JP2017075369A - Method for manufacturing three-dimensional molded article and apparatus for manufacturing three-dimensional molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To quickly manufacture a highly accurate three-dimensional molded article.SOLUTION: A method for manufacturing a three-dimensional molded article includes a layer formation step of forming layers by discharging a fluid composition containing a particle in a form of droplet from a discharge part. The layer formation step includes: a constitution layer formation step of forming a constitution layer corresponding to a configuration region of a three-dimensional molded article; and a support layer formation step of forming a support layer abutting on the constitution layer and supporting the constitution layer. In the support layer formation step, at least some droplet when forming the support layer is smaller than at least some droplet when forming the constitution layer at the constitution layer formation step.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a method for manufacturing a three-dimensional structure and a manufacturing apparatus for a three-dimensional structure.

Conventionally, the manufacturing method which manufactures a three-dimensional structure by laminating | stacking a layer is implemented. Among these, the manufacturing method which manufactures a three-dimensional structure is disclosed, forming a layer using the fluid composition containing particle | grains.
For example, Patent Document 1 discloses a manufacturing method in which a layer is formed using a metal paste, and a corresponding region of the three-dimensional structure is irradiated with a laser to produce a three-dimensional structure while being sintered or melted. Yes.

JP 2008-184622 A

  However, in the conventional method for manufacturing a three-dimensional structure, a three-dimensional structure is manufactured by forming a layer having a single thickness. For this reason, in order to increase the production rate, the layer thickness must be increased to increase the supply speed of the fluid composition containing particles such as metal paste (increase the supply amount per unit time). , Manufacturing accuracy was reduced. On the other hand, in order to increase the manufacturing accuracy, the thickness of the layer must be reduced, and a fluid composition containing particles such as a metal paste must be supplied with high accuracy, resulting in a reduction in manufacturing speed. Thus, in the conventional method for manufacturing a three-dimensional structure, the manufacturing speed and the manufacturing accuracy are traded off.

  Accordingly, an object of the present invention is to quickly produce a highly accurate three-dimensional structure.

  The manufacturing method of the three-dimensional structure according to the first aspect of the present invention for solving the above-described problem is a layer forming step of forming a layer by discharging a fluid composition containing particles from a discharge portion in a droplet state. The layer forming step includes a constituent layer forming step for forming a constituent layer corresponding to a constituent region of the three-dimensional structure, and a support layer forming for supporting the constituent layer in contact with the constituent layer. And at least some of the droplets when forming the support layer in the support layer forming step are more than at least some of the droplets when forming the constituent layer in the constituent layer forming step It is small.

According to this aspect, the support layer is formed with droplets smaller than the droplets used when forming the constituent layers. That is, a support layer that determines the shape of the contour of the three-dimensional structure is formed with relatively small droplets, and a constituent layer that forms the interior of the three-dimensional structure is formed with relatively large droplets. For this reason, while being able to form the support layer which determines the shape of the outline which needs to be formed with high accuracy in the three-dimensional structure, the inside which does not need to be formed with high precision in the three-dimensional structure is provided. The constituent layer to be configured can be formed quickly. Therefore, a highly accurate three-dimensional structure can be manufactured quickly.
Here, the “contour” is a portion that forms the shape of the surface of the three-dimensional structure. When a coating layer is provided on the surface of a three-dimensional structure, it may mean the lower layer of the coating layer.

  In the method for manufacturing a three-dimensional structure according to the second aspect of the present invention, in the first aspect, the layer forming step ejects droplets of different sizes as the ejection unit, It is performed using a 2nd discharge part, It is characterized by the above-mentioned.

According to this aspect, layer formation can be performed using the first discharge unit and the second discharge unit that discharge droplets of different sizes. For this reason, it is possible to easily discharge relatively large droplets and relatively small droplets.
Note that “discharging droplets of different sizes” means that both the first discharge unit and the second discharge unit can discharge one type of droplet, and the size of each droplet is different. It does not mean only the case, but at least one of the first discharge portion and the second discharge portion can discharge a plurality of types of droplets and can be discharged from the first discharge portion and the second discharge portion. This also includes the case where the sizes of are partially the same.

  The manufacturing method of the three-dimensional structure according to the third aspect of the present invention is characterized in that, in the first or second aspect, the method includes a stacking step in which the layer forming step is repeated in the stacking direction.

  According to this aspect, it has the lamination process which repeats a layer formation process in a lamination direction. For this reason, a three-dimensional structure can be easily manufactured by laminating layers.

  In the method for producing a three-dimensional structure according to the fourth aspect of the present invention, in any one of the first to third aspects, the layer forming step is included in the fluid composition that forms the constituent layer. And a bonding step of bonding the particles for forming the constituent layer.

According to this aspect, it has the coupling | bonding process which couple | bonds the particle for structure layer formation. For this reason, it becomes possible to manufacture a sturdy three-dimensional structure.
Note that “bonding particles” includes, for example, sintering particles or melting particles.

  In the method for producing a three-dimensional structure according to the fifth aspect of the present invention, in the fourth aspect, the coupling step is performed by applying energy to the constituent layer, or the constituent layer and the support layer. The binding force by the application of the energy in the constituent layer forming particles is stronger than the binding force in the support layer forming particles contained in the fluid composition forming the support layer.

According to this aspect, the bonding step is performed by applying energy to the constituent layer, or the constituent layer and the support layer, and the binding force by the application of energy in the constituent layer forming particles is fluidity to form the support layer. It is stronger than the binding force due to the application of energy in the particles for forming a support layer contained in the composition. For this reason, it is possible to bond the constituent layer forming particles relatively strongly, and to manufacture a sturdy three-dimensional structure.
The “bonding force in the particles for forming the support layer” means a bond force when energy is not applied to the support layer when energy is not applied to the support layer in the bonding process, and energy is applied to the support layer in the bonding process. In the case, it means a binding force in a state where energy is applied to the support layer.

  In the method for manufacturing a three-dimensional structure according to the sixth aspect of the present invention, in the fourth or fifth aspect, the layer forming step includes executing the support layer forming step a plurality of times to form the support layer into a plurality of layers. And forming the constituent layer corresponding to the thickness of the plurality of layers in a region corresponding to the plurality of layers by executing the constituent layer forming step, and executing the combining step to correspond to the plurality of layers It is characterized by binding particles for layer formation.

  According to this aspect, the support layer forming step is performed a plurality of times to form a plurality of support layers, and then the constituent layer forming step is performed to correspond to the thickness of the plurality of layers in the region corresponding to the plurality of layers. A layer is formed, and particles corresponding to the plurality of layers are bonded. That is, the number of constituent layer forming steps can be reduced. For this reason, a highly accurate three-dimensional structure can be manufactured particularly quickly.

  The manufacturing method of a three-dimensional structure according to a seventh aspect of the present invention is the method according to any one of the fourth to sixth aspects, wherein the layer forming step includes the thickness of the constituent layer and the thickness after the joining step. The size of the droplet is adjusted so that the thickness of the supporting layer corresponding to the constituent layer is aligned.

  According to this aspect, in the layer forming step, the size of the droplet is adjusted so that the thickness of the constituent layer and the thickness of the support layer corresponding to the constituent layer are aligned after the joining step. For this reason, adjustment of the layer thickness accompanying the layer thickness of a support layer and a structure layer differing becomes unnecessary, and a highly accurate three-dimensional molded item can be manufactured easily.

  In the method for producing a three-dimensional structure according to the eighth aspect of the present invention, in any one of the fourth to seventh aspects, the joining step is performed by heating the constituent layer and the support layer. The heating temperature is not less than the melting point of the constituent layer forming particles and not more than the melting point of the support layer forming particles contained in the fluid composition forming the support layer.

  According to this aspect, the bonding step is performed by heating the constituent layer and the support layer, and the heating temperature is not lower than the melting point of the constituent layer forming particles and not higher than the melting point of the support layer forming particles. For this reason, since a constituent layer (three-dimensional structure) can be melted without melting the support layer, the completed three-dimensional structure can be easily detached from the support layer.

  In the method for manufacturing a three-dimensional structure according to the ninth aspect of the present invention, in any one of the fourth to seventh aspects, the bonding step is performed by heating the constituent layer and the support layer. The heating temperature is equal to or higher than the sintering temperature of the constituent layer forming particles and is equal to or lower than the sintering temperature of the support layer forming particles included in the fluid composition forming the support layer. To do.

  According to this aspect, the bonding step is performed by heating the constituent layer and the support layer, and the heating temperature is not less than the sintering temperature of the constituent layer forming particles and not more than the sintering temperature of the supporting layer forming particles. It is. For this reason, since a structural layer (three-dimensional structure) can be sintered without sintering a support layer, the completed three-dimensional structure can be easily removed from a support layer.

  In the method for producing a three-dimensional structure according to the tenth aspect of the present invention, in any one of the first to ninth aspects, the particles for forming a support layer included in the fluid composition that forms the support layer. The particle size of is smaller than the particle size of the particles for forming a constituent layer contained in the flowable composition forming the constituent layer.

  According to this aspect, the particle diameter of the support layer forming particles is smaller than the particle diameter of the constituent layer forming particles. For this reason, the support layer which determines the shape of the outline which needs to be formed with high accuracy in the three-dimensional structure can be formed with high accuracy with particles having a relatively small particle diameter. Therefore, a highly accurate three-dimensional structure can be manufactured.

  The method for producing a three-dimensional structure according to an eleventh aspect of the present invention, in any one of the first to tenth aspects, comprises particles for forming a support layer included in the fluid composition that forms the support layer. Are particles containing at least one component of silica, alumina, titanium oxide, and zircon oxide, and the constituent layer forming particles contained in the fluid composition forming the constituent layer are aluminum, titanium, iron, copper , Magnesium, stainless steel, maraging steel, and particles containing at least one component.

  According to this aspect, the support layer forming particles are particles containing at least one component of silica, alumina, titanium oxide, and zircon oxide, and the constituent layer forming particles are aluminum, titanium, iron, copper, magnesium, Particles containing at least one component of stainless steel and maraging steel. For this reason, the constituent material particles can be melted and the support member forming particles can be easily controlled to have a low sintered density by the energy application step. Alternatively, it can be easily controlled so that the constituent material particles are sintered and the support member forming particles are not sintered. Thereby, it is possible to suppress an increase in loads such as separation work when removing the three-dimensional structure and molding work after removal while securing the strength of the three-dimensional structure.

  A three-dimensional structure manufacturing apparatus according to a twelfth aspect of the present invention forms a layer by discharging a fluid composition containing particles in the form of droplets, and discharging droplets from the discharge unit. A control unit that controls the configuration layer, the configuration unit corresponding to the configuration region of the three-dimensional structure, and a support layer that contacts the configuration layer and supports the configuration layer. Control is performed so that at least some of the droplets at the time of formation are smaller than at least some of the droplets at the time of forming the constituent layer.

  According to this aspect, the support layer is formed with droplets smaller than the droplets used when forming the constituent layers. That is, a support layer that determines the shape of the contour of the three-dimensional structure is formed with relatively small droplets, and a constituent layer that forms the interior of the three-dimensional structure is formed with relatively large droplets. For this reason, while being able to form the support layer which determines the shape of the outline which needs to be formed with high accuracy in the three-dimensional structure, the inside which does not need to be formed with high precision in the three-dimensional structure is provided. The constituent layer to be configured can be formed quickly. Therefore, a highly accurate three-dimensional structure can be manufactured quickly.

(A) is a schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention, (b) is an enlarged view of the B section shown to (a). (A) is a schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention, (b) is an enlarged view of the C section shown to (a). 1 is a schematic perspective view of a head base according to an embodiment of the present invention. The top view which illustrates notionally the relationship between arrangement | positioning of the head unit which concerns on one Embodiment of this invention, and the formation form of a fusion | melting part. Schematic explaining the formation form of a fusion | melting part notionally. The schematic diagram which shows the example of other arrangement | positioning of the head unit arrange | positioned at a head base. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. Schematic showing the manufacturing process of the three-dimensional structure based on one Example of this invention. The flowchart of the manufacturing method of the three-dimensional structure based on one Example of this invention.

Embodiments according to the present invention will be described below with reference to the drawings.
FIG.1 and FIG.2 is a schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention.
Here, although the manufacturing apparatus of the three-dimensional structure according to the present embodiment includes two types of material supply units (head bases), FIGS. 1 and 2 each show only one material supply unit. It is a figure and the other material supply part is abbreviate | omitted and represented. Moreover, the material supply part of FIG. 1 is a material supply part which supplies the constituent material of a three-dimensional structure, and is provided with the laser irradiation part for hardening (melting | melting) a constituent material. And the material supply part of FIG. 2 is a material supply part which supplies the material for support layer formation for forming the support layer which supports a constituent material, when modeling a three-dimensional molded item.
In addition, “three-dimensional modeling” in the present specification indicates that a so-called three-dimensional model is formed, and for example, a flat shape, that is, a so-called two-dimensional shape is formed with a thickness. To include. Further, “support” means not only the case of supporting from the lower side, but also the case of supporting from the lateral side and, in some cases, the case of supporting from the upper side.

A three-dimensional structure manufacturing apparatus 2000 (hereinafter, referred to as a forming apparatus 2000) illustrated in FIGS. 1 and 2 includes a base 110 and a driving device 111 as a driving unit included in the base 110, and illustrated X, Y, The stage 120 is provided so as to be movable in the Z direction or driven in the rotation direction around the Z axis.
Then, as shown in FIG. 1, one end is fixed to the base 110, and the constituent material discharge unit 1230 and the energy irradiation unit 1300 that discharge the constituent material of the three-dimensional structure are disposed on the other end. A head base support 130 is provided on which a head base 1100 that holds a plurality of head units 1400 is held and fixed.
In addition, as shown in FIG. 2, a support layer forming material discharge unit that discharges a support layer forming material that supports the three-dimensional structure to the other end, with one end fixed to the base 110. A head base support portion 730 on which a head base 1600 that holds a plurality of head units 1900 including 1730 is held and fixed.
Here, the head base 1100 and the head base 1600 are provided in parallel in the XY plane.
The constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 are different except that the size (dot diameter) of the droplets to be discharged and the discharged materials (the constituent materials and the support layer forming material) are different. The configuration is the same. However, it is not limited to such a configuration.

On the stage 120, layers 501, 502, and 503 in the process of forming the three-dimensional structure 500 are formed. Although details will be described later, layers having different thicknesses can be formed by discharging droplets having different dot diameters from the constituent material discharge unit 1230 and the support layer forming material discharge unit 1730. A thin layer can be formed by discharging a droplet having a relatively small dot diameter using the support layer forming material discharge unit 1730, and a droplet having a relatively large dot diameter can be formed by using the constituent material discharge unit 1230. A thick layer can be formed by ejection.
Since heat is generated by laser irradiation in forming the three-dimensional structure 500, the three-dimensional structure 500 may be formed on the sample plate 121 using the heat-resistant sample plate 121. By doing so, the stage 120 can be protected from heat generated by laser irradiation. As the sample plate 121, for example, by using a ceramic plate, high heat resistance can be obtained, and the reactivity with the constituent material of the three-dimensional structure to be melted (or sintered) is low, Alteration of the three-dimensional structure 500 can be prevented. In FIG. 1A and FIG. 2A, for convenience of explanation, three layers 501, 502, and 503 are illustrated, but the shape of the desired three-dimensional structure 500 (FIG. 1A and FIG. The layers are stacked up to the layer 50n in FIG.
Here, the layers 501, 502, 503,... 50 n are respectively formed from a support layer forming material discharged from a support layer forming material discharge unit 1730 and a constituent material discharge unit 1230. And a molten layer 310 (a constituent layer corresponding to a constituent area of the three-dimensional structure 500) formed of the constituent material to be discharged. Further, the constituent material ejected from the constituent material ejecting unit 1230 can be melted for each droplet by irradiating thermal energy from the energy irradiating unit 1300 immediately after ejection, and after forming one layer. The entire layer can be irradiated with thermal energy from the energy irradiation unit 1300 and melted layer by layer. Furthermore, the shape of the three-dimensional structure is completed by forming a plurality of molten layers 310 and support layers 300 without irradiating thermal energy from the energy irradiation unit 1300, and this is separated from the forming apparatus 2000. It is also possible to melt or sinter in a constant temperature bath (heating unit) provided in (1).

  FIG. 1B is an enlarged conceptual view of a B portion showing the head base 1100 shown in FIG. As shown in FIG. 1B, the head base 1100 holds a plurality of head units 1400. Although details will be described later, one head unit 1400 is configured by holding a constituent material discharge unit 1230 and an energy irradiation unit 1300 included in the constituent material supply device 1200 by a holding jig 1400a. The constituent material discharge unit 1230 includes a discharge nozzle 1230a and a discharge driving unit 1230b that discharges the constituent material from the discharge nozzle 1230a by the material supply controller 1500. Further, a laser irradiation unit 3100 for sintering the support layer forming material and a galvano mirror 3000 for positioning laser light from the laser irradiation unit 3100 are provided above the stage 120.

  FIG. 2B is an enlarged conceptual view of a C portion showing the head base 1600 shown in FIG. As shown in FIG. 2B, the head base 1600 holds a plurality of head units 1900. The head unit 1900 is configured by holding a support layer forming material discharge unit 1730 included in the support layer forming material supply apparatus 1700 by a holding jig 1900a. The support layer forming material discharge unit 1730 includes a discharge nozzle 1730a and a discharge driving unit 1730b that discharges the support layer forming material from the discharge nozzle 1730a by the material supply controller 1500.

  The forming apparatus 2000 according to the present embodiment includes a constituent material discharge unit 1230 and a support layer forming material discharge unit 1730 that discharge droplets having different dot diameters. Furthermore, each of the constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 has a configuration capable of discharging a plurality of droplets having different dot diameters (a configuration capable of forming layers having different layer thicknesses (thicknesses)). .

  In this embodiment, the energy irradiation unit 1300 is described as an energy irradiation unit that irradiates a laser that is an electromagnetic wave as energy (hereinafter, the energy irradiation unit 1300 is referred to as a laser irradiation unit 1300). By using a laser as the energy to be irradiated, the target supply material can be aimed and irradiated with energy, and a high-quality three-dimensional structure can be formed. Further, for example, it is possible to easily control the amount of irradiation energy (power, scanning speed) according to the type of material to be discharged, and a three-dimensional structure with a desired quality can be obtained. However, it is not limited to such a configuration, instead of the laser irradiation unit 1300, an energy applying unit that applies heat generated by arc discharge is provided, and the layers 501, 502, 503,. It is good also as a structure hardened by fuse | melting or sintering 50n. Needless to say, for example, the material to be discharged can be sintered and solidified, or melted and solidified. In other words, the material to be discharged may be a sintered material, a molten material, or a solidified material that is solidified by other methods.

  As shown in FIG. 1, the constituent material discharge unit 1230 is connected by a constituent material supply unit 1210 that stores constituent materials corresponding to each of the head units 1400 held by the head base 1100 and a supply tube 1220. . Then, a predetermined constituent material is supplied from the constituent material supply unit 1210 to the constituent material discharge unit 1230. The constituent material supply unit 1210 is supplied with a material (a paste-like constituent material containing metal particles (component layer forming particles)) including the raw material of the three-dimensional structure 500 formed by the forming apparatus 2000 according to the present embodiment. It is accommodated in the constituent material accommodating part 1210a as a material, and each constituent material accommodating part 1210a is connected to each constituent material discharge part 1230 by the supply tube 1220. In this manner, by providing the individual constituent material accommodating portions 1210a, a plurality of different types of materials can be supplied from the head base 1100.

  As shown in FIG. 2, the support layer forming material discharge unit 1730 has a support layer forming material supply unit 1710 that contains a support layer forming material corresponding to each head unit 1900 held by the head base 1600. And a supply tube 1720. Then, a predetermined support layer forming material is supplied from the support layer forming material supply unit 1710 to the support layer forming material discharge unit 1730. The support layer forming material supply unit 1710 includes a support layer forming material (ceramic particles (support layer forming particles)) that forms a support layer when the three-dimensional structure 500 is formed. Material) is accommodated as a supply material in a support layer forming material accommodating portion 1710a, and each support layer forming material accommodating portion 1710a is connected to each support layer forming material discharging portion 1730 by a supply tube 1720. . As described above, by providing the individual support layer forming material accommodating portions 1710 a, a plurality of different types of support layer forming materials can be supplied from the head base 1600.

For example, magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni) ) Or a mixed powder such as an alloy containing one or more of these metals (maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy) and a solvent. In addition, it can be used as a slurry (or paste) mixed material containing a binder.
In addition, general-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can be used. In addition, engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
Thus, there is no limitation in particular in a constituent material, Metals other than the said metal, ceramics, resin, etc. can be used.
Examples of the solvent include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, acetic acid acetates such as iso-propyl, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, acetylacetone Ketones such as ethanol; alcohols such as ethanol, propanol, butanol; tetraalkylammonium acetates; dimethyl sulfoxide, diethyl sulfoxide, etc. One type selected from these, including phosphine solvents; pyridine solvents such as pyridine, γ-picoline, and 2,6-lutidine; and ionic liquids such as tetraalkylammonium acetate (for example, tetrabutylammonium acetate). Alternatively, two or more kinds can be used in combination.
Examples of the binder include acrylic resin, epoxy resin, silicone resin, cellulosic resin, other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), and other thermoplastic resins.

In the present embodiment, the support layer forming material contains ceramics. As the support layer forming material, it is possible to use, for example, a slurry (or paste) mixed material containing a mixed powder of metal oxide, metal alkoxide, metal or the like, a solvent, and a binder.
However, the material for forming the support layer is not particularly limited, and metals, resins, and the like other than ceramics, such as the examples of the constituent materials described above, can be used.

  The forming apparatus 2000 includes a constituent material discharge unit 1230 provided in the above-described stage 120 and constituent material supply apparatus 1200 based on modeling data of a three-dimensional structure that is output from a data output device such as a personal computer (not shown). And a laser irradiation unit 1300 and a control unit 400 as control means for controlling the support layer forming material discharge unit 1730 provided in the support layer forming material supply apparatus 1700. Although not shown, the control unit 400 controls the stage 120, the constituent material discharge unit 1230 and the laser irradiation unit 1300, and the stage 120 and the support layer forming material supply device 1700 to be driven and operated in cooperation. A control unit is provided.

The stage 120 movably provided on the base 110 is a signal for controlling the start and stop of movement of the stage 120, the movement direction, the movement amount, the movement speed, and the like in the stage controller 410 based on the control signal from the control unit 400. Is sent to the drive device 111 provided in the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The constituent material discharge unit 1230 provided in the head unit 1400 controls the material discharge amount from the discharge nozzle 1230a in the discharge drive unit 1230b provided in the constituent material discharge unit 1230 in the material supply controller 1500 based on the control signal from the control unit 400. And a predetermined amount of the constituent material is discharged from the discharge nozzle 1230a by the generated signal.
Similarly, in the support layer forming material discharge unit 1730 provided in the head unit 1900, the discharge nozzle in the discharge drive unit 1730 b provided in the support layer forming material discharge unit 1730 in the material supply controller 1500 based on the control signal from the control unit 400. A signal for controlling the material discharge amount and the like from the 1730a is generated, and a predetermined amount of the support layer forming material is discharged from the discharge nozzle 1730a by the generated signal.

Further, the laser irradiation unit 1300 receives a control signal from the control unit 400 to the laser controller 430, and sends an output signal for irradiating a laser to any or all of the plurality of laser irradiation units 1300 from the laser controller 430.
Here, the laser irradiation from the laser irradiation unit 1300 is synchronized with the drive signal of the stage 120 by the stage controller 410, and is synchronized with the drive signal of the stage 120 by the stage controller 410, and the layers 501, 502, 503,. Controlled to irradiate a desired area of 50n.

Next, the head unit 1400 will be described in more detail. The head unit 1900 is the same as the head unit 1400 except that the laser irradiation unit 1300 is not provided and the support layer forming material discharge unit 1730 is configured in the same arrangement instead of the constituent material discharge unit 1230. It is the same composition. Therefore, a detailed description of the configuration of the head unit 1900 is omitted.
3 and 4 show an example of a holding form of the head unit 1400 held by the head base 1100 and the laser irradiation unit 1300 and the constituent material discharge unit 1230 held by the head unit 1400. Of these, FIG. It is an external view of the head base 1100 from the arrow D direction shown in FIG.
The following explanation is an example of melting and solidifying a desired region of the layers 501, 502, 503,... 50n, and sintering the desired region at a temperature lower than the temperature at the time of melting. It may be hardened.

As shown in FIG. 3, a plurality of head units 1400 are held on a head base 1100 by fixing means (not shown). Further, as shown in FIG. 4, in the head base 1100 of the forming apparatus 2000 according to the present embodiment, the first row head unit 1401, the second row head unit 1402, the third row from the bottom of the drawing. The head unit 1403 and the head unit 1404 in the fourth row are provided with a head unit 1400 in which four units are arranged in a staggered manner. 4A, the constituent material is discharged from each head unit 1400 while moving the stage 120 in the X direction with respect to the head base 1100, and the laser L is irradiated from the laser irradiation unit 1300. Thus, the melting part 50 (melting parts 50a, 50b, 50c and 50d) is formed. The formation procedure of the melting part 50 will be described later.
Although not shown, the constituent material discharge unit 1230 included in each of the head units 1401 to 1404 is connected to the constituent material supply unit 1210 via the discharge driving unit 1230b by a supply tube 1220, and the laser irradiation unit 1300 is connected to the laser controller 430. And is held by the holding jig 1400a.

  As shown in FIG. 3, the constituent material discharge unit 1230 discharges the material M, which is a constituent material of the three-dimensional structure, from the discharge nozzle 1230 a toward the sample plate 121 placed on the stage 120. The head unit 1401 illustrates a discharge form in which the material M is discharged in the form of droplets, and the head unit 1402 illustrates a discharge form in which the material M is supplied in a continuous form. The discharge form of the material M in the forming apparatus 2000 of the present embodiment is a droplet shape. However, it is also possible to use a part of the discharge nozzles 1230a that is continuous and capable of supplying constituent materials.

The material M discharged in the form of droplets from the discharge nozzle 1230a flies in a substantially gravitational direction and lands on the sample plate 121. The laser irradiation unit 1300 is held by a holding jig 1400a. Along with the movement of the stage 120, when the material M landed on the sample plate 121 enters the laser irradiation range, the material M melts and solidifies outside the laser irradiation range to form the melting part 50. The aggregate of the melting portions 50 is formed as a molten layer 310 (see FIG. 1) of the three-dimensional structure 500 formed on the sample plate 121.
However, instead of immediately irradiating the laser M from the laser irradiation unit 1300 to the material M ejected in the form of droplets from the ejection nozzle 1230a, the material M is ejected from the ejection nozzle 1230a and one layer is formed. It is also possible to irradiate the entire layer with the laser L while moving the laser irradiation unit 1300 after forming the minute layer.

Next, the formation procedure of the fusion | melting part 50 is demonstrated using FIG.4 and FIG.5.
FIG. 4 is a plan view for conceptually explaining the relationship between the arrangement of the head unit 1400 of the present embodiment and the formation form of the melting portion 50. FIG. 5 is a plan view conceptually showing the formation form of the melting part 50.

  First, when the stage 120 moves in the + X direction, the material M is discharged in droplets from the plurality of discharge nozzles 1230 a, and the material M is disposed at a predetermined position on the sample plate 121. When the stage 120 further moves in the + X direction, the material M is melted by entering the irradiation range of the laser L irradiated from the laser irradiation unit 1300. When the stage 120 further moves in the + X direction, the material M becomes out of the irradiation range of the laser L and solidifies to form the melted part 50.

  More specifically, as shown in FIG. 5A, first, the material M is moved from the plurality of discharge nozzles 1230a to a predetermined position of the sample plate 121 at a predetermined interval while moving the stage 120 in the + X direction. Arrange.

Next, as shown in FIG. 5B, a new material M is newly filled so as to fill the space between the materials M arranged at regular intervals while moving the stage 120 in the −X direction shown in FIG. Arrange. Then, when the stage 120 is continuously moved in the −X direction, the material M enters the irradiation range of the laser L and is melted (the melting portion 50 is formed).
Note that the time from when the material M is placed at a predetermined position until it enters the irradiation range of the laser L can be adjusted by the moving speed of the stage 120. For example, when the material M contains a solvent, drying of the solvent can be promoted by slowing the moving speed of the stage 120 and lengthening the time until it enters the irradiation range.
In addition, while moving the stage 120 in the + X direction, the material M is arranged from a plurality of discharge nozzles 1230a at predetermined positions on the sample plate 121 (so as not to be spaced apart) and moved in the same direction. A configuration that falls within the irradiation range of the laser L as it is (a configuration in which the melting portion 50 is not formed by the reciprocating movement of the stage 120 in the X direction, but a melting portion 50 is formed only by one side movement of the stage 120 in the X direction). Also good.

  By forming the melted portion 50 as described above, one head unit 1401, 1402, 1403, and 1404 in the X direction (first line in the Y direction) as shown in FIG. 4A. Are formed (melting parts 50a, 50b, 50c and 50d).

Next, the head base 1100 is moved in the −Y direction in order to form the melting part 50 (melting parts 50a, 50b, 50c, and 50d) of the second line in the Y direction of each head unit 1401, 1402, 1403, and 1404. . When the pitch between the nozzles is P, the movement amount is moved in the −Y direction by P / n (n is a natural number) pitch. In this embodiment, n is assumed to be 3.
By performing the same operation as described above as shown in FIG. 5A and FIG. 5B, the melted part 50 in the second line in the Y direction as shown in FIG. 4B. '(Melting part 50a', 50b ', 50c' and 50d ') is formed.

Next, the head base 1100 is moved in the −Y direction in order to form the melting part 50 (melting parts 50a, 50b, 50c, and 50d) of the third line in the Y direction of each head unit 1401, 1402, 1403, and 1404. . The movement amount is moved in the −Y direction by P / 3 pitch.
Then, by performing the same operation as described above as shown in FIG. 5A and FIG. 5B, the third line in the Y direction is melted as shown in FIG. 4C. Part 50 ''
(Melted portions 50a ″, 50b ″, 50c ″ and 50d ″) are formed, and the molten layer 310 can be obtained.

  In addition, the material M discharged from the component material discharge unit 1230 can be discharged from one of the head units 1401, 1402, 1403, and 1404, or a component material different from the other head units. Therefore, by using the forming apparatus 2000 according to this embodiment, a three-dimensional structure formed from different materials can be obtained.

  Note that in the first layer 501, before or after forming the melt layer 310 as described above, the support layer forming material is discharged from the support layer forming material discharge unit 1730 to melt the discharged material. The support layer 300 can be formed by the same method except that it does not. The support layer 300 is desirably in a sintered state. When the layers 502, 503,... 50n are stacked on the layer 501, the molten layer 310 and the support layer 300 can be formed in the same manner. Here, the layer (support layer 300) formed using the support layer forming material discharge unit 1730 is thinner than the layer (melt layer 310) formed using the constituent material discharge unit 1230 (from FIG. 7). FIG. 11).

  The number and arrangement of the head units 1400 and 1900 included in the forming apparatus 2000 according to the above-described embodiment are not limited to the above-described number and arrangement. FIG. 6 schematically shows an example of another arrangement of the head unit 1400 arranged on the head base 1100 as an example.

  FIG. 6A shows a form in which a plurality of head units 1400 are arranged in parallel with the head base 1100 in the X-axis direction. FIG. 6B shows a form in which the head units 1400 are arranged in a lattice pattern on the head base 1100. Note that the number of head units arranged in each case is not limited to the example shown.

Next, an example of a method for manufacturing a three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 7 is a schematic diagram illustrating an example of a manufacturing process of a three-dimensional structure that is performed using the forming apparatus 2000. Here, FIG. 7 represents an example of a manufacturing process in forming the completed body O of the three-dimensional structure having the shape represented in FIG.

First, from the state shown in FIG. 7A, the support layer forming material is discharged from the support layer forming material discharge unit 1730 as shown in FIG. A thin first support layer 300 is formed. Here, the support layer 300 is formed in an area (non-formation area of the three-dimensional structure) other than the formation area of the three-dimensional structure (area corresponding to the molten layer 310) in the layer.
Next, as shown in FIG. 7C, the support layer forming material is discharged from the support layer forming material discharge unit 1730, and the second layer having a relatively thin thickness is supported. Layer 300 is formed.

Next, as shown in FIG. 7D, a part corresponding to the formation region of the three-dimensional structure is formed by discharging the constituent material from the constituent material discharging unit 1230 and irradiating the laser L from the laser irradiation unit 1300. Then, the molten layer 310 having a relatively thick layer is formed.
As shown in FIG. 7D, the molten layer 310 formed by discharging the constituent material from the constituent material discharging unit 1230 and irradiating the laser L from the laser irradiation unit 1300 is a support layer forming material. The thickness is twice that of the support layer 300 formed by discharging the support layer forming material from the discharge portion 1730. However, as will be described later, the forming apparatus 2000 of the present embodiment can also form the molten layer 310 and the support layer 300 such that the melt layer 310 is three times as thick as the support layer 300 (FIG. 8). And FIG. 9).

Next, as shown in FIG. 7E, the support layer forming material is discharged from the support layer forming material discharge unit 1730 to form the support layer 300 having a relatively thin layer thickness. Here, the support layer 300 at this time is also formed in a region other than the formation region of the three-dimensional structure (region corresponding to the molten layer 310).
Next, as illustrated in FIG. 7F, the support layer forming material is discharged from the support layer forming material discharge unit 1730 to form the support layer 300 having a relatively thin layer thickness.
Next, as shown in FIG. 7G, a portion corresponding to the formation region of the three-dimensional structure is formed by discharging the constituent material from the constituent material discharge unit 1230 and irradiating the laser L from the laser irradiation unit 1300. Then, the molten layer 310 having a relatively thick layer is formed.

Next, as shown in FIGS. 7H to 7J, as in FIGS. 7E to 7G, a relatively thin support layer 300 and a relatively thin layer are formed. A thick molten layer 310 is formed.
In this way, the completed body O of the three-dimensional structure is completed. In FIG. 7 (k), the three-dimensional structure complete body O is removed from the sample plate 121, and the three-dimensional structure complete body O is developed (the support layer 300 is removed from the three-dimensional structure complete body O). )).

  Further, as shown in FIG. 7 (j) and the like, in this embodiment, the support layer 300 has an undercut portion (a portion that is convex in the XY plane direction with respect to the lower layer) in the upper layer. As a support layer in the lower layer, it is a layer (so-called support layer) capable of supporting this. However, the support layer is not limited to such a support layer. For example, the support layer is a layer formed on the entire upper surface of the sample plate 121 and can support the molten layer 310 in the first layer. Possible layers (so-called release layers) may be used. By providing such a release layer, it is possible to reduce (easily) post-processes associated with removing the completed three-dimensional object O from the sample plate 121. In the lower layer, the material M may be sintered by irradiating the laser L from the laser irradiation part.

Next, another example of the manufacturing method of the three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 8 is a schematic diagram illustrating a part of an example of a manufacturing process of a three-dimensional structure performed using the forming apparatus 2000. In FIG. 8, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the molten layer 310 can be easily understood.
Here, in the manufacturing method of the three-dimensional structure illustrated in FIG. 7, when forming the molten layer 310, the laser irradiation unit 1300 emits the laser L as soon as the constituent material is ejected from the constituent material ejection unit 1230. The constituent material was melted for each droplet. On the other hand, this manufacturing method of the three-dimensional structure shown in FIG. 8 includes one layer of molten layer 310 (specifically, a support layer 300 corresponding to one layer of molten layer 310 and one layer of molten layer 310). ) Is formed, and then the entire layer is irradiated with thermal energy from the energy irradiation unit 1300 and melted layer by layer.

First, as shown in FIG. 8A, the support layer forming material is discharged from the support layer forming material discharge unit 1730, so that the first support layer 300 having a relatively thin layer thickness is formed. Form. Here, the support layer 300 is formed in a region other than the formation region of the three-dimensional structure in the layer (region corresponding to the molten layer 310).
Next, as shown in FIG. 8B, the support layer forming material is discharged from the support layer forming material discharge unit 1730, and the second layer having a relatively thin thickness is supported. Layer 300 is formed.
Next, as shown in FIG. 8C, the support layer forming material is discharged from the support layer forming material discharge unit 1730, and the third layer having a relatively small thickness is supported. Layer 300 is formed.

Then, as shown in FIG. 8D, the constituent material is discharged from the constituent material discharge unit 1230, and the layer thickness is relatively thick at the portion corresponding to the formation region of the three-dimensional structure. Then, the molten layer 310 is formed.
As shown in FIG. 8D, the thickness H2 of the melted layer 310 before melting constituted by discharging the constituent material from the constituent material discharging unit 1230 is supported by the support layer forming material discharging unit 1730. It is thicker than the thickness H1 of the support layer 300 for three layers constituted by discharging the layer forming material. Here, in the forming method of the present embodiment, the molten layer 310 and the support layer 300 are formed so that the melt layer 310 is three times as thick as the support layer 300.
Here, as shown in FIG. 8E, next, the entire layer formed by the steps shown in FIGS. 8A to 8D is irradiated with the laser L from the laser irradiation unit 1300. Thus, the molten layer 310 is melted. At this time, the support layer 300 is sintered by the laser L irradiation. Then, by irradiation of the laser L to the entire layer, the thickness H2 ′ of the molten layer 310 after melting becomes equal to the thickness H1 ′ of the support layer 300 after sintering.
Thus, a desired three-dimensional structure can be manufactured by repeating the steps shown in FIGS. 8A to 8E.

Next, another example of the manufacturing method of the three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 9 is a schematic diagram illustrating a part of an example of a manufacturing process of a three-dimensional structure performed using the forming apparatus 2000. In FIG. 9, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the molten layer 310 can be easily understood.
Here, in the manufacturing method of the three-dimensional structure represented by FIGS. 7 and 8, when forming the molten layer 310, the laser L is irradiated from the laser irradiation unit 1300 to melt the constituent materials. On the other hand, the present manufacturing method of the three-dimensional structure shown in FIG. 9 was provided separately from the forming apparatus 2000 after forming the shape of the three-dimensional structure without irradiating the laser L from the laser irradiation unit 1300. This is an example in which a three-dimensional structure is melted by heating in a thermostat not shown.

FIG. 9A shows a formed product formed by the same method as the method for manufacturing the three-dimensional structure shown in FIG. 8 except that the laser L is not irradiated from the laser irradiation unit 1300. Here, the molten layer 310 before melting corresponds to the formation region of the three-dimensional structure, and the support layer 300 before sintering corresponds to the non-formation region of the three-dimensional structure.
And FIG.9 (b) represents the state which heated the formation represented by Fig.9 (a) in the thermostat not shown. As shown in FIG. 9B, the three-dimensional structure formation region (molten layer 310) is melted to form a three-dimensional structure complete body O, and the surrounding support layer 300 is sintered. . The heating temperature in the thermostatic bath is set to a temperature at which the metal particles contained in the constituent material are melted or higher and the ceramic particles contained in the support layer forming material are sintered without melting.

Next, another example of the manufacturing method of the three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 10 is a schematic diagram illustrating a part of an example of a manufacturing process of a three-dimensional structure performed using the forming apparatus 2000. In FIG. 10, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the molten layer 310 can be easily understood.
Here, in the manufacturing method of the three-dimensional structure represented by FIGS. 7 to 9, the thickness of one layer of the molten layer 310 is thicker than the thickness of one layer of the support layer 300. On the other hand, the present manufacturing method of the three-dimensional structure shown in FIG. 10 is an example in which the thickness of one layer of the support layer 300 is equal to the thickness of one layer of the molten layer 310. However, the viscosity of the constituent material is lower than the viscosity of the support layer forming material, and the spread of the XY plane of the droplet of the constituent material is larger than the spread of the XY plane of the droplet of the support layer forming material. . For this reason, the droplets of the constituent material are larger than the droplets of the material for forming the support layer.

First, as shown in FIG. 10A, the support layer forming material is discharged from the support layer forming material discharge unit 1730 to form the first support layer 300. Here, the support layer 300 is formed in a region other than the formation region of the three-dimensional structure in the layer (region corresponding to the molten layer 310).
Next, as illustrated in FIG. 10B, the constituent material is discharged from the constituent material discharge unit 1230 to form the molten layer 310 in a portion corresponding to the formation region of the three-dimensional structure. FIG. 10B shows a state immediately after the landing of the constituent material droplets.
Then, as shown in FIG. 10C, the constituent material droplets spread in the XY plane direction. However, since the droplet of the constituent material is larger than the droplet of the material for forming the support layer, the thickness H2 of the molten layer 310 is larger than the thickness H1 of the support layer 300.

Then, as shown in FIG. 10 (d), the entire layer formed by the steps shown in FIGS. 10 (a) to 10 (c) is irradiated with laser L from the laser irradiation unit 1300. Thus, the molten layer 310 is melted. At this time, the support layer 300 is sintered by the laser L irradiation. Then, by irradiation of the laser L to the entire layer, the thickness H2 ′ of the molten layer 310 after melting becomes equal to the thickness H1 ′ of the support layer 300 after sintering.
Thus, a desired three-dimensional structure can be manufactured by repeating the steps shown in FIGS. 10A to 10D.

Next, still another example of the method for manufacturing a three-dimensional structure performed using the forming apparatus 2000 according to the above-described embodiment will be described.
FIG. 11 is a schematic diagram illustrating a part of an example of a manufacturing process of a three-dimensional structure performed using the forming apparatus 2000. In FIG. 11, a plurality of auxiliary lines are drawn in the Z direction so that the thicknesses of the support layer 300 and the molten layer 310 can be easily understood.
Here, the manufacturing method of the three-dimensional structure according to the present embodiment shown in FIG. 11 is the formation apparatus 2000 after forming the shape of the three-dimensional structure without irradiating the laser L from the laser irradiation unit 1300. This is an example in which a three-dimensional structure is melted by heating in a thermostat (not shown) provided separately, and the thickness of one layer of the support layer 300 and the thickness of one layer of the molten layer 310 are equivalent. An example.

FIG. 11A shows a three-dimensional structure formed by the same method as the three-dimensional structure manufacturing method shown in FIG. 10 except that the laser irradiation unit 1300 does not irradiate the laser L. Represents. Here, the molten layer 310 before melting corresponds to the formation region of the three-dimensional structure, and the support layer 300 before sintering corresponds to the non-formation region of the three-dimensional structure.
And FIG.11 (b) represents the state which heated the formation represented by Fig.11 (a) in the thermostat not shown. As shown in FIG. 11B, the three-dimensional structure formation region (melted layer 310) is melted to form a three-dimensional structure complete body O, and the surrounding support layer 300 is sintered. . The heating temperature in the thermostatic bath is set to a temperature at which the metal particles contained in the constituent material are melted or higher and the ceramic particles contained in the support layer forming material are sintered without melting.

Next, an example of a method for producing a three-dimensional structure performed using the forming apparatus 2000 (an example corresponding to FIG. 11) will be described using a flowchart.
Here, FIG. 12 is a flowchart of the manufacturing method of the three-dimensional structure according to the present embodiment.
In addition, although this example is an example of the manufacturing method of the three-dimensional structure corresponding to FIG. 11, the manufacturing method of the three-dimensional structure corresponding to FIGS. Is possible.

  As shown in FIG. 12, in the three-dimensional structure manufacturing method of this embodiment, first, in step S110, data of the three-dimensional structure is acquired. Specifically, for example, data representing the shape of the three-dimensional structure is acquired from an application program or the like executed on a personal computer.

Next, in step S120, data for each layer is created. Specifically, in the data representing the shape of the three-dimensional structure, it is sliced according to the modeling resolution in the Z direction, and bitmap data (cross section data) is generated for each section.
At this time, the generated bitmap data is data that is distinguished by the formation region of the three-dimensional structure and the non-formation region of the three-dimensional structure. In other words, a region composed of droplets (small dots) with a relatively small dot diameter ejected from the support layer forming material ejection unit 1730 and a relative ejection from the component material ejection unit 1230. The data is formed so that a region composed of droplets (large dots) having a large dot diameter is distinguished for each layer.
Although there is no particular limitation on the difference in size between the large dots and the small dots, a high-precision three-dimensional structure is manufactured particularly effectively and quickly by making the large dots eight times or more the small dots. It becomes possible.

Next, in step S130, the data of the layer to be formed is data for forming a non-formation region (support layer 300) of the three-dimensional structure or data for forming a formation region (melt layer 310) of the three-dimensional structure. Determine whether. Note that. This determination is made by a control unit provided in the control unit 400.
If it is determined in this step that the data forms the support layer 300, the process proceeds to step S 140, and if it is determined that the data forms the melt layer 310, the process proceeds to step S 150.

In step S140, the support layer forming material is supplied in small dots by discharging the support layer forming material from the support layer forming material discharge unit 1730 based on the data for forming the support layer 300.
On the other hand, in step S150, the constituent material is supplied from the constituent material discharge unit 1230, thereby supplying the constituent material with large dots.
In step S160, steps S130 to S160 are repeated until the modeling of the three-dimensional structure based on the bitmap data corresponding to each layer generated in step S120 is completed.

And by step S170, in the thermostat not shown, the three-dimensional structure before melting formed in the above step is melted by heating (giving energy). In detail, the formation area (molten layer 310) of the three-dimensional structure is melted, and the surrounding support layer 300 is sintered.
In addition, also in the example of the manufacturing method of the three-dimensional structure corresponding to FIG. 9, this step can be similarly provided. Moreover, in the example of the manufacturing method of the three-dimensional structure corresponding to FIG. 7, this step can be provided after step S150. Moreover, in the example of the manufacturing method of the three-dimensional structure corresponding to FIG.8 and FIG.10, the step which judges whether the constituent material was supplied with respect to the molten layer 310 for one layer before step S160 is determined. When it is determined that the constituent material is supplied to the molten layer 310 for one layer, this step can be provided to be executable.

  When the modeling of the three-dimensional structure is completed, the three-dimensional structure is developed in step S180, and the three-dimensional structure manufacturing method of this embodiment is completed.

As described above, in the method of manufacturing a three-dimensional structure according to the present embodiment, the fluid composition containing particles is ejected from the ejection unit in the form of droplets to form a layer (from step S130 to step S170). )have. The layer forming step includes a constituent layer forming step (step S150) for forming a constituent layer (molten layer 310) corresponding to the constituent region of the three-dimensional structure, and a support for supporting the molten layer 310 in contact with the molten layer 310. And a support layer forming step (step S140) for forming the layer 300. Then, at least some of the droplets when forming the support layer 300 in the support layer forming step are smaller than at least some of the droplets when forming the molten layer 310 in the constituent layer forming step.
As described above, in the method for manufacturing a three-dimensional structure according to the present embodiment, the support layer 300 is formed with droplets smaller than the droplets used when the molten layer 310 is formed. That is, the support layer 300 that determines the shape of the contour of the three-dimensional structure is formed with relatively small droplets, and the molten layer 310 that forms the inside of the three-dimensional structure is formed with relatively large droplets. For this reason, while being able to form the support layer 300 which determines the shape of the outline which needs to be formed with high precision in the three-dimensional structure, it is possible to form with high precision, and it is not necessary to form the support layer 300 with high precision in the three-dimensional structure. Can be formed quickly. Therefore, a highly accurate three-dimensional structure can be manufactured quickly.

In other words, the forming apparatus 2000 according to the present embodiment discharges the fluid composition containing particles in the form of droplets (the constituent material discharge unit 1230 and the support layer forming material discharge unit 1730). And a control unit provided in the control unit 400 for controlling to form a layer by discharging droplets from the discharge unit. When the control unit forms the support layer 300, the constituent layer (the molten layer 310) corresponding to the constituent region of the three-dimensional structure and the support layer 300 that contacts the molten layer 310 and supports the molten layer 310 are formed. Control is performed so that at least some of the droplets are smaller than at least some of the droplets when the molten layer 310 is formed.
As described above, the forming apparatus 2000 of the present embodiment forms the support layer 300 with droplets smaller than the droplets used when forming the molten layer 310. That is, the support layer 300 that determines the shape of the contour of the three-dimensional structure is formed with relatively small droplets, and the molten layer 310 that forms the inside of the three-dimensional structure is formed with relatively large droplets. For this reason, while being able to form the support layer 300 which determines the shape of the outline which needs to be formed with high precision in the three-dimensional structure, it is possible to form with high precision, and it is not necessary to form the support layer 300 with high precision in the three-dimensional structure. Can be formed quickly. Therefore, a highly accurate three-dimensional structure can be manufactured quickly.

Further, in the method of manufacturing a three-dimensional structure according to the present embodiment, the layer forming step discharges droplets of different sizes as the discharge unit, the first discharge unit (support layer forming material discharge unit 1730) and the first discharge unit. It can be expressed that it is executed by using two discharge units (constituent material discharge unit 1230). For this reason, it is possible to easily discharge relatively large droplets and relatively small droplets.
Note that “discharging droplets of different sizes” means that both the first discharge unit and the second discharge unit can discharge one type of droplet, and the size of each droplet is different. It does not mean only a case. For example, at least one of the first ejection unit and the second ejection unit can eject a plurality of sizes (for example, the first ejection unit can eject droplets of 50, 100, and 150 pl, and the second ejection unit has 50, 150, and 300 pl). Meaning that the size of droplets that can be ejected from the first ejection unit and the second ejection unit is partially the same (for example, 50 pl). It is.
The correspondence relationship between the support layer forming material discharge unit 1730 and the constituent material discharge unit 1230 and the first discharge unit and the second discharge unit may be reversed.

  Moreover, the manufacturing method of the three-dimensional structure according to the present embodiment includes a stacking process in which the layer forming process is repeated in the stacking direction, as represented by repeating steps S130 to S160 in FIG. For this reason, a three-dimensional structure can be easily manufactured by laminating layers.

Moreover, the layer formation process of the manufacturing method of the three-dimensional structure according to the present embodiment includes a bonding process for bonding particles, which corresponds to step S170. For this reason, it becomes possible to manufacture a sturdy three-dimensional structure.
Note that “bonding particles” includes, for example, melting particles as in the present embodiment, sintering particles, and the like. Further, the particles may be bonded by containing a thermosetting resin or a photocurable resin in a fluid composition (constituent material) containing particles and curing the resin.

In addition, the bonding step of the method for manufacturing a three-dimensional structure according to the present embodiment is performed by applying energy to the molten layer 310 or the molten layer 310 and the support layer 300, and for forming the molten layer 310 included in the constituent material. The binding force due to the application of energy in the particles (metal particles) is the bonding force due to melting, and the energy in the particles for forming the support layer 300 (ceramic particles) included in the fluid composition forming the support layer 300 is not applied. Than the bonding force (corresponding to the embodiment shown in FIGS. 8 to 11) by the sintering by applying energy in the particles for forming the support layer 300 (corresponding to the embodiment shown in FIGS. 8 to 11). strong. For this reason, the particles for forming the molten layer 310 can be bonded relatively strongly, and a sturdy three-dimensional structure can be manufactured.
The example in which the bonding force of the particles for forming the molten layer 310 is stronger than the bonding force of the particles for forming the support layer 300 is not limited to this example. For example, when the bonding force of the particles for forming the molten layer 310 is a bonding force due to sintering and the bonding force of the particles for forming the support layer 300 is only a binding force due to components contained in the fluid composition, For example, the bonding force of the particles for bonding is a bonding force by sintering, and the bonding force of the particles for forming the support layer 300 is a bonding force by curing of the curable resin.

  Moreover, the layer formation process of the manufacturing method of the three-dimensional structure according to the present embodiment executes the support layer formation process a plurality of times to form a plurality of support layers 300, and executes the constituent layer formation process to form the plurality of layers. The melt layer 310 corresponding to the thickness of the plurality of layers is formed in the corresponding region, and the constituent layer forming particles corresponding to the plurality of layers can be bound by executing a joining step. That is, the number of constituent layer forming steps can be reduced. For this reason, a highly accurate three-dimensional structure can be manufactured particularly quickly.

  Further, in the layer forming step of the method for manufacturing a three-dimensional structure according to the present embodiment, after the bonding step, the droplets are formed so that the thickness of the molten layer 310 and the thickness of the support layer 300 corresponding to the molten layer 310 are aligned. The size has been adjusted. For this reason, the adjustment of the layer thickness accompanying the different layer thickness of the support layer 300 and the molten layer 310 becomes unnecessary, and a highly accurate three-dimensional structure can be manufactured easily.

  9 and 11 is performed by heating the molten layer 310 and the support layer 300 in the joining process of the manufacturing method of the three-dimensional structure according to the present embodiment. The heating temperature is not less than the melting point of the particles for forming the melt layer 310 and not more than the melting point of the particles for forming the support layer 300. Therefore, the melted layer 310 three-dimensional structure) can be melted without melting the support layer 300, so that the completed three-dimensional structure can be easily detached from the support layer 300.

  On the other hand, the heating temperature in the joining step may be equal to or higher than the sintering temperature of the constituent layer forming particles of the three-dimensional structure, and may be equal to or lower than the sintering temperature of the support layer 300 forming particles. Also in this way, the constituent layer (three-dimensional structure) can be sintered without sintering the support layer 300, and thus the completed three-dimensional structure can be easily removed from the support layer.

  Further, in the forming apparatus 2000 of the present embodiment, the particle size of the support layer 300 forming particles is smaller than the particle size of the molten layer 310 forming particles. For this reason, the support layer 300 which determines the shape of the outline which needs to be formed with high accuracy in the three-dimensional structure can be formed with high accuracy with particles having a relatively small particle diameter. Therefore, a highly accurate three-dimensional structure can be manufactured.

  Further, the particles for forming the molten layer 310 and the particles for forming the support layer 300 are not particularly limited, such as metal particles, ceramic particles, and resin particles, but the particles for forming the support layer 310 may be silica, alumina, titanium oxide, or zircon oxide. It is a particle containing at least any one component, and the particles for forming the molten layer 310 are preferably particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel. . By the energy application step, the constituent material particles can be easily melted and the support member forming particles can be easily controlled to have a low sintered density. Alternatively, it can be easily controlled so that the constituent material particles are sintered and the support member forming particles are not sintered. This is because it is possible to suppress an increase in loads such as a separation operation when removing the three-dimensional structure and a forming operation after removal while securing the strength of the three-dimensional structure.

  The present invention is not limited to the above-described embodiments, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features in the embodiments corresponding to the technical features in the embodiments described in the summary section of the invention are intended to solve part or all of the above-described problems, or one of the above-described effects. In order to achieve part or all, replacement or combination can be appropriately performed. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

50, 50a, 50b, 50c, 50d, 50e, 50f, 50g and 50h melting part,
110 base, 111 driving device, 120 stage (support),
121 sample plate, 130 head base support,
300 support layer, 310 melt layer (component layer), 400 control unit (control unit),
410 stage controller, 430 laser controller,
500 three-dimensional structure, 501, 502 and 503 layers,
730 head base support, 1100 head base,
1200 component material supply device, 1210 component material supply unit,
1210a Constituent material container, 1220 Supply tube,
1230 Constituent material discharge part (discharge part, second discharge part), 1230a discharge nozzle,
1230b discharge drive unit, 1300 energy irradiation unit (laser irradiation unit),
1400, 1401, 1402, 1403, 1404, 1405, 1406, 1407 and 1408 head units,
1400a holding jig, 1500 material supply controller,
1600 head base, 1700 support layer forming material supply device,
1710 support layer forming material supply unit, 1710a support layer forming material container,
1720 supply tube,
1730 support layer forming material discharge portion (discharge portion, first discharge portion),
1730a discharge nozzle, 1730b discharge drive unit, 1900, head unit,
1900a holding jig, 2000 forming device (manufacturing device for three-dimensional structure),
3000 Galvano mirror, 3100 laser irradiation part, L laser,
M material (constituent material), O Completed 3D object

Claims (12)

A layer forming step of forming a layer by discharging a fluid composition containing particles from a discharge unit in a droplet state;
The layer forming step includes
A constituent layer forming step of forming a constituent layer corresponding to the constituent area of the three-dimensional structure;
Forming a support layer in contact with the constituent layer and supporting the constituent layer, and
At least some of the droplets when forming the support layer in the support layer forming step are smaller than at least some of the droplets when forming the constituent layer in the constituent layer forming step. A manufacturing method of a three-dimensional structure. In the manufacturing method of the three-dimensional structure described in claim 1,
The method for producing a three-dimensional structure is characterized in that the layer forming step is performed using a first discharge unit and a second discharge unit that discharge droplets of different sizes as the discharge unit. In the manufacturing method of the three-dimensional structure according to claim 1 or 2,
The manufacturing method of the three-dimensional structure characterized by including the lamination process which repeats the said layer formation process in a lamination direction. In the manufacturing method of the three-dimensional structure according to any one of claims 1 to 3,
The method for producing a three-dimensional structure is characterized in that the layer forming step includes a joining step for joining the constituent layer forming particles contained in the flowable composition forming the constituent layer. In the manufacturing method of the three-dimensional structure described in claim 4,
The bonding step is performed by applying energy to the constituent layer or the constituent layer and the support layer,
A three-dimensional structure characterized in that the binding force by the application of energy in the constituent layer forming particles is stronger than the binding force in the support layer forming particles contained in the fluid composition forming the support layer. Manufacturing method. In the manufacturing method of the three-dimensional structure according to claim 4 or 5,
The layer forming step includes
The support layer forming step is performed a plurality of times to form a plurality of the support layers,
Performing the constituent layer forming step to form the constituent layer corresponding to the thickness of the plural layers in a region corresponding to the plural layers;
The manufacturing method of the three-dimensional structure characterized by performing the said joint process and couple | bonding the said particle for structure layer formation corresponding to the said multiple layers. In the manufacturing method of the three-dimensional structure according to any one of claims 4 to 6,
In the layer forming step, the size of the droplet is adjusted so that the thickness of the constituent layer and the thickness of the supporting layer corresponding to the constituent layer are aligned after the joining step. Manufacturing method of original model. In the manufacturing method of the three-dimensional structure according to any one of claims 4 to 7,
The bonding step is performed by heating the constituent layer and the support layer,
The three-dimensional structure characterized in that the heating temperature is not less than the melting point of the constituent layer forming particles and not more than the melting point of the support layer forming particles contained in the fluid composition forming the support layer. Manufacturing method. In the manufacturing method of the three-dimensional structure according to any one of claims 4 to 7,
The bonding step is performed by heating the constituent layer and the support layer,
The heating temperature is equal to or higher than the sintering temperature of the constituent layer forming particles and is equal to or lower than the sintering temperature of the support layer forming particles contained in the fluid composition forming the support layer. A manufacturing method of a three-dimensional structure. In the manufacturing method of the three-dimensional structure according to any one of claims 1 to 9,
The particle size of the support layer forming particles contained in the flowable composition forming the support layer is smaller than the particle size of the component layer forming particles contained in the flowable composition forming the component layer. The manufacturing method of the three-dimensional structure characterized by this. In the manufacturing method of the three-dimensional structure according to any one of claims 1 to 10,
The particles for forming a support layer contained in the flowable composition forming the support layer are particles containing at least one component of silica, alumina, titanium oxide and zircon oxide, and the fluid forming the constituent layer The constituent layer forming particles contained in the composition are particles containing at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, and maraging steel. Production method. A discharge unit that discharges the fluid composition containing particles in the form of droplets, and a control unit that controls to form a layer by discharging droplets from the discharge unit,
The control unit includes a constituent layer corresponding to a constituent region of the three-dimensional structure, and a support layer that contacts the constituent layer and supports the constituent layer. An apparatus for producing a three-dimensional structure, wherein the apparatus is controlled so as to be smaller than at least some of the droplets when forming the constituent layer.

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