JPH08156106A - 3D object manufacturing method - Google Patents

Abstract

(57) [Abstract] [Purpose] To provide a three-dimensional object manufacturing method having the dimensional accuracy and shape stability of the photo-curing resin pool method and the resource saving of the thermoplastic resin method. [Structure] A solid component produced by causing light to act locally as a curing accelerator on a photocurable substance that flows out from a nozzle whose spatial position is automatically controlled by a computer etc. and whose flow conditions are automatically controlled. A three-dimensional object having an arbitrary shape is manufactured by stacking.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a three-dimensional object manufacturing method. More specifically, the present invention relates to a method for automatically forming a three-dimensional shape by computer control.

With the progress of ergonomics and industrial design,
The technical demand for designing and manufacturing an object having a three-dimensional shape in which complicated curved surfaces are complicatedly combined has increased, and such shape design has become possible together with the development of CAD technology. At the same time, the technical demand for actually forming a designed shape by trial is inevitably increasing. CAD
If a complex three-dimensional shape can be manufactured quickly and inexpensively from the data generated in, the design shape can be confirmed and the prototype characteristics test can be efficiently performed, and the design work can be greatly improved and streamlined. It

[0003]

2. Description of the Related Art In response to such a need, clay and a wooden model have been conventionally produced by artistic skill.
The numerical data of D could not be utilized and automation was impossible. Prototypes using NC machine tools are often performed, or full-scale programming that requires man-hours is essential, and only shapes that can be machined can be created. For example, it is not possible to form intricate internal structures that do not require tools.

Recently, a new three-dimensional model making technique has appeared on the market. As such a technique, there is a photocurable resin pool method. This technology locally cures the pool liquid surface of solution-type photo-curable resin by a thin laser beam that is scanning-controlled by a computer, and sequentially raises the liquid surface to sequentially generate three-dimensional objects from the bottom of the model. There is a forming technology. Although this method is epoch-making as the first three-dimensional shape generation technology, it requires a large amount of chemically active photo-curable resin, and not only cost and time efficiency problems but also safety and waste treatment A flaw is pointed out.

Another technique is the thermoplastic resin method. This is a technique for forming a three-dimensional object while extruding a heat-melted thermoplastic resin from a thin nozzle whose position is controlled by a computer and cooling and solidifying the resin. This technique eliminates the drawback that resin is wasted because resin is directly supplied only to a substantial part of the object to be formed, but the controllability is poor and the dimensional accuracy is poor compared to the photocuring resin pool method, and There are problems such as insufficient cooling of the resin, remelting and shrinkage deformation.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a three-dimensional object manufacturing method which has the dimensional accuracy and shape stability of the photo-curing resin pool method and the resource saving of the thermoplastic resin method. To do. Further, it is an object of the present invention to provide a three-dimensional object manufacturing method that can be applied to substances other than resins such as metals and ceramics in order to expand the types of usable materials.

[0007]

The inventor of the present invention has conducted earnest research to achieve this object, and as a result, the light flowing out from a nozzle whose spatial position is automatically controlled by a computer or the like is automatically controlled. The inventors have invented a method for producing a three-dimensional object, which comprises locally applying a light as a hardening promoting factor to a curable substance and laminating the resulting solid component.

That is, in order to eliminate the above-mentioned problems, a compound nozzle in which a photocurable resin outflow nozzle and a curing light irradiation mechanism are combined is used, and while the photocurable resin that has flowed out is locally cured, the space of the compound nozzle is reduced. The inventor has invented a method of automatically controlling a physical position by a computer and forming an object having a three-dimensional shape. The curing light is condensed near the photocuring resin nozzle by a light irradiation optical system including an optical fiber, a lens or a reflecting mirror.

A specific example of the three-dimensional object manufacturing method of the present invention will be described with reference to the drawings. In FIG. 1, the position of the composite nozzle 1 in which the resin supply nozzle 2 and the light irradiation optical system are integrated is automatically controlled, and the uncured resin 4 is flowed out from the resin supply nozzle 2 at a predetermined position at an appropriate flow rate to cure the resin. A curing resin 5 is formed by irradiating the application light 3 and a three-dimensional object 6 for manufacturing is formed while being laminated. No photocurable resin pool is required in this method.

As illustrated in FIG. 2, it is possible to install the curing light emitting portion 3 separately from the resin nozzle 1 and locally control the light beam by controlling the position of the light beam. As a modification of this method, it is also possible to solidify the radiation curable resin with a radiation beam while letting it out from the nozzle.

A method using a two-component contact-curable resin, that is, a method of contact-curing the main component resin and a liquid or gaseous curing agent at the tip of the nozzle is also possible. Further, a method of causing the second component to flow out into a fluid pool of inexpensive components and contact-curing it is also possible.

Similarly, considering a combination of a hardening material and a hardening accelerating factor, a method utilizing a thixotropic substance (which exhibits fluidity by mechanical deformation or shaking) such as clay or high-concentration sludge, that is, a thixotropic substance. Stirring, shaking, ultrasonic irradiation,
It is also possible to use a phenomenon in which, when a liquid is shaken and liquefied by heating to flow out from a nozzle, the phenomenon that the rocking effect is not exerted at a certain distance from the nozzle and the plastic state is transitioned to is solidified.

In order to accelerate the local dry curing, it is conceivable to spray a dry gas or to irradiate infrared rays.
It is also conceivable to locally spray an acidic gas such as carbon dioxide gas or a liquid, or to let it flow out into the atmosphere to promote coagulation and solidification. Further, it is also possible to use a slurry obtained by kneading powder with a curable binder as a curable substance and controlling contact of the binder with a curing agent as a curability factor. These methods include pottery, porcelain, ceramics, carbon, graphite,
It is possible to form a three-dimensional shape using a sintered metal or the like as a material.

Furthermore, since metal is used as a material,
A method of controlling a molten metal such as a brazing material as a hardening accelerator by heat conduction or forced cooling is also possible.
FIG. 3 illustrates a specific example thereof, in which the positions of the two cooling guide plates (or rollers) are controlled and the local mold 4 is formed in the part which is being laminated to advance the shape formation. In the method using the molten metal, if a brazing material whose remelting temperature rises is adopted, the temperature control becomes easy because the generated solid does not remelt by the melt immediately after flowing out.

The method of the present invention can also be applied to refractory substances such as metals and ceramics and chemically active substances. That is, a solid (polymer, glass, metal, ceramic, or compound such as oxide or nitride obtained by chemically reacting raw material components in an atmosphere gas) rod or powder is supplied, and a focused laser or electron beam is supplied. It is melted by, and dropped or sprayed with carrier gas, vibrated by electromagnetic force, or driven to fly to be integrated and laminated. FIG. 4 shows a specific example. The raw material is melted by a light or electron beam whose converging point is controlled, and the three-dimensional object is integrated and laminated.

Furthermore, if the following construction techniques are combined, the degree of freedom in material selection and surface finishing can be expanded and dimensional accuracy can be improved. 1) Material that is extremely flexible and deforms by gravity 3
When manufacturing a three-dimensional object, a method in which the operation proceeds in a fluid having almost the same specific gravity as the solid component to be produced. 2) When the shape accuracy and surface accuracy directly obtained by laminating solid components are insufficient, surface finishing machining such as automatically controlled cutting and polishing unit and sandblasting, finishing such as impression pressing and spatula finishing, By applying a trowel or roller pressing, re-melting with a heated trowel or hot air blowing nozzle, or a softening process for each layer, it is possible to improve the dimensional finish, surface finish, and optional surface characteristics. It is possible to proceed with the applying step at the same time. FIG. 5 shows a specific example thereof. Cured product 7
In addition to the mechanisms 1, 2, and 3 for supplying and forming the above, the mechanisms 2, 4, and 5 for finishing the surface and shape of each laminated portion.

[0017]

According to the method of the present invention, a method having the dimensional accuracy and stability of the photo-curing resin method and the resource saving of the thermoplastic resin method can be realized, and the photo-curing resin and the photo-curing adhesive can be used. It has become possible to use materials that are distributed in many markets, such as adhesives, photocurable fillers, and two-component curable resins. Further, it can be applied to radiation-curable resins, sludge substances such as clay, metal powder slurries, molten metals such as solder, heat-resistant metals and ceramics, and chemical conversion substances. By performing the above operation in the same fluid as the solid component to be produced, it became possible to fabricate a three-dimensional object with an extremely flexible substance. By using other processing techniques together, it became possible to improve dimensional accuracy and surface finish, and to create an arbitrary surface condition.

[Brief description of drawings]

1 is a diagram for explaining the outline of the method of the present invention. <Figure 2> In the method of this invention, it is the explanation drawing of one concrete example which divided control of the nozzle for the hardening substance and the hardening accelerator. <Figure 3> In the method of this invention, it is the explanation drawing of one concrete example which also uses the local metallic mold. <Figure 4> In the method of this invention, it is the explanation drawing of the application example to the metal / ceramic. <Figure 5> In the method of this invention, it is the explanation drawing of one concrete example which combines finishing processing in combination.

[Explanation of symbols]

 In FIG. 1, 1 compound nozzle 2 resin supply nozzle 3 curing light 4 uncured resin 5 cured resin 6 three-dimensional object In FIG. 1, 1 nozzle for curable substance 2 position control mechanism 3 curing accelerator (ultraviolet) irradiation port 4 Curable substance (photocurable resin) 5 Solid component (product) 6 Ultraviolet beam 7 Three-dimensional object (manufactured product) In FIG. 1, 1 Nozzle for curable substance 2 Position control mechanism 3 Curing acceleration factor (ultraviolet) irradiation port 4 Local template 5 Curable substance (photocurable resin, etc.) 6 Solid component (product) 7 Curing accelerating factor (ultraviolet ray) In FIG. 1, 1 substance supply nozzle 2 position control mechanism 3 laser (electron beam) convergent irradiation nozzle 4 carrier Gas 5 Melt liquid 6 Melt flying droplet 7 Three-dimensional object (manufactured product) In FIG. 1, 1 Nozzle for curable substance 2 Position control mechanism 3 Curing accelerator (ultraviolet) irradiation port Processing unit (vibrator, rotating machine) 5 Processing terminal (vibrating iron, end mill, etc.) 6 Curable substance (photocurable resin) 7 Solid component (cured product) 8 Curing accelerating factor (ultraviolet ray) 7 3D object ( Production)

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[Procedure amendment]

[Submission date] December 17, 1992

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[Name of item to be amended] Claims

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[Claims]

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In order to accelerate the local dry curing, it is conceivable to spray a dry gas or to irradiate infrared rays.
It is also conceivable to locally spray an acidic gas such as carbon dioxide gas or a liquid, or to let it flow out into the atmosphere to accelerate the condensation and solidification. Furthermore, it is also possible to use a mud mixture obtained by kneading powder with a curable binder as a curable substance and controlling the contact of the binder with the curing agent as a curability factor. It is also possible to knead a fine powder of the forming substance together with a volatile liquid such as water and a caking aid such as oil and fat, and let it flow out from a nozzle at a temperature at which the volatile liquid evaporates rapidly and solidify. These methods include pottery, porcelain, ceramics, carbon,
It makes it possible to form a three-dimensional shape using graphite, sintered metal, or the like.

[Submission date] October 4, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

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[Brief description of drawings]

FIG. 1 is a diagram illustrating an outline of a method of the present invention.

FIG. 2 is an explanatory diagram of a specific example in which control of a nozzle for a curable substance and control of a curing accelerator are separated in the method of the present invention.

FIG. 3 is an explanatory view of a specific example in which a local mold is used together in the method of the present invention.

FIG. 4 is an explanatory diagram of an application example to metal / ceramic in the method of the present invention.

[Description of Reference Signs] In FIG. 1, 1 composite nozzle 2 resin supply nozzle 3 curing light 4 uncured resin 5 cured resin 6 three-dimensional object In FIG. 2, 1 curable substance nozzle 2 position control mechanism 3 curing acceleration factor ( Ultraviolet ray irradiation port 4 Curing substance 5 Solid component (product) 6 Ultraviolet beam 7 Three-dimensional object (manufactured product) In FIG. 1, 1 Curing substance nozzle 2 Position control mechanism 3 Curing acceleration factor (ultraviolet) irradiation port 4 Local template 5 Curable substance (photocurable resin, etc.) 6 Solid component (product) 7 Curing accelerating factor (UV) In FIG. 1, 1 Nozzle for curable substance 2 Position control mechanism 3 Curing accelerating factor (UV) irradiation port 4 Processing unit (vibrator, rotary machine) 5 Processing terminal (vibrating lever, end mill, etc.) 6 Curable substance (photocurable resin, etc.) 7 Solid component (cured product) 8 Curing acceleration factor ( Outside line)

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Claims (10)

[Claims] 1. A photocurable substance that flows out from a nozzle whose spatial position is automatically controlled by a computer or the like and whose flow conditions are automatically controlled, is caused by locally acting light as a curing promoting factor. A method for manufacturing a three-dimensional object having an arbitrary shape, which comprises stacking solid components. 2. The method for producing a three-dimensional object according to claim 1, wherein the photocurable substance is a radiation-curing resin, and the light of the curing-promoting factor is a radiation radiation. 3. The method according to claim 1, wherein the two-component contact hardening resin is brought into contact with each other at the tip of each nozzle.
How to make a three-dimensional object. 4. A second component in the fluid pool formed by the first component.
The method for producing a three-dimensional object according to claim 3, wherein the components are caused to flow out and locally hardened at the tip of the nozzle. 5. A phenomenon in which a thixotropic substance that fluidizes due to rocking such as clay or mud is made to flow in a shaking fluid state by stirring, vibrating, or irradiating ultrasonic waves, and flows out from a nozzle, and then transitions to a plastic state after the fluid flow is stopped. The method for manufacturing a three-dimensional object according to claim 1, which comprises using 6. The method for producing a three-dimensional object according to claim 1, wherein a brazing material such as solder or silver wax is caused to flow out from a nozzle whose temperature is controlled and is solidified by cooling. 7. A solid rod or powder is supplied, melted by a focused laser beam, an electron beam, etc., and dropped, blown by a carrier gas, or vibrated or driven by an electromagnetic force to fly. The method for producing a three-dimensional object according to claim 1, comprising stacking and stacking. 8. The three-dimensional structure according to claim 7, wherein the solid rod or powder is a polymer, glass, metal, ceramic, or compound such as oxide or nitride chemically reacted with atmospheric gas. How to make an object. 9. The three-dimensional structure according to claim 1, wherein when a three-dimensional object is made of a material which is extremely flexible and deforms by gravity, it is operated in a fluid having a specific gravity almost equal to that of the solid component to be produced. How to make an object. 10. When the shape accuracy and surface accuracy directly obtained by laminating solid components are insufficient, each layer is subjected to a combination of mechanical and thermal processing techniques such as cutting, spatula drawing, partial melting and sand blasting. The method for producing a three-dimensional object according to claim 1, wherein the steps of improving dimensional accuracy, surface finishing accuracy, and giving arbitrary surface characteristics are simultaneously performed.