WO2019216228A1 - Système de moulage, et, procédé de moulage - Google Patents

Système de moulage, et, procédé de moulage Download PDF

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Publication number
WO2019216228A1
WO2019216228A1 PCT/JP2019/017559 JP2019017559W WO2019216228A1 WO 2019216228 A1 WO2019216228 A1 WO 2019216228A1 JP 2019017559 W JP2019017559 W JP 2019017559W WO 2019216228 A1 WO2019216228 A1 WO 2019216228A1
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WO
WIPO (PCT)
Prior art keywords
modeling
structural layer
energy beam
irradiating
per unit
Prior art date
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PCT/JP2019/017559
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English (en)
Japanese (ja)
Inventor
長坂　博之
和樹 上野
浩一 安葉
慧 関口
Original Assignee
株式会社ニコン
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Publication of WO2019216228A1 publication Critical patent/WO2019216228A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • 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
    • B33Y10/00—Processes of additive manufacturing
    • 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

Definitions

  • the present invention relates to a technical field of a modeling system and a modeling method for forming a modeled object, for example.
  • Patent Document 1 describes a modeling system that forms a model on a base material by melting a powdered material with an energy beam and then solidifying the molten material.
  • a modeling system after forming a modeling object in a base material, it becomes a technical subject to isolate
  • an irradiation device that irradiates an energy beam and a supply device that supplies a material are provided, and the supplied material is melted by irradiating the energy beam onto a first modeling surface.
  • energy transmitted from the energy beam per unit area or per unit time to the first modeling surface and from the energy beam to the second modeling surface
  • the apparatus includes an irradiation device that irradiates an energy beam and a supply device that supplies a material, and melts the supplied material by irradiating the first modeling surface with the energy beam. Forming the first structure layer, and irradiating the energy beam to a second modeling surface that is at least a part of the surface of the first structure layer, thereby melting the supplied material.
  • a modeling system is provided that forms a second structural layer on the first structural layer, the size of which differs in at least one of the directions along the surface of the layer from the first structural layer.
  • the apparatus includes an irradiation apparatus that irradiates an energy beam and a supply apparatus that supplies a material, and the supply is performed by irradiating the first modeling surface with the energy beam having a first beam characteristic.
  • the first material layer is melted to form a first structure layer, and a second modeling surface that is at least a part of the surface of the first structure layer has a second beam characteristic different from the first beam characteristic.
  • a modeling system is provided that melts the supplied material by irradiating the energy beam to form a second structural layer on the first structural layer.
  • the apparatus includes an irradiation apparatus that irradiates an energy beam and a supply apparatus that supplies a material, irradiates the energy beam on a first modeling surface and supplies the material in the first supply aspect Forming a first structure layer, irradiating the second modeling surface which is at least a part of the surface of the first structure layer with the energy beam, and a second supply mode different from the first supply mode
  • a modeling system is provided that supplies the material to form a second structural layer on the first structural layer.
  • the irradiation device that irradiates the modeling surface with the energy beam, the supply device that supplies the material, and the relative positional relationship between the irradiation position of the energy beam and the modeling surface are changed.
  • At least one of the modeling surface and the irradiation position of the energy beam is moved to form the first structural layer, and the second modeling surface that is at least a part of the surface of the first structural layer is irradiated with the energy beam.
  • the second structure layer is moved to the first structure by moving at least one of the second modeling surface and the irradiation position of the energy beam in a second movement mode different from the first movement mode.
  • Molding system for forming the upper are provided.
  • the apparatus includes an irradiation device that irradiates an energy beam and a supply device that supplies a material, and melts the supplied material by irradiating the first modeling surface with the energy beam.
  • the first molten layer is formed to form a first structural layer, and the energy beam is applied to the second modeling surface that is at least a part of the surface of the first structural layer.
  • the second structural layer is formed by melting the material to form a second molten pool having a size different from that of the first molten pool in at least one of the directions along the surface of the first structural layer.
  • a modeling system for forming on the first structural layer is provided.
  • the apparatus includes: an irradiation device that irradiates an energy beam; and a supply device that supplies a material, and irradiates the first modeling surface with the energy beam and performs the first operation per unit time or per unit area.
  • the first structural layer is formed by supplying the material at a supply amount of 1 to form the first molten pool, and the energy is applied to a second modeling surface that is at least a part of the surface of the first structural layer. Irradiating a beam and supplying the material at a second supply amount different from the first supply amount per unit time or per unit area to form a second molten pool on the second modeling surface
  • a modeling system for forming a second structural layer on the first structural layer is provided.
  • the apparatus includes: an irradiation apparatus that irradiates an energy beam; and a supply apparatus that supplies a material.
  • the first structural surface is irradiated with the energy beam to form a first structural layer, and the first Irradiating the energy beam onto a second modeling surface that is at least a part of the surface of the one structural layer to form a second structural layer on the first structural layer, and having a resistance to destruction of the first structural layer
  • the modeling system which makes lower than the resistance with respect to the destruction of the said 2nd structure layer is provided.
  • the apparatus includes an irradiation device that irradiates an energy beam and a supply device that supplies a material, irradiates the first modeling surface with the energy beam and supplies the first material as the material.
  • a first structure layer Forming a first structure layer, irradiating a second modeling surface that is at least a part of the surface of the first structure layer with the energy beam, and supplying a second material as the material to form the second structure layer;
  • a modeling system is provided which is formed on a first structural layer, and the first material has a weaker bonding force with the first modeling surface than the second material.
  • FIG. 1 is a cross-sectional view showing the structure of the modeling system of this embodiment.
  • FIG. 2A to FIG. 2C is a cross-sectional view illustrating a state where light is irradiated and a modeling material is supplied in a certain region on the workpiece.
  • 3A, 3C, and 3E are cross-sectional views illustrating a process of forming a three-dimensional structure, and are illustrated in FIGS. 3B, 3D, and 3A.
  • Each of (f) is a top view which shows the process of forming a three-dimensional structure.
  • FIG. 4A is a plan view showing a molten pool for forming the lowermost structural layer
  • FIG. 4B is a melt for forming other structural layers other than the lowermost structural layer.
  • FIG. 5 is a graph showing the light intensity for forming the lowermost structural layer and the light intensity for forming other structural layers other than the lowermost structural layer.
  • 6A is a cross-sectional view showing the defocus amount of light for forming the lowermost structural layer, and FIG. 6B forms another structural layer other than the lowermost structural layer.
  • FIG. 6C is a graph showing the intensity distribution on the modeling surface of the light for forming the lowermost structural layer, and FIG. ) Is a graph showing the intensity distribution on the modeling surface of light for forming other structural layers other than the lowermost structural layer.
  • FIG. 7A is a timing chart showing the light irradiation time for forming the lowermost structural layer, and FIG.
  • FIG. 7B is for forming other structural layers other than the lowermost structural layer. It is a timing chart which shows the irradiation time of the light.
  • FIG. 8A is a timing chart showing the light irradiation time for forming the lowermost structural layer
  • FIG. 8B is for forming other structural layers other than the lowermost structural layer. It is a timing chart which shows the irradiation time of the light.
  • FIG. 9A is a graph showing the supply amount of the modeling material when forming the lowermost structural layer and the supply amount of the modeling material when forming other structural layers other than the lowermost structural layer
  • FIG. 9B is a cross-sectional view showing the modeling material supplied when forming the lowermost structural layer on the modeling surface
  • FIG. 9C shows another structure other than the lowermost structural layer. It is sectional drawing which shows the modeling material supplied when forming a layer on a modeling surface. 10 (a) and 10 (b) are cross-sectional views showing how the lowermost structural layer is formed, and FIG. 10 (c) and FIG. 10 (d) are the lowermost structure. It is sectional drawing which shows a mode that structure layers other than a layer are formed.
  • FIG. 11 is a graph showing the moving speed of the modeling head when forming the lowermost structural layer and the moving speed of the modeling head when forming other structural layers other than the lowermost structural layer.
  • FIG. 12F is a cross-sectional view showing one step of the first characteristic changing operation for changing the size of the structural layer by changing the size of the molten pool.
  • FIG. 13A to FIG. 13F is a cross-sectional view showing one step of the first characteristic changing operation for changing the size of the structural layer by changing the size of the molten pool.
  • FIG. 14A is a cross-sectional view showing a three-dimensional structure formed by the second modeling operation including the first characteristic changing operation
  • FIG. 14B is formed by the modeling operation of the first comparative example.
  • FIG. 14C and FIG. 14D each show a three-dimensional structure formed by the second modeling operation including the first characteristic changing operation. It is sectional drawing which shows a mode that it isolate
  • FIG. 15A is a plan view showing a three-dimensional structure formed by the second modeling operation including the first characteristic changing operation
  • FIG. 16 is a graph showing the light intensity for forming the lowermost structural layer and the light intensity for forming other structural layers other than the lowermost structural layer.
  • FIG. 17 is a graph showing the supply amount of the modeling material when forming the lowermost structural layer and the supply amount of the modeling material when forming other structural layers other than the lowermost structural layer.
  • FIG. 18A is a plan view showing a three-dimensional structure formed by the second modeling operation including the second characteristic changing operation
  • FIG. 18B is a diagram showing the second characteristic changing operation.
  • FIG. 19A is a cross-sectional view showing the wettability of the modeling material for forming the lowermost structural layer
  • FIG. 19B forms other structural layers other than the lowermost structural layer. It is sectional drawing which shows the wettability of the modeling material for this.
  • FIG. 20A is a plan view showing a three-dimensional structure formed by the second modeling operation including the third characteristic changing operation
  • FIG. 20B is a diagram showing the third characteristic changing operation. It is sectional drawing which shows a mode that the three-dimensional structure formed by 2 modeling operation
  • FIG. 20A is a plan view showing a three-dimensional structure formed by the second modeling operation including the third characteristic changing operation
  • FIG. 20B is a diagram showing the third characteristic changing operation. It is sectional drawing which shows a mode that the three-dimensional structure formed by 2 modeling operation
  • FIG. 20A is a cross-sectional view showing the wettability of the modeling material for
  • FIG. 21 is a cross-sectional view illustrating a three-dimensional structure according to a first modification.
  • FIG. 22A to FIG. 22D is a cross-sectional view showing a three-dimensional structure of a second modification.
  • FIG. 23A to FIG. 23C is a cross-sectional view showing a three-dimensional structure of a third modification.
  • FIG. 24A to FIG. 24C is a cross-sectional view showing a three-dimensional structure of a fourth modified example.
  • LMD Laser Metal Deposition
  • Laser overlay welding is available for direct metal deposition, direct energy deposition, laser cladding, laser engineered net shaping, direct write fabrication, and laser consolidation.
  • each of the X-axis direction and the Y-axis direction is a horizontal direction (that is, a predetermined direction in the horizontal plane), and the Z-axis direction is a vertical direction (that is, a direction orthogonal to the horizontal plane). Yes, it is substantially the vertical direction or the direction of gravity).
  • the rotation directions around the X axis, the Y axis, and the Z axis are referred to as a ⁇ X direction, a ⁇ Y direction, and a ⁇ Z direction, respectively.
  • the Z-axis direction may be the gravity direction.
  • the XY plane may be the horizontal direction.
  • FIG. 1 is a cross-sectional view showing an example of the structure of the modeling system 1 of the present embodiment.
  • the modeling system 1 is a three-dimensional structure (that is, a three-dimensional object having a size in any of the three-dimensional directions, and a three-dimensional object, in other words, an object having a size in the X, Y, and Z directions. ) ST can be formed.
  • the modeling system 1 can form the three-dimensional structure ST on the workpiece W that is a basis for forming the three-dimensional structure ST (for example, at least one of a base material, a workpiece, and a workpiece). .
  • the modeling system 1 can form the three-dimensional structure ST by performing additional processing on the workpiece W. When the workpiece W is a stage 13 described later, the modeling system 1 can form the three-dimensional structure ST on the stage 13.
  • the modeling system 1 When the workpiece W is an existing structure held by the stage 13 (note that the existing structure may be another three-dimensional structure ST formed by the modeling system 1), the modeling system 1 The three-dimensional structure ST can be formed on the existing structure. In this case, the modeling system 1 may form the three-dimensional structure ST integrated with the existing structure. The operation of forming the three-dimensional structure ST integrated with the existing structure is equivalent to the operation of adding a new structure to the existing structure. Or the modeling system 1 may form the three-dimensional structure ST separable from the existing structure.
  • FIG. 1 shows an example in which the workpiece W is an existing structure held by the stage 13. In the following, the description will be given using an example in which the workpiece W is an existing structure held by the stage 13.
  • the modeling system 1 can form a modeled object by the laser overlay welding method. That is, it can be said that the modeling system 1 is a 3D printer that forms an object using the additive manufacturing technique.
  • the additive manufacturing technology is also referred to as rapid prototyping, rapid manufacturing, or additive manufacturing.
  • the modeling system 1 forms the modeled object by processing the modeling material M with the light EL.
  • light EL for example, at least one of infrared light, visible light, and ultraviolet light can be used, but other types of light may be used.
  • the light EL is laser light.
  • the modeling material M is a material that can be melted by irradiation with light EL having a predetermined intensity or higher.
  • a modeling material M for example, at least one of a metallic material and a resinous material can be used. However, other materials different from the metallic material and the resinous material may be used as the modeling material M.
  • the modeling material M is a powdery or granular material. That is, the modeling material M is a granular material.
  • the modeling material M may not be a granular material, and for example, a wire-shaped modeling material or a gaseous modeling material may be used.
  • the modeling system 1 may form a modeled object by processing the modeling material M with an energy beam such as a charged particle beam.
  • the modeling system 1 includes a modeling head 11, a head drive system 12, a stage 13, and a control device 14, as shown in FIG. Furthermore, the modeling head 11 includes an irradiation system 111 and a material nozzle (that is, at least a part of a supply system that supplies the modeling material M) 112.
  • the irradiation system 111 is an optical system (for example, a condensing optical system) for emitting the light EL from the emitting unit 113. Specifically, the irradiation system 111 is optically connected to a light source (not shown) that emits light EL via an optical transmission member (not shown) such as an optical fiber. The irradiation system 111 emits light EL propagating from the light source via the light transmission member. The irradiation system 111 irradiates light EL from the irradiation system 111 downward (that is, on the ⁇ Z side). A stage 13 is disposed below the irradiation system 111.
  • a light source not shown
  • an optical transmission member such as an optical fiber.
  • the irradiation system 111 emits light EL propagating from the light source via the light transmission member.
  • the irradiation system 111 irradiates light EL from the irradiation system 111 downward (that is, on the
  • the irradiation system 111 can irradiate the light EL toward the workpiece W. Specifically, the irradiation system 111 irradiates the light EL to the irradiation area EA having a predetermined shape set on the workpiece W as an area to which the light EL is irradiated (typically condensed). Furthermore, the state of the irradiation system 111 can be switched between a state in which the irradiation area EA is irradiated with the light EL and a state in which the irradiation area EA is not irradiated with the light EL under the control of the control device 14.
  • the direction of the light EL emitted from the irradiation system 111 is not limited to just below (that is, the direction that coincides with the Z axis), and may be, for example, a direction inclined by a predetermined angle with respect to the Z axis.
  • the irradiation area EA may be, for example, a circular area, or may have another shape (for example, a rectangular shape).
  • the material nozzle 112 has a supply outlet (that is, supply port) 114 for supplying the modeling material M.
  • the material nozzle 112 supplies the modeling material M from the supply outlet 114 (for example, injection, ejection, or injection).
  • the material nozzle 112 is physically connected to a material supply device (not shown) that is a supply source of the modeling material M.
  • a powder transmission member such as a pipe (not shown) may be interposed between the material supply device and the material nozzle.
  • the material nozzle 112 supplies the modeling material M supplied from the material supply device via the powder transmission member.
  • the material nozzle 112 is drawn in a tube shape.
  • the shape of the material nozzle 112 is not limited to this tube shape.
  • the material nozzle 112 supplies the modeling material M downward (that is, on the ⁇ Z side).
  • a stage 13 is disposed below the material nozzle 112.
  • the material nozzle 112 supplies the modeling material M toward the workpiece W.
  • the traveling direction of the modeling material M supplied from the material nozzle 112 is a direction inclined by a predetermined angle (an acute angle as an example) with respect to the Z axis, but is directly below (that is, a direction coincident with the Z axis). May be.
  • a plurality of material nozzles 112 may be provided.
  • the material nozzle 112 is aligned with the irradiation system 111 such that the irradiation system 111 supplies the modeling material M toward the irradiation area EA where the light EL is irradiated. That is, the material nozzle 112 and the irradiation are set so that the supply area MA and the irradiation area EA set on the workpiece W as the area where the material nozzle 112 supplies the modeling material M coincides (or at least partially overlaps).
  • the system 111 is aligned.
  • the material nozzle 112 may be positioned so as to supply the modeling material M to the molten pool MP formed on the workpiece W by the light EL emitted from the irradiation system 111.
  • the material nozzle 112 may be aligned so that the supply region MA for supplying the modeling material M and the region of the molten pool MP partially overlap each other.
  • the head drive system 12 moves the modeling head 11.
  • the head drive system 12 moves the modeling head 11 along each of the X axis, the Y axis, and the Z axis.
  • the head drive system 12 may move the modeling head 11 along at least one of the ⁇ X direction, the ⁇ Y direction, and the ⁇ Z direction in addition to the X axis, the Y axis, and the Z axis.
  • the head drive system 12 includes, for example, a motor.
  • the irradiation area EA also moves with respect to the work W on the work W.
  • the head drive system 12 can change the positional relationship between the workpiece W and the irradiation area EA (in other words, the positional relationship between the stage 13 holding the workpiece W and the irradiation area EA) by moving the modeling head 11. It is. Moreover, the head drive system 12 can change the positional relationship between the workpiece W and the supply area MA (in other words, the positional relationship between the stage 13 holding the workpiece W and the supply area MA) by moving the modeling head 11. It is.
  • the head driving system 12 may move the irradiation system 111 and the material nozzle 112 separately. Specifically, for example, the head drive system 12 adjusts at least one of the position of the ejection unit 113, the orientation (or orientation) of the ejection unit 113, the position of the supply outlet 114, and the orientation (or orientation) of the supply outlet 114. It may be possible. In this case, the irradiation area EA where the irradiation optical system 111 irradiates the light EL and the supply area MA where the material nozzle 112 supplies the modeling material M can be controlled separately.
  • Stage 13 can hold workpiece W.
  • the stage 13 can further release the held workpiece W.
  • the irradiation system 111 described above irradiates the light EL in at least a part of the period in which the stage 13 holds the workpiece W.
  • the material nozzle 112 described above supplies the modeling material M in at least a part of the period in which the stage 13 holds the workpiece W.
  • a part of the modeling material M supplied by the material nozzle 112 may be scattered or spilled from the surface of the workpiece W to the outside of the workpiece W (for example, around the stage 13).
  • the modeling system 1 may include a collection device that collects the scattered modeling material M around the stage 13.
  • the control device 14 controls the operation of the modeling system 1.
  • the control device 14 may include, for example, a calculation device such as a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit), or a storage device such as a memory.
  • the control device 14 functions as a device that controls the operation of the modeling system 1 when the arithmetic device executes a computer program.
  • This computer program is a computer program for causing the control device 14 (for example, an arithmetic device) to perform (that is, execute) an operation to be described later that should be performed by the control device 14. That is, this computer program is a computer program for causing the control device 14 to function so as to cause the modeling system 1 to perform an operation described later.
  • the computer program executed by the arithmetic device may be recorded in a memory (that is, a recording medium) included in the control device 14, or any storage medium that is built in the control device 14 or externally attached to the control device 14. (For example, hard disk or semiconductor memory).
  • the arithmetic device may download a computer program to be executed from a device external to the control device 14 via a network interface.
  • the control device 14 may not be provided inside the modeling system 1, and may be provided as a server or the like outside the modeling system 1, for example.
  • the control device 14 and the modeling system 1 may be connected by a wired and / or wireless network (or a data bus and / or a communication line).
  • a wired network for example, a network using a serial bus type interface represented by at least one of IEEE 1394, RS-232x, RS-422, RS-423, RS-485, and USB may be used.
  • a network using a parallel bus interface may be used as the wired network.
  • a network using an interface compliant with Ethernet (registered trademark) represented by at least one of 10BASE-T, 100BASE-TX, and 1000BASE-T may be used.
  • a network using radio waves may be used.
  • An example of a network that uses radio waves is a network that conforms to IEEE 802.1x (for example, at least one of a wireless LAN and Bluetooth (registered trademark)).
  • a network using infrared rays may be used.
  • a network using optical communication may be used as the wireless network.
  • the control device 14 and the modeling system 1 may be configured so that various types of information can be transmitted and received via a network.
  • control device 14 may be capable of transmitting information such as commands and control parameters to the modeling system 1 via a network.
  • the modeling system 1 may include a receiving device that receives information such as commands and control parameters from the control device 14 via the network.
  • the 1st control apparatus which performs a part of process which the control apparatus 14 performs is provided in the modeling system 1, the 2nd which performs the other part of the process which the control apparatus 14 performs
  • a control device may be provided outside the modeling system 1.
  • the recording medium may include a device capable of recording a computer program (for example, a general-purpose device or a dedicated device in which the computer program is implemented in a state in which the computer program can be executed in at least one form such as software and firmware).
  • each process and function included in the computer program may be realized by a logical processing block realized in the control device 14 by the control device 14 (that is, the computer) executing the computer program, It may be realized by hardware such as a predetermined gate array (FPGA, ASIC) provided in the control device 14, or a logical processing block and a partial hardware module that realizes a part of hardware are mixed. It may be realized in the form of
  • the control device 14 controls the emission mode of the light EL by the irradiation system 111.
  • the emission mode includes, for example, at least one of the intensity of the light EL and the light emission timing.
  • the emission mode includes, for example, at least one of the length of the light emission time of the pulsed light and the ratio of the light emission time of the pulsed light to the extinction time (so-called duty ratio). Also good.
  • the control device 14 controls the movement mode of the modeling head 11 by the head drive system 12.
  • the movement mode includes, for example, at least one of a movement amount, a movement speed, a movement direction, and a movement timing.
  • control device 14 controls the supply mode of the modeling material M by the material nozzle 112.
  • the supply mode includes, for example, a supply amount (particularly, a supply amount per unit time).
  • the control device 14 may simultaneously control the emission mode of the light EL by the irradiation system 111 and the supply mode of the modeling material M by the material nozzle 112.
  • the modeling system 1 performs a modeling operation for forming the three-dimensional structure ST as described above.
  • the modeling system 1 compares the first modeling operation, which is a basic modeling operation for forming the three-dimensional structure ST on the workpiece W, with the three-dimensional structure ST formed by the first modeling operation.
  • At least one of the second modeling operation that is a modeling operation for forming the three-dimensional structure ST that can be easily separated (in other words, removed) from the workpiece W is performed.
  • the first modeling operation and the second modeling operation will be described in order.
  • the modeling system 1 forms the three-dimensional structure ST on the workpiece W based on the three-dimensional model data (for example, CAD (Computer Aided Design) data) of the three-dimensional structure ST to be formed.
  • the three-dimensional model data includes data representing the shape (particularly the three-dimensional shape) of the three-dimensional structure ST.
  • measurement data of a three-dimensional object measured by a measurement device provided in the modeling system 1 may be used.
  • measurement data of a 3D shape measuring machine provided separately from the modeling system 1 may be used.
  • a contact-type three-dimensional measuring machine and a non-contact type three-dimensional measuring machine having a probe that can move with respect to the workpiece W and can contact the workpiece W.
  • non-contact type 3D measuring machines include pattern projection 3D measuring machines, optical cutting 3D measuring machines, time-of-flight 3D measuring machines, and moire topography 3D measuring machines.
  • a holographic interferometric 3D measuring machine, a CT (Computed Tomography) 3D measuring machine, and an MRI (Magnetic Resonance Imaging) 3D measuring machine As the three-dimensional model data, design data of the three-dimensional structure ST may be used.
  • the modeling system 1 sequentially forms, for example, a plurality of layered partial structures (hereinafter referred to as “structural layers”) SL arranged along the Z-axis direction in order to form the three-dimensional structure ST.
  • structural layers layered partial structures
  • the modeling system 1 sequentially forms a plurality of structural layers SL obtained one by one by cutting the three-dimensional structure ST along the Z-axis direction.
  • a three-dimensional structure ST that is a stacked structure in which a plurality of structural layers SL are stacked is formed.
  • a flow of operations for forming the three-dimensional structure ST by sequentially forming the plurality of structural layers SL one by one will be described.
  • each structural layer SL Under the control of the control device 14, the modeling system 1 sets the irradiation area EA in a desired area on the modeling surface MS corresponding to the surface of the workpiece W or the surface of the formed structural layer SL, and the irradiation area EA Then, the light EL is emitted from the irradiation system 111. Note that an area occupied by the light EL emitted from the irradiation system 111 on the modeling surface MS may be referred to as an irradiation area EA. Moreover, the modeling system 1 does not need to set the irradiation area EA in the desired area on the modeling surface MS.
  • an area occupied by the light EL emitted from the irradiation system 111 on the modeling surface MS may be referred to as an irradiation area EA.
  • the focus position FP of the light EL (that is, the condensing position, in other words, the position where the light EL is most converged in the Z-axis direction or the traveling direction of the light EL) matches the modeling surface MS. ing. Note that the focus position FP of the light EL may be set at a position shifted in the Z-axis direction from the modeling surface MS. As a result, as shown in FIG.
  • a molten pool that is, a pool of liquid metal or resin or the like melted by the light EL in a desired region on the modeling surface MS by the light EL emitted from the irradiation system 111.
  • MP is formed.
  • the modeling system 1 sets a supply area MA in a desired area on the modeling surface MS under the control of the control device 14 and supplies the modeling material M from the material nozzle 112 to the supply area MA.
  • the modeling system 1 may not set the supply area MA in a desired area on the modeling surface MS. At this time, an area where the modeling material M is supplied from the material nozzle 112 may be referred to as a supply area MA.
  • the supply area MA is set to an area where the molten pool MP is formed. In other words, the supply area MA coincides with the area where the molten pool MP is formed. For this reason, the modeling system 1 will supply the modeling material M from the material nozzle 112 with respect to the molten pool MP, as shown in FIG.2 (b). As a result, the modeling material M supplied to the molten pool MP melts. When the light EL is no longer applied to the molten pool MP as the modeling head 11 moves, the modeling material M melted in the molten pool MP is cooled and solidified (that is, solidified). As a result, as shown in FIG.
  • the solidified modeling material M is deposited on the modeling surface MS.
  • a modeled object is formed by the solidified modeling material M deposit.
  • a modeling thing is formed by performing additional processing which adds the deposit of modeling material M to modeling surface MS.
  • a series of modeling processes including formation of the molten pool MP by irradiation of such light EL, supply of the modeling material M to the molten pool MP, melting of the supplied modeling material M and solidification of the molten modeling material M is performed as modeling. It repeats, changing the position in the XY plane of the modeling head 11 with respect to the surface MS. In other words, including the formation of the molten pool MP, the supply of the modeling material M, the melting of the modeling material M, and the solidification of the molten modeling material M while moving the modeling head 11 along the XY plane with respect to the modeling surface MS. A series of modeling processes is repeated. When the modeling head 11 moves with respect to the modeling surface MS, the irradiation area EA also moves with respect to the modeling surface MS.
  • a series of modeling processes is repeated while moving the irradiation area EA along the XY plane with respect to the modeling surface MS.
  • the light EL is selectively irradiated to the irradiation area EA set in the area where the modeled object should be formed, while the light EL is applied to the irradiation area EA set in the area where the modeled object should not be formed. Is not selectively irradiated.
  • the irradiation area EA is not set in the area where the shaped article should not be formed.
  • the modeling system 1 moves the irradiation area EA along a predetermined movement trajectory on the modeling surface MS, and at a timing according to the distribution of areas where the modeled object is to be formed (that is, the pattern of the structural layer SL).
  • Light EL is irradiated onto the modeling surface MS.
  • the modeling system 1 moves the area where the light EL is to be irradiated along the predetermined movement trajectory on the modeling surface MS, and moves the light when the area is positioned in the area where the modeling object is to be formed.
  • the EL is irradiated onto the modeling surface MS.
  • a structural layer SL corresponding to an aggregate of shaped objects made of the solidified modeling material M is formed on the modeling surface MS.
  • the irradiation area EA is moved with respect to the modeling surface MS.
  • the modeling surface MS may be moved with respect to the irradiation area EA.
  • the modeling system 1 repeatedly performs an operation for forming such a structural layer SL based on the three-dimensional model data under the control of the control device 14. 3A to FIG. 3F, specifically, the control device 14 first slices the three-dimensional model data at the stacking pitch to create slice data. Note that the control device 14 may at least partially correct the slice data according to the characteristics of the modeling system 1.
  • the modeling system 1 corresponds to the structure layer SL # 1 for the operation for forming the first structural layer SL # 1 on the modeling surface MS corresponding to the surface WS of the workpiece W under the control of the control device 14. To be performed based on the three-dimensional model data (that is, slice data corresponding to the structural layer SL # 1).
  • the structural layer SL # 1 is formed on the modeling surface MS as shown in FIGS. 3 (a) and 3 (b). Thereafter, the modeling system 1 sets the surface (typically, the upper surface) of the structural layer SL # 1 to a new modeling surface MS, and then the second structural layer SL # on the new modeling surface MS. 2 is formed.
  • the control device 14 first controls the head drive system 12 so that the modeling head 11 moves along the Z axis. Specifically, the control device 14 controls the head drive system 12 so that the irradiation area EA and the supply area MA are set on the surface of the structural layer SL # 1 (that is, a new modeling surface MS). The modeling head 11 is moved toward the + Z side.
  • the focus position FP of the light EL coincides with the new modeling surface MS.
  • the modeling system 1 operates on the structural layer SL # 1 based on the slice data corresponding to the structural layer SL # 2 in the same operation as the operation of forming the structural layer SL # 1 under the control of the control device 14.
  • the structural layer SL # 2 is formed.
  • the structural layer SL # 2 is formed.
  • the same operation is repeated until all the structural layers SL constituting the three-dimensional structure to be formed on the workpiece W are formed.
  • FIGS. 3E and 3F a plurality of structural layers SL are stacked along the Z axis (that is, along the direction from the bottom surface to the top surface of the molten pool MP).
  • a three-dimensional structure ST is formed by the stacked structure.
  • (2-2) Second modeling operation (modeling operation of the three-dimensional structure ST that can be easily separated from the workpiece W) Subsequently, the second modeling operation for forming the three-dimensional structure ST that can be easily separated (in other words, removed) from the workpiece W as compared with the three-dimensional structure ST formed by the first modeling operation will be described.
  • the second modeling operation is a modeling operation that forms the three-dimensional structure ST by sequentially forming the plurality of structural layers SL.
  • the second modeling operation is different from the first modeling operation described above in that it includes an operation for forming the three-dimensional structure ST that can be easily separated from the workpiece W.
  • Other features of the second modeling operation may be the same as other features of the first modeling operation.
  • an operation for forming the three-dimensional structure ST that can be easily separated from the workpiece W will be described.
  • the modeling system 1 includes a plurality of structures constituting the three-dimensional structure ST as operations for forming the three-dimensional structure ST that can be easily separated from the workpiece W under the control of the control device 14.
  • a characteristic changing operation is adopted in which a part of the characteristics of the layer SL is changed to a characteristic different from the characteristics of some of the other structural layers SL.
  • the modeling system 1 performs, as the characteristic changing operation, the lowermost structural layer SL among the plurality of structural layers SL (typically, the first layer formed on the modeling surface MS corresponding to the surface WS).
  • the structural layer SL # 1) has a characteristic other than the lowermost structural layer SL among the plurality of structural layers SL (typically, other structural layers SL formed on the lowermost structural layer SL).
  • the operation of changing to a characteristic different from the characteristic of the structural layer SL) is adopted.
  • the modeling system 1 performs, as the characteristic change operation, for example, a plurality of structural layers SL positioned in a lower layer including the lowermost structural layer SL among the plurality of structural layers SL.
  • the characteristics of the structural layer SL other than the plurality of structural layers SL located in the lower layer among the plurality of structural layers SL that is, the characteristics of the structural layer SL located above the structural layer SL located in the lower layer
  • the characteristics of the structural layer SL may include the size of the structural layer SL.
  • the characteristics of the structural layer SL include the size of the structural layer SL in at least one direction along the modeling surface MS (typically, at least one direction intersecting the stacking direction of the plurality of structural layers SL). May be.
  • the size of the structural layer SL may be referred to as the width of the structural layer SL.
  • the size of the structural layer SL means the size of the structural layer SL in at least one direction along the modeling surface MS.
  • the size of the structural layer SL can be the size of the structural layer SL in any direction in the XY plane.
  • the modeling system 1 sets the size of the lowermost structural layer SL (hereinafter, appropriately referred to as “structural layer SL_lowest”) as the characteristic changing operation, and changes the size of the structural layer SL other than the structural layer SL_lowest (hereinafter, appropriately “ A first characteristic changing operation for changing to a size different from the size of the structural layer SL_upper ”is performed.
  • the size of each structural layer SL may be the size of the structural layer SL in the same direction. More specifically, the modeling system 1 performs, for example, an operation for making the size of the structural layer SL_lowest smaller than the size of the structural layer SL_upper as the first characteristic changing operation.
  • the size of the structural layer SL_lowest is smaller than the size of the structural layer SL_upper, the size of the structural layer SL_lowest is not smaller than the size of the structural layer SL_upper. Is easily separated from the workpiece W.
  • the structural layer SL_lowest is separated from the work W, the structural layer SL_upper that is integrated with the work W via the structural layer SL_lowest is also separated from the work W.
  • the separation of the three-dimensional structure ST from the workpiece W is facilitated as compared with the case where the three-dimensional structure ST is formed by the first modeling operation.
  • the characteristics of the structural layer SL may include resistance to destruction of the structural layer SL (in other words, resistance to breakage, for example, toughness).
  • the characteristics of the structural layer SL may include the brittleness (in other words, brittleness) of the structural layer SL.
  • the modeling system 1 changes the resistance against the destruction of the lowermost structural layer SL_lowest to a different resistance from the resistance against the destruction of the other structural layers SL_upper other than the structural layer SL_lowest as the characteristic changing operation.
  • a second characteristic changing operation is performed. More specifically, the modeling system 1 performs, for example, an operation for making the resistance to destruction of the structural layer SL_lowest lower than the resistance to destruction of the structural layer SL_upper as the second characteristic changing operation.
  • the structural layer SL_upper may be formed in the same manner as the structural layer SL formed by the first modeling operation.
  • the modeling system 1 has a resistance to the destruction of the structural layer SL_lowest as the second characteristic changing operation, and the structural layer SL (typically, the structural layer SL_lowest) is formed by the first modeling operation. You may perform the operation
  • the resistance to destruction of the structural layer SL_lowest is low, the resistance to destruction of the structural layer SL_lowest is not low (that is, the structural layer SL (typically in the first modeling operation)
  • the structural layer SL_lowest is easily broken.
  • the second characteristic changing operation is an operation for making the structural layer SL_lowest more easily destroyed than the structural layer SL_upper.
  • the structural layer SL_lowest is destroyed, the structural layer SL_upper integrated with the work W is separated from the work W via the structural layer SL_lowest.
  • separation of the three-dimensional structure ST from the workpiece W is facilitated.
  • the characteristics of the structural layer SL may include a bonding force (in other words, adhesion force) of the structural layer SL to the workpiece W.
  • the modeling system 1 changes the bonding force of the lowermost structural layer SL_lowest to the workpiece W as a characteristic changing operation to a bonding force different from the bonding force of the other structural layer SL_upper to the workpiece W other than the structural layer SL_lowest.
  • a third characteristic changing operation is performed. More specifically, the modeling system 1 performs an operation for making the bonding force of the structural layer SL_lowest to the workpiece W weaker than the bonding force of the structural layer SL_upper to the workpiece W as the third characteristic changing operation.
  • the structural layer SL_upper may be formed in the same manner as the structural layer SL formed by the first modeling operation.
  • the modeling system 1 uses the bonding force of the structural layer SL_lowest to the workpiece W as the third characteristic changing operation, and the structural layer SL (typically, the structural layer SL_lowest) is formed by the first modeling operation. You may perform the operation
  • the bonding force of the structural layer SL_lowest to the workpiece W is weakened, the bonding force of the structural layer SL_lowest to the workpiece W is not weakened (that is, the structural layer SL (typical in the first modeling operation)
  • the structural layer SL_lowest is easily separated from the workpiece W.
  • the structural layer SL_upper coupled to the work W via the structural layer SL_lowest is also separated from the work W.
  • the separation of the three-dimensional structure ST from the workpiece W is facilitated as compared with the case where the three-dimensional structure ST is formed by the first modeling operation.
  • the modeling system 1 may change, for example, the formation conditions when forming the structural layer SL.
  • the modeling system 1 may change the formation conditions when forming the structural layer SL_lowest to the formation conditions different from the formation conditions when forming the structural layer SL_upper.
  • the formation conditions in the first characteristic changing operation may include the size of the molten pool MP.
  • the formation conditions may include the size of the molten pool MP in at least one direction along the modeling surface MS.
  • the size of the molten pool MP may be referred to as the width of the molten pool MP.
  • the size of the molten pool MP means the size of the molten pool MP in at least one direction along the modeling surface MS.
  • the size of the molten pool MP can be set to an arbitrary direction in the XY plane.
  • the modeling system 1 may change the size of the molten pool MP for forming the structural layer SL_lowest to a size different from the size of the molten pool MP for forming the structural layer SL_upper.
  • the size of each molten pool MP should just be taken as the size of the molten pool MP in the same direction.
  • the modeling system 1 sets the size of the molten pool MP for forming the structural layer SL_lowest to form the structural layer SL_upper. It may be smaller than the size of the molten pool MP. For example, as illustrated in FIG.
  • the molten pool MP formed on the modeling surface MS may become circular in the direction along the modeling surface MS.
  • the size of the molten pool MP may be referred to as the diameter of the molten pool MP.
  • the size of the molten pool MP differs in two directions orthogonal to each other along the modeling surface MS, for example, when the molten pool MP has an elliptical shape, the size of the molten pool MP in any one direction is set to It is good also as size.
  • the size along the Y direction of the molten pool MP for forming SL_lowest is compared with the size along the Y direction of the molten pool MP for forming the structural layer SL_upper.
  • the modeling system 1 may control the characteristics of the light EL irradiated by the irradiation system 111.
  • the modeling system 1 may change the characteristic of the light EL for forming the structural layer SL_lowest to a characteristic different from the characteristic of the light EL for forming the structural layer SL_upper. That is, when the modeling system 1 forms the structural layer SL_lowest, the characteristics of the light EL are the first characteristics for forming the structural layer SL_lowest (that is, for forming the small-sized molten pool MP). May be set.
  • the characteristics of the light EL are set to the second for forming the structural layer SL_upper (that is, for forming the large-sized molten pool MP).
  • a characteristic (typically, the second characteristic is different from the first characteristic) may be set.
  • the second characteristic can also be referred to as a characteristic of the light EL for forming the molten pool MP having a larger size than the small-sized molten pool MP formed by the light EL having the first characteristic.
  • the characteristics of the light EL in the first characteristic changing operation may include the intensity of the light EL per unit area (or energy per unit area) on the modeling surface MS.
  • the energy may be referred to as an energy amount.
  • the modeling system 1 may set the intensity of the light EL per unit area to the first intensity when forming the structural layer SL_lowest.
  • the modeling system 1 may set the intensity of the light EL per unit area to a second intensity larger than the first intensity when forming the structural layer SL_upper. .
  • the structural layer SL_lowest when forming the structural layer SL_lowest, at least one of energy transmitted from the light EL to the modeling surface MS per unit area and energy transmitted from the light EL to the modeling surface MS per unit time. Is at least one of energy transmitted from the light EL to the modeling surface MS per unit area and energy transmitted from the light EL to the modeling surface MS per unit time when forming the structural layer SL_upper. Less than. As the energy transmitted from the light EL to the modeling surface MS per unit area or unit time decreases, the modeling material M that melts on the modeling surface MS due to the irradiation of the light EL decreases.
  • the modeling material M melted on the modeling surface MS when forming the structural layer SL_lowest is less than the modeling material M melted on the modeling surface MS when forming the structural layer SL_upper.
  • the smaller the modeling material M melted on the modeling surface MS the smaller the size of the molten pool MP composed of the melted modeling material M.
  • the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper.
  • the characteristic of the light EL may be the intensity of the light EL per unit area per unit time (or energy per unit area) on the modeling surface MS.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the characteristics of the light EL in the first characteristic changing operation may include a defocus amount of the light EL with respect to the modeling surface MS.
  • the “defocus amount of the light EL with respect to the modeling surface MS” referred to here is a direction intersecting the modeling surface MS (typically, an orthogonal direction, for example, the Z-axis direction or the traveling direction of the light EL). ) May mean the amount of deviation between the modeling surface MS and the focus position FP of the light EL.
  • the modeling system 1 may set the defocus amount of the light EL to the first defocus amount when forming the structural layer SL_lowest.
  • the modeling system 1 may set the defocus amount of the light EL to a second defocus amount smaller than the first defocus amount when forming the structural layer SL_upper.
  • the defocus amount of the light EL becomes larger than zero (that is, the focus position of the light EL).
  • the defocus amount of the light EL is set so that the FP is set at a position shifted in the Z-axis direction from the modeling surface MS, and (ii) when forming the structural layer SL_upper, FIG.
  • the defocus amount of the light EL may be set so that the defocus amount of the light EL becomes zero (that is, the focus position FP of the light EL is set on the modeling surface MS).
  • the defocus amount of the light EL is larger than when forming the structural layer SL_upper (in other words, the focus position FP of the light EL). Is set to a position greatly deviated in the Z-axis direction from the modeling surface MS than when the structural layer SL_upper is formed), and (ii) the structural layer SL_upper is formed.
  • the defocus amount of the light EL is smaller than that in the case where the structural layer SL_lowest is formed (that is, the focus position FP of the light EL is more in the Z-axis direction from the modeling surface MS than in the case where the structural layer SL_lowest is formed.
  • the defocus amount of the light EL may be set so that it is set at a slightly deviated position.
  • the intensity distribution of the light EL on the modeling surface MS is an intensity that can melt the modeling material M (specifically, a predetermined intensity). The distribution is such that the range of the light EL having an intensity equal to or greater than the threshold value is narrowed.
  • the defocus amount of the light EL when the defocus amount of the light EL is large, the range on which the light EL is irradiated on the modeling surface MS becomes wide, but as a whole, only the light EL with a small intensity is irradiated. The energy transmitted per unit area or unit time from the light EL to the modeling surface MS is reduced.
  • the intensity distribution of the light EL on the modeling surface MS is a range of the light EL having an intensity for melting the modeling material M as shown in FIG. The distribution is such that is relatively wide.
  • the energy transmitted from the light EL per unit area or unit time is larger than in the above case.
  • the energy transmitted per unit area or unit time from the light EL with a large defocus amount to the modeling surface MS per unit area or unit with respect to the modeling surface MS from the light EL with a small defocus amount Less energy is transferred per hour.
  • the energy transmitted per unit area or per unit time from the light EL to the modeling surface MS when forming the structural layer SL_lowest is from the light EL to the modeling surface MS when forming the structural layer SL_upper.
  • the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the characteristic of the light EL in the first characteristic changing operation may include the irradiation time of the light EL per unit area.
  • the modeling system 1 may set the irradiation time of the light EL to a short first irradiation time when forming the structural layer SL_lowest.
  • the modeling system 1 may set the irradiation time of the light EL to a second irradiation time longer than the first irradiation time.
  • the modeling system 1 may irradiate pulsed light that is intermittently switched on and off as the light EL as illustrated in FIG.
  • the modeling system 1 may irradiate the light EL intermittently or in pulses when forming the structural layer SL_lowest.
  • the modeling system 1 forms the structural layer SL_upper, as shown in FIG. 7B, irradiation and non-irradiation are not switched intermittently (that is, continuous irradiation continues).
  • You may irradiate light as light EL.
  • the modeling system 1 may continuously irradiate the light EL when forming the structural layer SL_upper.
  • the irradiation time of the light EL is shortened by an amount corresponding to the time when the light EL is not irradiated as compared with the case where the structural layer SL_upper is formed.
  • the modeling system 1 forms the structural layer SL_lowest, as illustrated in FIG. 8A, pulsed light having a small duty ratio indicating the proportion of time during which the light EL is irradiated is used as the light EL. It may be irradiated.
  • the modeling system 1 irradiates a pulsed light having a duty ratio larger than that in the case of FIG.
  • the duty ratio of the light EL may be the ratio of the irradiation time to the period when the light EL repeats irradiation and non-irradiation periodically.
  • the irradiation time of the light EL is shortened by a smaller duty ratio than when the structural layer SL_upper is formed. The shorter the irradiation time of the light EL per unit area, the smaller the energy transmitted from the light EL to the modeling surface MS per unit area or unit time.
  • the energy transmitted from the light EL to the modeling surface MS per unit area or unit time is less when the irradiation time is shorter than when the irradiation time is long. Therefore, the energy transmitted from the light EL to the modeling surface MS per unit area or per unit time when forming the structural layer SL_lowest is from the light EL to the modeling surface MS when forming the structural layer SL_upper. Less energy is transferred per unit area or per unit time. For this reason, the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the modeling system 1 may control the supply mode of the modeling material M by the material nozzle 112. In this case, the modeling system 1 may change the supply mode of the modeling material M when forming the structural layer SL_lowest to a supply mode different from the supply mode when forming the structural layer SL_upper. That is, when the modeling system 1 forms the structural layer SL_lowest, the first aspect for forming the structural layer SL_lowest (that is, for forming the small-sized molten pool MP) is used as the supply mode of the modeling material M.
  • the supply mode may be set as follows.
  • the modeling system 1 uses a small-sized molten pool for forming the structural layer SL_upper as the supply mode of the modeling material M (that is, for forming the structural layer SL_lowest).
  • the second supply mode (typically, the second supply mode is different from the first supply mode) may be set to form a molten pool MP having a size larger than MP.
  • the supply mode of the modeling material M in the first characteristic changing operation is at least one of the supply amount of the modeling material M per unit time and the supply amount of the modeling material M per unit area (that is, the supply rate of the modeling material M). May be included.
  • the modeling system 1 may set the supply amount of the modeling material M to the first supply amount when forming the structural layer SL_lowest.
  • the modeling system 1 reduces the supply amount of the modeling material M compared to the case of FIG. 9A when forming the structural layer SL_upper (that is, in FIG. 9A).
  • the second supply amount may be set to be smaller than the first supply amount.
  • the light EL is easily shielded by the modeling material M supplied to the modeling surface MS.
  • the modeling material M is melted by irradiation with the light EL, when the modeling material M in an amount exceeding the meltable amount is supplied to the modeling surface MS, at least a part of the supplied modeling material M is the light EL. This is because it can function as a shield that shields the light EL without melting by irradiation. As a result, since the intensity of the light EL reaching the modeling surface MS is reduced, the energy transmitted from the light EL to the modeling surface MS per unit area or unit time is reduced.
  • the modeling system 1 shields at least a part of the supplied modeling material M against the light EL in order to reduce energy transmitted from the light EL to the modeling surface MS per unit area or unit time. It is used as.
  • the supply amount of the modeling material M is small, as illustrated in FIG. 9C, the light EL is hardly shielded by the modeling material M supplied to the modeling surface MS.
  • the intensity of the light EL reaching the modeling surface MS is larger than that in the case of FIG. 9B, the energy transmitted from the light EL to the modeling surface MS per unit area or unit time. Is larger than that in the case of FIG.
  • the energy transmitted per unit area or unit time from the light EL to the modeling surface MS under the condition where the supply amount of the modeling material M is large is the light EL when the supply amount of the modeling material M is small. Is less than the energy transmitted per unit area or per unit time to the modeling surface MS. That is, when the structural layer SL_lowest is formed, energy transmitted from the light EL to the modeling surface MS per unit area or per unit time is transmitted from the light EL to the modeling surface MS when the structural layer SL_upper is formed. Less energy is transferred per unit area or per unit time. For this reason, the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the size of the molten pool MP composed of the modeling material M that has been melted without being solidified is reduced by the amount of the modeling material M that has been cooled and solidified.
  • at least a part of the supplied modeling material M may be used as a coolant for cooling the molten pool MP in addition to or instead of using the light EL as a shield.
  • the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper. Become.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the supply mode of the modeling material M in the first characteristic changing operation may include the supply timing (or supply timing) of the modeling material M.
  • the modeling system 1 may supply the modeling material M to the modeling surface MS in advance before irradiating the light EL when forming the structural layer SL_lowest.
  • the modeling system 1 has an amount of modeling material M that can function as a shielding object that at least partially shields the light EL before the light EL is irradiated on the entire surface (or a part) of the modeling surface MS. It may be supplied in advance.
  • FIG. 10B after the modeling material M is supplied to the modeling surface MS, the modeling system 1 may irradiate the light EL.
  • the modeling system 1 does not need to supply the modeling material M during the period of irradiating the light EL as shown in FIG.
  • the modeling material M supplied in advance is supplied from the material nozzle 112 (for example, a newly supplied modeling material M and / or a gas ejected from the material nozzle 112 to supply a new modeling material M). Will not be blown away.
  • the modeling system 1 may supply the modeling material M in at least a part of the period during which the light EL is irradiated. As a result, at least a part of the modeling material M supplied in advance to the modeling surface MS is melted and integrated with the modeling surface MS, so that the structural layer SL_lowest is formed.
  • the modeling system 1 does not have to supply the modeling material M to the modeling surface MS in advance before irradiating the light EL when forming the structural layer SL_upper. . That is, as shown in FIG.
  • the modeling material M is applied to the irradiation area EA of the light EL while irradiating the light EL (or to the molten pool MP).
  • It may be supplied locally.
  • the modeling material M is not supplied to the modeling surface MS in advance, since the modeling material M is locally supplied, the shielding object in which at least a part of the locally supplied modeling material M shields the light EL. The possibility of functioning as is reduced. For this reason, the energy transmitted per unit area or unit time from the light EL to the modeling surface MS is larger than that in the case where a shielding object exists. Therefore, the size of the molten pool MP becomes larger than that in the case where a shield is present.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the modeling system 1 may control the movement mode of the modeling head 11.
  • the modeling system 1 may change the movement mode of the modeling head 11 when forming the structural layer SL_lowest to a movement mode different from the movement mode when forming the structural layer SL_upper. That is, when the modeling system 1 forms the structural layer SL_lowest, the movement mode of the modeling head 11 is the first for forming the structural layer SL_lowest (that is, for forming the small-sized molten pool MP). You may set to the movement mode.
  • the movement mode of the modeling head 11 is the molten pool for forming the structural layer SL_upper (that is, the molten pool formed in the first movement mode).
  • the second movement mode typically the second movement mode is different from the first movement mode to form a molten pool MP having a size larger than the size of the MP. Also good.
  • the movement mode in the first characteristic changing operation is a movement speed (for example, a movement speed in a direction along the modeling surface MS, and as an example, a movement speed in an arbitrary direction in the XY plane, typically in the X-axis direction. And / or the movement speed in the Y-axis direction).
  • the modeling system 1 may set the moving speed of the modeling head 11 to the first moving speed when forming the structural layer SL_lowest.
  • the modeling system 1 sets the moving speed of the modeling head 11 to a second moving speed that is slower than the first moving speed when forming the structural layer SL_upper. Also good.
  • the moving speed of the irradiation area EA on the modeling surface MS increases.
  • the moving speed of the irradiation area EA on the modeling surface MS increases, the irradiation time of the light EL per unit area on the modeling surface MS decreases. Accordingly, as the moving speed of the irradiation area EA on the modeling surface MS increases, the energy transmitted from the light EL to the modeling surface MS per unit area or unit time decreases.
  • the energy transmitted per unit area or unit time from the light EL to the modeling surface MS under the situation where the moving speed of the modeling head 11 is high (that is, the moving speed of the irradiation area EA is high)
  • the light EL is transmitted from the light EL to the modeling surface MS per unit area or per unit time under a situation where the moving speed of the head 11 is slower than the moving speed under the above situation (that is, the moving speed of the irradiation area EA is slow).
  • Less than energy that is, the energy transmitted per unit area or per unit time from the light EL to the modeling surface MS when forming the structural layer SL_lowest is from the light EL to the modeling surface MS when forming the structural layer SL_upper.
  • the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_lowest is smaller than the size of the molten pool MP formed on the modeling surface MS when forming the structural layer SL_upper.
  • the size of the structural layer SL_lowest becomes smaller than the size of the structural layer SL_upper, and the structural layer SL_lowest is easily separated from the workpiece W.
  • the supply amount per unit time of the modeling material M supplied to at least one of the irradiation area EA and the molten pool MP on the modeling surface MS decreases.
  • the size of the structural layer SL is smaller than when the supply amount is higher.
  • the structural layer SL_lowest is easily separated from the workpiece W.
  • the size of the molten pool MP and the size of the structure ST may not be proportional.
  • the modeling system 1 controls the movement mode of the stage 13 (and hence the movement mode of the modeling surface MS) in order to change the size of the molten pool MP. May be. This is because if the stage 13 moves, it can be considered that the irradiation area EA moves with respect to the modeling surface MS.
  • the control method of the movement aspect of the stage 13 may be the same as the control method of the movement aspect of the modeling head 11, the detailed description is abbreviate
  • the modeling system 1 may control the movement mode of the irradiation area EA.
  • region EA may be the same as the control method of the movement aspect of the modeling head 11, the detailed description is abbreviate
  • FIG. 12 (a) to FIG. 12 (f) and FIG. 13 (a) This will be described with reference to FIG.
  • the irradiation system 111 is modeled.
  • the surface EL is irradiated with light EL.
  • a molten pool MP is formed on the modeling surface MS.
  • the material nozzle 112 supplies the modeling material M to the irradiation area EA (or the molten pool MP) of the light EL.
  • the modeling material M supplied to the molten pool MP is melted, and the molten pool including the molten modeling material M on the modeling surface MS is raised from the modeling surface MS. MP is formed.
  • the modeling system 1 uses the light so that the size of the molten pool MP becomes small (for example, the first size R1 described above) under the control of the control device 14. Control at least one of the EL characteristics, the supply mode of the modeling material M, and the movement mode of the modeling head 11 is performed.
  • the surface of the lowermost structural layer SL_lowest is set as a new modeling surface MS.
  • the irradiation system 111 irradiates the modeling surface MS (that is, the surface of the structural layer SL_lowest) with the light EL.
  • a molten pool MP is formed in the structural layer SL_lowest.
  • the material nozzle 112 supplies the modeling material M to the light EL irradiation area EA (or the molten pool MP).
  • the modeling material M supplied to the molten pool MP is melted, and the molten pool including the melted modeling material M on the modeling surface MS is raised from the modeling surface MS.
  • MP is formed. That is, on the surface of the structural layer SL_lowest, the molten pool MP that includes the molten modeling material M and rises from the surface of the structural layer SL_lowest is formed.
  • the modeling system 1 controls the light EL so that the size of the molten pool MP becomes larger (for example, the second size R2 described above) under the control of the control device 14. At least one of the characteristics, the supply mode of the modeling material M, and the movement mode of the modeling head 11 is controlled.
  • the modeling material M melted in the molten pool MP is cooled and solidified (that is, solidified).
  • a modeled object constituting the structural layer SL_upper is formed on the structural layer SL_lowest by the solidified deposit of the modeling material M.
  • the larger the molten pool MP the more modeling material M is cooled and solidified.
  • the size of the solidified modeling material M deposit increases. For this reason, as shown in FIG.
  • the size of the structural layer SL_upper formed by forming the molten pool MP having a large size is the same as the structural layer formed by forming the molten pool MP having a small size. It becomes larger than the size of SL_lowest.
  • the surface of the formed structural layer SL_upper is set as a new modeling surface MS.
  • the light EL is irradiated from the irradiation system 111 to the modeling surface MS (that is, the surface of the formed structural layer SL_upper).
  • the molten pool MP is formed in the formed structural layer SL_upper.
  • the modeling material M is supplied from the material nozzle 112 to the light EL irradiation area EA (or the molten pool MP).
  • the modeling material M supplied to the molten pool MP is melted, and the molten pool including the molten modeling material M on the modeling surface MS is raised from the modeling surface MS.
  • MP is formed. That is, on the surface of the formed structural layer SL_upper, a molten pool MP that includes the molten modeling material M and rises from the surface of the formed structural layer SL_upper is formed.
  • the modeling system 1 can control the characteristics of the light EL and the modeling material M so that the size of the molten pool MP is increased (for example, the second size R2 described above) under the control of the control device 14. At least one of the supply mode and the movement mode of the modeling head 11 is controlled. Thereafter, when the light EL is no longer applied to the molten pool MP as the modeling head 11 moves, the modeling material M melted in the molten pool MP is cooled and solidified (that is, solidified). As a result, as shown in FIG. 13F, a modeled object constituting the new structure layer SL_upper is formed on the already formed structure layer SL_upper by the solidified deposit of the modeling material M.
  • the operation for forming a new structural layer SL_upper is repeated on the uppermost structural layer SL_uper among the plurality of formed structural layers SL_upper.
  • the second modeling operation including the first characteristic changing operation a plurality of sizes larger than the size of the structural layer SL_lowest are formed on the small structural layer SL_lowest as shown in FIG.
  • the three-dimensional structure ST having the structural layer SL_upper is formed. That is, the three-dimensional structure ST having a plurality of structural layers SL_upper having a width wider than the width of the structural layer SL_lowest is formed on the narrow structural layer SL_lowest.
  • the three-dimensional structure ST in which a portion where the structural layer SL_lowest is formed is substantially cut is formed. That is, the three-dimensional structure ST in which a cut is substantially formed in a portion coupled with the workpiece W is formed. In other words, the three-dimensional structure ST having a small contact area with the workpiece W (or the area of the coupling portion) is formed.
  • FIGS. 15A to 15C when the box-shaped three-dimensional structure ST shown in FIGS. 3A to 3F is formed by the second modeling operation, as shown in FIGS. 15A to 15C.
  • a wall-shaped structure ST1 extending along the X-axis direction
  • a wall-shaped structure ST2 extending along the X-axis direction and facing the structure ST1 along the Y-axis direction, and along the Y-axis direction.
  • a wall-like structure ST3 in which the + Y side end and the ⁇ Y side end are connected to the ⁇ X side ends of the structures ST1 and ST2, respectively, and extends along the Y-axis direction.
  • ST is formed.
  • the size in the Y-axis direction of the structural layer SL_lowest constituting the structure ST1 is smaller than the size in the Y-axis direction of the structural layer SL_upper constituting the structure ST1.
  • the size in the Y-axis direction of the structural layer SL_lowest constituting the structure ST2 is smaller than the size in the Y-axis direction of the structural layer SL_upper constituting the structure ST2.
  • the size in the X-axis direction of the structural layer SL_lowest constituting the structure ST3 is smaller than the size in the X-axis direction of the structural layer SL_upper constituting the structure ST3. Further, as shown in FIG. 15C, the size in the X-axis direction of the structural layer SL_lowest constituting the structure ST4 is smaller than the size in the X-axis direction of the structural layer SL_upper constituting the structure ST4.
  • the three-dimensional structure ST formed by the second modeling operation including the first characteristic changing operation is the workpiece W. It can be easily separated from the workpiece W by using the notches formed in the connecting portion. Specifically, as illustrated in FIG. 14C, the three-dimensional structure ST may be separated from the work W while including the structural layers SL_lowest and SL_upper, by separating the structural layer SL_lowest from the work W. . Alternatively, as shown in FIG.
  • the three-dimensional structure ST has a structure in which the structural layer SL_lowest is broken and a part of the structural layer SL_lowest is coupled to the workpiece W, and the remaining part of the structural layer SL_lowest is the workpiece. It may be separated from W. Accordingly, the structure layer SL_lowest may be separated from the workpiece W in a state where a part of the structure layer SL_lowest is removed from the three-dimensional structure ST. Alternatively, the three-dimensional structure ST may be broken at the boundary between the structural layer SL_lowest and the structural layer SL_upper.
  • the three-dimensional structure ST (that is, the three-dimensional structure ST including the structural layer SL_upper) may be separated from the work W in a state where the entire structural layer SL_lowest is coupled to the work W.
  • at least a part of the structural layer SL_lowest that remains coupled to the workpiece W may not be the structural layer SL constituting the three-dimensional structure ST.
  • the modeling system 1 forms the structural layer SL for separating the three-dimensional structure ST from the workpiece W as the structural layer SL_lowest, and then forms the structural layer SL constituting the three-dimensional structure ST as the structural layer SL_upper. May be formed on the structural layer SL_lowest.
  • the three-dimensional structure ST that can be easily separated from the workpiece W can be formed by the second modeling operation including the first characteristic changing operation.
  • the “destruction” in the present embodiment is caused by destruction caused by a physical action (for example, external force, impact as an example), destruction caused by an electric action, destruction caused by a magnetic action, or thermal action. It may include at least one of destruction, destruction caused by optical action, and destruction caused by chemical action.
  • “brittleness” refers to fragility to physical action, fragility to electrical action, fragility to magnetic action, fragility to thermal action, fragility to optical action, and fragility to chemical action. At least one of the above may be included.
  • the modeling system 1 may change, for example, the formation conditions when forming the structural layer SL in order to change the resistance to destruction of the structural layer SL.
  • the modeling system 1 may change the formation conditions when forming the structural layer SL_lowest to the formation conditions different from the formation conditions when forming the structural layer SL_upper.
  • the formation conditions in the second characteristic changing operation may include the characteristics of the light EL irradiated by the irradiation system 111.
  • the modeling system 1 may change the characteristic of the light EL for forming the structural layer SL_lowest to a characteristic different from the characteristic of the light EL for forming the structural layer SL_upper.
  • the modeling system 1 may set the characteristic of the light EL to the third characteristic for forming the structural layer SL_lowest with low resistance to destruction.
  • the modeling system 1 uses the fourth characteristic (typically, the fourth characteristic for forming the structural layer SL_upper having high resistance to destruction as the characteristic of the light EL. May be set differently from the third characteristic).
  • the characteristic of the light EL in the second characteristic changing operation may include the intensity of the light EL per unit area on the modeling surface MS (or the energy of the light EL per unit area).
  • the modeling system 1 may set the intensity of the light EL per unit area to the third intensity when forming the structural layer SL_lowest.
  • the third strength is higher than the fourth strength described later.
  • the third strength may be set based on a strength capable of evaporating the modeling material M. For example, the third strength may be set to be higher than the strength at which the modeling material M can be evaporated.
  • the structural layer SL_lowest when forming the structural layer SL_lowest, at least a part of the modeling material M supplied to the modeling surface MS is evaporated by irradiation with the light EL. For this reason, the modeling material M which only melts without evaporating decreases. As a result, only the modeling material M which is less than a sufficient amount for forming the structural layer SL_lowest is melted (and is not solidified). When the modeling material M less than such a sufficient amount is solidified to form the structural layer SL_lowest, many voids may be formed inside the structural layer SL_lowest due to the lack of the modeling material M. As the number of such voids increases, the structural layer SL_lowest becomes brittle.
  • the modeling system 1 sets the intensity of the light EL per unit area to a fourth intensity smaller than the third intensity when forming the structural layer SL_upper. Good.
  • the fourth strength may be set based on a strength capable of evaporating the modeling material M. For example, the fourth strength may be set to be less than a strength capable of evaporating the modeling material M.
  • the structural layer SL_upper is formed from a sufficient amount of the modeling material M to form the structural layer SL_upper, the void formed inside the structural layer SL_upper is formed inside the structural layer SL_lowest. Less than voids. As a result, the structural layer SL_upper becomes hard. In other words, the brittleness of the structural layer SL_upper becomes low. Accordingly, the resistance to destruction of the structural layer SL_upper is higher than that of the structural layer SL_lowest. That is, the resistance to destruction of the structural layer SL_lowest is lower than the resistance to destruction of the structural layer SL_upper.
  • the formation condition in the second characteristic changing operation may include a supply mode of the modeling material M by the material nozzle 112.
  • the modeling system 1 may change the supply mode of the modeling material M when forming the structural layer SL_lowest to a supply mode different from the supply mode when forming the structural layer SL_upper.
  • the modeling system 1 may set the supply mode of the modeling material M to the third supply mode for forming the structural layer SL_lowest having low resistance to destruction.
  • the supply mode of the modeling material M is the fourth supply mode for forming the structural layer SL_upper whose resistance to destruction is higher than that of the structural layer SL_lowest. (Typically, the fourth supply mode is different from the third supply mode).
  • the supply mode of the modeling material M in the second characteristic changing operation may include the supply amount of the modeling material M per unit time or per unit area (that is, the supply rate of the modeling material M).
  • the modeling system 1 may set the supply amount of the modeling material M to the third supply amount when forming the structural layer SL_lowest.
  • the third supply amount is smaller than a fourth supply amount described later.
  • the third supply amount may be set based on the amount of the modeling material M necessary for forming the structural layer SL_lowest. For example, the third supply amount may be set to be less than the amount of the modeling material M necessary for forming the structural layer SL_lowest.
  • the modeling system 1 sets the supply amount of the modeling material M to the fourth supply amount larger than the third supply amount when forming the structural layer SL_upper. Good.
  • the fourth supply amount may be set based on the amount of the modeling material M necessary for forming the structural layer SL_upper.
  • the fourth supply amount may be set to be equal to or more than the amount of the modeling material M necessary for forming the structural layer SL_upper.
  • the fourth supply amount may be set to be equal to or more than the amount of the modeling material M necessary for forming the structural layer SL_upper.
  • the formation conditions in the second characteristic changing operation may include the type of the modeling material M supplied from the material nozzle 112.
  • the modeling system 1 changes the type of the modeling material M supplied to form the structural layer SL_lowest to a type different from the type of the modeling material M supplied to form the structural layer SL_upper. Also good.
  • the modeling system 1 may supply the first type of modeling material M for forming the structural layer SL_lowest with low resistance to destruction.
  • the modeling system 1 when forming the structural layer SL_upper, the modeling system 1 supplies the second type of modeling material M for forming the structural layer SL_upper having a higher resistance to destruction than the structural layer SL_lowest. Good.
  • the first type of modeling material M may be more brittle than, for example, the second type of modeling material M.
  • the first type of modeling material M may be more fragile than the second type of modeling material M.
  • the resistance to destruction of the structural layer SL_lowest formed from the first type of modeling material M is lower than the resistance to destruction of the structural layer SL_upper formed from the second type of modeling material M.
  • the second modeling operation including the second characteristic changing operation as described above has a higher resistance to destruction than the structural layer SL_lowest on the structural layer SL_lowest having a low resistance to destruction.
  • a three-dimensional structure ST in which a plurality of structural layers SL_upper is formed is formed. Therefore, if an external force that does not destroy the structural layer SL_upper is applied to the structural layer SL_lowest while the structural layer SL_lowest can be destroyed, the structural layer SL_upper is destroyed as shown in FIG. The structural layer SL_lowest can be destroyed.
  • the structural layer SL_lowest is destroyed, the structural layer SL_upper integrated with the work W is separated from the work W via the structural layer SL_lowest.
  • the second characteristic changing operation is performed.
  • the three-dimensional structure ST formed by the second modeling operation including it can be easily separated from the workpiece W. Therefore, the second modeling operation including the second characteristic changing operation can form the three-dimensional structure ST that can be easily separated from the workpiece W.
  • the structural layer SL_lowest may not be the structural layer SL constituting the three-dimensional structure ST.
  • the modeling system 1 forms the structural layer SL to be destroyed in order to separate the three-dimensional structure ST from the workpiece W as the structural layer SL_lowest, and then the structural layer SL constituting the three-dimensional structure ST. May be formed on the structural layer SL_lowest as the structural layer SL_upper.
  • the modeling system 1 may change, for example, the formation conditions when forming the structural layer SL.
  • the modeling system 1 may change the formation conditions when forming the structural layer SL_lowest to the formation conditions different from the formation conditions when forming the structural layer SL_upper.
  • the formation conditions in the third characteristic changing operation may include the type of the modeling material M supplied from the material nozzle 112.
  • the modeling system 1 changes the type of the modeling material M supplied to form the structural layer SL_lowest to a type different from the type of the modeling material M supplied to form the structural layer SL_upper. Also good.
  • the modeling system 1 may supply a third type of modeling material M for forming the structural layer SL_lowest having a weak binding force to the workpiece W.
  • the modeling system 1 when forming the structural layer SL_upper, the modeling system 1 supplies the fourth type of modeling material M for forming the structural layer SL_upper that has a stronger binding force to the workpiece W than the structural layer SL_lowest. Also good.
  • the third type of modeling material M may be, for example, a material having a weaker bonding force with the workpiece W than the fourth type of modeling material M. Specifically, the lower the wettability of the modeling material M with respect to the surface WS of the workpiece W, the weaker the bonding force between the modeling material M and the workpiece W is.
  • the “state where the wettability of the modeling material M” in the present embodiment may mean “a state where the contact angle of the molten modeling material M is large”. Accordingly, the third type of modeling material M has lower wettability than the fourth type of modeling material M as shown in FIG. 19A (that is, the contact angle of the fourth type of modeling material M).
  • the modeling material M may be larger than the contact angle.
  • the fourth type of modeling material M may be a modeling material M having higher wettability than the third type of modeling material M.
  • the third type of modeling material M may include at least one of aluminum, titanium, copper, and tungsten, or the fourth type of modeling material M. May contain stainless steel (or the same material as that of the workpiece W).
  • the bonding force of the structural layer SL_lowest formed from the third type of modeling material M to the workpiece W is weaker than the bonding force of the structural layer SL_upper formed of the fourth type of modeling material M to the workpiece W. Become.
  • the bonding force to the work W is higher than the structural layer SL_lowest on the structural layer SL_lowest having a weak bonding force to the work W.
  • a three-dimensional structure ST in which a plurality of strong structural layers SL_upper is formed is formed.
  • the structural layer SL_lowest can be easily separated from the work W as compared with the case where the structural layer SL_lowest having a strong bonding force to the work W is formed on the work W.
  • the structural layer SL_upper that is integrated with the work W via the structural layer SL_lowest is also separated from the work W.
  • the three-dimensional structure ST formed by the second modeling operation including the third characteristic changing operation is the workpiece W. Can be easily separated from Therefore, the second modeling operation including the third characteristic changing operation can form the three-dimensional structure ST that can be easily separated from the workpiece W.
  • the modeling system 1 uses the characteristics of the lowermost structural layer SL_lowest among the plurality of structural layers SL as the characteristics of the lowermost structural layer SL_lowest among the plurality of structural layers SL. The characteristics are different from those of the other structural layer SL_upper. However, when a plurality of structural layers SL_upper are formed on the structural layer SL_lowest, as illustrated in FIG. 20, the modeling system 1 sets the characteristics of the structural layer SL_lowest to at least one of the plurality of structural layers SL_upper.
  • the characteristic may be the same as the characteristic of at least one other structural layer SL_upper among the plurality of structural layers SL_upper.
  • the modeling system 1 changes the characteristics of at least one structural layer SL_upper among the plurality of structural layers SL_upper to characteristics different from the characteristics of the structural layer SL_lowest.
  • the characteristics of at least one other structural layer SL_upper among the plurality of structural layers SL_upper may be the same as the characteristics of the structural layer SL_lowest. For example, as illustrated in FIG.
  • the modeling system 1 has the characteristics of the structural layer SL_upper1 that is in contact with the structural layer SL_lowest among the plurality of structural layers SL_upper (that is, the lowermost structural layer SL_upper1 among the plurality of structural layers SL_upper). May be changed to a characteristic different from the characteristic of the structural layer SL_lowest, while the characteristic of the remaining structural layer SL_upper2 among the plurality of structural layers SL_upper may be the same as the characteristic of the structural layer SL_lowest.
  • the modeling system 1 changes the characteristics of the plurality of structural layers SL_upper including the lowermost structural layer SL_upper1 in contact with the structural layer SL_lowest among the plurality of structural layers SL_upper from the characteristics of the structural layer SL_lowest.
  • the characteristics of the remaining structural layer SL_upper2 among the plurality of structural layers SL_upper may be the same as the characteristics of the structural layer SL_lowest.
  • the modeling system 1 uses the characteristics of the lowermost structural layer SL_lowest among the plurality of structural layers SL as the characteristics of the lowermost structural layer SL_lowest among the plurality of structural layers SL.
  • the characteristic is changed to a characteristic different from the characteristic of the other structural layer SL_upper.
  • the modeling system 1 has a plurality of structural layers SL (hereinafter referred to as “structural layer SL_lower”) having a structure other than the structural layers SL_lower among the plurality of structural layers SL.
  • the characteristic may be changed to a characteristic different from the characteristic of the layer SL (that is, the structural layer SL positioned above the structural layer SL_lower and hereinafter referred to as “structural layer SL_upper ′”).
  • the modeling system 1 may make the size of each of the plurality of structural layers SL_lower smaller than the size of the structural layer SL_upper ′.
  • the sizes of the plurality of structural layers SL_lower may be the same.
  • the sizes of at least two of the plurality of structural layers SL_lower may be different.
  • the size of the plurality of structural layers SL_lower may be different so that the size of the structural layer SL_lower becomes larger toward the upper layer.
  • Such a structural layer SL_lower that increases in size toward the upper layer can be formed by forming a molten pool MP that increases in size toward the upper layer on the modeling surface MS.
  • the modeling system 1 may make the resistance force to each destruction of the plurality of structural layers SL_lower lower than the resistance force to the destruction of the structural layer SL_upper '.
  • the resistance to destruction of the plurality of structural layers SL_lower may be the same.
  • the resistance to destruction of at least two of the plurality of structural layers SL_lower may be different.
  • the resistance to destruction of the plurality of structural layers SL_lower may be different so that the resistance to destruction of the structural layer SL_lower becomes higher toward the upper layer.
  • the modeling system 1 may make the bonding force of each of the plurality of structural layers SL_lower lower than the bonding force of the structural layer SL_upper 'to the workpiece W.
  • the bonding strength of the plurality of structural layers SL_lower to the workpiece W may be the same.
  • the bonding forces to at least two workpieces W among the plurality of structural layers SL_lower may be different.
  • the bonding strength of the plurality of structural layers SL_lower to the workpiece W may be different so that the bonding strength of the structural layer SL_lower to the workpiece W becomes stronger toward the upper layer.
  • the modeling system 1 forms the plurality of structural layers SL_upper ′ on the structural layer SL_lower, at least one of the plurality of structural layers SL_upper ′ is formed.
  • the characteristic of one structural layer SL_upper ' is changed to a characteristic different from the characteristic of the structural layer SL_lower, while the characteristic of at least one other structural layer SL_upper' among the plurality of structural layers SL_upper 'is changed to the characteristic of the structural layer SL_lower. You may make it the same characteristic as a characteristic.
  • the first structural layer SL # 1 formed on the modeling surface MS corresponding to the surface WS of the workpiece W is used as the lowermost structural layer SL_lowest.
  • the second and subsequent structural layers SL may be used as the lowermost structural layer SL_lowest.
  • the structural layer SL formed on at least one existing structural layer SL_exist formed on the workpiece W may be used as the lowermost structural layer SL_lowest.
  • the modeling system 1 has at least one structural layer SL (hereinafter, referred to as “structural layer SL_upper”) having the characteristics of the structural layer SL_lowest formed (in other words, stacked) on the structural layer SL_lowest. You may change into the characteristic different from the characteristic of.
  • the modeling system 1 sets the size of the structural layer SL_lowest formed on the plurality of existing structural layers SL_exist formed on the workpiece W on the structural layer SL_lowest.
  • the size may be smaller than the size of the plurality of structural layers SL_upper ′′ formed.
  • the modeling system 1 applies a resistance force to the destruction of the structural layer SL_lowest formed on the plurality of existing structural layers SL_exist formed on the workpiece W to the structural layer.
  • the resistance against destruction of the plurality of structural layers SL_upper ′′ formed on SL_lowest may be lower. For example, as illustrated in FIG.
  • the modeling system 1 has a bonding force of the structural layer SL_lowest formed on the plurality of existing structural layers SL_exist formed on the workpiece W to the structural layer SL_exist.
  • the bonding strength of the plurality of structural layers SL_upper ′′ formed on the structural layer SL_lowest to the structural layer SL_exist may be weakened.
  • the three-dimensional structure ST including at least the structural layer SL_upper ′′ can be easily separated from the existing structure SL_exist.
  • the modeling system 1 when the modeling system 1 forms the plurality of structural layers SL_upper '' on the structural layer SL_lowest, the modeling system 1 out of the plurality of structural layers SL_upper ''
  • the characteristic of at least one structural layer SL_upper '' is changed to a characteristic different from that of the structural layer SL_lowest, while the characteristic of at least one other structural layer SL_upper '' among the plurality of structural layers SL_upper '' is changed.
  • the characteristics may be the same as the characteristics of the structural layer SL_lowest.
  • the modeling system 1 is configured so that the characteristics of the plurality of structural layers SL_lower formed on the existing structural layer SL_exist formed on the workpiece W are as follows. May be changed to a characteristic different from the characteristic of at least one structural layer SL_upper ′′ formed on the structural layer SL_lower (in other words, stacked).
  • the size of the structural layer SL in contact with the work W (that is, the lowermost structural layer SL_lowest) and the resistance to breakage are made easy to separate the molded object ST from the work W.
  • At least one of the force and the bonding force to the workpiece W is changed from that of the structural layer SL (that is, the structural layer SL_upper) thereon.
  • the structural layer SL that is, the structural layer SL_upper
  • the size of the molten pool MP and the size of the molten pool MP when another structural layer SL is formed among the plurality of structural layers SL may be changed.
  • the supply mode of the modeling material M when forming one structural layer SL among the plurality of structural layers SL and the modeling material M when forming another structural layer SL among the plurality of structural layers SL The supply mode may be changed.
  • the intensity of the light EL per unit area (or energy per unit area) on the modeling surface MS, the defocus amount of the light EL with respect to the modeling surface MS, and the light per unit area It may be at least one of the EL irradiation times.
  • a supply mode of the modeling material M at least one of the supply amount of the modeling material M per unit time and the supply amount of the modeling material M per unit area and at least one of the supply timings of the modeling material M are used. There may be.
  • the movement mode of the modeling head 11 may be at least one of the movement speed of the modeling head 11 and the movement speed of the workpiece W.
  • the modeling system 1 may model the size of the plurality of structural layers SL # 1 to SL # 10 so as to gradually increase toward the upper side. Further, as shown in FIG. 24B, the modeling system 1 may model so that the sizes of the plurality of structural layers SL # 1 to SL # 10 gradually decrease toward the top. Alternatively, the modeling system 1 models the size of the plurality of structural layers SL # 1 to SL # 10 so as to gradually increase and then gradually increase as shown in FIG. 24C. Also good. In the examples shown in FIGS. 24A to 24C, the sizes of the plurality of structural layers SL # 1 to SL # 10 are continuously changed. However, as shown in FIG. Alternatively, it may be discontinuous (discrete).
  • the example shown in FIG. 24A is based on the size of the molten pool MP when a certain structural layer SL (for example, the structural layer SL # 2) is formed among the plurality of structural layers SL # 1 to SL # 10.
  • the size of the molten pool MP when forming the structural layer SL is smaller (when attention is paid to the structural layer SL # 1). ) Or larger (when attention is paid to the structural layer SL # 3).
  • the irradiation system 111 irradiates the modeling surface MS of the workpiece W (the surface facing the + Z side of the workpiece W) with the light EL to form the molten pool MP on the modeling surface MS of the workpiece W.
  • the modeling material M is supplied to the molten pool MP.
  • the modeling material M supplied to the molten pool MP is melted and then cooled and solidified (that is, solidified).
  • the lowermost structural layer SL # 1 is formed by the solidified deposit of the modeling material M.
  • the irradiation system 111 irradiates the surface directed to the + Z side in the structural layer SL # 1 with light EL, thereby forming the molten pool MP on the modeling surface MS that is at least a part of the surface of the structural layer SL # 1. .
  • the modeling material M is supplied to the molten pool MP.
  • the modeling material M supplied to the molten pool MP is melted and then cooled and solidified (that is, solidified).
  • the second structural layer SL # 2 is formed by the solidified deposit of the modeling material M.
  • the intensity of the light EL when forming the lowermost structural layer SL # 1 is weaker than the intensity of the light EL when forming the second structural layer SL # 2.
  • the size of the molten pool MP formed when forming the lowermost structural layer SL # 1 is smaller than the size of the molten pool MP formed when forming the second structural layer SL # 2. .
  • the size of the second structural layer SL # 2 (typically the dimension in the Y direction) is larger than the size of the lowermost structural layer SL # 1 (typically the dimension in the Y direction).
  • a large shaped object is formed.
  • the intensity of the light EL when forming each structural layer SL is set so as to increase gradually as the order of creation of the structural layer SL is later (as the position of the structural layer SL in the Z direction increases), and the + Z axis
  • the size of the molten pool MP at the time of forming each structural layer SL is set so that it gradually increases as the order of creation of the structural layer SL is later (as the position of the structural layer SL in the Z direction becomes higher).
  • a shaped object can be formed in which the size in the Y direction gradually increases with distance from the workpiece W in the + Z-axis direction.
  • the intensity of the light EL when forming each structural layer SL is gradually decreased as the order of creation of the structural layer SL is later (as the position of the structural layer SL in the Z direction increases).
  • a modeled object is formed in which the size in the Y direction gradually decreases as the distance from the workpiece W increases in the + Z-axis direction.
  • the intensity of the light EL when forming each structural layer SL is gradually increased as the order in which the structural layers SL are created becomes later (as the position of the structural layer SL in the Z direction increases). Is set so that it gradually increases after being reduced in size, and a shaped object is formed that gradually increases after the size in the Y direction gradually decreases with increasing distance from the workpiece W in the + Z-axis direction.
  • the three-dimensional structure ST may have a shape extending in the X direction.
  • the size of the molten pool MP and the size of the structural layer SL described above may be sizes in a direction intersecting with the extending direction (X direction).
  • the size in the direction intersecting with the extending direction (X direction) may be a direction along the structural layer SL (Y direction as an example), and a direction in which a plurality of structural layers SL are stacked (as an example). Z direction).
  • the Y-direction size of the structural layer SL # 1 extending in the X direction may be different from the Y-direction size of the structural layer SL # 2 extending in the X direction adjacent to the structural layer SL # 1.
  • the Z-direction size of the structural layer SL # 1 extending in the X direction may be different from the Z-direction size of the structural layer SL # 2 extending in the X direction adjacent to the structural layer SL # 1.
  • the moving speed of the modeling head 11 when forming each structural layer SL is increased as the order in which the structural layer SL is created (the Z-direction position of the structural layer SL increases). It may be set so as to gradually become slower, and a modeled object whose Y-direction size gradually increases as the distance from the workpiece W in the + Z-axis direction may be formed.
  • the moving speed of the modeling head 11 when forming each structural layer SL is increased as the order in which the structural layers SL are created (the position of the structural layer SL in the Z direction increases).
  • the moving speed of the modeling head 11 when forming each structural layer SL is increased as the order in which the structural layers SL are created (the position of the structural layer SL in the Z direction increases). It may be set so that it becomes gradually slower after being gradually accelerated, and a shaped object that gradually increases after the size in the Y direction gradually decreases as it moves away from the workpiece W in the + Z-axis direction may be formed. .
  • the degree of freedom regarding the shape of the three-dimensional structure ST can be improved, or the accuracy of the shape of the three-dimensional structure ST can be improved.
  • the accuracy of the shape of the three-dimensional structure ST may be the difference between the design data of the three-dimensional structure ST (as an example, the design dimension) and the actual shape of the three-dimensional structure ST.
  • the modeling system 1 includes the head drive system 12 that moves the modeling head 11.
  • the modeling system 1 may include a stage drive system that moves the stage 13 in addition to or instead of the head drive system 12.
  • the stage drive system may move the stage 13 in at least one of the X-axis direction, the Y-axis direction, the Z-axis direction, the ⁇ X direction, the ⁇ Y direction, and the ⁇ Z direction.
  • the movement of the stage 13 by the stage drive system changes the relative positional relationship between the stage 13 and the modeling head 11 in the same manner as the movement of the modeling head 11 by the head driving system 12, and consequently the workpiece W and the irradiation area.
  • the relative positional relationship with the EA is changed.
  • the modeling system 1 moves the irradiation area EA with respect to the modeling surface MS by moving the modeling head 11.
  • the modeling system 1 may move the irradiation area EA with respect to the modeling surface MS by deflecting the light EL in addition to or instead of moving the modeling head 11.
  • the irradiation system 111 may include, for example, an optical system (for example, a galvanometer mirror) that can deflect the light EL.
  • the modeling system 1 melts the modeling material M by irradiating the modeling material M with the light EL.
  • the modeling system 1 may melt the modeling material M by irradiating the modeling material M with an arbitrary energy beam.
  • the modeling system 1 may include a beam irradiation device that can irradiate an arbitrary energy beam in addition to or instead of the irradiation system 111.
  • Optional energy beams include, but are not limited to, charged particle beams such as electron beams, ion beams, or electromagnetic waves.
  • the modeling system 1 can form the three-dimensional structure ST by the laser overlay welding method.
  • the modeling system 1 may form the three-dimensional structure ST from the modeling material M by other methods capable of forming the three-dimensional structure ST.
  • other methods include a powder bed fusion method (Powder Bed Fusion) such as a powder sintering additive manufacturing method (SLS: Selective Laser Sintering).
  • SLS powder sintering additive manufacturing method
  • the powder bed fusion bonding method irradiates the modeling material M supplied in advance with the light EL or the like.
  • the three-dimensional structure ST is formed.
  • a binder jetting method Binder Jetting
  • LMF laser metal fusion method
  • the modeling system 1 includes the control device 14. However, the modeling system 1 may not include the control device 14.
  • the control device 14 may be provided outside the modeling system 1. In this case, the control device 14 and the modeling system 1 may be connected by a wired or wireless communication line.
  • the modeling system 1 may be operated using a recording medium in which a signal representing an operation procedure of the modeling system 1 is recorded in advance. Moreover, you may make it a part (head drive system 12 as an example) bear a part of function of the control apparatus 14.
  • Appendix 5 An irradiation device for irradiating an energy beam; Material supply device and With A second modeling surface that is at least a part of the surface of the first structure layer by melting the supplied material by irradiating the energy beam on the first modeling surface to form a first structure layer
  • the second structural layer having a size different from that of the first structural layer in at least one of the directions along the surface of the first structural layer by melting the supplied material by irradiating the energy beam on the first structural layer Is formed on the first structural layer Modeling system.
  • the size of the second structural layer is larger than the first structural layer in at least one of the directions along the surface of the first structural layer The modeling system described in Appendix 5.
  • the first and second structural layers have a shape extending in a direction intersecting the at least one direction within the surface of the first structural layer.
  • the modeling system according to any one of appendices 3 to 7.
  • the size of the first structure layer and the size of the second structure layer are different from each other.
  • Appendix 9 Irradiating the energy beam having the first beam characteristic to form the first structure layer; Irradiating the energy beam having a second beam characteristic different from the first beam characteristic to form the second structural layer
  • Appendix 10 An irradiation device for irradiating an energy beam; Material supply device and With Irradiating the first modeling surface with the energy beam having the first beam characteristics to melt the supplied material to form a first structure layer; Melting the supplied material by irradiating a second shaped surface, which is at least part of the surface of the first structural layer, with the energy beam having a second beam characteristic different from the first beam characteristic. And forming the second structure layer on the first structure layer. Modeling system. [Appendix 11] The beam characteristics include the intensity or energy of the energy beam per unit area The modeling system according to appendix 9 or 10.
  • [Appendix 12] Irradiating the energy beam having a first intensity or first energy per unit area to form the first structure layer;
  • the second structural layer is formed by irradiating the energy beam having a second intensity different from the first intensity or a second energy different from the first energy per unit area.
  • [Appendix 13] The second strength is greater than the first strength per unit area
  • [Appendix 14] The second energy is larger than the first energy per unit area Additional modeling 12 or 13 modeling system.
  • the beam characteristics include the defocus amount of the energy beam The modeling system according to any one of appendices 9 to 14.
  • [Appendix 16] Irradiating the energy beam in which a defocus amount with respect to the first modeling surface is set to a first set amount to form the first structure layer;
  • the second structural layer is formed by irradiating the energy beam in which the defocus amount with respect to the second modeling surface is set to a second set amount different from the first set amount.
  • the modeling system according to any one of appendices 9 to 15.
  • the second set amount is smaller than the first set amount
  • the beam characteristics include the irradiation time when the energy beam is irradiated The modeling system according to any one of appendices 9 to 17.
  • [Appendix 21] Irradiating the energy beam intermittently or in pulses to form the first structural layer, .Continuously irradiating the energy beam to form the second structural layer
  • the modeling system according to any one of appendices 18 to 20.
  • [Appendix 22] Energy transmitted from the energy beam having the first beam characteristic to the first modeling surface per unit area or unit time, and from the energy beam having the second beam characteristic to the second The first and second beam characteristics are set so that the energy transmitted per unit area or unit time with respect to the modeling surface is different.
  • [Appendix 23] Energy transmitted from the energy beam having the first beam characteristic to the first modeling surface per unit area or unit time is transmitted from the energy beam having the second beam characteristic to the second.
  • the first and second beam characteristics are set so as to be less than energy transmitted per unit area or unit time with respect to the modeling surface
  • the supply device supplies material to the irradiation position of the energy beam The modeling system according to any one of appendices 1 to 23.
  • the irradiation device irradiates the energy beam to the material supplied by the supply device The modeling system according to any one of appendices 1 to 24.
  • [Appendix 26] Irradiating the energy beam and supplying the material in a first supply manner to form the first structural layer; Irradiating the energy beam and supplying the material in a second supply mode different from the first supply mode to form the second structure layer
  • the modeling system according to any one of appendices 1 to 25.
  • Appendix 27 An irradiation device for irradiating an energy beam; Material supply device and With Irradiating the first modeling surface with the energy beam and supplying the material in a first supply mode to form a first structure layer;
  • a second structure is formed by irradiating a second modeling surface which is at least a part of the surface of the first structure layer with the energy beam and supplying the material in a second supply mode different from the first supply mode.
  • the supply mode includes the supply amount of the material per unit time or per unit area.
  • [Appendix 29] Irradiating the energy beam and supplying the material at a first supply amount per unit time or per unit area to form the first structure layer; Irradiating the energy beam and supplying the material at a second supply amount different from the first supply amount per unit time or per unit area to form the second structure layer
  • the second supply amount is smaller than the first supply amount The modeling system described in appendix 29.
  • the supply mode includes the supply timing of the material
  • the modeling system according to any one of appendices 26 to 29.
  • [Appendix 32] Irradiating the energy beam after supplying the material to the first modeling surface to form the first structure layer; The material is locally supplied to the second modeling surface and irradiated with the energy beam to form the second structural layer.
  • [Appendix 33] The first structural layer is formed by irradiating the energy beam without supplying the material after supplying the material to the first modeling surface.
  • [Appendix 34] After supplying the material to the first modeling surface, the energy beam is irradiated to form the first structure layer integrated with the first modeling surface.
  • Appendix 35 ⁇ ⁇ ⁇ Use at least part of the material as a shield to shield the energy beam
  • Appendix 36 When the material is supplied in the first supply mode, energy transmitted from the energy beam to the first modeling surface per unit area or unit time and the material in the second supply mode The first and second supply modes are set so that the energy transmitted from the energy beam to the second modeling surface per unit area or per unit time is different.
  • Appendix 37 When the material is supplied in the first supply mode, energy transmitted per unit area or unit time from the energy beam to the first modeling surface is the material in the second supply mode.
  • the first and second supply modes are set so that the energy is less than the energy transmitted per unit area or unit time from the energy beam to the second modeling surface.
  • a moving device for moving at least one of the positions; Irradiating the energy beam and moving at least one of the first modeling surface and the irradiation position of the energy beam in a first movement mode to form the first structural layer; Irradiating the energy beam and moving the second structure layer by moving at least one of the second modeling surface and the irradiation position of the energy beam in a second movement mode different from the first movement mode.
  • An irradiation device that irradiates the modeling surface with an energy beam; A supply device for supplying materials; A moving device that moves at least one of the first modeling surface and the energy beam irradiation position so as to change a relative positional relationship between the irradiation position of the energy beam and the modeling surface; With Irradiating the first modeling surface with the energy beam and moving at least one of the first modeling surface and the irradiation position of the energy beam in a first movement mode to form a first structure layer; The second modeling surface and the energy are irradiated in a second movement mode different from the first movement mode by irradiating a second modeling surface which is at least a part of the surface of the first structural layer.
  • a second structural layer is formed on the first structural layer by moving at least one of the beam irradiation positions.
  • Modeling system [Appendix 40] The moving mode includes a moving speed of at least one of the first modeling surface, the second modeling surface, and the irradiation position of the energy beam. The modeling system according to appendix 38 or 39. [Appendix 41] Irradiating the energy beam and moving at least one of the first modeling surface and the irradiation position of the energy beam at a first moving speed to form the first structural layer; The second structural layer is formed by irradiating the energy beam and moving at least one of the second modeling surface and the irradiation position of the energy beam at a second movement speed different from the first movement speed. The modeling system described in appendix 40.
  • the second moving speed is slower than the first moving speed
  • the modeling system described in appendix 40 The modeling system described in appendix 40.
  • Appendix 43 When at least one of the first modeling surface and the irradiation position of the energy beam moves in the first movement mode, the energy beam is transmitted per unit area or unit time to the first modeling surface. Or at least one of the second modeling surface and the irradiation position of the energy beam in the second movement mode per unit area from the energy beam to the second modeling surface or The first and second movement modes are set so that the energy transmitted per unit time is different.
  • the modeling system according to any one of appendices 38 to 42.
  • the second structural layer is formed on the first structural layer by forming a second molten pool having a size different from the first molten pool in at least one of the directions along the surface of the structural layer.
  • the modeling system according to any one of appendices 1 to 44.
  • An irradiation device for irradiating an energy beam Material supply device and With Irradiating the first modeling surface with the energy beam to melt the supplied material to form a first molten pool to form a first structural layer; Among the directions along the surface of the first structural layer by melting the supplied material by irradiating the energy beam onto a second modeling surface that is at least part of the surface of the first structural layer The second structural layer is formed on the first structural layer by forming a second molten pool having a size different from the first molten pool in at least one direction. Modeling system.
  • the size of the second molten pool in the at least one direction is larger than the size of the first molten pool in the at least one direction Additional modeling 45 or the modeling system of 46.
  • Appendix 48 When forming the first structural layer, the first molten pool is moved in the first direction within the first modeling surface, When forming the second structural layer, the second molten pool is moved in the second direction in the second modeling surface, The first direction and the second direction are parallel to each other, The at least one direction intersects the first direction and the second direction 48.
  • the modeling system according to any one of appendices 45 to 47.
  • [Appendix 49] Irradiating the energy beam having the first beam characteristic to form the first molten pool; Irradiating the energy beam having a second beam characteristic different from the first beam characteristic to form the second molten pool
  • the beam characteristics include the intensity or energy of the energy beam per unit area
  • [Appendix 51] Irradiating the energy beam having a first intensity or first energy per unit area to form the first molten pool; Irradiating the energy beam having a second intensity different from the first intensity or a second energy different from the first energy per unit area to form the second molten pool
  • the second intensity per unit area is greater than the first intensity per unit area The modeling system according to appendix 51.
  • the second energy per unit area is greater than the first energy per unit area The modeling system according to appendix 51 or 52.
  • the beam characteristics include the defocus amount of the energy beam The modeling system according to any one of appendices 49 to 53.
  • Appendix 55 Irradiating the energy beam in which a defocus amount with respect to the first modeling surface is set to a first set amount to form the first molten pool, The second molten pool is formed by irradiating the energy beam in which the defocus amount with respect to the second modeling surface is set to a second set amount different from the first set amount.
  • the modeling system according to appendix 54 [Appendix 56] The second set amount is smaller than the first set amount The modeling system according to appendix 55. [Appendix 57]
  • the beam characteristics include the irradiation time when the energy beam is irradiated The modeling system according to any one of appendices 49 to 56.
  • [Appendix 60] Irradiating the energy beam intermittently or in pulses to form the first molten pool, .Continuously irradiating the energy beam to form the second molten pool
  • the modeling system according to any one of appendices 57 to 59.
  • the modeling system according to any one of appendices 49 to 60.
  • the first and second beam characteristics are set so as to be less than energy transmitted per unit area or unit time with respect to the modeling surface
  • the modeling system according to appendix 61.
  • the supply device supplies material to the irradiation position of the energy beam The modeling system according to any one of appendices 45 to 62.
  • the irradiation device irradiates the energy beam to the material supplied by the supply device The modeling system according to any one of appendices 45 to 63.
  • [Appendix 65] Irradiating the energy beam and supplying the material in a first supply manner to form the first molten pool; Irradiating the energy beam and supplying the material in a second supply mode different from the first supply mode to form the second molten pool
  • the modeling system according to any one of appendices 45 to 64.
  • the supply mode includes the supply amount of the material per unit time or per unit area. The modeling system according to appendix 65.
  • the second modeling surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam and the second supply amount is different from the first supply amount per unit time or per unit area.
  • a second structural layer is formed on the first structural layer by supplying a material and forming a second molten pool on the second modeling surface.
  • Modeling system. [Appendix 69] The second supply amount is smaller than the first supply amount The modeling system according to appendix 67 or 68. [Appendix 70] The supply mode includes the supply timing of the material The modeling system according to any one of appendices 65 to 69.
  • [Appendix 71] Irradiating the energy beam after supplying the material to the first modeling surface to form the first molten pool; The material is locally supplied to the second modeling surface and irradiated with the energy beam to form the second molten pool.
  • [Appendix 72] After the material is supplied to the first modeling surface, the first molten pool is formed by irradiating the energy beam without supplying the material.
  • [Appendix 73] The first structure layer integrated with the first modeling surface is formed by forming the first molten pool by irradiating the energy beam after supplying the material to the first modeling surface.
  • the first and second supply modes are set so that the energy is less than the energy transmitted per unit area or unit time from the energy beam to the second modeling surface.
  • the modeling system according to appendix 75. [Appendix 77] Irradiation of the first modeling surface, the second modeling surface, and the energy beam so as to change a relative positional relationship between at least one of the first and second modeling surfaces and the irradiation position of the energy beam.
  • a moving device for moving at least one of the positions; Irradiating the energy beam and moving at least one of the first modeling surface and the irradiation position of the energy beam in a first movement mode to form the first molten pool;
  • the second molten pool is irradiated by irradiating the energy beam and moving at least one of the second modeling surface and the irradiation position of the energy beam in a second movement mode different from the first movement mode.
  • the modeling system according to appendix 81.
  • Appendix 83 At least a part of the surface of the first structure layer formed on the first modeling surface is set as a new first modeling surface, and the new first structure is formed on the formed first structure layer.
  • the plurality of first structure layers are formed such that the size of the plurality of first structure layers in at least one of the directions along the surfaces of the plurality of first structure layers increases toward the upper layer.
  • the first structure layer is formed by irradiating the first modeling surface with the energy beam to form a first molten pool, The first molten pool is formed such that the size of the first molten pool in at least one of the directions along the surfaces of the plurality of first structural layers increases toward the upper layer.
  • the plurality of first structure layers are formed such that the size of the plurality of first structure layers in at least one of the directions along the surfaces of the plurality of first structure layers is reduced toward the upper layer.
  • the first structure layer is formed by irradiating the first modeling surface with the energy beam to form a first molten pool, The first molten pool is formed such that the size of the first molten pool in at least one of the directions along the surfaces of the plurality of first structural layers is reduced toward the upper layer.
  • [Appendix 88] ⁇ Lower resistance to destruction of the first structural layer than resistance to destruction of the second structural layer
  • the modeling system according to any one of appendices 1 to 87.
  • An irradiation device for irradiating an energy beam Material supply device and With A first structure layer is formed by irradiating the first modeling surface with the energy beam, and a second structure is formed by irradiating the second modeling surface, which is at least part of the surface of the first structure layer. Forming a layer on the first structural layer; ⁇ Lower resistance to destruction of the first structural layer than resistance to destruction of the second structural layer Modeling system.
  • the brittleness of the first structural layer is made higher than the brittleness of the second structural layer by forming more voids in the first structural layer than in the second structural layer.
  • the first structure layer is formed by supplying a first material that is more brittle than the second material supplied as the material to form the second structure layer to form the first structure layer.
  • the brittleness of the second structural layer is made higher than the brittleness of the second structural layer
  • the modeling system according to any one of appendices 88 to 90.
  • [Appendix 92] Irradiating the energy beam having the first beam characteristic to form the first structure layer; Irradiating the energy beam having a second beam characteristic different from the first beam characteristic to form the second structural layer
  • the modeling system according to any one of appendices 88 to 91.
  • the beam characteristics include the intensity or energy of the energy beam per unit area
  • [Appendix 94] Irradiating the energy beam having a third intensity or third energy per unit area to form the first structure layer;
  • the second structural layer is formed by irradiating the energy beam having a fourth intensity larger than the third intensity or a fourth energy smaller than the third energy per unit area.
  • the first structural layer is formed by irradiating the energy beam having an intensity or energy capable of evaporating the material.
  • the modeling system according to any one of appendices 92 to 94.
  • [Appendix 96] Irradiating the energy beam and supplying the material in a third supply manner to form the first structural layer; Irradiating the energy beam and supplying the material in a fourth supply mode different from the third supply mode to form the second structure layer
  • the supply mode includes the supply amount of the material per unit time or per unit area. The modeling system described in appendix 96.
  • [Appendix 98] Irradiating the energy beam and supplying the material at a third supply amount per unit time or per unit area to form the first structure layer; Irradiating the energy beam and supplying the material at a fourth supply rate larger than the third supply amount per unit time or per unit area to form the second structure layer
  • [Appendix 99] The first material is supplied as the material to form the first structure layer, The second material is supplied as the material to form the second structure layer, The first material has a weaker bonding force with the first modeling surface than the second material.
  • the modeling system according to any one of appendices 1 to 98.
  • the object having the first modeling surface on at least a part of the surface includes stainless steel,
  • the first material includes at least one of aluminum, titanium, copper and tungsten,
  • the second material includes the same material as the object The modeling system according to any one of appendices 99 to 100.
  • the first structure layer is formed on the first structure layer that has been formed by setting at least a part of the surface of the first structure layer formed on the first structure surface as a new first structure surface.
  • To form a plurality of stacked first structure layers Among the plurality of first structure layers, at least a part of the surface of one first structure layer positioned at the uppermost layer is set as the second modeling surface, and the second structure layer is set as the first structure layer.
  • Appendix 104 Irradiating the first modeling surface with an energy beam to form the first structural layer; Irradiating the energy beam onto a second modeling surface that is at least a part of the surface of the first structure layer to form a second structure layer on the first structure layer; Including Energy transmitted from the energy beam to the first modeling surface per unit area or unit time and transmitted from the energy beam to the second modeling surface per unit area or unit time Different energy Forming method.
  • Appendix 105 The energy transmitted per unit area or unit time to the first modeling surface is less than the energy transmitted per unit area or unit time to the second modeling surface The modeling method described in appendix 104.
  • [Appendix 106] Irradiating the first modeling surface with an energy beam to form the first structural layer;
  • the second structure surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam, and the size in at least one of the directions along the surface of the first structure layer is the first structure.
  • a modeling method including [Appendix 107] The size of the second structural layer is larger than the first structural layer in at least one of the directions along the surface of the first structural layer The modeling method described in appendix 106.
  • [Appendix 108] Irradiating the first modeling surface with an energy beam to form a first molten pool to form a first structural layer; Irradiating the second modeling surface with the energy beam to form a second molten pool having a size different from that of the first molten pool in at least one of the directions along the surface of the first structural layer. Forming the second structure layer on the first structure layer; A modeling method including [Appendix 109] The second molten pool is larger than the first molten pool The modeling method described in appendix 108.
  • [Appendix 110] Irradiating the first modeling surface with an energy beam to form the first structural layer; Irradiating the energy beam onto a second modeling surface that is at least a part of the surface of the first structure layer to form a second structure layer on the first structure layer; Including ⁇ Make the resistance to destruction of the first structural layer higher than the resistance to destruction of the second structural layer Forming method.
  • [Appendix 111] Irradiating the first modeling surface with an energy beam and supplying a first material to form a first structural layer; Irradiating the second modeling surface, which is at least part of the surface of the first structural layer, with the energy beam and supplying the second material to form the second structural layer on the first structural layer; Including The first material has a weaker bonding force with the first modeling surface than the second material. Forming method.
  • [Appendix 112] Further comprising separating the second structural layer from the first modeling surface. The modeling method according to any one of appendices 104 to 111.
  • Separating the second structural layer includes detaching the second structural layer from the first modeling surface by breaking the first structural layer or separating the first structural layer from the first modeling surface.
  • the modeling method according to attachment 112. [Appendix 114] Supplying material to at least the first modeling surface and the second modeling surface; Irradiating the first modeling surface with the energy beam having a first beam characteristic to melt the supplied material to form a first structural layer; The material supplied by irradiating the second shaped surface, which is at least a part of the surface of the first structural layer, with the energy beam having a second beam characteristic different from the first beam characteristic. Melting to form a second structural layer on the first structural layer. Forming method.
  • [Appendix 115] Supplying material to at least the first modeling surface and the second modeling surface; Irradiating the first modeling surface with the energy beam and supplying the material in a first supply mode to form a first structure layer;
  • the second modeling surface which is at least a part of the surface of the first structural layer, is irradiated with the energy beam, and the material is supplied in a second supply mode different from the first supply mode. Forming a structural layer on the first structural layer Forming method.
  • [Appendix 116] Irradiating the modeling surface with an energy beam; Supplying materials, Moving at least one of the first modeling surface and the irradiation position of the energy beam so as to change a relative positional relationship between the irradiation position of the energy beam and the modeling surface; Irradiating the first modeling surface with the energy beam and moving at least one of the first modeling surface and the irradiation position of the energy beam in a first movement mode to form a first structure layer; , The second modeling surface and the energy are irradiated in a second movement mode different from the first movement mode by irradiating a second modeling surface which is at least a part of the surface of the first structural layer.
  • a first structural layer is formed by irradiating the first modeling surface with the energy beam and supplying the material at a first supply amount per unit time or per unit area to form a first molten pool.
  • the second modeling surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam and the second supply amount is different from the first supply amount per unit time or per unit area.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; A process of forming the second structural layer on the first structural layer by irradiating the second modeling surface, which is at least a part of the surface of the first structural layer, with the energy beam is executed by the modeling system. Control and In the control, energy transmitted from the energy beam to the first modeling surface per unit area or per unit time, and per unit area or unit time from the energy beam to the second modeling surface Different from the energy transmitted per hit Control device.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; The second structure surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam, and the size in at least one of the directions along the surface of the first structure layer is the first structure.
  • a process of forming a second structural layer different from the layer on the first structural layer is controlled by the modeling system Control device.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of supplying materials to at least the first modeling surface and the second modeling surface; A process of melting the supplied material to form a first structural layer by irradiating the first modeling surface with the energy beam having a first beam characteristic is performed by the modeling system.
  • Control to In the control the energy is supplied by irradiating the second modeling surface, which is at least part of the surface of the first structural layer, with the energy beam having a second beam characteristic different from the first beam characteristic.
  • the material is melted to form a second structure layer on the first structure layer. Control device.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of supplying materials to at least the first modeling surface and the second modeling surface; Irradiating the first modeling surface with the energy beam and supplying the material in a first supply mode to form a first structural layer; The second modeling surface, which is at least a part of the surface of the first structural layer, is irradiated with the energy beam, and the material is supplied in a second supply mode different from the first supply mode.
  • a process of forming a structural layer on the first structural layer is controlled to be executed by the modeling system Control device.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Processing to irradiate the modeling surface with an energy beam, Processing to supply materials, A process of moving at least one of the first modeling surface and the irradiation position of the energy beam so as to change a relative positional relationship between the irradiation position of the energy beam and the modeling surface; A process of irradiating the first modeling surface with the energy beam and moving at least one of the irradiation position of the first modeling surface and the energy beam in a first movement mode to form a first structure layer; , The second modeling surface and the energy are irradiated in a second movement mode different from the first movement mode by irradiating a second modeling surface which is at least a part of the surface of the first structural layer.
  • Control is performed such that a process of forming at least one of the irradiation positions of the beam to form the second structural layer on the first structural layer is executed by the modeling system.
  • Control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of forming the first structural layer by irradiating the first modeling surface with an energy beam to form the first molten pool; Irradiating the second modeling surface with the energy beam to form a second molten pool having a size different from that of the first molten pool in at least one of the directions along the surface of the first structural layer.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material;
  • a first structural layer is formed by irradiating the first modeling surface with the energy beam and supplying the material at a first supply amount per unit time or per unit area to form a first molten pool.
  • Processing to The second modeling surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam and the second supply amount is different from the first supply amount per unit time or per unit area.
  • a process of forming a second structural layer on the first structural layer by supplying a material and forming a second molten pool on the second modeling surface is controlled to be executed by the modeling system.
  • Control device A control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; A process of forming the second structural layer on the first structural layer by irradiating the second modeling surface, which is at least a part of the surface of the first structural layer, with the energy beam is executed by the modeling system.
  • a control device for controlling a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of irradiating the first modeling surface with an energy beam and supplying a first material to form a first structural layer; Irradiating the second modeling surface, which is at least part of the surface of the first structural layer, with the energy beam and supplying a second material to form the second structural layer on the first structural layer.
  • the first material has a weaker bonding force with the first modeling surface than the second material. Control device.
  • Appendix 127 A program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; A process of irradiating the second modeling surface, which is at least part of the surface of the first structure layer, with the energy beam to form the second structure layer on the first structure layer; In the control, energy transmitted from the energy beam to the first modeling surface per unit area or per unit time, and per unit area or unit time from the energy beam to the second modeling surface Causes the computer to execute a process for differentiating the energy transmitted upon hitting Program.
  • Appendix 128 A program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; The second structure surface that is at least a part of the surface of the first structure layer is irradiated with the energy beam, and the size in at least one of the directions along the surface of the first structure layer is the first structure. Causing a computer to execute a process of forming a second structural layer different from the first layer on the first structural layer Program.
  • a program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of supplying materials to at least the first modeling surface and the second modeling surface; Irradiating the first modeling surface with the energy beam having a first beam characteristic to melt the supplied material to form a first structure layer; In the control, the energy is supplied by irradiating the second modeling surface, which is at least part of the surface of the first structural layer, with the energy beam having a second beam characteristic different from the first beam characteristic. Causing the computer to execute a process of melting the material and forming a second structural layer on the first structural layer. Program.
  • Appendix 130 A program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of supplying materials to at least the first modeling surface and the second modeling surface; Irradiating the first modeling surface with the energy beam and supplying the material in a first supply mode to form a first structural layer; The second modeling surface, which is at least a part of the surface of the first structural layer, is irradiated with the energy beam, and the material is supplied in a second supply mode different from the first supply mode.
  • a computer executing a process of forming a structural layer on the first structural layer; Program.
  • a program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Processing to irradiate the modeling surface with an energy beam, Processing to supply materials, A process of moving at least one of the first modeling surface and the irradiation position of the energy beam so as to change a relative positional relationship between the irradiation position of the energy beam and the modeling surface; A process of irradiating the first modeling surface with the energy beam and moving at least one of the irradiation position of the first modeling surface and the energy beam in a first movement mode to form a first structure layer; , The second modeling surface and the energy are irradiated in a second movement mode different from the first movement mode by irradiating a second modeling surface which is at least a part of the surface of the first structural layer.
  • a computer executing a process of moving at least one of the irradiation positions of the beam to form the second structure layer on the first structure layer;
  • Program. [Appendix 132] A program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of forming the first structural layer by irradiating the first modeling surface with an energy beam to form the first molten pool; Irradiating the second modeling surface with the energy beam to form a second molten pool having a size different from that of the first molten pool in at least one of the directions along the surface of the first structural layer.
  • a program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; Irradiating the first modeling surface with an energy beam to form a first structural layer; A process of irradiating the second modeling surface, which is at least part of the surface of the first structure layer, with the energy beam to form the second structure layer on the first structure layer; The computer executes a process for making the resistance to destruction of the first structural layer higher than the resistance to destruction of the second structural layer. Program.
  • Appendix 135 A program for causing a computer to control a modeling system including an irradiation device for irradiating an energy beam and a supply device for supplying a material; A process of irradiating the first modeling surface with an energy beam and supplying a first material to form a first structural layer; Irradiating a second modeling surface that is at least part of the surface of the first structure layer with the energy beam and supplying a second material to form a second structure layer on the first structure layer; Let the computer run, The first material has a weaker bonding force with the first modeling surface than the second material.
  • Program. [Appendix 136] A recording medium on which the computer program according to any one of appendices 127 to 135 is recorded.
  • the present invention is not limited to the above-described embodiments, and can be appropriately changed without departing from the spirit or idea of the invention that can be read from the claims and the entire specification, and a modeling system with such changes, A modeling method, a control device, a computer program, and a recording medium are also included in the technical scope of the present invention.

Abstract

La présente invention concerne un système de moulage comprenant un dispositif d'irradiation qui irradie un faisceau d'énergie, et un dispositif d'alimentation qui alimente un matériau, où : le faisceau d'énergie est irradié sur une première surface moulée pour faire fondre le matériau et former une première couche structurée ; le faisceau d'énergie est irradié sur une seconde surface moulée, qui est au moins une partie d'une surface de la première couche structurée, pour faire fondre le matériau et former une seconde couche structurée sur la première couche structurée ; et l'énergie transmise depuis le faisceau d'énergie à la première surface moulée par surface unitaire ou par unité de temps est différente de l'énergie transmise à partir du faisceau d'énergie vers la seconde surface moulée par surface unitaire ou par unité de temps.
PCT/JP2019/017559 2018-05-09 2019-04-25 Système de moulage, et, procédé de moulage WO2019216228A1 (fr)

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