desired three-dimensionally shaped object has not been obtained yet, the process returns to the powder layer forming step (S1). Thereafter, by repeating the powder layer forming step (S1) to the cutting step (S3) to further laminate and cut the solidified layer, a desired three-dimensionally shaped object is finally obtained.

[Production method of the present invention]
The manufacturing method according to one aspect of the present invention is characterized by the formation of a solidified layer with respect to the powder bed fusion bonding method described above. In particular, a characteristic is given to the density of the surface portion of a three-dimensionally shaped object obtained by forming a solidified layer.

  In the manufacturing method according to one embodiment of the present invention, a “density change region” in which the density of the three-dimensionally shaped object is locally different is provided in a surface portion including the inclined surface of the three-dimensionally shaped object. In other words, a “density change region” is provided in the three-dimensionally shaped object such that the density of the three-dimensionally shaped object changes along the surface portion including the inclined surface. As shown in FIGS. 1 and 2, in manufacturing the three-dimensionally shaped object 100, the density change region 150 is formed so as to have a thickness from the surface 110 of the object to the inside.

In particular, in the manufacturing method according to one embodiment of the present invention, the density change in accordance with “the angle formed by the surface of the modeled object including the inclined surface and the stacking direction of the solidified layer (hereinafter, also simply referred to as“ surface angle ”)” The density of the region 150 is locally different. In short, in the density change region 150, the density is locally changed according to the surface angle of the modeled object surface 110. This means that when the three-dimensionally shaped object 100 having the inclined surface is manufactured, the solidified layer is formed so that the density of the three-dimensionally shaped object changes according to the surface angle of the three-dimensional object. . In the embodiment shown in FIG. 1, in accordance with the surface angle (for example, θ _A , θ _B , θ _{C as shown} ) of the object surface 110 including the inclined surface, the area near the target surface (150A, 150B, 150C) Have different densities from each other. Similarly, in the embodiment shown in FIG. 2, according to the surface angles (for example, θ _a , θ _b , θ _c , θ _d , and θ _{e as shown} ) of the object surface 110 including the inclined surface, the target object is provided. The densities of the near-surface regions (150a, 150b, 150c, 150d, 150e) are different from each other. As can be seen from FIGS. 1 and 2, in the present invention, "the angle between the surface of the surface portion including the inclined surface and the stacking direction of the solidified layer" (i.e., "surface angle") is defined as "the surface angle". Among the angles formed by the lamination direction, it particularly indicates an angle on the side forming an acute angle. Note that, as will be described later, in one embodiment of the present invention, the surface portion including the outermost surface of the three-dimensionally shaped object has a density that gradually changes along the cross-sectional contour of the outermost surface. Is preferably produced.

  In the present specification, the “surface portion including the inclined surface of the three-dimensionally shaped object” refers to the surface of the three-dimensionally shaped object as viewed in cross section of the three-dimensionally shaped object as shown in FIGS. 1 and 2. It substantially means the surface portion of the modeled object in which the angle (that is, the “surface angle”) formed with the lamination direction of the solidified layer is not constant. In this specification, the expression "providing a density change region where the density of the three-dimensionally shaped object is locally different on the surface portion including the inclined surface of the three-dimensionally shaped object" is broadly defined for each local region. Means that density change regions having different densities are provided on the surface portion of the modeled object including the inclined surface. In a narrow sense, such an expression forms a density change region in which the density varies locally depending on the magnitude of the surface angle of the three-dimensionally shaped object when viewed in a sectional view of the three-dimensionally shaped object as illustrated. It means that it is provided with a thickness from the object surface. As can be understood from such a description, the term “inclined surface” as used in the present specification refers to a surface of a three-dimensionally shaped object where the angle formed with respect to the stacking direction is not constant in a cross-sectional view. And particularly preferably such a surface aspect in which the angle changes progressively along the surface of the object in question. It should be noted that such an inclined surface may have, for example, the form of “non-smooth surface” or “plurality of sub-planes” as illustrated in FIG. 1, or as illustrated in FIG. It may have the form of a “smooth surface” or a “curved surface”.

  Further, the expression such as “in the density change region, the surface in the surface portion including the inclined surface locally varies the density according to the angle formed by the solidification layer stacking direction” is used in the density change region in the density change region. This means that the density change and the degree of the surface inclination of the three-dimensionally shaped object have a correlation with each other. In other words, it can be said that the surface portion forming the surface angle has a density corresponding to the magnitude of the surface angle of the three-dimensionally shaped object.

  The magnitude of the surface angle will be described in detail with reference to the cross-sectional views of the three-dimensionally shaped object shown in FIGS. 1 and 2. When the angle formed by the surface of the three-dimensionally shaped object with respect to the lamination direction of the solidified layer constituting the three-dimensionally shaped object is smaller (that is, when the surface angle is small), the surface of the three-dimensionally shaped object is relatively steep. , And the degree of surface inclination becomes larger. In short, in such a case, it can be said that the degree of inclination is larger. On the other hand, when the angle formed by the surface of the three-dimensionally shaped object with respect to the stacking direction of the solidified layers constituting the three-dimensionally shaped object is larger (that is, when the surface angle is large), the surface of the three-dimensionally shaped object is relatively non- The surface becomes steep, and the degree of surface inclination becomes smaller. In short, in such a case, it can be said that the degree of inclination is smaller. In addition, as shown in FIG. 2, when the inclined surface of the three-dimensionally shaped object is curved, a tangent passing through the surface of the object in cross-sectional view may be used as the “virtual surface”. That is, the angle formed by the “virtual surface” and the “solidification layer stacking direction” may be used as the surface angle.

  In the manufacturing method according to one embodiment of the present invention, the density change region 150 has a density change, but is preferably provided as a low-density region as a whole. Although merely an example, the density change region 150 may be provided as a low-density region having a solidification density of 40 to 90%. In such a case, a region other than the density change region 150 (for example, the region 155 located inside the density change region as shown in FIGS. 1 and 2) is a high-density region (a region having a solidification density of 91 to 100%). ) May be provided. In other words, while the density change region 150 forms a low-density region having a solidification density of 40 to 90% as a whole, the three-dimensional shaping is performed such that the density in the low-density region gradually changes according to the surface angle. It is preferable to carry out the production of the product. A three-dimensionally shaped object having such a density change region 150 can be more suitably used as a mold. Specifically, when a three-dimensionally shaped object obtained by the manufacturing method according to one embodiment of the present invention is used as a mold, the density change region 150 can be used as a "venting region", And high-quality transfer characteristics can be suitably provided.

  As can be seen from the above description, the “density change region” in the present invention indicates a region in which at least one or more densities are different within the region. Such a density change region may have different densities in the region as described above, but the density in the region may be different from the density in other regions. In this regard, the density change region may form a low-density region having a lower density than a region other than the region. In such a case, a portion having a relatively high density with a large surface angle in the density change region may have a lower density than a region other than the density change region from a macroscopic viewpoint.

  In particular, in one embodiment of the present invention, even in a ventilation region provided on a surface portion including an “inclined surface”, both generation of a weld line and surface roughness of a molded product can be more effectively reduced. This will be described in detail. For example, let us assume a ventilation region having a fine hole shape as shown in FIG. As can be seen from the embodiment shown in the drawing, the surface openings of the micropores differ depending on the size of the surface angle in the ventilation region having an “inclined surface”. As a result, the occurrence of weld lines and the roughness of the molded product surface are reduced. You will be affected. For example, it is assumed that the “angle formed between the surface of the modeled object and the stacking direction of the solidified layer” is small. In such a case, since the surface opening of the fine holes is larger (see FIG. 3), the outgassing efficiency is high and the occurrence of weld lines can be reduced, but the surface of the molded article tends to be rough due to the large surface opening (fineness). The reason is that the raw material resin easily enters the micropores through the openings in the larger surface openings of the holes). Conversely, it is assumed that the “angle formed between the surface of the modeled object and the direction of lamination of the solidified layer” is large. In such a case, since the surface opening of the micropores is smaller (see FIG. 3), the roughness of the surface of the molded article can be reduced, but the gas venting efficiency can be reduced due to the small surface openings (see FIG. 3). Small surface openings have greater resistance to gas passage). In this regard, in one aspect of the present invention, a ventilation area whose density locally changes according to the magnitude of the surface angle can be provided. It is possible to take into account both the reduction in size and the size.

  In a preferred embodiment, the density increases relatively as the surface angle decreases in the density change region. That is, at a local surface portion where the surface angle becomes relatively small, the density of the three-dimensionally shaped object is relatively increased. Thereby, even in a local portion where the surface angle is small and the roughness of the molded product surface is generally concerned, such roughness can be suppressed. Without being bound by a particular theory, it is presumed that the higher the density of the three-dimensionally shaped object, the smaller the surface opening of the micropores on the inclined surface can be. By way of example based on the aspect shown in FIG. 1, the local portion 150C having a relatively small surface angle in the density change region 150 may have a higher density than the local portion 150A having a relatively large surface angle. Further, according to the example shown in FIG. 2, the local portion 150d or 150e having a relatively small surface angle in the density change region 150 is, for example, smaller than the local portion 150b or 150a having a relatively large surface angle. The density may be increased. In this way, the surface opening size of the micropores at the local portion where the surface angle is relatively small (in short, at a portion where the degree of inclination is larger) does not need to be too large, and the raw material resin becomes fine during molding. It becomes difficult to enter the holes, and the roughness of the molded product surface can be reduced.

  In the manufacturing method according to one embodiment of the present invention, the density in the density change region may be gradually changed along the surface portion including the inclined surface. In other words, the change in density according to the surface angle may be referred to as “gradual change”. This means that as the surface angle decreases or increases, the density of the local portion of the density change region changes stepwise. In short, it means that the density of the local portion of the density change region is changed stepwise as the degree of the surface inclination increases or decreases. By way of example based on the embodiment shown in FIG. 1, the density of such a portion may be gradually increased with the local portions 150A → 150B → 150C where the surface angle becomes relatively small. The same applies to the embodiment shown in FIG. 2, and the local portion 150a → 150b → 150c → 150d → 150e where the surface angle becomes relatively small, the density of such a portion may be gradually increased. This makes it easier to optimize both the gas venting efficiency and the surface roughness of the molded product in the entire ventilation area. In particular, the improvement in outgassing efficiency can be mainly brought about by the lower outgassing resistance in the parts having relatively low density. On the other hand, the reduction in the roughness of the molded product surface can be mainly brought about by the relatively high density of the portion where the surface angle is originally small and the roughness of the molded product surface is concerned. This is because a portion having a relatively high density has fewer voids into which the resin enters, and therefore contributes to a reduction in the roughness of the molded product surface.

  In addition, the region where the angle between the stacking direction of the solidified layer and the surface of the modeled object is substantially 0 ° may be, for example, a high-density region having a solidification density of 91 to 100%. 1 and 2, the surface area of “151” may be formed as a high-density area. When a three-dimensionally shaped object is used as a mold, a region where the stacking direction of the solidified layer and the angle between the surface of the formed object is substantially 0 ° is a region in which weld lines are less likely to be generated. This is because it can be used to improve the structural strength of the three-dimensionally shaped object. In other words, it is possible to achieve both improvement of the degassing efficiency and reduction of the roughness of the molded product surface while securing the strength required for the mold. As can be seen from FIGS. 1 and 2, the “mode in which the region where the surface angle is substantially 0 ° is the high-density region” is the outermost region (or the inclined surface portion) in the horizontal direction of the three-dimensional structure. At least a part of the peripheral region that is more inside with respect to the "high-density region through which air cannot pass".

  In a preferred embodiment, the density change region has a microporous structure. That is, in the manufacturing method according to one embodiment of the present invention, fine holes may be formed to serve as a “density change region” of the three-dimensional structure. Since the micropores form voids in the three-dimensionally shaped object, when the three-dimensionally shaped object is used as a mold, the micropores serve as vents and can contribute to gas release. The term “micropores” in the present specification refers to pores having an average pore size on the order of microns, for example, an average pore size of about 10 to 150 μm (based on a cross-sectional image of a three-dimensionally shaped object. Average pore size).

The microporous structure can be obtained by relatively lowering the irradiation energy of the light beam irradiating the powder region when the solidified layer is formed. For example, a region of a three-dimensionally shaped object having no micropore structure, that is, a high-density region (for example, a solidification density of 91 to 100%) is irradiated with a light beam having an irradiation energy density E of about 8 to 15 J / mm ^2. On the other hand, in a density change region having a micropore structure (for example, a solidification density of 40 to 90%), a light beam having an irradiation energy density E of about 1 to 7 J / mm ² may be used. In addition, energy density E = laser output (W) / (scanning speed (mm / s) × scanning pitch (mm)) (manufacturing conditions are, for example, powder lamination thickness: 0.05 mm, laser type: CO ₂ (Carbon dioxide gas laser, spot diameter: 0.5 mm) The above numerical range of the irradiation energy is only an example, and may depend on the type of the powder material. It should be noted that the value of the irradiation energy density E can be appropriately changed depending on the type of the powder material forming the powder layer.

The “solidification density (%)” in the present specification substantially means a solidification cross-sectional density (an occupation ratio of a solidification material) obtained by performing image processing on a cross-sectional photograph of a three-dimensionally shaped object. The image processing software used is Scion Image ver. 4.0.2 (freeware manufactured by Scion). After binarizing the cross-sectional image into a solidified part (white) and a void part (black), the image by counting the number of pixels Px _white of all pixels number Px _all and solidification portion (white), it is possible to obtain a solidified sectional density [rho _S by equation 1 below. When a metal powder is used as the powder material, “solidification density” corresponds to “sintering density”.
[Equation 1]

  The formation of the microporous structure includes (a) adjusting the irradiation energy (output energy) of the light beam, (b) adjusting the scanning speed of the light beam, (c) adjusting the scanning pitch of the light beam, d) It can also be performed by adjusting the condensing diameter of the light beam. For example, to lower the solidification density, (a) reduce the irradiation energy (output energy) of the light beam, (b) increase the scanning speed of the light beam, and (c) increase the scanning pitch of the light beam. (D) It can also be achieved by increasing the converging diameter of the light beam. Conversely, in order to increase the solidification density, in addition to (a) increasing the output energy of the light beam, (b) reducing the scanning speed of the light beam, (c) narrowing the scanning pitch of the light beam, d) It can also be achieved by reducing the focused diameter of the light beam. These (a) to (d) may be performed alone, or may be performed in various combinations with each other.

  The micropore structure provides the three-dimensional shaped object with micropores. Such micropores are preferably "row-shaped micropores". That is, in the manufacturing method according to one embodiment of the present invention, it is preferable to form the row-shaped fine holes 158 in which the voids form a row for the fine hole structure 157 (see FIG. 4). As shown in FIG. 4, the row-shaped fine holes 158 may have a form in which voids extend in a row along the stacking direction of the solidified layer. In the local portion of the density change region in which the row-shaped fine holes 158 are provided, the gap is continuous in a row in a state where the seam is reduced or in a state without the seam, so that the resistance at the time of degassing is further reduced, and “ It is easy to improve the "gas release efficiency". Note that the fine holes may be random holes. That is, random fine holes 159 in which voids are randomly distributed may be provided as the fine holes 157 (see FIG. 4). Since the random fine holes 159 have random voids as shown in FIG. 4, gas can be released from any direction, and the anisotropy in the gas releasing direction is reduced. On the other hand, the random micropores 159 can exhibit characteristics such that the raw material resin is unlikely to enter the pores (although not limited to a particular theory, this is because such micropores are elongated because of randomness). However, it is considered that the gap itself is small, and the small gaps are randomly present, so that the resistance when the resin enters can be said to be large.) Therefore, the random fine holes 159 can contribute to preventing the roughness of the molded product surface.

  As can be seen from the embodiment shown in FIG. 4, the structures provided with the row-shaped fine holes 158 and the random fine holes 159 in the present invention are referred to as “vertical hole communication structure” and “micropore random arrangement structure”, respectively. Can also.

  The row-shaped fine holes 158 and the random fine holes 159 can be obtained by appropriately adjusting various scanning conditions and / or irradiation energy conditions of the light beam at the time of forming the solidified layer. Although not particularly limited, the row-shaped fine holes 158 can be obtained by intersecting the scanning path P of the light beam between the solidified layers in forming the solidified layers adjacent to each other in the stacking direction (FIG. 4). See figure below). Such a mode of “crossing of scanning paths” corresponds to a mode of performing light beam irradiation such that the scanning paths P form a “lattice” between adjacent solidified layers. On the other hand, the random fine holes 159 can be obtained by narrowing the laser scanning pitch relatively to the row-shaped fine hole forming conditions and increasing the scanning speed to lower the irradiation energy density.

  As described above, in the structure having the random fine holes 159, the raw material resin is unlikely to enter the fine holes, so that the density change region may be formed to take advantage of the characteristics. Specifically, random micropores may be formed at locations where the surface angle is small. Thereby, even in a region where the surface angle is small and the surface roughness of the molded product is generally concerned, such roughness can be effectively suppressed by “random micropores”. In the example shown in FIG. 1, random fine holes may be provided in a local portion 150C having a relatively small surface angle in the density change region 150, for example. Further, in the example shown in FIG. 2, random fine holes may be provided in, for example, the local portions 150e and / or 150d having a relatively small surface angle in the density change region 150. As a more specific example, random micropores may be provided on a surface portion having a relatively small surface angle, and row-shaped micropores may be provided on a surface portion having a relatively large surface angle. As a result, the roughness can be suppressed even in a local portion where the surface angle is small and the roughness of the surface of the molded product is generally concerned, and on the other hand, the surface is provided in a portion where the surface angle is large. Desired gas release can be achieved by the row-shaped fine holes having low resistance during gas release.

  In a preferred embodiment, a hollow passage communicating with the outside of the three-dimensionally shaped object is provided inside the three-dimensionally shaped object. That is, in the manufacturing method according to one embodiment of the present invention, it is preferable to form a hollow path that is in fluid communication with the outside. When a three-dimensionally shaped object is used as a mold, such a hollow path may be used as a ventilation path or as a temperature control medium path. In the manufacturing method according to one embodiment of the present invention, the hollow path can be formed by setting a part of the region where the solidified layer is formed to be a non-irradiated portion that is not irradiated with a light beam. That is, by locally providing the “non-irradiated portion that is not irradiated with the light beam and does not solidify” in the region where the solidified layer is formed (that is, the region where the three-dimensionally shaped object is formed), the finally obtained third order is obtained. A hollow path can be formed in the original shaped object.

  When the hollow channel 160 is used as a ventilation channel, it is preferable to provide the hollow channel 160 and the microporous structure 157 in fluid communication with each other (see FIG. 5). Thus, “gas release” in the case where the three-dimensionally shaped object 100 is used as a mold can be performed via the microporous structure 157 and the hollow path 160. The gas existing in the mold cavity space at the time of filling the molten raw material or the gas generated from the molten raw material is discharged from the micropore structure 157 (that is, the micropores) on the die surface to the outside of the die cavity space, and then is discharged. The air is finally discharged to the outside of the mold via the air passage 160. Since the hollow passage 160 has a larger size than the micropores of the micropore structure 157, the fluid resistance at the time of degassing can be reduced, and “gas degassing efficiency” can be easily improved.

  Hollow passages used as "vents" may extend entirely over the density change region (e.g., extend through all local portions of the density change region with different densities). May be allowed). As shown in FIG. 5, at least a part of the hollow path 160 may be extended along the inclined surface of the three-dimensionally shaped object. In other words, at least a part of the hollow path 160 may be extended along the “formed object surface 110 including the inclined surface”. In such a case, the communication between the microporous structure 157 of the density change region 150 and the hollow passage 160 can be more easily established, and the fluid resistance at the time of degassing can be more effectively reduced. As can be seen from the cross-sectional view shown in FIG. 5, the extension of the hollow path 160 may penetrate or cross the microporous structure 157 (preferably, the extension of the hollow path 160 is (They may penetrate or traverse the microporous structure 157 while being along the inclined surface.) For example, in a cross-sectional view as illustrated, the hollow path 160 is formed such that the shortest separation distance between at least a part of the hollow path 160 and the “modeled object surface 110 including the inclined surface” is substantially constant. It may extend.

  As shown in FIG. 6, the hollow channel 160 used as a ventilation channel may partially include or include a “solidified portion 159 ′ made of random micropores”. The random micropores allow gas flow in any direction to pass. Therefore, by arranging such random micropores locally in the hollow passage, it is possible to improve the structural strength of the three-dimensionally shaped object provided with the hollow passage while securing a flowable state. .

  The manufacturing method according to one embodiment of the present invention is suitably used for manufacturing a three-dimensional shaped object having an inclined surface (for example, a mold having an inclined surface). Although it is only one example, in the manufacturing method according to one embodiment of the present invention, a mold for obtaining a “molded article having an inner surface and an outer surface” may be manufactured as a three-dimensional shaped object. For example only, a mold for a cylindrical molded product may be manufactured. More specifically, in order to obtain a mold 300 (see FIG. 8) for molding the cylindrical molded article 200 as shown in FIG. 7, a three-dimensional shaped object may be manufactured. As used herein, the term “tubular molded article” refers to a molded article having a “cylindrical” overall appearance, one end forming an open end, and the other end forming a closed end. pointing.

  In the present invention, in particular, the mold may be a mold for the inner surface of a molded article (that is, a mold for the inner surface of a molded article). In the case of a mold 300 as shown in FIG. 8, it corresponds to an inner surface mold for obtaining the inner surface of a cylindrical molded product. Such an inner surface mold may be a slide core.

  In the case of the mold 300 as an “inner mold”, a density change region may be provided in a cavity surface portion (particularly, a surface portion including an inclined surface) for an inner surface of a molded product. As a preferable example, the tip portion 350 of the inner surface mold may be provided as a three-dimensionally shaped object, and the region of the foremost surface 355 may be a density change region (see FIG. 8). Generally, a weld line is easily generated at the tip portion (particularly, inside the closed end) of a “molded product having an inner surface and an outer surface” such as a tubular molded product 200. In order to reduce such a weld line, an “inclined surface” is used. The "form" vent area can be more extensively provided in the mold. That is, in one embodiment of the present invention, a ventilation area can be provided more widely in the mold cavity surface area where weld lines are particularly likely to occur, and both the occurrence of weld lines and the surface roughness of a molded product can be reduced. Can be.

[Three-dimensional shaped object of the present invention]
A three-dimensional molded object according to one embodiment of the present invention is obtained by the above-described manufacturing method. Therefore, the three-dimensional molded object according to one embodiment of the present invention is formed by stacking solidified layers formed by irradiating the powder layer with a light beam, and has an inclined surface (that is, the outermost surface of the inclined form). Having. In particular, in the three-dimensionally shaped object 100 according to one embodiment of the present invention, the “density change region” 150 in which the density is locally different is provided on the surface 110 of the formed object including the inclined surface. The density in the region 150 is locally different depending on “the angle formed by the surface of the modeled object 110 including the inclined surface and the stacking direction of the solidified layer” (see FIGS. 1 and 2). In other words, the three-dimensionally shaped object includes a density change region in which the density changes along the surface of the object, and such a region has a density change according to the degree of the surface inclination of the object. .

  The presence of the density change region 150 allows the three-dimensional structure 100 according to one embodiment of the present invention to be more suitably used as a mold. Specifically, when the three-dimensionally shaped object 100 is used as a mold, the density change region 150 can be used as a “vent region”, and as described above, both the degassing characteristics and the high-quality transfer characteristics are achieved. It can be suitably provided.

  In a preferred embodiment of the three-dimensionally shaped object, the density of the density change region gradually changes along the surface portion including the inclined surface. That is, in the density change region, the change according to the degree of the surface inclination is a gradual change. This means that as the surface angle of the modeled object becomes smaller or larger, the density of the local portion of the density change region changes stepwise. In short, it means that as the degree of inclination of the three-dimensionally shaped object increases or decreases, the density of the local portion of the density change region gradually changes.

  For example, in the three-dimensional structure 100 shown in FIG. 1, the local portion 150A → 150B → 150C in which the surface angle becomes relatively small, the density of the portion gradually increases. The same applies to the three-dimensionally shaped object 100 shown in FIG. 2, and the local portion 150a → 150b → 150c → 150d → 150e where the surface angle becomes relatively small, the density of the portion gradually increases. ing. When a three-dimensionally shaped object having such a gradual density change is used as a mold, it becomes easier to optimize both the ventilation efficiency and the surface roughness of the molded product as a whole ventilation area. .

  Preferably, in the density change region, the smaller the surface angle is, the higher the density is. In such a case, even in a region where the surface angle is small and the surface roughness of the molded product is generally concerned, such roughness can be suppressed. By way of example only, in the three-dimensional molded object 100 shown in FIG. 1, the local portion 150B having a relatively small surface angle in the density change region 150 is five times smaller than the local portion 150A having a relatively large surface angle. -40% higher density (e.g., 5-30% or 5-20% higher density), and similarly, the local portion 150C having a relatively small surface angle is 5% less than the local portion 150B having a relatively large surface angle. The density may be ４０40% higher (eg, 5-30% or 5-20% higher density). Further, in the three-dimensional structure 100 shown in FIG. 2, the local portion 150b having a relatively small surface angle in the density change region 150 has a density higher by 5 to 30% than the local portion 150a having a relatively large surface angle. (For example, 5-20% or 5-10% higher density), and similarly, the local portion 150c having a relatively small surface angle is made 5-30% higher in density than the local portion 150b having a relatively large surface angle. (Eg, 5-20% or 5-10% higher density). Furthermore, the local portion 150d having a relatively small surface angle has a density higher than that of the local portion 150c having a relatively large surface angle by 5 to 30% (for example, 5 to 20% or 5 to 10% higher density). Similarly, the local portion 150e having a relatively small surface angle may be 5-30% higher in density than the local portion 150d having a relatively large surface angle (eg, 5-20% or 5-10% higher density). ).

  In one preferred embodiment of the three-dimensionally shaped object, the density change region has a microporous structure. When such a three-dimensionally shaped object is used as a mold, the fine holes serve as vents, which can contribute to gas release. It is preferable that the micropore structure 157 has “row-shaped micropores 158 in which voids form a row” and / or “random micropores 159 in which voids are randomly distributed” (see FIG. 4).

  As shown in FIG. 4, it is preferable that the row-shaped fine holes 158 have a form in which voids extend in a row along the stacking direction of the solidified layer. In the density change region in which the row-shaped fine holes 158 are provided, the gaps are continuous in a row with a reduced number of seams or a seamless state, so that the resistance at the time of gas removal is further reduced, and the gas removal efficiency is improved. It is easier to improve. On the other hand, in the density change region in which the random fine holes 159 are provided, as shown in FIG. 4, the voids are randomly distributed, so that gas can be released from any direction, and the anisotropy in the gas release direction is reduced. Is reduced.

  In view of the fact that the molten raw material is unlikely to enter the random micropores and the roughness of the molded article surface is easily prevented, it is preferable that the density change region is provided with random micropores at local portions where the surface angle is relatively small. . Thereby, even in a region where the surface angle is small and the roughness of the molded product surface is generally concerned, such roughness can be more effectively suppressed by the “random micropores”. In the three-dimensional structure 100 shown in FIG. 1, it is preferable that random fine holes 159 are provided in a local portion 150 </ b> C having a relatively small surface angle, for example, in the density change region 150. Similarly, in the three-dimensional structure 100 shown in FIG. 2, it is preferable that random fine holes 159 are provided in, for example, the local portions 150 e and / or 150 d having relatively small surface angles in the density change region 150. . In such a case, row-shaped fine holes are provided in the local portions 150A and / or 150B (as shown in FIG. 1) or 150a, 150b and / or 150c (as shown in FIG. 2) of the density change region 150 where the surface angle is relatively large. You may be.

  In a preferred embodiment, the three-dimensional shaped object has a hollow passage therein, and the hollow passage communicates with the outside of the three-dimensional shaped object. When the three-dimensionally shaped object is used as a mold, the hollow path may be a ventilation path or a temperature control medium path. For example, as shown in FIG. 9, the three-dimensional molded object 100 has at least two hollow paths (160A, 160B), one of the hollow paths 160A forms a ventilation path, and the other hollow path 160B has A temperature control medium path may be formed. The hollow path 160A as the ventilation path may have a diameter (more specifically, “cross-sectional dimension perpendicular to the gas flow direction”) of, for example, about 0.5 to 3 mm. On the other hand, the hollow path 160B as the temperature control medium path may have a diameter (more specifically, “cross-sectional dimension perpendicular to the flow direction of the temperature control medium”) of, for example, about 3 to 15 mm.

  When the three-dimensional structure 100 is used as a mold and the hollow path 160A is used as a ventilation path, the hollow path 160A and the microporous structure 157 are preferably in fluid communication with each other. This is because a mold that can be suitably “gas-released” is provided via the microporous structure 157 and the hollow path 160A. The hollow path 160A can be provided in a larger size than the fine holes, and the fluid resistance at the time of degassing can be reduced. Therefore, when filling the molten raw material, the gas from the mold cavity space can be efficiently discharged to the outside of the mold through the hollow path 160A communicating with the microporous structure 157.

  In the three-dimensional structure according to one embodiment of the present invention, the hollow path serving as the ventilation path may extend to cover the entire density change region. For example, as shown in FIG. 5, it is preferable that at least a part of the hollow path 160 extends along the contour shape of the surface 110 of the three-dimensional structure 100. In such a case, the fluid communication between the microporous structure 157 in the density change region and the hollow passage 160 can be more easily achieved. As shown in the cross-sectional view of FIG. 5, the hollow path 160 extends so that the shortest distance between at least a part of the hollow path 160 and the surface 110 of the three-dimensional structure 100 is substantially constant. You may. Like the extending form of the hollow passage 160, the density change region 150 may be provided along the surface 110 of the three-dimensionally shaped object with a substantially constant thickness (see FIG. 5). In such a case, a relatively large number of high-density regions 155 can be provided inside the density change region 150, and the three-dimensional shaped object 100 more preferable in terms of structural strength can be obtained. In addition, from the viewpoint of increasing the overall structural strength of the three-dimensional structure 100, as shown in FIG. 6, a “solidified portion 159 ′ made of random micropores” is provided in a part of the hollow passage 160 used as an air passage. It may be provided.

  Although only one example, the three-dimensional shaped object may be a mold for obtaining a “molded article having an inner surface and an outer surface”. For example, the three-dimensional molded object may be a mold for molding a cylindrical molded product 200 as shown in FIG. One specific example of such a molding die is a die 300 as shown in FIG. Examples of the cylindrical molded product 200 include a water-flowing product (such as a shower head and a water outlet product) and a piping product. In a preferred embodiment, the three-dimensional shaped object is a mold, especially for the inner surface of the molded article. The mold 300 illustrated in FIG. 8 is an inner surface mold for obtaining the inner surface of the cylindrical molded product 200. Such an inner surface mold may be a slide core.

  When the three-dimensionally shaped object is a mold for the inner surface of the molded product, the density change region is provided on the cavity surface portion (particularly, the surface portion including the inclined surface) for the inner surface of the molded product. Is preferred. For example, in the case where the three-dimensionally shaped object is a mold for a cylindrical molded product, it is preferable that the density change region is a ventilation region in the mold. That is, in such a mold, a density change region (particularly, a density change region having a microporous structure) can be positively used for “gas release” during injection molding.

  As shown in FIG. 8, it is preferable that the three-dimensionally shaped object form a tip portion 350 of a mold 300 to be an “inner mold”. Then, at least a part of a region of the forefront surface 355 of the mold 300 may be a density change region. In such a mold 300, both the occurrence of weld lines and the surface roughness of a molded product can be more effectively reduced. This is because where a weld line is likely to occur at the tip (particularly the inner tip) of the cylindrical molded product, the ventilation area for reducing the weld line can be made wider.

  As shown in FIG. 8, in the mold 300 serving as the inner surface mold, the “temperature control medium path” is located behind the “hollow path 160A (vent path) in fluid communication with the density change region of the microporous structure”. Is preferably positioned. More specifically, as shown in the perspective view of FIG. 8, in the mold 300, the foremost extending portion of the “hollow path 160B used as a temperature control medium path” is the same as the “hollow path 160A used as a ventilation path”. It is preferable to be located behind the foremost extension. Thereby, more preferable temperature control can be achieved while performing “gas release” from the front end surface of the mold 300.

  Other details such as the three-dimensionally shaped object according to one embodiment of the present invention and further specific embodiments are described in the above-mentioned "Production method of the present invention". The description is omitted.

  The embodiments of the present disclosure have been described above, but they merely show typical examples of the scope of the present disclosure. Accordingly, those skilled in the art will readily appreciate that the present invention is not limited to the embodiments described above, and that various changes can be made.

  For example, in the above description, the mode in which the density of the three-dimensionally shaped object changes in the direction along the surface of the three-dimensionally shaped object is described. However, the direction of the density change is not limited to the “direction along the surface”. As shown in FIG. 10, a mode in which the density of the three-dimensional structure 100 changes toward the inside of the three-dimensional structure 100 may be adopted. In the embodiment shown in FIG. 10, the density of 150A ′, 150B ′, 150C ′ located relatively inside is lower than the density of 150A, 150B, 150C located relatively outside (front side). Good. Preferably, the density gradually decreases from the surface toward the inside. In such an embodiment, it is easier to optimize both the gas release efficiency and the surface roughness of the molded product as a whole in the ventilation region.

  Furthermore, as shown in FIG. 11, the outer peripheral portion 152 of the three-dimensionally shaped object 100 has a region of random micropores or a high-density region (91) regardless of the surface angle of the three-dimensionally shaped object 100. (A region having a solidification density of １００100%). By appropriately using such an aspect, the degree of freedom in designing a three-dimensionally shaped object used as a mold is increased.

  Further, in the above, the aspect of manufacturing the mold for the inner surface of the molded product as the three-dimensionally shaped object having the “density change region” has been described, but the present invention is not necessarily limited thereto. In the present invention, a “density change region” may be provided in the outer surface mold of the molded product. That is, it is conceivable to manufacture a mold for the outer surface of a molded product according to the present invention. This is particularly true when a two-layer molded product (two-color molded product) is obtained as a molded product. In the two-layer molding, where the outer surface of the molded product of the first layer becomes a non-design surface, a density change region is provided on a cavity surface portion (particularly, a surface portion including an inclined surface) for such a non-design surface. A mold may be manufactured.

  By implementing the method of manufacturing a three-dimensionally shaped object according to the present disclosure, various articles can be manufactured. For example, when the three-dimensionally shaped object is made of a metal material, the three-dimensionally shaped object can be used as a mold for a plastic injection molding die, a press die, a die casting die, a casting die, a forging die, or the like. it can. On the other hand, when the three-dimensionally shaped object is made of a resin material, the three-dimensionally shaped object can be used as a resin molded product.

Cross-reference of related applications

  The present application is based on the Paris Convention based on Japanese Patent Application No. 2017-085437 (filing date: April 24, 2017, title of invention: "Method of manufacturing three-dimensionally shaped object and three-dimensionally shaped object"). Claim priority. All content disclosed in that application is incorporated herein by this reference.

Reference Signs List 22 powder layer 24 solidified layer L light beam 100 three-dimensional shaped object 110 surface 150 including inclined surface surface 150 density change region 157 micropore structure 158 row micropores 159 random micropores 160 hollow paths θ _A , θ _B , θ _C surface angle θ _a , θ _b , θ _c , θ _d , θ _e surface angle

Claims (16)

(I) irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) new powder on the obtained solidified layer. Forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer, wherein the powder layer formation and the solidified layer formation are alternately repeated to produce a three-dimensionally shaped object manufacturing method. And
A density change region where the density of the three-dimensionally shaped object is locally different is provided on a surface portion including an inclined surface of the three-dimensionally shaped object,
A method for manufacturing a three-dimensionally shaped object, wherein in the density change region, the density locally varies according to an angle between a surface of the surface portion including the inclined surface and a stacking direction of the solidified layer. The method for manufacturing a three-dimensionally shaped object according to claim 1, wherein the density of the density change region is gradually changed along the surface portion including the inclined surface. 3. The method according to claim 1, wherein the density is relatively increased as the angle decreases in the density change region. 4. The method for manufacturing a three-dimensionally shaped object according to claim 1, wherein the density change region has a microporous structure. The method for manufacturing a three-dimensionally shaped object according to claim 4, wherein, for the micropore structure, row-shaped micropores in which voids form rows and / or random micropores in which voids are randomly distributed are formed. The method for manufacturing a three-dimensionally shaped object according to claim 5, wherein the random micropores are formed at locations where the angle is relatively small in the surface portion including the inclined surface. The method for manufacturing a three-dimensionally shaped object according to any one of claims 1 to 6, wherein a hollow path communicating with the outside of the three-dimensionally shaped object is provided inside the three-dimensionally shaped object. The method according to claim 7, wherein the hollow path and the microporous structure are provided in fluid communication with each other. The method for manufacturing a three-dimensionally shaped object according to claim 7 or 8, wherein at least a part of the hollow path extends along the inclined surface of the three-dimensionally shaped object. As the three-dimensional shaped object, to produce a mold for the inner surface of the molded product,
The method for manufacturing a three-dimensionally shaped object according to any one of claims 1 to 9, wherein the density change region is provided in the surface portion for the inner surface of the molded product in the inner surface mold. It is a three-dimensional shaped object that is composed of a solidified layer laminated and has an inclined surface,
A density change region where the density of the three-dimensionally shaped object is locally different is provided on a surface portion including the inclined surface,
The three-dimensional structure, wherein the density is locally different in the density change region according to an angle between a surface of the surface portion including the inclined surface and a stacking direction of the solidified layer. The three-dimensional structure according to claim 11, wherein the density of the density change region is gradually different along the surface portion including the inclined surface. The three-dimensional structure according to claim 11, wherein the smaller the angle in the density change region, the higher the density. The density change region has a microporous structure,
The three-dimensional structure according to any one of claims 11 to 13, wherein the micropore structure has row-shaped micropores in which voids form rows and / or random micropores in which voids are randomly distributed. . A hollow path is provided inside the three-dimensional structure, and the hollow path communicates with the outside of the three-dimensional structure,
The three-dimensional structure according to claim 14, wherein the hollow passage and the microporous structure are in fluid communication with each other. The three-dimensional shaped object is a mold for the inner surface of a molded product,
The three-dimensional shaped object according to any one of claims 11 to 15, wherein in the inner surface mold, the density change region is provided in the surface portion for the inner surface of the molded product.

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