WO2017154971A1 - 三次元形状造形物の製造方法 - Google Patents
三次元形状造形物の製造方法 Download PDFInfo
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- WO2017154971A1 WO2017154971A1 PCT/JP2017/009205 JP2017009205W WO2017154971A1 WO 2017154971 A1 WO2017154971 A1 WO 2017154971A1 JP 2017009205 W JP2017009205 W JP 2017009205W WO 2017154971 A1 WO2017154971 A1 WO 2017154971A1
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- solidified layer
- layer
- powder
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- shaped object
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Images
Classifications
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B22—CASTING; POWDER METALLURGY
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1017—Multiple heating or additional steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/16—Both compacting and sintering in successive or repeated steps
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- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B22—CASTING; POWDER METALLURGY
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates to a method for manufacturing a three-dimensional shaped object.
- this invention relates to the manufacturing method of the three-dimensional shaped molded article which forms a solidified layer by light beam irradiation to a powder layer.
- a method for producing a three-dimensional shaped object by irradiating a powder material with a light beam has been conventionally known.
- a three-dimensional shaped object is manufactured by alternately repeating powder layer formation and solidified layer formation based on the following steps (i) and (ii).
- the obtained three-dimensional shaped object can be used as a mold.
- organic resin powder is used as the powder material, the obtained three-dimensional shaped object can be used as various models.
- a metal powder is used as a powder material and a three-dimensional shaped object obtained thereby is used as a mold.
- the squeezing blade 23 is moved to form a powder layer 22 having a predetermined thickness on the modeling plate 21 (see FIG. 6A).
- the solidified layer 24 is formed from the powder layer 22 by irradiating a predetermined portion of the powder layer 22 with the light beam L (see FIG. 6B).
- a new powder layer 22 is formed on the obtained solidified layer 24, and a light beam is irradiated again to form a new solidified layer 24.
- the solidified layer 24 is laminated (see FIG.
- a three-dimensional structure composed of the laminated solidified layer 24 is formed.
- a shaped object can be obtained. Since the solidified layer 24 formed as the lowermost layer is coupled to the modeling plate 21, the three-dimensional modeled object and the modeling plate 21 form an integrated object, and the integrated object can be used as a mold.
- the irradiated portion of the powder layer irradiated with the light beam becomes the solidified layer 24 through a sintering phenomenon or a melt solidification phenomenon.
- shrinkage stress as shown in FIG. 7A may be generated due to a reduction in the gap between the powder materials.
- warpage deformation is likely to occur in the integrated object of the three-dimensional shaped object 100 and the base modeling plate 21 (see FIG. 7B). That is, there is a possibility that a desired shape cannot be obtained for the three-dimensional shaped object 100.
- an object of the present invention is to provide a method for manufacturing a three-dimensional shaped object with reduced warpage deformation.
- a method for manufacturing a product Provided is a method of manufacturing a three-dimensional shaped object, wherein at least one preceding solidified layer formed in advance with respect to a subsequent solidified layer formed later is formed at a temperature condition relatively higher than that of the subsequent solidified layer.
- Sectional view schematically showing heating means for modeling plate Sectional drawing schematically showing the process mode of stereolithography combined processing in which the powder sintering lamination method is carried out (FIG. 6A: at the time of forming the powder layer
- FIG. 6A at the time of forming the powder layer
- FIG. 6B at the time of forming the solidified layer
- 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 refers to the region of the three-dimensional shaped object to be manufactured. Therefore, by irradiating the powder existing at the predetermined location with a light beam, the powder is sintered or melted and solidified to form a three-dimensional shaped object.
- solidified layer means “sintered layer” when the powder layer is a metal powder layer, and means “cured layer” when the powder layer is a resin powder layer.
- the “up and down” direction described directly or indirectly in the present specification is a direction based on the positional relationship between the modeling plate and the three-dimensional shaped object, for example, and is based on the modeling plate.
- the side on which the shaped object is manufactured is “upward”, and the opposite side is “downward”.
- FIG. 6 schematically shows a process aspect of stereolithographic composite processing
- FIGS. 8 and 9 are flowcharts of the main configuration and operation of the stereolithographic composite processing machine capable of performing the powder sintering lamination method and the cutting process. Respectively.
- the stereolithography combined processing machine 1 includes a powder layer forming means 2, a light beam irradiation means 3, and a cutting means 4, as shown in FIG.
- the powder layer forming means 2 is means for forming a powder layer by spreading a powder such as a metal powder or a resin powder with 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 laminated solidified layer, that is, the surface of the three-dimensional shaped object.
- the powder layer forming means 2 mainly comprises a powder table 25, a squeezing blade 23, a modeling table 20, and a modeling plate 21, as shown in FIG.
- the powder table 25 is a table that can be moved 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 in the horizontal direction to obtain the powder layer 22 by supplying the powder 19 on the powder table 25 onto the modeling table 20.
- the modeling table 20 is a table that can be moved 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 arranged on the modeling table 20 and serves as a base for a three-dimensional modeled object.
- the light beam irradiation means 3 mainly has a light beam oscillator 30 and a galvanometer mirror 31, as shown in FIG.
- the light beam oscillator 30 is a device that emits a light beam L.
- the galvanometer mirror 31 is means for scanning the emitted light beam L into the powder layer 22, that is, scanning means 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 cutting the side surface of the laminated solidified layer, that is, the surface of the three-dimensional shaped object.
- the drive mechanism 41 is means for moving the end mill 40 to a desired location to be cut.
- the operation of the optical modeling complex 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.
- the modeling table 20 is lowered by ⁇ t (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 ⁇ t.
- the squeezing blade 23 is moved in the horizontal direction from the powder material tank 28 toward the modeling tank 29 as shown in FIG.
- 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).
- the powder material for forming the powder layer 22 include “metal powder having an average particle diameter of about 5 ⁇ m to 100 ⁇ m” and “resin powder such as nylon, polypropylene, or ABS having an average particle diameter of about 30 ⁇ m to 100 ⁇ m”. it can.
- the solidified layer forming step (S2) is a step of forming the solidified layer 24 by light beam irradiation.
- the light beam L is emitted from the light beam oscillator 30 (S21), and the light beam L is scanned to a predetermined location on the powder layer 22 by the galvano mirror 31 (S22).
- the powder at a predetermined location of the powder layer 22 is sintered or melted and solidified to form a solidified layer 24 as shown in FIG. 6B (S23).
- a carbon dioxide laser, an 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 alternately repeated. Thereby, as shown in FIG.6 (c), the some solidified layer 24 is laminated
- the cutting step (S3) is a step for cutting the side surface of the laminated solidified layer 24, that is, the surface of the three-dimensional shaped object.
- a cutting step is started by driving the end mill 40 (see FIG. 6C and FIG. 8) (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 shaped object.
- the end mill 40 is driven. Specifically, a cutting process is performed on the side surface of the laminated solidified layer 24 while the end mill 40 is moved by the drive mechanism 41 (S32).
- the present invention is characterized in the formation mode of the solidified layer in the above-described powder sintering lamination method.
- the temperature condition is relatively changed for the formation of a plurality of solidified layers constituting the three-dimensional shaped object.
- at least one preceding solidified layer 24A formed in advance with respect to the subsequent solidified layer 24B to be formed later is formed at a temperature condition relatively higher than that of the subsequent solidified layer 24B. That is, in the present invention, the solidified layer that precedes in time is formed under a higher temperature condition than the solidified layer that is subsequently formed.
- the inventors of the present application have an inward stress that can be a main factor causing warpage deformation of the finally obtained three-dimensional shaped object in the interface region between the modeling plate and the three-dimensional shaped object.
- the present invention has been devised based on the idea of how to reduce the inward stress in the interface region.
- the inventors of the present application based on the idea of how to form a force in the direction opposite to the inward stress in the interface region in order to reduce the warp deformation of the three-dimensional shaped object. Invented the invention.
- the preceding solidified layer 24A is formed on the modeling plate 21 under a relatively high temperature condition (see FIG. 2A).
- the subsequent solidified layer 24B is formed on the preceding solidified layer 24A under a relatively low temperature condition (see FIG. 2B).
- the three-dimensional shaped object 100 is finally obtained (see FIG. 2C).
- the present invention has a technical idea of positively forming a solidified layer located on the bottom side of a three-dimensionally shaped object and a solidified layer other than the bottom side under different temperature conditions. Have.
- preceding means “preceding” in time, and therefore the term “preceding solidified layer” refers to a solidified layer formed relatively early. Yes.
- subsequent solidified layer refers to a solidified layer formed relatively later. It points to that.
- high temperature condition in this specification means that the temperature at the time of forming the solidified layer is broadly defined, and in a narrow sense, the powder layer (for the solidified layer). This means that the temperature of the powder layer corresponding to the precursor layer is high. Therefore, in a typical example, “relatively high temperature condition” means that the temperature of the powder layer for forming the preceding solidified layer is higher than the temperature of the powder layer for forming the subsequent solidified layer. Means.
- a relatively high temperature condition may be formed by the temperature of the modeling plate. That is, a relatively high temperature condition for forming the pre-solidified layer may be achieved by the temperature of the modeling plate.
- the pre-solidified layer is formed directly on the modeling plate, and it is preferable that the heat of the modeling plate is transferred to the “powder layer for forming the pre-solidified layer” to be “relatively high temperature condition”. .
- the modeling plate needs to be at a high temperature, and therefore heating of the modeling plate is preferred.
- the modeling plate is heated, the modeling plate is heated, and the heat of the heated modeling plate is transferred to the “powder layer for forming the pre-solidified layer” to obtain “relatively high temperature condition”. Will be.
- the warped deformation of the finally obtained three-dimensional shaped object can be reduced by forming the preceding solidified layer at a temperature condition relatively higher than that of the subsequent solidified layer.
- the assumed mechanism is described in detail on the assumption that it is not bound by a specific theory.
- the pre-solidified layer is formed under a relatively high temperature condition, the modeling plate heated to that temperature tends to generate stress toward the outside due to thermal expansion.
- the preceding solidified layer is formed, the shrinkage stress is applied to the solidified layer 24 by reducing the voids between the powder materials as in the phenomenon described with reference to FIGS. 7A and 7B. Can occur. As shown in FIG.
- the stress 21 ′ generated in the modeling plate 21 heated to a high temperature is caused by thermal expansion to the last, so that the direction of the stress 21 ′ is expanded, that is, “outward”, whereas This is opposite to the direction of the stress 24A ′ generated in the solidified layer 24A. Accordingly, when the three-dimensional shaped object is manufactured, the stresses (24A ', 21') act so as to cancel each other, and as a result, warping deformation of the three-dimensional shaped object can be prevented.
- the subsequent solidified layer can also be formed under high temperature conditions.
- the stress generated during the manufacture of the three-dimensional shaped object is relatively large particularly in the initial stage of manufacture, and the stress is small thereafter (see FIG. 4). More specifically, as can be seen from FIG. 4, a particularly large stress is generated near the bottom surface of the three-dimensional shaped object, and the stress decreases as the position becomes farther from the bottom surface of the three-dimensional shaped object. That is, the stress generated when the subsequent solidified layer is formed is not large.
- “high temperature” is not preferable because it can adversely affect the dimensional accuracy of the three-dimensional shaped object. Therefore, the temperature condition of the subsequent solidified layer does not need to be higher than the temperature condition of the pre-solidified layer, and “the pre-solidified layer is formed at a temperature condition relatively higher than that of the subsequent solidified layer”.
- the height level of the pre-solidified layer formed under a high temperature condition may be within a certain range, considering the phenomenon that a large stress is generated near the bottom surface of the three-dimensional shaped object. That is, in the manufacturing method of the present invention, the thickness of at least one preceding solidified layer may be within a predetermined height range from the modeling plate. Although it is only an example to the last, the thickness of this at least 1 prior
- the preceding solidified layer that is within 5 mm from the upper surface of the modeling plate (for example, if the thickness of one prior solidified layer is 0.05 mm, the solidified layers from the first layer to the 100th layer) are relative to each other.
- the film is formed under a high temperature condition.
- heating of the modeling plate is started prior to the formation of the first powder layer in contact with the modeling plate. That is, heating of the modeling plate is started before forming the first powder layer used for forming at least one preceding solidified layer on the modeling plate.
- the modeling plate is heated, and an outward stress 21 ′ against the “large stress 24 A ′ generated near the bottom surface of the three-dimensional modeled object” can be more suitably generated in the modeling plate 21 (FIG. 3). reference). That is, the warp deformation of the three-dimensional shaped object can be prevented more efficiently.
- the modeling plate prepared here may be a modeling plate conventionally used in the powder sintering lamination method.
- the material of the modeling plate is steel, cemented carbide, high-speed tool steel, alloy tool steel And at least one material selected from the group consisting of stainless steel and carbon steel for machine structure.
- the modeling plate is only a “plate”, it is typically preferable that the modeling plate has a flat shape as a whole.
- the specific shape of the modeling plate may be any shape as long as it provides a “base” for the manufactured three-dimensional modeled object. Therefore, the shape of the modeling plate is not particularly limited to the rectangular parallelepiped shape, and may be a disk shape or a polygonal column shape.
- a heating method of a modeling plate For example, the following can be mentioned.
- -Partial heating of the modeling plate by irradiating the surface of the modeling plate with a light beam -Overall heating of the shaping plate using heaters located inside and / or on the side of the shaping plate -Heating the entire modeling plate using a heater installed inside or on the side of the modeling table that supports the modeling plate -Total heating of the modeling plate by flowing warm water or steam to the temperature control tube provided inside the modeling table that supports the modeling plate -Full or partial heating of the shaping plate by infrared radiation -Whole or partial heating of the shaping plate by electromagnetic induction heating
- the “overall heating” in the above example means that the modeling plate is entirely heated so that heat is transmitted to the central portion of the modeling plate.
- a heat insulating material 60 may be provided on the bottom surface and the side surface of the modeling table 20 provided with the heater or the temperature control tube 50 (see FIG. 5).
- a resin material may be used as the heat insulating material 60.
- a prior solidified layer A powder layer is formed on the modeling plate 21 that has been heated to a high temperature by heat treatment, and a light beam is irradiated on the powder layer to form a prior solidified layer 24A (see FIG. 2A). ). Since the powder layer used for forming the pre-solidified layer 24A is in contact with the modeling plate 21, the heat from the modeling plate 21 that has been heated is transferred to the powder layer. In this manner, the pre-solidified layer 24A is formed under the condition that the powder layer has a high temperature (particularly, the temperature that is relatively higher than the temperature of the powder layer for forming the subsequent solidified layer). That is, the preceding solidified layer 24A is formed by irradiating the powder layer having a relatively high temperature with a light beam.
- the preceding solidified layer 24A may be only one layer or may be composed of a plurality of layers (see the drawing in FIG. 2A). Although not particularly limited, for example, the pre-solidified layer 24A may comprise 1 to 100 layers, preferably 1 to 50 layers, more preferably 1 to 20 layers.
- the subsequent solidified layer 24B to be formed later is formed under a temperature condition relatively lower than that of the previous solidified layer 24A.
- the subsequent solidified layer 24B may be formed under a relatively low temperature condition so that the temperature difference from the temperature condition during the formation of the previous solidified layer 24A is, for example, less than 100 ° C.
- the preceding solidified layer 24A is formed under a relatively high temperature condition so that the temperature difference from the temperature condition at the time of forming the subsequent solidified layer 24B is less than 100 ° C., for example.
- the preceding solidified layer is formed at a temperature condition relatively higher than that of the subsequent solidified layer, but it is not easy to directly control the temperature conditions of the preceding solidified layer and the subsequent solidified layer. Therefore, for example, the temperature conditions of the preceding solidified layer and the subsequent solidified layer may be controlled by appropriately changing the set temperature of a heater or the like provided on the modeling plate in contact with the prior solidified layer or the modeling table immediately below the modeling plate. In other words, the “relatively high temperature condition” may be formed by increasing the set temperature of the heating source provided on the modeling plate or the modeling table at the time of forming the preceding solidified layer rather than the subsequent solidified layer.
- the thickness of the powder layer formed on the modeling plate may not be uniform due to the thermal expansion of the modeling plate.
- the distance between the squeezing blade and the shaping plate may be measured, and the irradiation condition of the light beam on the local portion of the powder layer may be appropriately changed according to the distance. . This can reduce inconveniences such as “the density of the solidified layer is not uniform due to a local difference in the thickness of the powder layer”.
- the light beam irradiation speed is increased or the light beam irradiation output is decreased for the powder layer portion located at a location where the separation between the squeezing blade and the modeling plate is relatively small. You can do it.
- the light beam irradiation speed may be lowered or the light beam irradiation output may be increased. It's okay.
- One embodiment of the present invention as described above includes the following preferred modes.
- First aspect (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
- a method for manufacturing a product A method for producing a three-dimensional shaped object, wherein at least one preceding solidified layer formed in advance with respect to a subsequent solidified layer formed later is formed at a temperature condition relatively higher than that of the subsequent solidified layer.
- Said 1st aspect WHEREIN The manufacturing method of the three-dimensional shaped molded article in which the thickness of the said at least 1 said prior solidification layer exists in the predetermined height range from the said modeling plate.
- Third aspect In the said 1st aspect or the 2nd aspect, the manufacturing method of the three-dimensional shape molded article which forms the said relatively high temperature conditions with the temperature of the said modeling plate.
- Fourth aspect Said 3rd aspect WHEREIN: Prior to formation of the powder layer of the 1st layer which contact
- Various articles can be manufactured by carrying out the manufacturing method of a three-dimensional shaped object according to an embodiment of the present invention.
- the powder layer is an inorganic metal powder layer and the solidified layer is a sintered layer
- the resulting three-dimensional shaped article is a plastic injection mold, a press mold, a die-cast mold, It can be used as a mold such as a casting mold or a forging mold.
- the powder layer is an organic resin powder layer and the solidified layer is a hardened layer
- the obtained three-dimensional shaped article can be used as a resin molded product.
Abstract
Description
(i)粉末層の所定箇所に光ビームを照射し、かかる所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程。
(ii)得られた固化層の上に新たな粉末層を形成し、同様に光ビームを照射して更なる固化層を形成する工程。
(i)粉末層の所定箇所に光ビームを照射して当該所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および
(ii)得られた固化層の上に新たな粉末層を形成し、当該新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程
により粉末層形成および固化層形成を造形プレート上で交互に繰り返して行う三次元形状造形物の製造方法であって、
後に形成される後続固化層に対して先行して形成される少なくとも1つの先行固化層を後続固化層よりも相対的に高い温度条件で形成する、三次元形状造形物の製造方法が提供される。
まず、本発明の製造方法の前提となる粉末焼結積層法について説明する。特に粉末焼結積層法において三次元形状造形物の切削処理を付加的に行う光造形複合加工を例として挙げる。図6は、光造形複合加工のプロセス態様を模式的に示しており、図8および図9は、粉末焼結積層法と切削処理とを実施できる光造形複合加工機の主たる構成および動作のフローチャートをそれぞれ示している。
本発明は、上述の粉末焼結積層法において固化層の形成態様に特徴を有している。
まず、造形プレートを準備する。ここで準備する造形プレートは、粉末焼結積層法で常套的に用いられる造形プレートであってよい。例えば粉末として金属粉末を用いることによって固化層として焼結層(鉄系材料から成る焼結層)を形成する場合、造形プレートの材質は、スチール、超硬合金、高速度工具鋼、合金工具鋼、ステンレス鋼および機械構造用炭素鋼から成る群から選択される少なくとも1種類の材質であってよい。また、造形プレートは、あくまでも“プレート”ゆえ、典型的には全体として扁平状になっていることが好ましい。造形プレートの具体的な形状は、製造される三次元形状造形物に対して“土台”を供するものであれば、いずれの形状でもよい。それゆえ、造形プレートの形状は、直方体形状に特に限定されず、円板形状または多角柱形状などであってもよい。
造形プレートに対して加熱処理を行う。かかる加熱処理によって、造形プレートが高温化され熱膨張が生じることになる。熱膨張が生じると、造形プレートが膨らむ方向、すなわち外向きに応力が生じることになる。
- 造形プレートの表面を光ビーム照射することによる造形プレートの部分加熱
- 造形プレートの内部および/または側面に配置したヒータを用いる造形プレートの全体加熱
- 造形プレートを支持する造形テーブルの内部または側面に設置したヒータを用いる造形プレートの全体加熱
- 造形プレートを支持する造形テーブルの内部に設けられた温調管に対して温水または蒸気を流すことによる造形プレートの全体加熱
- 赤外線放射による造形プレートの全体加熱または部分加熱
- 電磁誘導加熱による造形プレートの全体加熱または部分加熱
なお、上記例示における「全体加熱」とは造形プレートの中心部分まで熱が伝わるように造形プレートが全体的に高温化されることを意味している。
加熱処理により高温化された造形プレート21上に粉末層を形成し、かかる粉末層に光ビームを照射して先行固化層24Aを形成する(図2(a)参照)。先行固化層24Aの形成のために用いられる粉末層は造形プレート21に接するので、高温化された造形プレート21からの熱が、かかる粉末層へと伝わることになる。このように粉末層が高い温度を有する条件下(特には、後続固化層形成のための粉末層の温度よりも相対的に高い温度となる条件下)で先行固化層24Aの形成を行う。つまり、相対的に高い温度を有する粉末層に対して光ビームを照射して先行固化層24Aを形成する。
先行固化層24Aの形成後、先行固化層24A上に新たな粉末層を形成し、かかる粉末層に光ビームを照射して後続固化層24Bを形成する(図2(b)参照)。後続固化層24Bの形成を繰り返し実施すると、最終的に三次元形状造形物100を得ることができる(図2(c)参照)。なお、“高い温度”というものは三次元形状造形物100の寸法精度の点で原則好ましくないので、後続固化層24Bの温度条件は、先行固化層24Aの温度条件よりも高くする必要はない。換言すれば、後続固化層24Bの不必要な熱膨張を防止する観点から、後刻に形成する後続固化層24Bは先行固化層24Aよりも相対的に低い温度条件で形成することが好ましい。具体的には、先行固化層24Aの形成時における温度条件との温度差が例えば100℃未満となるように後続固化層24Bの形成を相対的に低い温度条件下で行ってよい。このことは、後続固化層24Bの形成時における温度条件との温度差が例えば100℃未満となるように相対的に高い温度条件下で先行固化層24Aの形成を行うことを意味している。
本発明では、先行固化層を後続固化層よりも相対的に高い温度条件で形成するが、先行固化層および後続固化層の温度条件を直接制御することは容易でない。そのため、例えば、先行固化層と接する造形プレートまたはその直下の造形テーブルに設けたヒータなどの設定温度を適宜変更することによって、先行固化層および後続固化層の温度条件を制御してよい。換言すれば、造形プレートまたは造形テーブルに設けられた加熱源の設定温度を後続固化層よりも先行固化層の形成時に高くすることによって“相対的に高い温度条件”を形成してよい。
造形プレートの加熱によって「相対的に高い温度」を形成する場合、造形プレートの熱膨張に起因して、その造形プレート上に形成される粉末層の厚さが均一とならない場合が考えられる。かかる場合、粉末層の形成に先立ってスキージング・ブレードと造形プレートとの間の距離を測定し、当該距離に応じて粉末層の局所的な箇所に対する光ビームの照射条件を適宜変更してよい。これにより「粉末層の厚さの局所的な違いに起因して固化層の密度が均一にならなくなる」といった不都合を減じることができる。具体的には、スキージング・ブレードと造形プレートとの間の離隔寸法が相対的に小さい箇所に位置する粉末層部分に対しては光ビーム照射速度をより上げたり、光ビーム照射出力をより小さくしたりしてよい。一方、スキージング・ブレードと造形プレートとの間の離隔寸法が相対的に大きい箇所に位置する粉末層部分に対しては光ビーム照射速度をより下げたり、光ビーム照射出力をより大きくしたりしてよい。
第1態様:
(i)粉末層の所定箇所に光ビームを照射して該所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および
(ii)得られた固化層の上に新たな粉末層を形成し、該新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程
により粉末層形成および固化層形成を造形プレート上で交互に繰り返して行う三次元形状造形物の製造方法であって、
後に形成される後続固化層に対して先行して形成される少なくとも1つの先行固化層を該後続固化層よりも相対的に高い温度条件で形成する、三次元形状造形物の製造方法。
第2態様:
上記第1態様において、前記少なくとも1つの前記先行固化層の厚みが前記造形プレートから所定の高さ範囲内にある、三次元形状造形物の製造方法。
第3態様:
上記第1態様又は第2態様において、前記相対的に高い温度条件を前記造形プレートの温度により形成する、三次元形状造形物の製造方法。
第4態様:
上記第3態様において、前記造形プレートに接する第1層目の粉末層の形成に先立って該造形プレートの加熱を開始する、三次元形状造形物の製造方法。
24A 先行固化層
24B 後続固化層
100 三次元形状造形物
Claims (4)
- (i)粉末層の所定箇所に光ビームを照射して該所定箇所の粉末を焼結又は溶融固化させて固化層を形成する工程、および
(ii)得られた固化層の上に新たな粉末層を形成し、該新たな粉末層の所定箇所に光ビームを照射して更なる固化層を形成する工程
により粉末層形成および固化層形成を造形プレート上で交互に繰り返して行う三次元形状造形物の製造方法であって、
後に形成される後続固化層に対して先行して形成される少なくとも1つの先行固化層を該後続固化層よりも相対的に高い温度条件で形成する、三次元形状造形物の製造方法。 - 前記少なくとも1つの前記先行固化層の厚みが前記造形プレートから所定の高さ範囲内にある、請求項1に記載の三次元形状造形物の製造方法。
- 前記相対的に高い温度条件を前記造形プレートの温度により形成する、請求項1に記載の三次元形状造形物の製造方法。
- 前記造形プレートに接する第1層目の粉末層の形成に先立って該造形プレートの加熱を開始する、請求項3に記載の三次元形状造形物の製造方法。
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WO2020218449A1 (ja) * | 2019-04-26 | 2020-10-29 | パナソニックIpマネジメント株式会社 | 三次元形状造形物の製造方法および三次元形状造形物を製造するための装置 |
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CN108778576B (zh) | 2021-03-12 |
JP6688997B2 (ja) | 2020-04-28 |
CN108778576A (zh) | 2018-11-09 |
US20190076923A1 (en) | 2019-03-14 |
KR20180110075A (ko) | 2018-10-08 |
US10898953B2 (en) | 2021-01-26 |
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JPWO2017154971A1 (ja) | 2019-01-10 |
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