JP2000272018A - Method for producing three-dimensional object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a three-dimensional object which can produce an accurate fabricated object of high strength irrespective of its complexity in shape. SOLUTION: In a method for producing a three-dimensional object by laminating curing layers 2, in which a powdery material 1 is to be cured, in turn, an embedding member 3 is installed, the material 1 is packed around the member 3 and cured in the neighborhood of the member 3 to be integrated with it, and the layers 2 are laminated in turn.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a three-dimensional object by obtaining a three-dimensional object by laminating a cured layer in which a powder material is cured.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 40, there is known a method for producing a three-dimensional object by obtaining a three-dimensional object by laminating a cured layer 2 in which a powder material 1 is cured. .
This is disclosed in Japanese Patent No. 2620353 as a "method for manufacturing parts by selective sintering", in which a powder material 1 made of an inorganic material such as a metal or an organic material such as a resin is deposited. There, a light beam (laser beam 12) such as a laser or a directional energy beam is irradiated and hardened to form a hardened layer 2, and the hardened layers 2 are sequentially laminated to form a three-dimensional shaped object. .

In this case, as shown in FIG. 40 (a), a powder material 1 is supplied from a hopper 29 into an enclosing structure 30, from which a laser beam 12 is applied to a predetermined portion as shown in FIG. 40 (b). Irradiation is performed selectively, and this is repeated to form the cured layer 2 in a laminated manner. The laser beam 12 is illuminated from a laser head 31, and its traveling path includes a scanning system including a prism 32.
The operation is performed such that the direction is changed at 33, and a predetermined portion of the powder material 1 which is the uppermost layer in the surrounding structure 30 is selectively irradiated. Therefore, in this case, a molded article having a complicated shape can be manufactured relatively easily.

[0004]

However, in the above conventional technique, the packing density of the powder material 1 is low and the density after irradiation and curing does not reach 100%. There was a problem that the material was weaker than the original mechanical strength. In addition, there is a problem that a step of scanning with the laser beam 12 is required to form the hardened layer 2, and furthermore, the amount of scanning data within the contour of the modeled object is large, so that the modeling time is prolonged. In addition, since the powder material 1 shrinks when cured, the cured layer 2 is deformed, and there is a problem that a molded article cannot be manufactured with high accuracy.

SUMMARY OF THE INVENTION The present invention has been made in order to solve all of the problems in the conventional technique described above, and an object of the present invention is to easily produce a high-strength, high-precision molded article having a complicated shape. It is an object of the present invention to provide a method for producing a three-dimensional shape.

[0006]

According to a first aspect of the present invention, there is provided a method for producing a three-dimensional shaped object by sequentially laminating a cured layer in which a powder material is cured. A burying member is installed, a powder material is filled around the burying member, and the powder material is cured so as to be integrated with the burying member in the vicinity of the burying member. This is a manufacturing method in which layers are sequentially formed.

Therefore, in this case, by forming the burying member firmly at a high density, it is possible to manufacture a molded article having high strength as a whole. In addition, it is only necessary to sequentially cure the powder material in the vicinity of the burying member only in the form of a layer, and in this case, the amount of scanning data for scanning with the beam for curing is reduced within the contour line of the modeled object. The time is shortened, and the molding time of a complicated shape can be reduced. In addition, since the amount of the powder material to be cured is reduced, deformation due to shrinkage at the time of curing is also prevented, and a highly accurate molded article can be manufactured.

According to a second aspect of the present invention, there is provided the method of manufacturing a three-dimensional object according to the first aspect, wherein the embedding member is installed on a plate surrounded by a peripheral wall. Lowering the plate sequentially from the upper end of the peripheral wall by the dimension corresponding to the thickness of the hardened layer, filling the space surrounded by the peripheral wall with the powder material every time the plate is lowered and curing It is characterized by the following.

Therefore, in this case, in particular, while the burying member is lowered by a dimension corresponding to the thickness of the hardened layer,
Since the same hardened layer is sequentially formed on the periphery, it can be easily filled with powdered material every time after hardening, and the setting of the distance of the beam to irradiate it becomes easy. I can do it.

According to a third aspect of the present invention, there is provided a method of manufacturing a three-dimensional article according to the first or second aspect, wherein the embedding member is formed by laminating and integrating sheet materials. It is a feature.

Therefore, in this case, in particular, even a molded article having a complicated shape can be easily manufactured by forming the embedding member embedded therein by lamination and integration of the sheet material.

According to a third aspect of the present invention, there is provided a method for manufacturing a three-dimensional article according to the third aspect, wherein each sheet material is sequentially added before each formation of each cured layer. A burying member is formed by stacking and installing.

Therefore, in this case, in particular, it is not necessary to laminate and integrate the sheet materials in advance, and each time the respective cured layers are formed, the respective sheet materials are successively laminated and installed to form the embedded layer. The member can be easily formed, and the burying member does not hinder the filling of the powder material.

According to a third aspect of the present invention, there is provided the method of manufacturing a three-dimensional article according to the fourth aspect, wherein the powder material is filled in through holes formed in each of the stacked sheet materials. Each sheet material is bonded by filling and curing the powder material.

Therefore, in this case, particularly, the sheet materials are bonded by the curing of the powder material filled in the through holes, so that the bonding strength between the sheet materials is improved and the sheet is affected by the heat effect during the curing of the powder material. Deformation of the material is also prevented, and high strength and high precision of the modeled object can be achieved.

According to a third aspect of the present invention, there is provided a method of manufacturing a three-dimensional article according to the fifth aspect, wherein a through hole is communicated between each sheet material. It is.

Therefore, in this case, especially, the sheet materials are joined by the curing of the powder material filled in the through holes communicating between the sheet materials, so that the sheet materials are positioned with respect to each other and joined without lateral displacement. In addition, it is possible to further increase the strength and accuracy of the molded object.

According to a third aspect of the present invention, there is provided the method of manufacturing a three-dimensional object according to the third or fourth aspect, wherein the thickness of each sheet material is determined by adjusting the inclination of the outer surface of the embedding member. It is characterized in that the change is set so as to be thick at a part that becomes tight and to become thin at a part where the inclination becomes gentle.

Therefore, in this case, especially in a portion where the outer surface of the burying member has a steep inclination, the thickness of the sheet material is changed and set so as to be thicker, so that the number of laminated sheets is reduced, and the molding time is reduced. Further shortening can be achieved. Conversely, at the portion where the inclination of the outer surface of the embedding member becomes gentle, the thickness of the sheet material is changed and set so as to be thin, and the step generated at the end of the sheet material is small,
The surface near the horizontal of the modeled object can be finished smoothly.

According to a third aspect of the present invention, there is provided the method for manufacturing a three-dimensional object according to the third or fourth aspect, wherein the solidified powder layer in which the powder material is solidified is formed between the sheet materials. It is characterized by being formed interposed.

Therefore, in this case, especially when the lamination surface of the sheet material has a complicated shape, a powder solidification layer for solidifying the powder material is interposed between the sheet materials to form the solidified powder. The layer can be easily formed at an accurate position to easily cope with the production of a molded article having a fine and complicated shape.

According to a third aspect of the present invention, there is provided the method of manufacturing a three-dimensional object according to the third or fourth aspect, wherein the outer surface of the embedding member is stepped between the sheet materials. The step-shaped recess is filled with a powder material so that the upper surface thereof is tapered substantially along the same step slope, and is cured.

Therefore, in this case, in particular, the outer surface of the embedding member having a step shape is tapered substantially along the same step slope by the powder material which fills and hardens the step-shaped recess. The surface of the modeled object can be finished smoothly. In addition, when the polishing is performed, the shaving amount is reduced, and the finishing time can be shortened.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an embodiment corresponding to claims 1 and 2 of the present invention. Are sequentially laminated to obtain a three-dimensional shaped object,
The embedding member 3 is installed, and the periphery of the embedding member 3 is filled with the powder material 1, and the powder material 1 is cured near the embedding member 3 so as to be integrated therewith, Hardened layer 2
Are sequentially laminated.

In the method of manufacturing a three-dimensionally shaped object according to this embodiment, the embedding member 3 is placed on a plate 5 surrounded by the peripheral wall 4, and the plate 5 is moved from the upper end 6 of the peripheral wall 4 to the hardened layer. 2 is sequentially lowered by the dimension L corresponding to the thickness of 2,
The powder material 1 is filled and hardened in the space 7 surrounded by the peripheral wall 4 every time the plate 5 is lowered.

In this case, as shown in FIG. 1A, the burying member 3 is previously set on the plate 5, and
As shown in FIG. 1, the plate 5 is lowered by a dimension L corresponding to the thickness of the hardened layer 2, and the powder material 1 is placed in a space 7 surrounded by the peripheral wall 4 formed as shown in FIG. Fill. Here, a slider 11 is provided around the plate 5 so as to slide in close contact with the inner surface of the peripheral wall 4, and a space 7 from which the powder material 1 does not leak is defined from the upper end 6 of the peripheral wall 4. (Dimension L).

Next, as shown in FIG. 1D, only the powder material 1 in the vicinity of the burying member 3 is irradiated with the beam 12 to be cured, and at this time, the cured layer 2 where the powder material 1 is cured Is also integrated with the outer surface of the burying member 3. here,
A light beam such as a laser or a directional energy beam is irradiated as the beam 12, and the powder material 1 is hardened by sintering. The powder material 1 is made of an inorganic material such as a metal or an organic material such as a resin, and only necessary portions are selectively sintered by the beam 12 to be efficiently and surely hardened. The material of the burying member 3 is preferably the same material as the powder material 1 because the powder material 1 is hardened and bonded and integrated with the burying member 3, and the burying member 3 has a high density and a high strength. Although it is formed, another material which is inexpensive and has high strength may be employed.

The steps shown in FIGS. 1 (b) to 1 (d) are repeated, and finally the model is completed as shown in FIG. 1 (e). In this case, a metal component, a mold, and the like can be manufactured by curing and laminating the powder material 1 made of a metal, and a resin component can be manufactured using the powder material 1 made of a resin. It is also possible to manufacture mixed shaped objects and parts.

Therefore, in the method for manufacturing a three-dimensionally shaped object according to the present embodiment, by forming the burying member 3 firmly at a high density, it is possible to manufacture a molded article having high strength as a whole. In addition, it is only necessary to sequentially cure the powder material 1 only in the vicinity of the burying member 3 as a layer structure, and at this time, the amount of scanning data for scanning the beam 12 for curing is small within the contour of the modeled object. As a result, the scanning time is shortened, and the shaping time of a complicated shape can be reduced. In addition, since the amount of the powder material 1 to be hardened is reduced, deformation due to shrinkage during hardening is also prevented, and a highly accurate molded article can be manufactured.

In the method for manufacturing a three-dimensionally shaped object according to this embodiment, the buried member 3 is lowered by the dimension L corresponding to the thickness of the hardened layer 2, and the hardened layer 2 is sequentially laminated around the buried member 3. Since the powder material 1 is formed, the powder material 1 can be easily filled each time after curing, and the distance setting of the beam 12 to be irradiated onto the powder material 1 becomes easy, so that the optimum manufacturing equipment can be provided. Moreover, in this case, since the plate 5 is lowered from the upper end portion 6 of the peripheral wall body 4 by the dimension L corresponding to the thickness of the hardened layer 2, the powder material 1 is reduced to the thickness dimension corresponding to the dimension L. Filled exactly the right amount.

FIG. 2 shows another embodiment corresponding to the first to third aspects of the present invention. In the method for manufacturing a three-dimensionally shaped article according to this embodiment, the sheet material 8 is laminated and integrated to form the burying member 3. Are formed. In this case, the sheet material 8 is made of an inorganic material or an organic material,
Installed on top.

Therefore, in this case, in particular, even in the case of a shaped article having a complicated shape, it is possible to easily manufacture the embedding member 3 by embedding the sheet material 8 by lamination and integration. it can. Other than that,
The configuration and the steps are the same as those of the embodiment shown in FIG. 1, and the same operation and effect as in the above-described embodiment are exerted.

FIG. 3 shows still another embodiment corresponding to claims 1 to 4 of the present invention. In the method for manufacturing a three-dimensionally shaped article according to this embodiment, each time a cured layer 2 is formed, Each of the sheet materials 1 is sequentially stacked and installed to form the embedding member 3. In this case, the sheet material 8 is cut into a predetermined size and shape, and its thickness dimension is formed substantially equal to the dimension L corresponding to the thickness of the cured layer 2.
The sheet material 8 is previously set on the plate 5 before the plate 5 is lowered, but the sheet material 8 may be set on the plate 5 after the plate 5 is lowered. The steps of FIGS. 3A and 3B may be interchanged.

Therefore, in this case, in particular, it is not necessary to laminate and integrate the sheet materials 8 in advance to form the embedding member 3, and each time each of the hardened layers 2 is formed, the respective sheet materials 8 are successively applied. The burying member 3 can be easily formed by stacking the burying members 3, and the burying member 3 does not hinder the filling of the powder material 1. Also, since the burying member 3 does not protrude upward from the filled powder material 1, the beam
There is no hindrance to the hardening work of the powder material 1 irradiated with 12. Except for this, the configuration is the same as that of the embodiment shown in FIG. 2 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

In each of the above embodiments, as shown in FIG. 4, the powdery material 1 is filled in a region other than the upper layer from the lower layer. That is, the powder material 1 is filled around the contour of the sheet material 8, and the powder material 1 is not interposed between the sheet materials 8. In this case, the gap between the end faces of each sheet material 8 is closed by the hardened layer 2 of the powder material 1 and is firmly adhered to prevent the sheet material 8 from being turned up and deformed from the same end face. And the influence of thermal distortion and the like is small, so that a high-precision molded object can be obtained.

In each of the above embodiments, as shown in FIG. 5, the powder material 1 is applied between the sheet materials 8, and
By melting or sintering the powder material 1 between the sheet materials 8, the respective sheet materials 8 can be joined to each other. In this case, as shown in FIGS.
The powder material 1 is applied to the surface of the lower sheet material 8 to form a powder adhesive layer 13, and the upper sheet material 8 is placed on the powder adhesive layer 13 as shown in FIG. As shown in (d), the sheet material 8 is placed on the sheet material 8 in the upper layer.
Is irradiated with a beam 12 of a laser or the like, thereby melting or sintering the powder bonding layer 13 so that the powder bonding layer 13
Thereby, the upper and lower sheet materials 8 are adhesively bonded to each other.

Therefore, in this case, the adhesive strength between the sheet materials 8 is improved, and the mechanical strength of the molded article can be enhanced. In this case, the powder material 1 having a melting point lower than that of the sheet material 8 is used, whereby the sheet material 8 can be formed without being damaged by the thermal influence of the beam 12. A highly accurate model can be obtained without causing deformation of the material 8.

FIG. 6 shows still another embodiment corresponding to claims 1 to 5 of the present invention. In the method for manufacturing a three-dimensionally shaped article according to this embodiment, the sheet material 8 to be laminated is perforated. The through-holes 9 are filled with the powder material 1 and the powder material 1 is cured to bond the sheet materials 8 together. In this case, as shown in FIGS. 6A and 6B, the powder material 1 is placed around the sheet material 8 and in each through hole 9 from above the sheet material 8 in which a plurality of through holes 9 are formed. 6C, the sheet material 8 is irradiated with a beam 12 such as a laser from above the sheet material 8 to cure the powder material 1 filled around the sheet material 8 and in each through hole 9. Let it. The steps of FIG. 6A to FIG. 6C are repeated, and finally a model is completed as shown in FIG.

Therefore, in this case, in particular, since the sheet materials 8 are bonded by the curing of the powder material 1 filled in the through holes 9, the bonding strength between the sheet materials 8 is improved, and Deformation of each sheet material 8 due to heat influence during curing is also prevented, and high strength and high precision of the modeled object can be achieved. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

FIG. 7 shows still another embodiment corresponding to the first to sixth aspects of the present invention. In the method for manufacturing a three-dimensionally shaped article of this embodiment, a through hole 9 is formed between each sheet material 8. They are communicating. In this case, the through holes 9 communicate with all the sheet materials 8, and the communicated through holes 9 are provided at a plurality of locations.

Accordingly, in this case, in particular, the respective sheet materials 8 are combined by the curing of the powder material 1 filled in the through holes 9 communicating between the sheet materials 8, so that the respective sheet materials 8 are positioned with respect to each other. It is connected without lateral displacement, and it is possible to further increase the strength and accuracy of the modeled object. Except for this, the configuration is the same as that of the embodiment shown in FIG. 6 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

In this embodiment, as shown in FIG. 8, the through holes 9 may be formed so as to be inclined and communicate with each other. In this case, the through holes 9 may be alternately inclined in different directions for each layer of the sheet material 8 as shown in FIG. 8A, or a plurality of layers of the sheet material 8 as shown in FIG. The through holes 9 may be alternately inclined in different directions every 8. In this case, it is difficult for the sheet materials 8 to peel off from each other in the direction in which the sheet materials 8 are overlapped, and it is possible to further increase the strength of the modeled object.

In this embodiment, as shown in FIG. 9, the upper through-holes 9b of the two through-holes 9 communicating between the upper and lower sheet materials 8 are filled with the lower through-holes 9a. An escape hole for the material 1 may be used. In this case, when the powder material 1 filled in the lower through hole 9a hardens, the swelling deformation due to the condensation of the powder material 1 is caused by the upper through hole 9a.
Since it is released and absorbed by 9b, the adhesion between the sheet materials 8 can be improved.

In this embodiment, as shown in FIG. 10, the through holes 9b, 9a communicating between the upper and lower sheet materials 8 are formed.
And the through-hole 9c which does not communicate with the second member may be provided together. In this case, positioning between the sheet materials 8 can be performed by the communicating two through holes 9b and 9a, and the bonding strength between the sheet materials 8 can be increased by the non-communicating through holes 9c.

In this embodiment, as shown in FIG. 11, the diameter of the through holes 9 communicating between the sheet materials 8 may be different between the layers of each sheet material 8. In this case, the upper and lower through holes 9c and 9a are formed with a large diameter, and the middle through hole 9b is formed with a small diameter. In addition, as shown in FIG. 12, chamfering may be applied to each opening edge of the through holes 9b and 9a communicating between the sheet materials 8 in the upper and lower layers. In these cases,
In the direction in which the sheet materials 8 are superposed, the sheet materials 8 are less likely to peel off from each other, and the adhesive strength between the sheet materials 8 can be improved.

In this embodiment, as shown in FIG. 13, each through hole 9 communicating between the sheet materials 8 may be formed in a tapered shape. In this case, as shown in FIG. 13 (a), the lower through-hole 9a in which the powder material 1 is filled and hardened and the upper through-hole 9b, which is a relief hole, have the same inclination and the same size. It may be formed in a tapered hole shape.
As shown in FIG. 13B, the through-holes 9 communicating with each other over a plurality of layers may be formed in a tapered shape with the same inclination and the same size. Alternatively, as shown in FIG. The communicating through-holes 9 are formed in a tapered shape by changing the size of the through-holes 9 so that the inclinations are continuous with each other. You may arrange it. In these cases, in the direction in which the sheet materials 8 overlap, each sheet material 8
Are not easily separated from each other, the adhesive strength between the sheet materials 8 can be improved, and the positioning work is also facilitated.

FIG. 14 shows still another embodiment corresponding to the first to fourth and seventh aspects of the present invention. In the method of manufacturing a three-dimensionally shaped article according to this embodiment, the thickness of each sheet material 8 is set to be embedded. The thickness of the outer surface of the member 3 is changed so that it is thick at a portion where the inclination K is steep (a portion where the inclination K is close to the vertical direction) and thin at a portion where the inclination K is gentle (a portion where the inclination K is close to the horizontal direction). To set. In this case, FIG.
As shown in FIG. 15A, by increasing the thickness of the sheet material 8 at a position where the slope K is close to the vertical direction, the number of layers is reduced, and as shown in FIG. By reducing the thickness of the sheet material 8 at a portion that comes closer, the step generated at the end portion is reduced.

Therefore, in this case, particularly, at a portion where the inclination K of the outer surface of the burying member 3 is steep, the thickness of the sheet material 8 is changed so as to be thicker, and the number of laminated sheets 8 is reduced. Therefore, the molding time can be further reduced. Conversely, in a portion where the inclination K of the outer surface of the embedding member 3 becomes gentle, the thickness of the sheet material 8 is changed and set so as to be thin, and the step generated at the end of the sheet material 8 becomes small. The surface near the horizontal of the modeled object can be finished smoothly.

In the method of manufacturing a three-dimensionally shaped article according to this embodiment, as shown in FIG. 16A, the sheet material 8 may be integrally formed for each layer so as to have a uniform thickness. As shown in b), a plurality of layers of the sheet material 8 may be integrally formed at a specific portion and the thickness thereof may be different.
Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

FIG. 17 shows still another embodiment corresponding to claims 1 to 4 and 8 of the present invention. In the method of manufacturing a three-dimensionally shaped article according to this embodiment, the powder material 1 is placed between the sheet materials 8.
Is formed with a powder solidified layer 10 to be solidified.
In this case, the solidified powder layer 10 is provided in place of the sheet material 8, and the upper and lower sheet materials 8 are firmly joined.

Therefore, in this case, particularly when the lamination surface of the sheet material 8 has a fine and complicated shape, for example, when the cut-out shape is complicated or when islands with independent contour lines are generated many times, Instead of the sheet material 8, a powder solidified layer 10 where the powder material 1 is solidified is formed at the site, so that the powder solidified layer 10 can be easily formed at an accurate position to form a complicated shape. It can easily cope with the manufacture of products.

In the method for manufacturing a three-dimensionally shaped object according to the present embodiment, as shown in FIG. 18, a plurality of solidified powder layers 10 can be provided to differ in thickness. in this case,
In order to obtain a thick powder solidified layer 10, application and curing of the powder material 1 may be repeated a plurality of times, which is simple and easy as compared with changing the thickness of the sheet material 8, and special mechanisms and devices are also required. It becomes unnecessary. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

FIG. 19 shows still another embodiment corresponding to the first to fourth and ninth aspects of the present invention. In the method of manufacturing a three-dimensionally shaped article according to this embodiment, the outer surface of the embedding member 3 is A step-like shape is formed between the sheet materials 8, and the step-like concave portion is filled with the powder material 1 so that the upper surface thereof is tapered substantially along the step-like slope and is cured. In this case, the step becomes larger as shown in FIG. 20, but becomes smaller along the step slope K as shown in FIG. 21. Here, each (a) of FIGS. 20 and 21 shows the whole shape, each (b) shows a main part in a state where the powder material 1 is cured by irradiating the beam 12, and each (c) shows the same powder material. Reference numeral 1 denotes a cured layer 2 that has been cured.

Therefore, in this case, in particular, the outer surface of the embedding member 3 having the step shape has a tapered shape substantially along the same step inclination K by the powder material 1 which fills and hardens the step-shaped recess. Therefore, the surface of the modeled object can be finished smoothly. In addition, when the polishing is performed, the shaving amount is reduced, and the finishing time can be shortened.

In the method of manufacturing a three-dimensionally shaped object according to the present embodiment, the stepped concave portion can be filled with the powder material 1 so that the upper surface thereof is tapered by employing a vibration device. . For example, as shown in FIG. 22, after filling the powder material 1, the plate 5 is raised to apply vibration to the plate 5, and unnecessary powder material 1 is shaken off to form a tapered upper surface. In this case, FIG.
As shown in FIG. 22, with the plate 5 lowered to a predetermined position, the space 7 surrounded by the peripheral wall 4 is filled with the powder material 1 and then, as shown in FIG. It is raised to the highest position and vibrated, and the unnecessary powder material 1 is shaken off to make its upper surface tapered. Then, as shown in FIG. 22 (c), the plate 5 is lowered to a predetermined position. In this state, the cured layer 2 is formed by irradiating the beam 12 only to the powder material 1 near the periphery of the uppermost sheet material 8. Except for this, the configuration is the same as that of the embodiment shown in FIG. 3 and the steps are the same, and the same operation and effect as in the above-described embodiment are exerted.

In the method for manufacturing a three-dimensionally shaped object according to the present invention, the powder material 1 is cured by sintering and the sheet material 8 is formed into a predetermined shape by irradiating a light beam such as a laser or a directional energy beam. In this way, by employing a light beam, local heating can be performed in a pinpoint manner, and the sheet material 8 can be cut without adversely affecting heat. At this time, the light beam can be freely and accurately scanned in accordance with the contour shape.

In the method of manufacturing a three-dimensional object according to the present invention, the cut shape of the sheet material 8 is such that, when a box-shaped object is manufactured as shown in FIG. It is formed so that a space for filling the material 1 is formed. That is, the lowermost sheet material 8 may have a shape (required dimension A) conforming to the modeled object, but the other sheet material 8 thereon has a space (filling space) at its edge portion in consideration of the filling amount of the powder material 1. Cut slightly smaller to ensure the part size B). In this case, the edge portion of each sheet material 8 is securely bonded, and a molded article having a required size A and having a predetermined box shape can be obtained with high accuracy.

As shown in FIG. 24, when an island portion 14 having an independent contour line is formed on the lamination surface of the sheet material 8, a shape having a connecting portion 15 for connecting the island portion 14 and other portions is provided. Then, the sheet material 8 is cut and formed. In this case, after the sheet material 8 is laminated and joined, or after the fabrication of the modeled object is completed, as shown in FIGS. 24A and 24D, the connecting portion 15 is cut and removed. Therefore, in this case, when the cut sheet material 8 is transported, as shown in FIG. 24 (b), the island portion 14 is integrated with the other portions at the connecting portion 15, and is easily transported. Further, as shown in FIG. 24 (c), when the sheet materials 8 are laminated and joined,
The connecting portion 15 is integrated with other portions at the connecting portion 15, so that the positioning operation can be easily performed.

In the method for manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed, for example, by cutting the sheet material 8 into a shape having positioning sides 16 around the sheet material 8 as shown in FIG. The positioning can be performed by bringing the positioning side portion 16 into contact with the positioning pin 17. In this case, as shown in FIG. 25B, the sheet material 8 is cut and formed into a shape in which the positioning sides 16 arranged at right angles to the two sides are joined to the other parts via the connecting parts 15 together with the islands 14. Then, as shown in FIG. 25 (c), the sheet material 8 is positioned and installed by laminating both positioning side portions 16 with at least three positioning pins 17, and finally, the sheet material 8 is finally bonded to the sheet material 8 as shown in FIG. As shown in a), all the connecting portions 15 and the positioning side portions 16 are cut and removed. In addition, positioning pin
17 is provided, for example, on the plate 5.

In the method for producing a three-dimensionally shaped article according to the present invention, the sheet material 8 can be positioned as shown in FIG. That is, in this case, the sheet material 8
Is cut into a shape having a positioning side 16 on its entire circumference, and the positioning side 16 is brought into contact with the inner wall surface of the peripheral wall body 4 to position the sheet material 8. Here, as shown in FIG. 26 (a), the sheet material 8 has a positioning side portion 16 arranged so as to surround the entire periphery thereof.
Is cut and formed together with the island portion 14 and the other portion via the connecting portion 15, and the outer edge of the positioning side portion 16 abuts on the inner wall surface of the peripheral wall body 4 as shown in FIG. By doing so, the sheet material 8 is positioned and installed, and is laminated and joined. Finally, all the connecting portions 15 and the positioning side portions 16 are cut and removed.

As shown in FIGS. 25 and 26, when the positioning of the sheet material 8 is performed, the positioning operation is facilitated, the area for filling the powder material 1 is reduced, and the amount of the powder material 1 is reduced. As a result, a high-precision modeled object can be obtained.

In the method for manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIG. 27, a pusher 19 projecting from the pusher movable device 18 so as to be able to advance and retreat is brought into contact with the outer edge portion of the sheet material 8. The positioning of the sheet material 8 can also be performed. Here, FIG. 27A shows a state at the time of positioning, and FIG. 27B shows a state of releasing the positioning. Further, as shown in FIG. 28, the movable pins 21 projecting from the pin movable device 20 so as to be able to advance and retreat are inserted into and engaged with the positioning holes 22 formed in the respective sheet materials 8 so that the respective sheet materials can be engaged. 8 can also be performed. here,
FIG. 28A shows a state at the time of positioning, and FIG.
Indicates a positioning release state. As described above, when the positioning of the sheet material 8 is performed, the light beam irradiation is accurately scanned along the contour of the sheet material 8, and each sheet material 8 is scanned.
Adhesion between them is performed well, the adhesive strength is improved, and improvement in modeling accuracy can be expected.

In the method for manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 so as to be engaged therewith. As shown in FIG.
May be erected on the plate 5 so as to be movable therewith. In this case, while the positioning of the sheet material 8 is easily performed, the steps shown in FIGS. 29A and 29B and the step of irradiating the powder material 1 with the beam 12 to form the hardened layer 2 are repeated. 29 (c), the molded object is completed. At this time, the movable pin 21 is embedded in the molded object as a part of the embedding member 3.

In the method of manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 so as to be engaged therewith. As shown in FIG. 30, the tip portion of the movable pin 21 is swaged (swaging portion 23), and FIG.
As shown in FIG. 31, the powder material 1 is filled into the positioning holes 22 of the upper sheet material 8, and the powder material 1 is hardened and bonded to the tip of the movable pin 21 (bond hardening portion 24).
As shown in (b), the positioning hole 22 of the sheet material 8 in the same layer can be formed in a chamfered shape (chamfered portion 25). In this case, it becomes difficult for the sheet material 8 to come off from the movable pin 21 and the strength of each sheet material 8 in the laminating direction is increased.

In the case where the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 as shown in FIG. As shown in FIG. 32A, the movable pin 21 can be communicated with and inserted into all the sheet materials 8 or as shown in FIG.
As shown in (b), a plurality of movable pins 21 may be inserted between both upper and lower sheet materials 8.

In the method for manufacturing a three-dimensionally shaped article according to the present invention, the positioning of the sheet material 8 is performed by inserting the movable pin 21 into the positioning hole 22 formed in each sheet material 8 so as to be engaged therewith. Next, as shown in FIG. 33, the movable pin 21 is formed so as to protrude from the upper surface of the lower sheet material 8, and
May be inserted into the positioning holes 22 of the upper sheet material 8.

In this case, as shown in FIG. 33 (a), the powder material 1 is applied to the upper surface of the lower layer sheet material 8, and FIG.
As shown in FIG. 3 (b), a part of the powder material 1 is irradiated with a beam 12 in a spot shape and cured to form a movable pin 21.
As shown in FIG. 3 (c), the uncured and remaining powder material 1 is removed and the movable pin 21 is projected from the upper surface of the lower sheet material 8 to form the lower sheet material 8 as shown in FIG. 33 (d). The sheet material 8 of the upper layer is laminated on the sheet material 8, and the movable pins 21 are inserted into the positioning holes 22 of the sheet material 8 of the upper layer.
Are inserted and engaged to position both sheet materials 8 with each other,
Thereafter, as shown in FIGS. 33 (e) and (f), a separate powder material 1 is filled, and the powder material 1 near the periphery of the upper sheet material 8 is irradiated with the beam 12 to form a hardened layer 2. By repeating these steps, a molded object is completed.

Therefore, in this case, the trouble of separately setting and forming the movable pin 21 in advance can be omitted, and the shape and size of the movable pin 21 can be freely set corresponding to the positioning holes 22. In the process of laminating the sheet materials 8, the strength of each sheet material 8 in the laminating direction can be easily increased.

In the method of manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIGS. 34 and 35, a positioning rib 26 is formed so as to protrude from the upper surface of the lower sheet material 8, and the upper positioning The sheet material 8 can be positioned relative to each other by making the outer edges of the sheet material 8 abut against each other.

In this case, as shown in FIG. 34A, the powder material 1 is applied on the upper surface of the lower sheet material 8, and FIG.
As shown in FIG. 3B, a part of the powder material 1 is irradiated with the beam 12 linearly and hardened to form a positioning rib 26, and FIG.
As shown in FIG. 4 (c) and FIG. 35 (a), the uncured and remaining powder material 1 is removed so that the positioning ribs 26 protrude from the upper surface of the lower sheet material 8, and FIG. 35
As shown in (b), an upper layer sheet material 8 is laminated on the lower layer sheet material 8, and at this time, one side of the outer peripheral portion of the upper layer sheet material 8 is placed on the positioning rib 26.
34, the two sheet materials 8 are positioned relative to each other, and thereafter, as shown in FIGS. 34 (e), (f) and 35 (c),
A separate powder material 1 is filled, a beam 12 is applied to the powder material 1 near the other side of the outer side portion of the upper sheet material 8 to form a hardened layer 2, and these steps are repeated to form a molding. The thing is completed.

Therefore, also in this case, the trouble of separately setting and forming the positioning ribs 26 in advance can be omitted, the shape and size of the positioning ribs 26 can be set freely, and the sheet material 8 can be laminated. The strength of each sheet material 8 in the laminating direction can be easily increased in the step of performing.

In the method of manufacturing a three-dimensionally shaped article according to the present invention, as shown in FIGS. 36 (a) and 36 (b), a projection 27 is formed on the lower surface of the upper sheet material 8 and the projection 27 is formed on the lower layer. By engaging the upper surface of the sheet material 8 in a biting manner, the two sheet materials 8 can be positioned with respect to each other. In this case, as shown in FIG. 37, a processing machine 28 for vertically moving the punch up and down is provided, and the punch of the processing machine 28 is downwardly pressed onto the upper sheet material 8 so that the lower surface of the upper sheet material 8 is formed. The protruding projections 27 may be engaged with the upper surface of the lower sheet material 8 to be locked.

In the method of manufacturing a three-dimensionally shaped object according to the present invention, as shown in FIGS. 38 and 39, as a final step after all of the predetermined powder material 1 has been hardened by sintering, a mechanical Processing may be performed. All the steps in this case will be described in the order of the steps (a) to (e) in FIGS. First, as shown in FIG. 38 (a) and FIG. 39 (a), a metal sheet material 8 wound up in a roll is fed out and irradiated with a beam 12, so that a through hole 9 (such as a through hole) is formed. A common hole for bonding is formed and cut into a predetermined shape along the contour line. Next, the sheet material 8 cut into a predetermined shape is placed on the plate 5 surrounded by the peripheral wall body 4, and as shown in FIGS. 38 (b) to (d) and FIGS. 39 (b) to (d), As in the embodiment shown in FIG. 7, the powder material 1 is filled around the sheet material 8 and in each through hole 9 from above the sheet material 8 in which the plurality of through holes 9 are formed. A beam 12 is irradiated from above the sheet material 8 to harden the powder material 1 filled around the sheet material 8 and in the through holes 9. These steps are repeated twice to complete a two-layered structure.

In this case, the beam 12 is irradiated from the laser irradiation device A, the powder material 1 is supplied and filled by the material supply device B, and the powder material 1 is sintered and hardened by the irradiation of the beam 12. Thus, the through hole 9 and the contour portion of the sheet material 8 are bonded. FIG. 38
39 (e), as shown in FIG. 39 (e), as a final step, the upper surface of the modeled object is machined. In this case, the hardened portion of the powder material 1 (the hardened portion inside and around the through hole 9) The layer 2) protrudes from the upper surface of the object, and the protruding portion is cut off by the processing device C.

[0075]

As described above, according to the method for producing a three-dimensional object according to the first aspect of the present invention, a high-strength molded object can be produced, and the powder material only around the periphery of the buried member is layered. Since it is only necessary to sequentially cure the composition, it is possible to shorten the molding time even for complicated shapes,
Deformation due to shrinkage during curing of the powder material is also prevented, and a high-precision molded article can be manufactured.

According to the method for producing a three-dimensionally shaped article according to the second aspect of the present invention, in particular, the powder material can be easily filled each time after curing, and the setting of the distance of the beam to be irradiated thereon can be easily performed. Thus, it is possible to make the most suitable manufacturing equipment.

According to the method for manufacturing a three-dimensionally shaped object according to the third aspect of the present invention, in particular, even for a shaped object having a complicated shape, the embedding member is formed by laminating and integrating sheet materials. , Can be easily manufactured.

Further, according to the method of manufacturing a three-dimensionally shaped article according to the fourth aspect of the present invention, it is not particularly necessary to previously laminate and integrate the sheet material, and the embedding member can be simply formed. Thus, the burying member does not hinder the filling of the powder material.

Further, according to the method for manufacturing a three-dimensionally shaped article according to the fifth aspect of the present invention, in particular, by hardening the powder material filled in the through holes, the bonding strength between the sheet materials is improved and the powder material hardens. Deformation of each sheet material due to the heat effect at the time is also prevented, and it is possible to achieve higher strength and higher accuracy of the modeled object.

According to the method for manufacturing a three-dimensionally shaped article according to the sixth aspect of the present invention, in particular, the sheet materials are positioned relative to each other by the curing of the powder material filled in the through holes communicating between the sheet materials. It can be joined without lateral displacement, so that the molded object can be further enhanced in strength and accuracy.

Further, according to the method for manufacturing a three-dimensionally shaped article according to the seventh aspect of the present invention, the sheet material becomes thicker and the number of laminated sheets is reduced, particularly at a portion where the inclination of the outer surface of the burying member is steep. In the part where the inclination becomes gentle, the sheet material becomes thinner, the step generated at the end becomes smaller, and the surface near the horizontal of the molded object is smoothly finished. be able to.

According to the method for manufacturing a three-dimensionally shaped article according to the eighth aspect of the present invention, in particular, a powder solidified layer in which the powder material is solidified between the sheet materials can be easily formed at a precise position to achieve fine Therefore, it is possible to easily cope with the production of a shaped article having a complicated shape.

According to the method of manufacturing a three-dimensional object according to the ninth aspect of the present invention, in particular, the outer surface of the embedding member having a step shape is tapered so that the surface of the molded object can be finished smoothly. And when it is polished,
The shaving amount is reduced, and the finishing time can be shortened.

[Brief description of the drawings]

FIGS. 1A to 1E are schematic cross-sectional views showing a method for manufacturing a three-dimensionally shaped object according to an embodiment of the present invention, in each of the manufacturing steps.

FIGS. 2A to 2E are schematic cross-sectional views illustrating a method of manufacturing a three-dimensionally shaped object according to another embodiment, in each of the manufacturing steps.

FIGS. 3A to 3E are schematic cross-sectional views illustrating a method for manufacturing a three-dimensionally shaped object according to still another embodiment, in each of the manufacturing steps.

FIG. 4 is a schematic cross-sectional view illustrating a method for laminating sheet materials in the three-dimensionally shaped article manufacturing method according to the embodiment.

FIGS. 5A to 5D are schematic cross-sectional views illustrating another laminating method of the sheet material in the method for manufacturing a three-dimensionally shaped article according to the same embodiment, respectively, in the laminating process.

FIGS. 6A to 6D are schematic cross-sectional views showing a method of manufacturing a three-dimensionally shaped object according to still another embodiment, in each of the manufacturing steps.

FIG. 7 is a schematic cross-sectional view illustrating a method of manufacturing a three-dimensionally shaped object according to still another embodiment.

FIGS. 8A and 8B are schematic cross-sectional views illustrating different lamination modes of a sheet material in the method of manufacturing a three-dimensional article according to the embodiment.

FIG. 9 is a schematic cross-sectional view illustrating a lamination mode of a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention.

FIG. 10 is a schematic cross-sectional view illustrating another laminating mode of the sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention.

FIG. 11 is a schematic cross-sectional view illustrating still another laminating mode of the sheet material in the method for producing a three-dimensionally shaped article of the present invention.

FIG. 12 is a schematic cross-sectional view illustrating still another laminating aspect of a sheet material in the method for producing a three-dimensionally shaped article of the present invention.

FIG. 13 is a view illustrating still another laminating aspect of the sheet material in the method for producing a three-dimensionally shaped article according to the present invention, wherein FIGS.
(C) Schematic sectional views of different lamination modes.

FIG. 14 is a schematic cross-sectional view showing a method of manufacturing a three-dimensionally shaped object according to still another embodiment.

FIGS. 15A and 15B are schematic cross-sectional views illustrating a method for manufacturing a three-dimensionally shaped object according to the same embodiment.

FIGS. 16A and 16B are schematic cross-sectional views illustrating different lamination modes of the sheet material in the method of manufacturing a three-dimensionally shaped article according to the same embodiment.

FIG. 17 is a schematic sectional view showing a method for manufacturing a three-dimensionally shaped object according to still another embodiment.

FIG. 18 is a schematic cross-sectional view showing another laminating mode of the sheet material in the three-dimensionally shaped article manufacturing method according to the embodiment.

FIG. 19 is a schematic sectional view showing a method of manufacturing a three-dimensionally shaped object according to still another embodiment.

FIG. 20 shows a comparative example for explaining the method for manufacturing a three-dimensionally shaped object according to the same embodiment, where (a) is a schematic sectional view thereof,
(B) and (c) are main part enlarged sectional views showing the manufacturing process.

21 (a) is a schematic cross-sectional view showing a method for manufacturing a three-dimensionally shaped object according to the same embodiment, and FIGS. 21 (b) and (c) are enlarged cross-sectional views of essential parts showing the manufacturing process.

FIGS. 22A to 22C are schematic cross-sectional views illustrating a method of filling and curing a powder material in a method of manufacturing a three-dimensionally shaped article according to the same embodiment.

FIG. 23 is a schematic cross-sectional view illustrating a cut shape of a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention.

FIG. 24 is a view illustrating another cut shape of the sheet material in the method for producing a three-dimensionally shaped article of the present invention, wherein (a) and (b) are schematic plan views in different states, respectively, and (c) and (d). Is a schematic cross-sectional view in a different state.

25A to 25C are diagrams illustrating a method for positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, wherein FIGS.
The schematic plan view in each different state.

26A and 26B are diagrams illustrating another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention, wherein FIG. 26A is a schematic plan view, and FIG.

27A and 27B are diagrams illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, wherein FIG.
(B) Schematic side views in different states.

28A and 28B are diagrams illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, wherein FIG.
(B) Schematic sectional views in different states.

FIGS. 29A and 29B are diagrams illustrating still another method of positioning a sheet material in the method for producing a three-dimensionally shaped article of the present invention, wherein FIG.
(C) is a schematic cross-sectional view in the positioning process.

FIG. 30 is a schematic cross-sectional view illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article of the present invention.

FIGS. 31A and 31B are diagrams illustrating still another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, wherein FIG.
(B) Schematic cross-sectional views of different method embodiments.

FIGS. 32A and 32B are diagrams illustrating still another method of positioning a sheet material in the method for producing a three-dimensionally shaped article of the present invention, wherein FIG.
(B) Schematic cross-sectional views of different method embodiments.

FIG. 33 is a view illustrating still another method of positioning a sheet material in the method of manufacturing a three-dimensionally shaped article according to the present invention, wherein FIG.
(F) Schematic sectional views in the positioning process.

34A and 34B are diagrams illustrating still another method for positioning a sheet material in the method for manufacturing a three-dimensionally shaped article of the present invention, wherein FIG.
(F) Schematic sectional views in the positioning process.

FIG. 35 (a) to (d) show a method for positioning the sheet material.
(C) A schematic plan view in each positioning process.

36A and 36B are diagrams illustrating still another method of positioning a sheet material in the method for manufacturing a three-dimensionally shaped article according to the present invention, wherein FIG.
(B) Schematic sectional views of different shapes.

FIG. 37 is a schematic side view illustrating equipment in the sheet material positioning method.

FIG. 38 is a drawing illustrating all steps including final machining in the method for producing a three-dimensionally shaped article of the present invention, wherein (a) to (a) to (d) of FIG.
(E) Schematic sectional views in each of the steps.

FIG. 39 is a schematic perspective view showing each of the steps (a) to (e).

FIGS. 40A and 40B show a conventional method for manufacturing a three-dimensionally shaped object, wherein FIG. 40A is an overall perspective view thereof, and FIG.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 powder material 2 hardened layer 3 burying member 4 peripheral wall 5 plate 6 upper end 7 space 8 sheet material 9 through hole 10 powder solidified layer

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Isao Fuwa Inside Matsushita Electric Works Co., Ltd. 1048 Kadoma Kadoma, Osaka Prefecture (72) Inventor Yoshiyuki Uchino 1048 Kazuma Kazuma Kadoma City, Osaka Pref. Matsushita Electric Works Co., Ltd. F term (reference) 4F213 AA44 AC04 WA25 WB01 WL03 WL13 WL26 WL62 WL67 WL93 WL95 4K018 CA14

Claims (9)

[Claims] 1. A method for producing a three-dimensionally shaped object by sequentially forming a cured layer in which a powder material is cured to obtain a three-dimensionally shaped object. A method of manufacturing a three-dimensionally shaped article, comprising filling a powder material around a member, curing the powder material in the vicinity of the embedding member so as to be integrated therewith, and sequentially forming a hardened layer. 2. An embedding member is placed on a plate surrounded by a peripheral wall, and the plate is sequentially lowered from the upper end of the peripheral wall by a dimension corresponding to the thickness of the hardened layer. 2. The method for producing a three-dimensionally shaped object according to claim 1, wherein the powder material is filled and hardened in the space enclosed by the symbols every time the plate is lowered. 3. The method according to claim 1, wherein the embedding member is formed by laminating and integrating sheet materials. 4. The method for producing a three-dimensionally shaped object according to claim 3, wherein each of the sheet materials is sequentially laminated and installed before each hardened layer is formed to form an embedding member. 5. The sheet material according to claim 4, wherein each of the sheet materials to be laminated is filled with a powder material in a through hole formed therein, and the powder material is cured to bond the sheet materials. 3D shape manufacturing method. 6. The method for producing a three-dimensionally shaped article according to claim 5, wherein a through hole is communicated between each sheet material. 7. The thickness of each sheet material is changed so as to be thick at a portion where the inclination of the outer surface of the embedding member is steep and to be thin at a portion where the inclination is gentle. The method for producing a three-dimensional object according to the above. 8. The method according to claim 3, wherein a powder solidification layer for solidifying the powder material is formed between the sheet materials. 9. An outer surface of the embedding member is stepped between the sheet materials, and the stepped recess is filled with a powder material such that the upper surface thereof is tapered substantially along the same step inclination. The method for producing a three-dimensionally shaped article according to claim 3, wherein the three-dimensionally shaped article is cured.