WO2019082341A1

WO2019082341A1 - Molded article and manufacturing method therefor

Info

Publication number: WO2019082341A1
Application number: PCT/JP2017/038750
Authority: WO
Inventors: 隆司當間
Original assignee: 武藤工業株式会社
Priority date: 2017-10-26
Filing date: 2017-10-26
Publication date: 2019-05-02
Also published as: JPWO2019082341A1

Abstract

The molded article according to the present invention is characterized by comprising a composite material obtained by combining a first material which is a powder sintered material, and a second material which is different from the first material, wherein the first and second materials, in the composite material, mutually restrict the relative movement in three directions in which the two materials intersect with each other.

Description

Shaped object and method of manufacturing the same

The present invention relates to a shaped article and a method of manufacturing the same.

For example, Patent Document 1 discloses a three-dimensional modeling apparatus that manufactures a three-dimensional object based on three-dimensional design data. As a method of such a three-dimensional shaping apparatus, various methods such as an optical shaping method, a powder sintering method, an inkjet method, a molten resin extrusion molding method, etc. have been proposed and commercialized.

As an example, in a three-dimensional modeling apparatus adopting a molten resin lamination method, a modeling head for discharging molten resin to be a material of a modeled object is mounted on a three-dimensional moving mechanism, and the modeling head is moved in three dimensions. The molten resin is laminated while discharging the molten resin to obtain a shaped article. In addition, the three-dimensional modeling apparatus adopting the inkjet method also has a structure in which a modeling head for dropping a heated thermoplastic material is mounted on a three-dimensional moving mechanism.

As a method of using such a three-dimensional shaping apparatus, several methods have been proposed for producing a shaped article from a composite material in which a plurality of different materials are combined. There are many advantages in producing a shaped object from a composite material over producing it from a single material. However, on the other hand, there is a problem in terms of physical strength due to the junction, such as delamination between materials. And this is a problem which should be considered even when using a three-dimensional modeling device.

JP 2002-307562 A

An object of the present invention is to provide a shaped article formed of a combination of a plurality of different materials and having high physical strength, and a method of manufacturing the same.

A three-dimensional object according to an embodiment of the present invention includes a composite material in which a first material which is a powder sintered material and a second material different from the first material are combined, and in the composite material, the first material and It is characterized in that relative movement in three directions in which the second material intersects with each other is restricted.

The method for producing a shaped article according to the embodiment of the present invention is a method for producing a shaped article including a composite material in which a first material which is a powder sintered material and a second material different from the first material are combined. When the portion formed of the first material is a first material portion and the portion formed of the second material is a second material portion, the first material portion has a gap in the first direction. And laminating a first layer including a portion arranged in a second direction and a second layer arranged with a gap in a second direction in which the first material portion intersects the first direction, and The first material portion and the first material portion of the second layer are joined to form a first structure body, and the second material is filled in a gap of the first structure body, and then the second material body is formed. Are cured to form the second material portion.

According to the present invention, it is possible to provide a shaped article formed of a combination of a plurality of different materials and having high physical strength, and a method of manufacturing the same.

It is a perspective view which shows the structure of the three-dimensional modeling apparatus used with the manufacturing method of the molded article which concerns on 1st Embodiment. It is a front view which shows the structure of the three-dimensional modeling apparatus. It is a perspective view which shows the structure of the XY stage of the three-dimensional modeling apparatus. It is a top view which shows the structure of the raising / lowering table of the three-dimensional modeling apparatus. It is a functional block diagram showing composition of a computer (control device) used with a manufacturing method of a modeling thing concerning the embodiment. It is a perspective view of the modeling thing concerning the embodiment. FIG. 2 is a cross-sectional view in the XY direction of the three-dimensional object according to the same embodiment. FIG. 2 is a cross-sectional view in the XY direction of the three-dimensional object according to the same embodiment. It is a figure explaining the manufacturing method of the modeling thing concerning the embodiment. It is a figure explaining the manufacturing method of the modeling thing concerning the embodiment. It is a figure explaining the manufacturing method of the modeling thing concerning the embodiment. It is a figure explaining the manufacturing method of the modeling thing concerning the embodiment. It is a figure explaining the manufacturing method of the modeling thing concerning the embodiment. It is a perspective view of the modification of the modeling thing concerning the embodiment. It is a perspective view of the modification of the modeling thing concerning the embodiment. It is a perspective view of the modification of the modeling thing concerning the embodiment. It is a figure explaining the modeling thing concerning a 2nd embodiment.

Hereinafter, the molded article according to the embodiment and the method for manufacturing the same will be described with reference to the drawings.

First Embodiment
First, a three-dimensional modeling apparatus used in the manufacturing method will be described on the premise that the three-dimensional object and the manufacturing method thereof according to the first embodiment will be described.
FIG. 1 is a perspective view showing the configuration of a three-dimensional modeling apparatus (hereinafter sometimes referred to as a “3D printer”) used in the method of manufacturing a modeled object according to the present embodiment.
The 3D printer 100 includes a frame 11, an XY stage 12, a modeling stage 13, an elevating table 14, and a guide shaft 15.
A computer 200 is connected to the 3D printer 100 as a control device for controlling the 3D printer 100. In addition, a driver 300 for driving various mechanisms in the 3D printer 100 is also connected to the 3D printer 100.

As shown in FIG. 1, the frame 11 has, for example, a rectangular outer shape, and is provided with a framework of a metal material such as aluminum. At four corners of the frame 11, for example, four guide shafts 15 are formed to extend in the Z direction of FIG. 1, that is, in the direction perpendicular to the plane of the molding stage 10. The guide shaft 15 is a linear member which defines the direction in which the elevating table 14 is moved in the vertical direction as described later. The number of guide shafts 15 is not limited to four, and is set to a number that can stably maintain and move the lifting table 14.
The modeling stage 13 is a stage on which the model S is placed, and is a stage on which a thermoplastic resin discharged from a modeling head described later is deposited.

As shown in FIGS. 1 and 2, the elevating table 14 has the guide shaft 15 penetrating at its four corners, and is configured to be movable along the longitudinal direction (Z direction) of the guide shaft 15. . The lifting table 14 is provided with

rollers

34 and 35 in contact with the guide shaft 15. The

rollers

34 and 35 are rotatably installed at arm portions 33 formed at two corners of the lift table 14. As the

rollers

34, 35 rotate while being in contact with the guide shaft 15, the elevating table 14 can be smoothly moved in the Z direction. Further, as shown in FIG. 2, the lifting table 14 transmits a driving force of the motor Mz by a power transmission mechanism including a timing belt, a wire, a pulley and the like, whereby predetermined intervals (for example, 0.1 mm pitch) in the vertical direction are obtained. To move. The motor Mz is preferably, for example, a servomotor, a stepping motor, or the like. The actual position of the lifting table 14 in the height direction is measured continuously or intermittently in real time using a position sensor (not shown), and correction is appropriately applied to enhance the position accuracy of the lifting table 14. It is good. The same applies to the forming

heads

25A and 25B described later.

The XY stage 12 is mounted on the upper surface of the lift table 14. FIG. 3 is a perspective view showing a schematic configuration of the XY stage 12. The XY stage 12 includes a frame 21, an X guide rail 22, a Y guide rail 23,

reels

24A and 24B, forming

heads

25A and 25B, and a forming head holder H. Both ends of the X guide rail 22 are fitted into the Y guide rail 23 and held slidably in the Y direction. The

reels

24A, 24B are fixed to the modeling head holder H, and move in the XY directions following the movement of the

modeling heads

25A, 25B held by the modeling head holder H. The thermoplastic resin used as the material of the object S is a string-like resin (

filaments

38A and 38B) having a diameter of about 3 to 1.75 mm, and is usually held in a state of being wound by the

reels

24A and 24B. At the time of molding, the

molding heads

25A and 25B are fed into the

molding heads

25A and 25B by motors (extenders) provided to the

molding heads

25A and 25B described later.

Alternatively, the

reels

24A and 24B may be fixed to the frame 21 or the like without being fixed to the modeling head holder H, and the movement of the modeling head 25 may not be followed. Further, although the configuration is such that the

filaments

38A and 38B are fed into the modeling head 25 in the exposed state, it may be fed into the

modeling heads

25A and 25B with a guide (for example, a tube, a ring guide, etc.) interposed. . In the case of the present embodiment, the

filaments

38A and 38B are resins that decompose at a temperature lower than the temperature at which the powder sintered material cures and shrinks, and for example, nylon, polycarbonate, polybutylene terephthalate (PBT), acrylic Resin materials, such as nitrile butadiene styrene copolymer resin (ABS) and an elastomer, can be used.

In FIGS. 1 to 3, the shaping head 25A is configured to melt and discharge the filament 38A, and the shaping head 25B is configured to melt and discharge the filament 38B, and independent shapings for different filaments are provided. A head is prepared. However, the present invention is not limited to this, and a configuration is also possible in which only a single shaping head is prepared, and a plurality of types of filaments (resin materials) are selectively melted and discharged by a single shaping head. It can be adopted.

The

filaments

38A, 38B are fed from the

reels

24A, 24B into the shaping heads 25A, 25B via the tubes Tb. The forming heads 25A, 25B are held by the forming head holder H and configured to be movable along the X, Y guide rails 22, 23 together with the

reels

24A, 24B. Further, although not shown in FIGS. 2 and 3, an extruder motor for feeding the

filaments

38A, 38B downward in the Z direction is disposed in the shaping heads 25A, 25B. The forming

heads

25A and 25B may be movable together with the forming head holder H while maintaining a fixed positional relationship with each other in the XY plane, but the positional relationship between the forming

heads

25A and 25B may be changed also in the XY plane. It may be configured.

Although not shown in FIGS. 2 and 3, motors Mx and My for moving the modeling heads 25 A and 25 B relative to the XY stage 12 are also provided on the XY stage 12. The motors Mx and My are preferably servomotors, stepping motors, etc., for example.

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

The CPU 301 receives various signals from the computer 200 via the input / output interface 307 and controls the entire driver 300. The filament feeding device 302 instructs and controls the feed amount (pushing amount or retracting amount) of the

filaments

38A, 38B to the shaping heads 25A, 25B to the extruder motor in the shaping heads 25A, 25B according to the control signal from the CPU 301 Do.

The current switch 304 is a switch circuit for switching the amount of current flowing to the heater 26. By switching the switching state of the current switch 304, the current flowing to the heater 26 increases or decreases, thereby controlling the temperature of the shaping heads 25A and 25B. Further, the motor driver 306 generates a drive signal for controlling the motors Mx, My, Mz in accordance with the control signal from the CPU 301.

FIG. 5 is a functional block diagram showing a configuration of the computer 200 (control device). The computer 200 includes a spatial filter processing unit 201, a slicer 202, a modeling scheduler 203, a modeling instruction unit 204, and a modeling vector generation unit 205. These configurations can be realized by a computer program inside the computer 200.

The spatial filter processing unit 201 receives from outside the master 3D data indicating the three-dimensional shape of the three-dimensional object to be formed, and performs various data processing on the formation space in which the three-dimensional object is formed based on the master 3D data. . Specifically, as described later, the spatial filter processing unit 201 divides the modeling space into a plurality of modeling units Up (x, y, z) as necessary, and the plurality of modeling units based on master 3D data. Each function Up has a function of giving property data indicating characteristics to be given to each modeling unit. The necessity of division into the forming units and the size of the individual forming units are determined by the size and shape of the formed object S to be formed. For example, in the case where a simple plate material is formed, the division into the formation unit is unnecessary.

The modeling instruction unit 204 provides the spatial filter processing unit 201 and the slicer 202 with instruction data on the content of modeling. The instruction data includes, for example, the following. These are merely examples, and all of these instructions may be input, or only a part may be input. Also, an instruction different from the items listed below may be input.
(I) Size of one forming unit Up (ii) forming order of a plurality of forming units Up (iii) types of materials used in the forming unit Up (iv) blending of different types of materials in the forming unit Up Direction to form the same kind of material continuously in ratio (v) forming unit Up

Note that the modeling instruction unit 204 may receive input of instruction data from an input device such as a keyboard or a mouse, or may be provided with instruction data from a storage device that stores modeling content. .

In addition, the slicer 202 has a function of converting each of the modeling units Up into a plurality of slice data. The slice data is sent to the modeling scheduler 203 in the subsequent stage. The formation scheduler 203 has a role of determining the formation procedure, the formation direction, and the like in the slice data in accordance with the above-described property data. Further, the formation vector generation unit 205 generates a formation vector according to the formation procedure and the formation direction determined in the formation scheduler 203. The data of this formation vector is transmitted to the driver 300. The driver 300 controls the 3D printer 100 in accordance with the received data of the formation vector.

Next, the three-dimensional object S1 manufactured using the 3D printer 100 will be described.
FIG. 6 is a perspective view of a three-dimensional object according to the present embodiment, and FIGS. 7 and 8 are cross-sectional views of the same three-dimensional object in the XY direction. Note that broken lines in FIGS. 6 to 7 are auxiliary lines for assisting in understanding of the structure, and are assumed to be actually integrated.

The three-dimensional object S1 includes a plurality of layers L1 to L12 stacked in the Z direction. Each layer Li (i is an integer of 1 to 12) is formed of a plurality of different materials blended in a predetermined ratio. Specifically, the first material M1 is a powder sintered material, for example, powder sintered metal such as copper, nickel, chromium, titanium, tungsten, molybdenum, ceramic, powder sintered resin, etc. It can be used. The material M1 starts to cure and shrink at a temperature higher than the decomposition temperature of the material Mb used at least in the manufacturing method described later. The second material M2 can be filled in the gaps of the structure of the material M1, which will be described later, such as a material having the property of flowing at a predetermined temperature (hereinafter sometimes referred to as "flowable material") or a powder material. It is a material and is a material different from the material M1. The fluid material referred to here corresponds to, for example, heat-melting metals such as iron, aluminum, copper, and brass, thermoplastic resins, and the like. However, when using the material M2 as the flowable material, the material M2 needs to be a material that melts at a temperature lower than at least the decomposition temperature of the material M1. In the following description, the case where the material M2 is a fluid material is mainly described.

In the lowermost layer L1, as shown in FIG. 7, the material portions P1 formed of the material M1 and the material portions P2 formed of the material M2 are alternately arranged in the Y direction and stretched in a stripe shape along the X direction Including parts. Hereinafter, the direction in which a plurality of different materials are arranged may be referred to as “arrangement direction”. In this sense, the arrangement direction of the material portions P1 and P2 in the layer L1 is the Y direction.

The ratio of the width wy1 in the Y direction of the material portion P1 to the width wy2 in the Y direction of the material portion P2 in the layer L1 is 1: 5. In other words, the compounding ratio of the material M1 to the material M2 in the layer L1 is 1: 5.

On the other hand, in the layer L2 immediately above the layer L1, as shown in FIG. 8, the material portions P1 and the material portions P2 are alternately arranged in the X direction and include portions extending in a stripe along the Y direction. . That is, the arrangement direction of the material portions P1 and P2 in the layer L2 is the X direction intersecting the arrangement direction of the layer L1. The ratio of the width wx1 in the X direction of the material portion P1 to the width wx2 in the X direction of the material portion P2 in the layer L2 is 1: 4. In other words, the compounding ratio of the material M1 to the material M2 in the layer L2 is 1: 4. The material portion P1 of the layer L2 is joined to the material portion P1 of the layer L1 in the Z direction, as shown in FIG. Similarly, material portion P2 of layer L2 bonds with material portion P2 of layer L1 in the Z direction.

Thus, the odd-numbered layers Lo (o is an odd number of 1 to 12) including the layer L1 include portions in which the material portions P1 and P2 extend in the Y direction as the arrangement direction and in the stripe shape along the X direction . On the other hand, the even-numbered layers Le (e is an even number of 1 to 12) including the layer L2 include portions in which the material portions P1 and P2 extend in a stripe shape with the X direction as the arrangement direction and the Y direction. The material portion P1 of the layer Lj (j is an integer of 1 to 12) is joined to the material portion P1 of the layers Lj-1 and Lj + 1 adjacent in the Z direction in the Z direction. Similarly, the material portion P2 of the layer Lj joins in the Z direction with the material portion P2 of the layers Lj-1 and Lj + 1. That is, focusing on the material portions P1 of all the layers Li, the material portions P1 as a whole have a well-like structure (hereinafter referred to as "well-like structure"). Similarly, focusing on the material portion P2 of all the layers Li, the material portion P2 also has a well-gage structure as a whole. Further, the parallel crosses of the material portion P1 and the material portion P2 are fitted to each other, and the relative movement in the X direction, the Y direction, and the Z direction is restricted. That is, the three-dimensional object S1 is a structure in which the material portions P1 and P2 are integrally combined without using an adhesive, a screw or the like.

Further, the compounding ratio of the materials M1 and M2 in each layer Li can be freely set. In the case of the shaped article S1, in the layer L1 to the layer L10, the compounding ratio of the materials M1 and M2 gradually changes from 1: 5 to 5: 1, and the compounding ratio of the material M1 increases as it is in the upper layer. In the layers L10 to L12, the compounding ratio of the materials M1 and M2 is constant at 5: 1. That is, the three-dimensional object S1 has the property of changing stepwise from the layer L1 having a large amount of the material M2 to the appearance of the material M2 to the layer L10 to L12 having a large amount of the material M1 and a high appearance of the material M1. Here, generally, in view of the fact that the structure in which the powdery body is sintered is higher in hardness than the structure in which the fluid is hardened, the material portion P1 formed by sintering the material M1 is The hardness is higher than the material portion P2 formed by curing the material M2, and conversely, the material portion P2 is more flexible than the material portion P1. That is, the shaped article S1 has the property that the flexibility is higher toward the layer L1 and the hardness is higher toward the layers L10 to L12.

From the above, it should be considered that the three-dimensional object S1 is a composite material in which the material M1 having high hardness and the material M2 having high flexibility are firmly joined by fitting the well girder structures without using mechanical joining or adhesive joining. You can also.

Next, a method of manufacturing the object S1 will be described with reference to FIGS. 9 to 13. Note that broken lines in FIGS. 9 to 13 are auxiliary lines for assisting in understanding of the structure, and in actuality are integrated.

First, as shown in FIG. 9, a 3D printer 100 is used to form a layer L1 ′ to be the layer L1. Here, the material portion Pb formed of the material Mb is formed at the portion of the layer L1 where the material portion P2 is disposed. Specifically, in the Y direction, material portions Pb which are stretched in the Y direction are arranged while leaving a gap g in the place where the material portion P1 is disposed. At this time, the material portion Pb is formed such that the ratio of the width wyg in the Y direction of the gap g to the width wyb in the Y direction of the material portion Pb is 1: 5. Here, the material Mb is a material having a decomposition temperature lower than the temperature at which the material M1 cures and shrinks in the baking process of the post process, and, for example, nylon, polycarbonate, polybutylene terephthalate (PBT), acrylonitrile-butadiene-styrene copolymer Resin materials, such as a polymeric resin (ABS) and an elastomer, can be used.

Subsequently, as shown in FIG. 10, the 3D printer 100 is used to form a layer L2 ′ to be the layer L2 on the layer L1 ′. Here, the material portion Pb is formed in the portion of the layer L2 where the material portion P2 is disposed. Specifically, in the Y direction, material portions Pb to be stretched in the Y direction are arranged while leaving a gap g in the portion where the material portion P1 of the layer L2 is disposed. At this time, the material portion Pb is formed such that the ratio of the width wxg in the X direction of the gap g to the width wxb in the X direction of the material portion Pb is 1: 4.

Subsequently, as shown in FIG. 11, using the 3D printer 100, layers L3 ′ to L12 ′ to be layers L3 to L12 are sequentially formed on the layer L2 ′. Here, as in the steps shown in FIGS. 8 and 9, the material portion Pb is formed in the portion of the layers L3 to L12 where the material portion P2 is disposed. Specifically, in the odd-numbered layer Lo ′, the material portions Pb to be stretched in the Y direction are arranged while leaving a gap g in the place where the material portion P1 of the layer Lo is disposed in the Y direction. On the other hand, in the even-numbered layer Le ′, the material portions Pb to be stretched in the X direction are arranged while leaving a gap g in the portion where the material portion P1 of the layer Le is disposed in the X direction. At this time, the material portion Pb is formed such that the width in the X direction of the gap g and the material portion Pb becomes a predetermined ratio for each layer Li ′. By the steps shown in FIGS. 9 to 11, a material portion Pb having a parallel cross section similar to that of the material portion P2 is formed at the formation portion of the material portion P2, and the structure S1 ⁽³⁾ shown in FIG. 11 is formed. In place of the structural body S1 ⁽³⁾ , a structural body of another material obtained by inverting this as a negative body may be prepared.

Subsequently, as shown in FIG. 12, with the material portion Pb of the structure S1 ⁽³⁾ as a core, the powder material M1 is filled in the gap g. The material M1 is pressurized and filled in the structure S1 ⁽³⁾ . Therefore, in the steps shown in FIGS. 9 to 11, it is desirable to use a material Mb that deforms the structural body S1 ⁽³⁾ . Here, the material M1 is, for example, from the decomposition temperature of the material Mb among powder sintered materials such as powder sintered metals such as copper, nickel, chromium, titanium, tungsten, and molybdenum, ceramics, powder sintered resin, etc. It is a material that cures and shrinks at high temperatures. By this process, a structure S1 ′ ′ which is a complex of the material portion Pb which is the core and the material M1 is formed. It should be noted that, since the material portion Pb has the well girder structure as described above, the material M1 is also filled in the form of the well girder structure fitted with the material portion Pb.

Subsequently, the structure S1 ′ ′ is compressed and then fired to sinter the powdered material M1. Here, as described above, the material Mb has a decomposition temperature lower than the temperature at which the material M1 cures and shrinks. Therefore, the material portion Pb is not decomposed and scattered and does not remain in the middle of the firing with respect to the structure S1 ′ ′ without preventing the curing shrinkage of the material M1. By this process, as shown in FIG. 13, a structure S1 'is formed in which only the material portion P1 having a parallel cross section formed of the material M1 remains.

Finally, the material portion P1 of the structure S1 'is used as a core, and the gap g of the structure S1' is filled with the fluid material M2 by heat and pressure treatment. Here, the material M2 is a material having a property of flowing at a predetermined temperature, and for example, a metal that melts heat, such as iron, aluminum, copper, or brass, a thermoplastic resin, or the like can be used. However, the material M2 needs to be a material which is different from the material M1 in relation to the material M1 and which melts at a temperature lower than the decomposition temperature of the material M1 at least. Thereafter, the material M2 is cooled and cured. In addition, various kinds of curing treatments such as heat treatment and addition of a curing agent can also be used for curing of the material M2 depending on its properties. By this process, the material portion P2 of the well girder structure fitted with the material portion P1 is formed, and the shaped article S1 shown in FIG. 6 is completed.
The above is the manufacturing method of modeling object S1.

Next, the effects of the object S1 and the method of manufacturing the same will be described.
For example, hardness is required for a knife such as a kitchen knife or a knife. However, if these cutters are manufactured solely from hard materials such as high speed steels and cemented carbides, they become brittle products susceptible to twisting and impact. Therefore, the blade is required to have not only hardness but also toughness. In this respect, a traditional Japanese sword is mentioned as a knife having both hardness and toughness. In the case of a traditional Japanese sword, while using a hard steel material with a large amount of carbon at the center of the blade, by using a flexible steel material with a small amount of carbon outside the blade, the hardness of the cutting edge and high toughness of the whole are realized. There is. As described above, by using a composite material in which materials having different properties are combined, it is possible to expect an improvement in quality that can not be realized by using only one material.

In that respect, the shaped product S1 is formed of a combination of the relatively hard material portion P1 and the relatively flexible material portion P2, and the compounding ratio of the material M1 and the material M2 is from the layer L1 to the layer L10. ~ L12 will gradually increase. In other words, the structure S1 has a structure in which the flexibility is higher toward the layer L1 and the hardness is higher toward the layers L10 to L12. In addition, since the material portions P1 and P2 both have a parallel cross section structure and they are fitted to each other, there is a fear of peeling between the material portion P1 and the material portion P2 than in the case of using adhesive bonding or mechanical bonding. High mechanical strength can be realized.

And, if the shaped object S1 is applied, a shaped object having characteristics like a Japanese sword can be easily realized. For example, if a shaped object is produced in which a shaped object in which the shaped object S1 is inverted in the Z direction is further placed on the layer L12 of the shaped object S1, the shaped object has higher flexibility toward the outside in the Z direction. The hardness is higher. And this characteristic is exactly the same as that of a Japanese sword.

In addition, the characteristics of the Japanese sword are realized by adjusting the amount of carbon contained in iron by the manual operation of a sword smith, but in this case the quality may vary depending on the skill of the sword smith, and it takes time to manufacture. The problem was that it was a problem. In this respect, according to the manufacturing method according to the present embodiment, the use of the 3D printer 100 makes it possible to use a 3D product having the same characteristics as a Japanese sword with an industrially constant quality regardless of the manufacturer's experience or the like. It can be mass-produced.

Furthermore, although the three-dimensional object S1 combines different materials using a well girder structure, when a flat plate-like knife such as a kitchen knife is manufactured from a three-dimensional object having such a structure, the crest due to the different material (metal) is displayed. It can also appear on the cutting edge. By using this, it is possible to bring out an apparent uniqueness like a Damascus steel blade.

In addition, the cutter including the above-mentioned Japanese sword is one of the application examples of this embodiment, and this embodiment is not limited to this. The three-dimensional object according to the present embodiment is a material that can be filled in a gap between a powder-sintered material and a structure of a powder-sintered material such as a fluid material or a powder material (for example, a structure S1 ′ of FIG. 13). It is sufficient if it is a combination of and its variations are various.

For example, the direction in which the compounding ratio of materials changes can also be set arbitrarily. Although the structure S1 is changed in the Z direction, it is also possible to change it in the Y direction as in the structure S1A shown in FIG. 14, for example, by devising the arrangement of the material portions P1 and P2 in each layer. It can be made to change with respect to an X direction and a Y direction like structure S1B shown in FIG. Similarly, as in the structure S1C shown in FIG. 16, it is also possible to change in the Y direction and the Z direction.

In addition, the number of types of materials to be combined may be two as in the shaped object S1, or three or more. In addition, the compounding ratio of the materials for each layer may be gradually changed as in the case of the shaped product S1, or may be sharply changed or constant. Further, as to the characteristics of the materials to be combined, a combination focusing on flexibility and hardness as in the shaped object S1 may be used, or a combination focusing on magnetism or conductivity may be used. As described above, according to the present embodiment, since the degree of freedom of the structure and the material is high, it is possible to realize a three-dimensional object having various characteristics.
As described above, according to the present embodiment, it is possible to provide a shaped article formed of a combination of a plurality of different materials and having high physical strength, and a method of manufacturing the same.

Second Embodiment
Although the first embodiment has described the three-dimensional object having a structure in which the well girder structure is fitted to each other, the present invention is not limited to this. Thus, in the second embodiment, one application example having another structure will be described.

The three-dimensional object S2 according to the present embodiment is an end mill. In the case of end mills and drills, it is desirable that the cutting edge be hard in terms of cutting ability and wear. On the other hand, not only the twisting force is always applied during use, but also when processing a work in which different materials are combined, the load fluctuation becomes large at the interface of these materials, and in the worst case, it is broken. Therefore, also in the case of an end mill or a drill, high toughness as well as high hardness is required as with a blade.

So, in this embodiment, let modeling thing S2 (end mill) be the following structures.
FIG. 17 is a view for explaining a three-dimensional object according to the second embodiment. In the figure, A is a side view of the shaped article S2, and in the figure, B to D show the structure of each portion of the shaped article S2.

The three-dimensional object S2 of the present embodiment is substantially cylindrical as a whole, and comprises a blade base S2a disposed on the left side of A in FIG. 17, a blade edge S2c disposed on the right side, and a middle portion S2b connecting them.

The object S2 includes a plurality of layers L stacked in the axial direction Da. Each layer L of the three-dimensional object S2 includes a material portion P1 formed of the material M1 and a material portion P2 formed of the material M2 as shown in FIGS.

However, in the case of the shaped object S2, the arrangement pattern of the material portions P1 and the material portions P2 in each layer L is different from that of the shaped object S1. Specifically, the odd-numbered layers Lo (o is an odd number) are arranged such that the material portion P1 (or the material portion P2) extends radially from the center of each layer Lo, as shown in B to D in FIG. ing. That is, in the layer Lo, the material portion P1 and the material portion P2 are arranged with the circumferential direction Dθ as the arrangement direction. On the other hand, in the even-numbered layers Le (e is an even number), as shown by B to D in FIG. 17, the material parts P1 and the material parts P2 are alternately arranged concentrically alternately from the central axis CA. There is. That is, in the layer Le, the material portion P1 and the material portion P2 are arranged with the radial direction Dr intersecting the circumferential direction Dθ as the arrangement direction. Then, the material portion P1 of the layer Li (i is an integer) is joined with the material portion P1 of the layers Li-1 and Li + 1 in the axial direction Da. Similarly, the material portion P2 of the layer Li bonds in the axial direction Da with the material portion P2 of the layers Li-1 and Li + 1. As described above, even when the layers Lo in which the material portions P1 or P2 are radially arranged and the layers Le in which the material portions P1 and P2 are concentrically arranged are alternately laminated, the material portions P1 and the material of the entire object S2 are Since the portion P2 is fitted to each other, the material portion P1 and the material portion P2 can be firmly integrated, as in the case of using the well girder structure.

Moreover, as for molded article S2, the compounding ratio of the materials M1 and M2 is changed with blade origin S2a, middle part S2b, and blade edge | tip S2c.
Specifically, in the layer Lo of the blade source S2a to the middle portion S2b, as shown in A and B in FIG. 17, the material portions P1 are radially arranged, and the material portion P2 is filled in the other places. Then, the number of linear portions of the material portion P1 emerging from the central axis CA increases from the blade base S2a to the middle portion S2b. Similarly, in the layer Lo of the middle portion S2b to the blade edge S2c, as shown in FIG. 17 and FIG. 17C, the material portions P2 are radially arranged, and the material portion P1 is filled in the other places. Then, the number of linear portions of the material portion P2 emerging from the central axis CA decreases from the middle portion S2b to the cutting edge S2c. On the other hand, in the layer Le, the material portions P1 and the material portions P2 are alternately arranged concentrically. Then, the thickness tr2 of the material portion P2 in the radial direction Dr gradually decreases and the thickness tr1 of the material portion P1 in the radial direction Dr gradually increases from the blade base S2a to the blade edge S2c. By arranging the material portions P1 and P2 in this manner, it is possible to form a three-dimensional object S2 having a highly flexible blade source S2a and a cutting edge S2c having high hardness. In the case of an end mill, a force is applied in the rotational direction, so that not only an isotropic characteristic with respect to the circumferential direction Dθ is required, but also a characteristic capable of withstanding a torsional force with respect to the axial direction Da is required. In this respect, in the case of the parallel crosses as in the first embodiment, anisotropic characteristics appear in the circumferential direction Dθ. However, in the case of the present embodiment, the arrangement pattern concentric with the radial arrangement pattern By combining these, it is possible to realize an isotropic characteristic with respect to the circumferential direction Dθ and a characteristic that can withstand a twisting force with respect to the axial direction Da.

The embodiment of the present invention is not limited to the structure such as the shaped object S2 shown in FIG. 17, and the embodiments of the present invention are different as long as the arrangement directions of different materials intersect in each layer and similar materials are joined at this intersection. The material parts can be fitted to one another. This enables integration of a plurality of different materials as in the case of the shaped object S1 or the shaped object S2. And it is also possible to manufacture a three-dimensional object of any shape from such freedom of structure. For example, a chisel is required to be as strong in torsion as an end mill, but if the embodiment of the present invention is applied, it is also possible to realize a chisel having a free edge shape that is strong in torsion.

From the above, according to the present embodiment, it is possible to manufacture a three-dimensional object having desired characteristics including shape by changing not only the combination of materials and the compounding ratio of materials but also the arrangement pattern of the materials of each layer. it can.

[Others]
While certain embodiments of the invention have been described above, these embodiments have been presented by way of example only, and are not intended to limit the scope of the invention. These novel embodiments can be implemented in other various forms, and various omissions, replacements and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and the gist of the invention, and are included in the invention described in the claims and the equivalent scope thereof.

10: modeling stage, 11: frame, 12: XY stage, 13: modeling stage, 14: lifting table, 15: guide shaft, 21: frame, 22 · · X guide rail, 23 · · · Y guide rail, 24A, 24B · · · reel, 25A, 25B · · · forming head, 26 · · · heater 33 33 arm portion 34 35 · · · Roller, 38A, 38B: filament, 100: 3D printer, 200: computer, 201: spatial filter processor, 202: slicer, 203: modeling scheduler,
204: modeling instruction unit, 205: modeling vector generation unit, 300: driver, 301: CPU, 302: filament feeding device, 303: head control device, 304: current Switch, 306: motor driver, 307: input / output interface, H: modeling head holder, L: layer, M1, M2, Mb: material, Mx, My, Mz: motor , P1, P2, Pb: material part, S, S1, S2: shaped object, S2a: blade tip, S2b: middle part, S2c: blade edge, Tb: tube, Up ... modeling unit.

Claims

A composite material in which a first material which is a powder sintered material and a second material different from the first material are combined,
A three-dimensional object characterized in that, in the composite material, relative movement in three directions in which the first material and the second material intersect with each other is restricted.
Comprising a first layer and a second layer,
When the portion formed of the first material is a first material portion and the portion formed of the second material is a second material portion:
The first layer includes portions in which the first material portion and the second material portion are alternately arranged in a first direction,
The second layer includes portions alternately arranged in a second direction in which the first material portion and the second material portion intersect the first direction, and the first material portion of the first layer Bonding the first material portion of the second layer, and bonding the second material portion of the first layer to the second material portion of the second layer. Shaped object.
The shaped article according to claim 2, wherein the first layer includes a portion extending along a third direction in which the first material portion and the second material portion intersect the first direction.
The three-dimensional object according to claim 2 or 3, wherein the second layer includes a portion extending along a fourth direction in which the first material portion and the second material portion intersect the second direction. .
The compounding ratio of the first material to the second material of the first layer is different from the compounding ratio of the first material to the second material of the second layer. The shaped article according to any one of the above.
The three-dimensional structure according to any one of claims 2 to 5, wherein a compounding ratio of the first material and the second material changes stepwise in a predetermined direction.
The shaped article according to any one of claims 1 to 6, wherein the first material is a ceramic, a powder sintered metal, or a powder sintered resin.
The shaped article according to any one of claims 1 to 7, wherein the second material is a metal or a thermoplastic resin having a property of flowing at a predetermined temperature.
The shaped article according to any one of claims 1 to 8, wherein the second material is a material which is cured by a cooling or curing treatment.
What is claimed is: 1. A method of producing a shaped article comprising a composite material in which a first material which is a powder sintered material and a second material different from the first material are combined,
When the portion formed of the first material is a first material portion and the portion formed of the second material is a second material portion:
A first layer including a portion in which the first material portion is arranged with a gap in a first direction, and a first layer in which the first material portion is arranged with a gap in a second direction crossing the first direction Forming a first structure in which the first material portion of the first layer and the first material portion of the second layer are joined together by laminating two layers;
After filling the second material into the gaps of the first structure, the second material is cured to form the second material portion.
When a portion formed of a third material different from the first material is used as a third material portion:
Before forming the first structure, a second structure including the third material portion is formed at a location to be a gap of the first structure,
In forming the first structure, after filling the first material into a gap in which the third material portion is not formed in the second structure, the first material is sintered to form the first structure. The method of manufacturing a shaped article according to claim 10, wherein the first material portion is formed.
The method according to claim 11, wherein the third material is a resin.
The method for producing a shaped article according to any one of claims 10 to 12, wherein the second structure is formed by a 3D printer.
The shaped article according to any one of claims 10 to 13, wherein the third material decomposes at a temperature lower than a temperature at which the first material cures and shrinks due to sintering with respect to the first material. Production method.