JP2004277878A - Apparatus and method for manufacturing three dimensionally shaped article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus for manufacturing a three dimensionally shaped article, which eliminates the effects of fume and scattered powders, and to provide a manufacturing method. <P>SOLUTION: This manufacturing apparatus comprises a light beam irradiation means 3 for sintering powders in an irradiated portion by irradiating a predetermined portion of a powder layer 10 formed on a stage with a light beam, and a powder feeding means 2 for forming the powder layer onto the stage and an already sintered layer. The light beam irradiation means 3 is arranged at the position deviated from the position directly above an area to be irradiated with the light beam, so as to diagonally irradiate the powder layer 10 with the light beam. The fume produced by heating due to light beam radiation onto the powder layer ascends toward the just above position, but because the light beam irradiates the portion from the deviated position from the just above position, the cloudiness of the light beam irradiation means (when the means is sectioned by the chamber, an aperture arranged in a chamber so as to transmit the light beam) caused by the fume is reduced. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention provides a three-dimensional shaped article for producing a desired three-dimensional shaped article by forming a sintered layer by irradiating a powder layer made of inorganic or organic powder with a light beam and laminating the sintered layer. The present invention relates to a manufacturing apparatus and a manufacturing method.

  The powder layer formed on the stage is irradiated with a light beam (directional energy beam, for example, a laser) to form a sintered layer, and a new powder layer is formed on the sintered layer and irradiated with the light beam. It is known in Japanese Laid-open Patent Publication No. 1-502890 (Patent Document 1) and the like to manufacture a three-dimensional shaped object by repeatedly forming a sintered layer and laminating the sintered layers. Yes.

  In this case, a powder supply means for supplying a stage and powder to form a powder layer in a chamber maintained in a predetermined atmosphere is arranged, and a light beam irradiation means arranged outside the chamber is provided in a portion immediately above the stage in the chamber. The light beam is irradiated to the powder layer through the light-transmitting window (including those formed with lenses).

  By the way, when the powder is irradiated with a high energy light beam to sinter the powder (including a case where the powder is once melted and then solidified), fumes (such as metal vapor if the powder is a metal powder) are generated. This fume rises and attaches or burns onto the window at the position directly above, causing the window to fog up and lowering the light beam transmittance, so that the sintering is unstable or the density of the sintered part is increased. This can cause a problem that the strength of the three-dimensional shaped object is lowered. Moreover, the light beam transmittance is also reduced by powder that is scattered and floating or powder that adheres to the window.

  In addition, the three-dimensional shaped object obtained after the completion of sintering must be taken out from the chamber, but the one shown in Patent Document 1 does not consider the take-out mechanism, and is taken out manually. This is the current situation. However, if the modeled object to be manufactured has a size of, for example, 500 mm × 500 mm × 100 mm, and is manufactured with a metal powder having a specific gravity of about 6 to 8, the obtained modeled object has a weight of 150 to 200 kg. Therefore, since it cannot be taken out by human power, a crane is used. However, in the above case where the light beam irradiating means is located above the stage in the chamber, the light beam irradiating means must be moved when taking out the modeled object by the crane. In this case, the optical axis positioning reproducibility is high. Since it is lost, the processing accuracy is extremely lowered, or adjustment work is required for each modeling process.

As shown in JP-T-2002-527613 (Patent Document 2), the stage side can be moved, so that interference between the light beam irradiation means and the crane can be avoided. In this case, there is a risk that the powder may be caught in the movable stage and tilted, so that it becomes difficult to ensure the positioning reproducibility of the stage, and the mechanism becomes very complicated.
JP-T-1-502890 JP-T-2002-527613

  The present invention has been made in view of the above points, and the main object of the present invention is to provide a manufacturing apparatus and a manufacturing method of a three-dimensional shaped object that can eliminate the influence of fumes and scattered powder. In addition, another object is to provide a manufacturing apparatus and a manufacturing method of a three-dimensional shaped object that can easily take out the manufactured object from the chamber.

  Thus, the three-dimensional shaped article manufacturing apparatus according to the present invention includes a light beam irradiation means for irradiating a predetermined position of a powder layer formed on a stage with a light beam to sinter powder at an irradiation position, and on the stage. And a powder supply means for supplying the powder layer onto the sintered layer that has already been sintered, and the light beam irradiation means is disposed at a position shifted from a position immediately above the irradiation range of the light beam and is oblique to the powder layer. The three-dimensional shaped article manufacturing method according to the present invention is characterized by irradiating a light beam from a direction and sintering by irradiating a predetermined portion of the powder layer with a light beam. A new powder layer is laminated on the surface of the formed sintered layer, and a new sintering united with the lower sintered layer by irradiating a predetermined portion of the new powder layer with a light beam and sintering. Manufacturing a 3D model by repeating the formation of layers Upon that, is characterized in that by irradiating a light beam from an oblique direction shifted from the position immediately above the irradiation range performing sintering.

  Fume generated by irradiating and heating the light beam to the powder layer rises and goes to the position directly above. By irradiating the light beam from a position avoiding this position, light beam irradiation means It is intended to reduce fume fogging (a window provided in the chamber in order to transmit a light beam when the chamber is partitioned).

  At this time, the light beam irradiating means preferably includes beam shape correcting means for making the light beam spot shape on the irradiation surface substantially circular. Despite the irradiation from an oblique direction, the powder layer can be irradiated with a circular spot-shaped light beam, and stable sintering can be performed.

  Fume interception between the light beam emitting part of the light beam irradiating means and the light beam irradiation range output by the light beam irradiating means, which is light transmissive and blocks the passage of fumes generated from the sintered part by the light beam irradiation. By arranging the means, it is possible to prevent the light transmittance from decreasing more reliably.

  Further, if a capturing means for capturing a fume is provided at a position immediately above the irradiation range of the light beam, it is possible to more reliably prevent a decrease in light transmittance due to the fume.

  Furthermore, an opening for taking out the sintered three-dimensional shaped object and closing it with an openable / closable lid at a position immediately above the irradiation range of the light beam in the chamber in which the stage and the powder supply means are arranged. After the sintering is completed, the unsolidified powder on the stage is removed, and then the opening is opened and the three-dimensional shaped object that is sintered through the opening is taken out from the chamber. Thus, the molded object can be taken out with a crane or the like without causing interference with the light beam irradiation means, and the powder can be prevented from being scattered outside the chamber.

  In addition, after the sintering is completed, the amount of residual fumes and oxygen are measured by measuring the amount of residual fumes in the chamber and the concentration of oxygen in the chamber while cleaning the atmosphere in the chamber and replacing the atmosphere gas with air. It is possible to prevent the external environment from being soiled by opening the opening when the concentration falls below a predetermined value and taking out the three-dimensional shaped object.

  In the present invention, sintering is performed by irradiating a light beam from an oblique direction shifted from a position immediately above the irradiation range, and since the light beam irradiation means is not located at the position immediately above, the light beam is irradiated onto the powder layer. The fume generated by heating and moving to the position directly above fogs the light beam irradiation means (a window provided in the chamber for transmitting the light beam when it is partitioned by the chamber), thereby transmitting the light beam. Can be prevented, and a modeled object using a crane or other equipment can be taken out from the chamber without any trouble.

  Hereinafter, the present invention will be described in detail based on an example of an embodiment. A three-dimensional shaped article manufacturing apparatus in the illustrated example includes a powder layer forming unit 2, a light beam irradiation unit 3, a removing unit 4, and a powder layer forming unit. 2 and the removal means 4 are composed of a chamber 5 in which the powder layer forming means 2 is powdered on a stage 20 that moves up and down by driving a cylinder in a space surrounded by the outer periphery. The metal powder in the tank 23 is supplied by the squeegee blade 21 and leveled to form the powder layer 10 having a predetermined thickness Δt1 on the stage 20.

  The light beam irradiating means 3 irradiates the powder layer 10 with a laser output from the laser oscillator 30 via a scanning optical system such as a galvano mirror 31, and is disposed outside the chamber 5. The light beam emitted from the beam irradiation means 3 is irradiated to the powder layer through a light-transmitting window 50 provided in the chamber 5. The window 50 is made of a material that allows laser light to pass therethrough. When the laser oscillator 30 is a carbon dioxide laser, a flat plate made of ZnSe or the like can be used. It may be formed as a lens (for example, an Fθ lens).

  The removing means 4 is configured such that a milling head 41 is provided on the base portion of the powder layer forming means 2 via an XY drive mechanism 40. In addition, this invention is applicable also in the manufacturing apparatus of the three-dimensional shape molded article which is not equipped with this removal means 4. FIG.

  As shown in FIG. 2, the three-dimensional shaped object manufactured in this product is supplied by the blade 21 with the powder overflowed from the powder tank 23 on the surface of the modeling base 22 on the upper surface of the stage 20 and simultaneously leveled by the blade 21. Then, the first powder layer 10 is formed, and a portion of the powder layer 10 to be cured is irradiated with a light beam (laser) L to sinter the powder, and the sintered layer 11 integrated with the base 22 is formed. Form. Thereafter, the stage 20 is lowered a little and the powder is supplied again and leveled by the blade 21 to form the second powder layer 10 on the first powder layer 10 (and the sintered layer 11). Then, the portion of the second powder layer 10 to be cured is irradiated with a light beam (laser) L to sinter the powder to form a sintered layer 11 integrated with the lower sintered layer 11. . For example, iron powder having an average particle diameter of 3 μm can be used as the powder, but is not limited thereto.

  The stage 20 is lowered to form a new powder layer 10, and a process of irradiating a light beam to make the required portion a sintered layer 11 is repeated, thereby forming a desired three-dimensional shape as a laminate of the sintered layers. When a carbon dioxide laser can be suitably used as the light beam, and the thickness Δt1 of the powder layer 10 is used as a molding die, etc. The thickness is preferably about 0.05 mm. The irradiation path (hatching path) of the light beam can be created in advance from three-dimensional CAD data as shown in FIG. For example, contour shape data of each cross section obtained by slicing STL data generated from a three-dimensional CAD model at an equal pitch (0.05 mm pitch when Δt1 is 0.05 mm) is used.

  Then, the powder layer 10 is formed and the light beam is irradiated to repeatedly form the sintered layer 11. The total thickness of the sintered layer 11 is, for example, that of the milling head 41 in the removing means 4. Once the required value is obtained from the tool length, etc., the removal means 4 is operated once to cut the surface of the modeled object so far, thereby removing the low-density surface layer from the powder adhering to the modeled surface. At the same time, the portion having a high density can be entirely exposed on the surface of the modeled object by cutting into the portion having a high density inside. If the tool of the removing means 4 has a diameter of 1 mm, an effective blade length (neck length) of 3 mm and a depth of 3 mm, and the powder layer 10 has a thickness of 0.05 mm, the sintered layer 11 Since the excessively sintered portion hangs down by about 0.1 mm to 0.5 mm at the time of formation, the removing means 4 is operated each time the 40 sintered layers 11 are laminated, for example, and the cutting is performed once by the previous cutting removal. Further, it is preferable to cut with an overlap of about 1 mm.

  The cutting path by the removing means 4 may be created in advance from three-dimensional CAD data in the same manner as the light beam irradiation path. In this case, the machining path is determined by applying contour line processing, but the Z direction pitch does not need to stick to the stacking pitch at the time of sintering, and in the case of a gentle slope, by interpolating with a finer Z direction pitch, Keep a smooth surface.

  Here, when the powder is irradiated with a light beam and sintered, fumes 6 are generated as described above. Since the fumes 6 reach the position immediately above the irradiation range A of the light beam so as to stand up, here, the window 50 in the chamber 5 is arranged at a position shifted laterally from the position just above, and the light beam with respect to the powder layer 10 is disposed. Is performed from an oblique direction. That is, by removing the position of the window 50 from the position directly above, the possibility that the fume 6 adheres to or burns into the inner surface of the window 50 is reduced. Note that it is preferable that the window 50 and the irradiation range A do not overlap. However, even if they partially overlap, if the light beam L does not pass through the overlapping portion of the window 50, there is a problem. Never become.

  By the way, the fact that the light beam is always applied to the powder layer 10 obliquely from above means that the light beam spot that hits the powder layer 10 becomes an ellipse instead of a circle, and the shape depends on the distance from the window 50. Will also change. For this purpose, here, a beam shape correcting means 35 is arranged in front of the scanning optical system composed of the galvanometer mirror 31 and the like in the light beam irradiating means 3, and a substantially circular spot is formed on the powder layer 10 as the irradiation surface. The beam is irradiated.

  FIG. 5 shows an example of the beam shape correcting means 35, which includes a pair of cylindrical lenses 36 and 37, and a rotation drive mechanism 38 that rotates the lenses 36 and 37 around the axis of the light beam. In the case where the pair of cylindrical lenses 36 and 37 are arranged side by side in the axial direction of the light beam, either one or both of the lenses 36 and 37 can be rotated and at the same time the optical axis direction of the light beam. The distance between each other can be changed individually.

  When passing the light beam through the lens system which is the cylindrical lenses 36 and 37, as shown in FIG. 5, in the state where the axial directions of the arc convex surfaces g of both the lenses 36 and 37 are orthogonal, FIG. As shown, an ordinary light beam L having a circular cross section is obtained. The beam diameter can be enlarged or reduced by adjusting the distance between the lenses 36 and 37. If the axial directions of the convex arcs g of the lens 36 and the lens 37 are parallel to each other and are oriented in the vertical direction, as shown in FIG. 6 (b), light having an elliptical cross section with the major axis oriented in the vertical direction. If the beam L can be obtained, and the axial directions of the convex arcs g of the lenses 36 and 37 are parallel and are oriented horizontally or obliquely, the major axes are respectively shown in FIGS. 6 (c) and 6 (d). A light beam L having an elliptical cross section facing the direction can be obtained. Furthermore, if the axial direction of the arc convex surface g of the lenses 36 and 37 is made to intersect at a constant angle between the parallel state and the orthogonal state, the ratio of the major axis to the minor axis of the elliptical cross section can be arbitrarily adjusted. Can do.

  Then, by making the light beam L having an elliptical cross section that becomes a substantially circular spot beam when reaching the irradiation surface, which is the surface of the powder layer 10, emitted from the beam shape correcting means 35, In spite of irradiating the light beam L from an oblique direction, a substantially circular spot beam can be applied to the irradiated surface. In particular, by correcting the cross-sectional shape of the light beam according to the irradiation angle that varies depending on the irradiation position of the light beam L, a circular spot beam can always be applied to the irradiation surface.

  In this example, two cylindrical lenses 36 and 37 are used as the light beam shape correcting means 35. However, the circular spot beam is simply changed to an elliptical spot beam whose major axis is directed to a specific direction. It may be composed of a lens.

  FIG. 7 shows another example. This is because the fume 6 cannot be completely prevented from adhering to the window 50 simply by shifting the window 50 that transmits the light beam L in the chamber 5 from the position immediately above the irradiation range of the light beam L. The chamber 5 is bisected by a fume blocking means that blocks the passage of the fume 6, the stage 20 is disposed on one of the chambers 5, and the window 50 serving as the final emission portion of the light beam L is disposed on the other.

  The fume blocking means here may be a transparent plate 60 as shown in FIG. 7 (a), but an air curtain (gas curtain) 61 is preferably used as shown in FIG. 7 (b). In particular, if the gas curtain 61 is formed of an atmospheric gas such as nitrogen gas supplied into the chamber 5 to make the inside of the chamber 5 a non-oxidizing atmosphere, the fume does not reach the window 50 side while maintaining the atmosphere. It can be easily realized.

  FIG. 8 shows another example. This is one in which the fume capturing means 7 is arranged at a position immediately above the irradiation range of the light beam L. The fume capturing means 7 in the illustrated example is composed of an air pump 70 and a filter 71, and the atmospheric gas in the chamber 5 is sucked from the suction port that opens to the position directly above and passed through the filter 71. To capture. The sucked atmospheric gas is circulated in the chamber 5, but if the air curtain 61 is configured at this time, a decrease in light transmittance due to the fumes 6 can be prevented extremely reliably and reasonably. can do.

  The filter 71 may be any filter as long as it is effective for capturing the fume 6 and powder, and may be a labyrinth type or a cyclone type. If the powder is a magnetic material, a magnet may be used.

  FIG. 9 shows the chamber 5 provided with an opening 52 that can be opened and closed by a lid 51 in the ceiling portion directly above the irradiation range of the light beam L. The opening 52 is provided for taking out the manufactured object by the crane 8. Since the inside of the chamber 5 is filled with an inert gas at the time of sintering, the opening 52 is covered with packing or the like. The chamber 5 is hermetically sealed when 51 is closed.

  The opening / closing structure of the lid 51 may be a rotary type with a hinge shown in FIG. 9, or a folding type lid 51 or a sliding type lid 51 as shown in FIG. The opening / closing structure is not limited to the illustrated example.

  Further, as shown in FIG. 11, when the fume capturing means 7 is used in combination, the fume capturing means 7 can also be moved away from the position immediately above by sliding movement or the like, and the fume capturing means 7 is attached to the lid 51. Is provided so as not to prevent the removal of the modeled object through the opening 52.

  At the time when the sintering is completed, in addition to the modeled object, the powder that has not been solidified remains on the stage 20, and as shown in FIG. 12, the unsolidified powder is sucked using the suction nozzle 55. As shown in FIG. 13, the powder is blown off from the stage 20 by rotating the stage 20 while the stage 20 is raised, and the removal of the powder from the stage 20 is completed. It is preferable that the lid 51 is opened at that time. In FIG. 13, 91 is a motor for driving the rotation of the stage 20, and 92 is a gear.

  Further, as described above, the chamber 5 is filled with the inert gas or the fumes remain, so that the atmosphere gas in the chamber 5 is sucked by the vacuum pump 81 shown in FIG. While performing the cleaning process of the atmosphere in the chamber 5 by the air supply to the atmosphere and the replacement process of the atmosphere gas and air, the measurement of residual fumes and dust in the chamber by the particle counter 85, and the chamber 5 by the oxygen concentration sensor 86 The oxygen concentration is measured and the lid 51 is opened when the residual fume amount and the oxygen concentration are lower than the predetermined values, respectively, and the three-dimensional shaped object is taken out from the opening 52. preferable. In the figure, 83 is a pump for sending an inert gas (nitrogen gas) into the chamber 5, and C is a control device for controlling the operation of the manufacturing apparatus, to which the particle counter 85 and the oxygen concentration sensor 86 are connected. In addition to the powder layer forming means 2, the light beam irradiating means 3 and the removing means 4, the control device C opens and closes a valve 86 disposed between the pumps 81 and 83 and the compressor 82 and the chamber 5, and covers the lid 51. Also controls the opening and closing of.

  By the way, in order to prepare for removal of the modeled object by the crane 8, as shown in FIG. 15 (a), a screw hole 88 for a suspension bolt is formed in the modeled object at the time of sintering. As shown, a suspension bolt screw hole 88 may be provided in the plate 29 interposed between the stage 20 and the three-dimensional shaped object.

It is a fracture perspective view of an example of an embodiment of the invention. It is operation | movement explanatory drawing same as the above. It is a schematic sectional drawing same as the above. It is explanatory drawing same as the above. It is a perspective view of a beam shape correction means same as the above. (a), (b), (c), and (d) are explanatory diagrams of beam shape correction by the beam shape correction means described above. (a) (b) is a schematic sectional drawing of another example, respectively. It is a schematic sectional drawing of another example. Furthermore, it is sectional drawing of another example. (a) (b) is sectional drawing which shows the other example of the opening-closing structure of a lid | cover. It is sectional drawing of another example. It is sectional drawing of another example. (a) (b) is sectional drawing of another example. It is a block diagram of another example. (a) (b) is sectional drawing of a different example.

Explanation of symbols

2 Powder layer supply means 3 Light beam irradiation means L Light beam

Claims (8)

  A light beam irradiation means for irradiating a predetermined portion of the powder layer formed on the stage with a light beam to sinter the powder at the irradiation position, and supplying the powder layer on the stage and on the already sintered sintered layer A powder supply means, and the light beam irradiation means is arranged at a position shifted from a position immediately above the irradiation range of the light beam and irradiates the powder layer with the light beam from an oblique direction. Production equipment for original shaped objects.   2. The apparatus for manufacturing a three-dimensional shaped object according to claim 1, wherein the light beam irradiating means includes beam shape correcting means for making the light beam spot shape on the irradiation surface substantially circular.   Fume interception between the light beam emitting part of the light beam irradiating means and the light beam irradiation range output by the light beam irradiating means, which is light transmissive and blocks the passage of fumes generated from the sintered part by the light beam irradiation. The apparatus for producing a three-dimensional shaped object according to claim 1 or 2, wherein means are provided.   The three-dimensional shaped article manufacturing apparatus according to any one of claims 1 to 3, further comprising a capturing unit that captures fume at a position immediately above the irradiation range of the light beam.   At the position directly above the light beam irradiation range in the chamber in which the stage and powder supply means are arranged, there is an opening for taking out the sintered three-dimensional shaped object and closed with an openable / closable lid The apparatus for producing a three-dimensional shaped article according to any one of claims 1 to 4, wherein the three-dimensional shaped article is provided.   A new powder layer is laminated on the surface of the sintered layer formed by irradiating and sintering a light beam to a predetermined part of the powder layer, and the predetermined part of the new powder layer is irradiated with a light beam and sintered. When manufacturing a three-dimensional shaped object by repeatedly forming a new sintered layer integrated with the lower sintered layer, the light beam is obliquely shifted from the position immediately above the irradiation range. A method for producing a three-dimensional shaped object characterized by performing irradiation and sintering.   After the sintering is completed, the unsolidified powder on the stage is removed, and then the openable opening that is provided at a position immediately above the irradiation range of the light beam in the chamber in which the stage and the powder supply means are arranged. The method for producing a three-dimensional shaped object according to claim 6, wherein the part is opened and the three-dimensional shaped object is taken out through the opening.     After the sintering is completed, the residual fume amount and oxygen concentration are measured by measuring the residual fume amount in the chamber and the oxygen concentration in the chamber while cleaning the atmosphere in the chamber and replacing the atmospheric gas with air. 8. The method for producing a three-dimensional shaped object according to claim 7, wherein the three-dimensional shaped object is taken out by opening the opening when each of the values falls below a predetermined value.

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