WO2017086317A1

WO2017086317A1 - Optical shaping device

Info

Publication number: WO2017086317A1
Application number: PCT/JP2016/083842
Authority: WO
Inventors: 哲夫法貴; 玉水　雅巳; 保片山
Original assignee: 株式会社写真化学; 株式会社セザック
Priority date: 2015-11-20
Filing date: 2016-11-15
Publication date: 2017-05-26
Also published as: JP2017094563A; JP6767007B2

Abstract

This optical shaping device is provided with a resin holding part, an optical unit, a housing, and a cleaning unit. The resin holding part is stored in the housing. The resin holding part holds a photocurable resin. The photocurable resin has a shaping surface. Clean air purified by the cleaning unit is supplied into an internal space that is in contact with the shaping surface of the photocurable resin in the housing. In this state, light is applied on the shaping surface of the photocurable resin by the optical unit. Accordingly, a three-dimensionally shaped product is produced on the shaping surface by means of stereolithography.

Description

Stereolithography equipment

The present invention relates to an optical modeling apparatus for manufacturing a three-dimensional modeled object.

Stereolithography technology is known as a technology for manufacturing a three-dimensional modeled object (for example, see Patent Document 1). In the three-dimensional figure creating apparatus described in Patent Document 1, a liquid photosensitive resin is stored in a container, and a work table is fixed immediately below the liquid surface of the photosensitive resin. Beam-like light is irradiated onto the liquid surface of the photosensitive resin from an exposure device arranged at the top of the container so that the lowermost cross-sectional figure of the three-dimensional figure to be drawn is drawn. The portion of the photosensitive resin irradiated with light is solidified.

Thereafter, the work table is sunk by a certain amount. In this state, the exposure apparatus irradiates the surface of the photosensitive resin again with beam-like light so that a cross-sectional figure above the already drawn portion of the three-dimensional figure to be drawn is drawn. By repeating this operation, cross sections of the solidified resin are laminated, and a three-dimensional figure is created on the work table.
JP 56-144478 A JP-A-9-85839

Patent Document 2 describes that a fine three-dimensional model having a size of about mm or several tens of μm can be manufactured by an optical modeling technique. However, in practice, it is difficult to manufacture a modeled object with high accuracy even if light drawing is performed finely.

An object of the present invention is to provide an optical modeling apparatus capable of manufacturing a modeled object with high accuracy.

(1) An optical modeling apparatus according to one aspect of the present invention is an optical modeling apparatus that manufactures a three-dimensional modeled object by an optical modeling method, and a resin holding unit that holds a photocurable resin so as to have a modeling surface. An optical unit that irradiates light onto the modeling surface of the photocurable resin held by the resin holding unit, a housing that houses the resin holding unit, and a filter in an internal space that contacts the modeling surface of the photocurable resin in the housing And a gas supply unit that supplies the purified gas purified by the above.

In this stereolithography apparatus, the resin holding part is accommodated in the casing. The photocurable resin is held by the resin holding part. Clean gas by the gas supply unit is supplied to the internal space in contact with the modeling surface of the photocurable resin in the housing. In this state, light is irradiated to the modeling surface of the photocurable resin by the optical unit.

According to this configuration, foreign substances are prevented from being mixed into the modeling surface of the photocurable resin by the clean gas. Moreover, since heat is dissipated by the flowing clean gas, the influence of heat on the optical unit is reduced. Thereby, light can be irradiated to the desired position of the modeling surface without being affected by heat. As a result, a modeled object can be manufactured with high accuracy.

(2) The optical unit is disposed above the resin holding unit, the modeling surface is the upper surface of the photocurable resin held by the resin holding unit, and the internal space is located between the optical unit and the modeling surface, A housing | casing may have a side part and a gas supply part may be arrange | positioned so that clean gas may be supplied to internal space from a side part.

In this case, since the optical unit and the gas supply unit do not interfere with each other, the stereolithography apparatus can be miniaturized. Moreover, it becomes easy to supply clean gas to the internal space in contact with the modeling surface. Thereby, mixing of the foreign material to a modeling surface and exhaust heat of internal space can be performed more easily.

(3) The stereolithography apparatus may further include a rectifying member that guides the clean gas supplied to the internal space by the gas supply unit in the horizontal direction. In this case, a flow of clean gas along the modeling surface of the photocurable resin can be formed. Thereby, it can prevent reliably that the particle | grains which float in internal space adhere to a modeling surface. Moreover, since clean gas can be efficiently supplied to the internal space in contact with the modeling surface, the gas supply unit does not need to supply a large amount of clean gas. Therefore, the operation cost of the optical modeling apparatus can be reduced.

(4) The rectifying member may include first and second rectifying plates respectively disposed on both sides of the internal space so as to face each other. In this case, the clean gas supplied to the internal space by the gas supply unit can be easily guided in the horizontal direction by the first and second rectifying plates.

(5) The rectifying member further includes a third rectifying plate disposed in an upper portion of the internal space, and the third rectifying plate has a passage portion through which light irradiated from the optical unit to the modeling surface passes. Also good. In this case, the clean gas supplied to the internal space by the gas supply unit can be easily guided in the horizontal direction by the third rectifying plate without blocking the light irradiated to the modeling surface from the optical unit.

(6) The housing may be provided with a take-out portion that enables removal of the shaped object, and the take-out portion may be arranged to face the gas supply portion with the resin holding portion interposed therebetween. In this case, since the extraction unit is located downstream of the clean gas supplied by the gas supply unit, the clean gas is supplied from the gas supply unit toward the extraction unit. Thereby, it is prevented that the foreign material which generate | occur | produces when a user takes out a molded article mixes in a resin holding part.

(7) The housing may have an opening for dissipating heat to the outside. In this case, the heat generated in the internal space can be dissipated to the outside with a simple configuration.

According to the present invention, a shaped article can be manufactured with high accuracy.

FIG. 1 is a perspective view of an optical modeling apparatus according to an embodiment of the present invention. FIG. 2 is a side view of the optical modeling apparatus of FIG. FIG. 3 is a schematic diagram illustrating the configuration of the resin holding portion, the clean unit, the rectifying unit, and the optical unit of FIG. FIG. 4 is a diagram visually showing shape data of a model to be manufactured. FIG. 5 is a diagram for explaining the operation of the resin holding unit and the optical unit. FIG. 6 is a diagram for explaining the operation of the resin holding unit and the optical unit. FIG. 7 is a schematic diagram showing the configuration of the optical modeling apparatus according to the first modification. FIG. 8 is a schematic diagram showing a configuration of an optical modeling apparatus according to the second modification. FIG. 9 is an enlarged view of a modeled object manufactured by a conventional optical modeling apparatus.

(1) Configuration of Stereolithography Apparatus Hereinafter, the stereolithography apparatus according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of an optical modeling apparatus according to an embodiment of the present invention. FIG. 2 is a side view of the optical modeling apparatus 100 of FIG. FIG. 3 is a schematic diagram illustrating the configuration of the resin holding unit 30, the clean unit 40, the rectifying unit 50, and the optical unit 60 of FIG. In FIG. 1 and FIG. 2, directions indicated by arrows in the horizontal plane are referred to as an X direction and a Y direction.

1 and 2, the optical modeling apparatus 100 includes a main body frame 10, a control unit 20, a resin holding unit 30, a clean unit 40, a rectifying unit 50, an optical unit 60, and a housing 70. The main body frame 10, the control unit 20, the resin holding unit 30, the rectifying unit 50 and the optical unit 60 are accommodated in the housing 70. In FIGS. 1 and 2, the portion of the housing 70 that houses the optical unit 60 is not shown.

The main body frame 10 includes a bottom surface portion 11, an intermediate surface portion 12, an upper surface portion 13, a plurality of support columns 14, and a plurality of reinforcement portions 15. Each of the bottom surface portion 11, the middle surface portion 12, and the top surface portion 13 has a substantially rectangular shape. The bottom surface portion 11, the middle surface portion 12, and the top surface portion 13 are arranged in a horizontal posture in this order from the bottom to the top. Each support column 14 extends in the vertical direction and supports the bottom surface portion 11, the middle surface portion 12, and the top surface portion 13. Each reinforcing portion 15 extends in the horizontal direction and is attached between adjacent struts 14 so as to reinforce the plurality of struts 14.

A plurality of wheels 16 and a plurality of support portions 17 are provided on the lower surface of the bottom surface portion 11. The plurality of wheels 16 and the plurality of support portions 17 protrude downward from the bottom of the housing 70. When the stereolithography apparatus 100 is moved, the plurality of wheels 16 come into contact with the installation surface, and the plurality of support portions 17 are separated from the installation surface. In this case, the optical modeling apparatus 100 can be easily moved by rolling the plurality of wheels 16 on the installation surface. On the other hand, when the stereolithography apparatus 100 is not moved, the plurality of support portions 17 are in contact with the installation surface, and the plurality of wheels 16 are separated from the installation surface. Thereby, the optical modeling apparatus 100 can be fixed so that it cannot move.

The control unit 20 includes, for example, a central processing unit (CPU) (not shown). The control unit 20 controls the operations of the resin holding unit 30 and the optical unit 60. In the example of FIGS. 1 and 2, the control unit 20 is disposed on the upper surface of the bottom surface portion 11 of the main body frame 10.

As shown in FIG. 3, the resin holding unit 30 includes a storage unit 31, a stage 32, and an elevating unit 33. The reservoir 31 is a container having an upper opening, and is disposed on the upper surface of the upper surface portion 13 of the main body frame 10 of FIG. The storage unit 31 stores liquid (fluid) photocurable resin. The stage 32 is disposed in the vicinity of the horizontal surface (upper surface) of the photocurable resin stored in the storage unit 31. In the present embodiment, the upper surface of the photocurable resin is the modeling surface 34. An internal space of the housing 70 is formed between the modeling surface 34 of the resin holding unit 30 and the optical unit 60. The internal space is in contact with the modeling surface 34.

The light is irradiated to the modeling surface 34. The raising / lowering part 33 is attached to the stage 32 so that the stage 32 can be raised / lowered. When the stage 32 is lowered, the layer of the photocurable resin partially cured by the light irradiation is lowered, and an uncured photocurable resin layer is formed on the processed layer. The upper surface of the uncured photocurable resin becomes a new modeling surface 34. By repeating this operation, a three-dimensional shaped object is manufactured.

The clean unit 40 includes a fan 41, a filter 42, and a power supply device 43. The power supply device 43 supplies power to the fan 41. The filter 42 in the present embodiment is a HEPA (High Efficiency Particulate Air) filter. The opening (particle removal performance) of the filter 42 is, for example, 1 μm or more and 10 μm or less, and in this example, 10 μm. In the present embodiment, the clean unit 40 is disposed on a side surface portion 72 of the casing 70 described later so as to be positioned above one end portion in the Y direction of the middle surface portion 12 of the main body frame 10 in FIG. The fan 41 supplies the clean gas purified by the filter 42 to the internal space in contact with the modeling surface 34 in the Y direction. The flow of clean gas is shown by the white arrows in FIG. In the present embodiment, the clean gas is clean air. An inert gas such as nitrogen gas purified as a clean gas may be used.

The rectifying unit 50 includes rectifying

plates

51, 52, and 53. The rectifying

plates

51 and 52 are respectively arranged along both side surfaces in a portion between the middle surface portion 12 and the upper surface portion 13 of the main body frame 10 (FIG. 1). Thus, the rectifying

plates

51 and 52 face each other across the internal space above the resin holding portion 30 in the X direction. The rectifying plate 53 is horizontally disposed on the lower surface of the upper surface portion 13 of the main body frame 10 (FIG. 1) so as to cover the upper side of the resin holding portion 30. The rectifying plate 53 is formed with a passage portion 53a that is a circular opening. The passage portion 53a of the rectifying plate 53 overlaps the modeling surface 34 in the vertical direction. The rectifying plates 51 to 53 rectify the clean gas supplied by the clean unit 40 in the Y direction. Thereby, the clean gas flows along the modeling surface 34.

The optical unit 60 is disposed on the upper surface of the upper surface portion 13 of the main body frame 10 (FIG. 1). The optical unit 60 includes a light source 61, a light intensity modulator 62, a beam expander 63, a lens 64, and two galvanometer mirrors 65 and 66. The light source 61 is a laser transmitter, for example, and emits laser light having a wavelength in the ultraviolet region (for example, 255 nm to 405 nm). The light intensity modulator 62 modulates the intensity of light passing through the light intensity modulator 62. The beam expander 63 expands the diameter of light that passes through the beam expander 63. The lens 64 gives a focus to the light passing through the lens 64.

The galvanometer mirror 65 includes an actuator part 65a and a mirror part 65b. The actuator unit 65a is a motor having a vertical rotation axis. The mirror part 65b is attached to the rotating shaft of the actuator part 65a. As the actuator portion 65a rotates, the reflection angle of the light reflected by the mirror portion 65b changes in the horizontal plane.

The galvanometer mirror 66 has the same configuration as the galvanometer mirror 65, and includes an actuator portion 66a and a mirror portion 66b. The actuator portion 66a is a motor having a horizontal rotation axis. The galvanometer mirror 66 is arranged so that the rotation axis of the actuator section 66a is orthogonal to the rotation axis of the actuator section 65a of the galvanometer mirror 65 in the horizontal plane. As the actuator 66a rotates, the reflection angle of the light reflected by the mirror 66b changes in the vertical plane.

The light emitted from the light source 61 sequentially passes through the light intensity modulator 62, the beam expander 63, and the lens 64, is reflected by the two galvanometer mirrors 65 and 66, and passes through the passage portion 53a of the rectifying plate 53. Here, a focal point of light is formed on the modeling surface 34 by the lens 64. Further, when the

actuator portions

65a and 66a of the galvanometer mirrors 65 and 66 are rotated, the light is scanned on the modeling surface 34 in two directions orthogonal to each other. Thereby, an arbitrary shape can be drawn on the modeling surface 34 with light.

(2) Configuration of Case As shown in FIG. 1, the case 70 includes a door portion 71 extending in the vertical direction and three

side surface portions

72, 73, 74 extending in the vertical direction. In FIG. 1, the side surface portions 72 to 74 are indicated by dotted lines, and in FIG. 2, the side surface portions 72 to 74 are not shown. The door part 71 and the side part 72 are arrange | positioned so that both the side surfaces of the main body frame 10 in a Y direction may be obstruct | occluded, respectively. In this example, the door part 71 is a one-sided door configured to be openable and closable. The

side surface portions

73 and 74 are arranged so as to block both side surfaces of the main body frame 10 in the X direction.

The part of the housing 70 facing the clean unit 40 with the resin holding part 30 interposed therebetween constitutes an outlet 75 for taking out a molded article manufactured by the resin holding part 30. The user can take out the manufactured shaped article from the take-out part 75 by opening the door part 71. Further, the user can operate the resin holding part 30 by opening the door part 71. The door portion 71 is formed with a window portion 76 that blocks transmission of light near the photosensitive wavelength of the photocurable resin. The user can visually recognize the inside of the housing 70 through the window 76.

In this embodiment, the housing 70 is a non-sealed housing and has air permeability. In the example of FIG. 1, a plurality of openings 77 are formed in the door portion 71. In addition, an opening (not shown) is formed in each of the side surfaces 72 to 74. Even when heat is generated in the housing 70 by the clean unit 40 and the optical unit 60, the heat is dissipated to the outside through the plurality of openings 77 and the like. In this case, heat can be dissipated to the outside with a simple configuration.

(3) Operation of the optical modeling apparatus An example of the manufacturing operation of the modeled object by the optical modeling apparatus 100 will be described. FIG. 4 is a diagram visually showing shape data of a model to be manufactured. FIG. 4A is three-dimensional CAD (Computer Aided Design) data indicating the three-dimensional shape of the modeled object. FIG. 4B is cross-sectional data showing a cross section for each position in the vertical direction of the modeled object. In FIG.4 (b), the several cross section of the molded article based on several cross section data is illustrated in the state laminated | stacked on the up-down direction. In the example of FIGS. 4A and 4B, the model to be manufactured is a wine glass.

2 acquires the three-dimensional CAD data shown in FIG. 4 (a). Moreover, the control part 20 produces | generates the cross-sectional data of FIG.4 (b) based on the acquired three-dimensional CAD data at the predetermined | prescribed space | interval in an up-down direction. Further, the control unit 20 controls the resin holding unit 30 and the optical unit 60 based on the generated plurality of cross-sectional data. 5 and 6 are diagrams for explaining the operations of the resin holding unit 30 and the optical unit 60. FIG.

First, as shown in FIG. 5A, the elevating unit 33 is moved to the initial position. Thereby, the upper surface of the stage 32 is located directly under the liquid surface (modeling surface 34) of the photocurable resin stored in the storage unit 31. Next, light is irradiated from the optical unit 60 onto the surface of the photocurable resin so that the lowermost one of the plurality of cross sections shown in FIG. 4B is drawn. Thereby, as shown in FIG.5 (b), the part of the photocurable resin irradiated with light solidifies, and the lowest part of the molded article W is manufactured on the modeling surface 34. As shown in FIG.

Subsequently, the stage 32 is lowered by a predetermined distance. The descending amount of the stage 32 is substantially equal to the interval in the vertical direction of the plurality of cross sections in FIG. In this state, the modeling surface 34 is irradiated with light from the optical unit 60 so that a cross section adjacent above the lowermost part of the modeled object W is drawn. Thereby, as shown to Fig.6 (a), the part of the photocurable resin to which light was irradiated solidifies, and the upper part of the lowest part of the molded article W is further manufactured.

Thereafter, the stage 32 is further lowered by a predetermined distance. Moreover, light is irradiated to the modeling surface 34 from the optical unit 60 so that the cross section of the part above the already manufactured part of the molded article W is drawn. By repeating these, as shown in FIG.6 (b), the molded article W is manufactured on the modeling surface 34. FIG.

As shown in FIG. 3, after the modeling object W is completed, the user U takes out the modeling object W from the extraction unit 75. Here, the take-out part 75 and the clean unit 40 face each other across the resin holding part 30 in the Y direction. According to this arrangement, the extraction unit 75 is located downstream of the clean gas supplied by the clean unit 40, so that clean gas is supplied from the clean unit 40 toward the extraction unit 75. Thereby, it is prevented that the foreign material which generate | occur | produces when the user U takes out the molded article W mixes in the storage part 31. FIG. Further, the foreign matter is prevented from adhering to the modeling surface 34.

(4) Modification (a) First Modification In the above embodiment, the optical modeling apparatus 100 includes the rectifying plates 51 to 53, but the present invention is not limited to this. The optical modeling apparatus 100 may not include some or all of the rectifying plates 51 to 53. FIG. 7 is a schematic diagram illustrating a configuration of the optical modeling apparatus 100 according to the first modification. 7, illustration of the main body frame 10 and the control unit 20 of FIG. 1 is omitted. The same applies to FIG. 8 described later. As shown in FIG. 7, the optical modeling apparatus 100 according to the first modification does not include the rectifying plates 51 to 53.

(B) Second Modification In the above embodiment, the clean unit 40 is arranged to supply clean gas in a direction parallel to the horizontal plane, but the present invention is not limited to this. The clean unit 40 may be arranged to supply clean gas in the other direction. FIG. 8 is a schematic diagram illustrating the configuration of the optical modeling apparatus 100 according to the second modification. As shown in FIG. 8, the optical modeling apparatus 100 according to the second modification is arranged so as to supply clean gas downward. Further, the optical shaping apparatus 100 according to the second modified example does not include the rectifying plates 51 to 53, but is not limited thereto, and may include a part or all of the rectifying plates 51 to 53.

(5) Effect FIG. 9 is an enlarged view of a model W manufactured by a conventional optical modeling apparatus. A model W in FIG. 9 is different from the model W in FIGS. 5 and 6. As shown in part A of FIG. 9, fine foreign matters such as lint are mixed in the modeled object W manufactured by the conventional optical modeling apparatus. In this case, the accuracy of the shaped article W is greatly reduced.

In the optical modeling apparatus 100 according to the present embodiment, the clean gas from the clean unit 40 is supplied to the internal space in contact with the modeling surface 34 of the photocurable resin. In this case, foreign substances are prevented from entering the modeling surface 34 of the photocurable resin by the clean gas. Moreover, since heat is dissipated by the flowing clean gas, the influence of heat on the optical unit is reduced. Thereby, light can be irradiated to the desired position of the modeling surface 34 without being influenced by heat. As a result, the shaped article W can be manufactured with high accuracy.

Also, the clean unit 40 supplies clean gas from the side surface 72 of the housing 70 to the internal space. In this case, since the optical unit 60 and the clean unit 40 do not interfere with each other, the optical modeling apparatus 100 can be reduced in size. In addition, it becomes easy to supply clean gas to the internal space in contact with the modeling surface 34. Thereby, mixing of the foreign material into the modeling surface 34 and exhaust heat of the internal space can be performed more easily.

Further, the clean gas is guided in the horizontal direction by the rectifying plates 51-53. In this case, a flow of clean gas along the modeling surface 34 can be formed. Thereby, it is possible to reliably prevent particles floating in the internal space from adhering to the modeling surface 34. Moreover, since clean gas can be efficiently supplied to the internal space in contact with the modeling surface 34, the clean unit 40 does not need to supply a large amount of clean gas. Therefore, the operation cost of the optical modeling apparatus 100 can be reduced.

(6) Other Embodiments (a) In the above embodiment, the photocurable resin has a liquid state, but the present invention is not limited to this. For example, the photocurable resin may have fluidity by adding a powder material such as ceramic as an additive.

(B) In the above embodiment, the upper surface of the photocurable resin is the modeling surface 34, but the present invention is not limited to this. The modeling surface 34 may be the other part of the photocurable resin. For example, the modeling surface 34 may be the lower surface of the photocurable resin.

(C) In the above embodiment, the optical modeling apparatus 100 includes the main body frame 10, but the present invention is not limited to this. The optical modeling apparatus 100 may not include the main body frame 10.

(D) In the above embodiment, the casing 70 is a non-sealed casing and has air permeability, but the present invention is not limited to this. When the casing 70 is provided with a configuration in which the cleaning gas supplied by the clean unit 40 is circulated, the casing 70 may be a sealed casing and may not have air permeability.

(7) Correspondence relationship between each constituent element of claim and each element of the embodiment Hereinafter, an example of correspondence between each constituent element of the claim and each element of the embodiment will be described. It is not limited to examples.

In said embodiment, the molded article W is an example of a molded article, the optical modeling apparatus 100 is an example of an optical modeling apparatus, the modeling surface 34 is an example of a modeling surface, and the resin holding part 30 is a resin holding part. It is an example. The optical unit 60 is an example of an optical unit, the case 70 is an example of a case, the filter 42 is an example of a filter, the clean unit 40 is an example of a gas supply unit, and the side part 72 is a side part. It is an example. The rectifying unit 50 is an example of a rectifying member, the rectifying plates 51 to 53 are examples of first to third rectifying plates, the passage portion 53a is an example of a passage portion, and the extraction portion 75 is an example of an extraction portion. The opening 77 is an example of the opening.

As the constituent elements of the claims, various other elements having configurations or functions described in the claims can be used.

The present invention can be effectively used for an optical modeling apparatus.

Claims

An optical modeling apparatus for manufacturing a three-dimensional model by an optical modeling method,
A resin holding part for holding a photocurable resin so as to have a modeling surface;
An optical unit for irradiating light on the modeling surface of the photocurable resin held by the resin holding unit;
A housing for housing the resin holding portion;
An optical modeling apparatus comprising: a gas supply unit configured to supply a clean gas purified by a filter to an internal space of the photocurable resin in the housing that is in contact with the modeling surface.
The optical unit is disposed above the resin holding portion,
The modeling surface is an upper surface of a photocurable resin held by the resin holding portion,
The internal space is located between the optical unit and the modeling surface,
The housing has side portions;
The optical modeling apparatus according to claim 1, wherein the gas supply unit is arranged to supply the clean gas from the side surface part to the internal space.
The optical modeling apparatus according to claim 2, further comprising a rectifying member that guides the clean gas supplied to the internal space by the gas supply unit in a horizontal direction.
The stereolithography apparatus according to claim 3, wherein the rectifying member includes first and second rectifying plates respectively disposed on both side portions of the internal space so as to face each other.
The rectifying member further includes a third rectifying plate disposed at an upper portion of the internal space,
5. The optical modeling apparatus according to claim 3, wherein the third rectifying plate has a passage portion through which light irradiated from the optical unit to the modeling surface passes.
The housing is provided with a take-out portion that enables removal of a shaped object,
The stereolithography apparatus according to any one of claims 2 to 5, wherein the extraction unit is disposed so as to face the gas supply unit with the resin holding unit interposed therebetween.
The stereolithography apparatus according to any one of claims 1 to 6, wherein the casing has an opening for dissipating heat to the outside.