JP6020672B2 - Three-dimensional modeling apparatus and manufacturing method of modeled object - Google Patents

Description

  The present invention relates to a three-dimensional modeling apparatus that forms a three-dimensional object from a photocurable material, a modeled object formed by this method, and a method for manufacturing a modeled object.

  Conventionally, a modeling apparatus for forming a three-dimensional modeled object is known as an apparatus called rapid prototyping and is widely used for business purposes. Generally, a three-dimensional modeling apparatus forms a modeled object layer by layer based on shape data for each predetermined thickness of an object to be modeled, that is, shape data for each layer.

  As one of the main methods of a three-dimensional modeling apparatus, for example, an optical modeling method is a method in which a desired part of a resin is cured and drawn by partially selectively irradiating a photocurable resin with laser light, and a modeled object is formed. Is a method of forming.

  Among stereolithography methods, for example, there are a free liquid surface method and a regulated liquid surface method. In the free liquid level method, the liquid level of the photocurable resin is exposed in the air, and the laser light is drawn by focusing on the interface between the air and the liquid level. In the free liquid level method, there is a problem that the accuracy of resin lamination (accuracy of thickness for each layer and accuracy of the surface state of the resin for each layer) varies depending on the surface accuracy of the liquid surface.

  Therefore, in the regulated liquid level method, the liquid level of the photocurable resin is regulated by, for example, a flat glass surface, and the laser beam is drawn through the glass and focused on the interface between the liquid level and the glass surface. Ru

  The stereolithography apparatus described in Patent Document 1 employs a regulated liquid level method. This stereolithography apparatus includes a position regulating mechanism for preventing the glass from being bent and keeping the glass flat (for example, the paragraph [0077] of the specification of Patent Document 1, FIGS. 7 to 10).

JP 2009-137048 A

  In the regulated liquid level method using glass as in Patent Document 1, it is necessary to peel off the cured resin from the glass after the formation of each layer. However, as the modeling area of each layer increases, the force required for peeling increases, and in some cases, the modeled object may collapse or the modeled object may peel off from the base (the stage on which the modeled object is stacked). .

  Moreover, when the modeling area of each layer becomes large as mentioned above, glass will be distorted by the shrinkage force at the time of hardening of resin, or glass will be pulled and bent to the side with resin. Thereby, the flatness of each layer of a modeling thing deteriorates. In this respect, the above-mentioned Patent Document 1 only considers the bending of the glass, and no measures are taken for the phenomenon that the glass is pulled in the direction opposite to the bending direction.

  Furthermore, the higher the viscosity of the photo-curable resin, the greater the pressure applied by the resin to the pedestal surface and the glass surface, which distorts the glass surface and prevents the thickness of each layer of the resin from being controlled to a preset thickness. There is also a problem.

  In view of the circumstances as described above, the object of the present invention is to be able to cleanly peel the cured layer of the material from the regulating body that regulates the surface of the material forming the modeled object, to increase the flatness of each layer, or to each layer Another object of the present invention is to provide a three-dimensional modeling apparatus capable of controlling the thickness of the film with high accuracy. Moreover, the objective is to provide the manufacturing method of the molded article formed by the method, and a molded article.

In order to achieve the above object, a three-dimensional modeling apparatus according to an embodiment of the present invention is provided.
Stage,
A regulating body that has a surface and is arranged to face the stage such that a part of the surface is closer to the stage than other regions;
An irradiation unit that irradiates an energy ray to a slit region that is a region between the stage side and a partial region of the surface;
A moving mechanism for relatively moving the stage and the regulating body.

  Since the restricting body is arranged so that a partial area of the surface of the restricting body is closest to the stage, the material is irradiated with energy rays and cured in a partial area of the surface or in the vicinity thereof. That is, the material is substantially cured in the slit region between the stage side and the partial region, and the two are relatively moved by the moving mechanism so that the surface of the regulating body moves away from the stage on the downstream side of the regulating body. Go to. Thereby, the hardened layer of material can be peeled off from a regulation body neatly.

  Further, the slit region is formed not by a wide planar region but by a partial region of the surface of the regulating body. Therefore, as described above, the material is easily peeled off from the regulation body. Moreover, even if the contraction force when the material is cured is applied to the regulating body, the regulating body is not distorted or deformed. Thereby, the flatness of each cured layer can be increased, and the thickness of each cured layer can be controlled with high accuracy.

The partial area may be one-dimensional or two-dimensional. In the case of two dimensions, the partial area may be a flat surface or a curved surface. Even if the partial region is actually a curved surface, there is no problem as long as the surface of the hardened layer of the model has a surface that can maintain the desired planar accuracy.

  As described above, according to the present invention, the hardened layer (modeled object) of the material can be peeled cleanly from the regulating body that regulates the surface of the material, the flatness of each layer is increased, or the thickness of each layer is controlled with high accuracy. can do.

FIG. 1 is a perspective view showing a three-dimensional modeling apparatus according to the first embodiment of the present invention. FIG. 2 is a front view of the three-dimensional modeling apparatus as viewed in the Y-axis direction. FIG. 3 is a schematic side view showing the three-dimensional modeling apparatus and a block diagram showing the configuration of the control system. FIG. 4 is a diagram illustrating operations of the three-dimensional modeling apparatus in order. FIG. 5 is a diagram illustrating operations of the three-dimensional modeling apparatus in order. FIG. 6 is an enlarged view of the state of the slit region and its surroundings. FIG. 7 is an enlarged view of the resin liquid and the cured layer on the modeling stage shown in FIG. FIG. 8 is a diagram showing a pattern of exposure processing for one layer viewed in the Z-axis direction. FIG. 9 is a side view showing the main part of the three-dimensional modeling apparatus according to the second embodiment of the present invention. FIGS. 10A and 10B are a side view and a front view, respectively, showing the main part of the three-dimensional modeling apparatus according to the third embodiment of the present invention. FIG. 11 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the fourth embodiment of the present invention. It is a figure for demonstrating operation | movement of the three-dimensional modeling apparatus shown in FIG. FIGS. 13A to 13F are views showing the main part of a three-dimensional modeling apparatus according to the fifth embodiment of the present invention. FIG. 14 is a diagram for explaining a sixth embodiment of the present invention. FIGS. 15A to 15C are diagrams illustrating an example of a modeled object having an overhang-like portion. FIG. 16 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the seventh embodiment of the present invention. FIG. 17 is a diagram of an optical system and electrical configuration blocks used in the three-dimensional modeling apparatus shown in FIG. FIG. 18 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the seventh embodiment of the present invention. FIG. 19 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the ninth embodiment of the present invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
(Configuration of 3D modeling equipment)
FIG. 1 is a perspective view showing a three-dimensional modeling apparatus according to the first embodiment of the present invention. FIG. 2 is a front view of the three-dimensional modeling apparatus as viewed in the Y-axis direction.

  The three-dimensional modeling apparatus 100 faces the base 1, two side walls 2 erected on the rear side of the base 1, a modeling stage 15 disposed between the side walls 2, and the modeling stage 15. And a drum 10 as a restricting body arranged in this manner.

  FIG. 3 is a schematic side view showing the three-dimensional modeling apparatus 100 and a block diagram showing the configuration of its control system.

  The drum 10 as a regulating body regulates the height of the surface of the material supplied from the supply nozzle onto the modeling stage 15 as will be described later. The drum 10 is formed in a substantially cylindrical shape, for example, glass. The drum 10 is formed with a through hole in the X-axis direction, that is, in a tubular shape, and the beam member 4 for supporting the irradiation unit 30 passes through the through hole (inside the cylinder) of the drum 10 as described later. Is provided.

  The drum 10 may be made of acrylic or other transparent resin instead of glass. The drum 10 is not necessarily limited to these materials, and any material can be used as long as it transmits the energy rays irradiated from the irradiation unit 30.

  The inner diameter of the drum 10 is about 30 to 70 mm, and the thickness of the wall is about 2 mm. However, these ranges can be changed as appropriate.

  The modeling stage 15 is supported by the lifting mechanism 14 so as to be lifted and lowered. The modeling stage 15 and the lifting mechanism 14 are mounted on the moving base 11, and the moving base 11 is movable by a Y-axis moving mechanism 70 (see FIG. 3). The Y-axis moving mechanism 70 includes a Y-axis moving motor 72 and a guide rail 71 that is laid on the base 1 and guides the movement of the moving base 11.

  As shown in FIGS. 1 and 2, a plurality of guide rollers that rotatably support the drum 10 around an axis along the X-axis direction are provided inside the side wall 2. For example, three guide rollers 5, 6 and 7 are provided on one side wall 2. The guide roller 7 holds the inner peripheral surface of the drum 10 downward, and the two guide rollers 5 and 6 support the outer peripheral surface (surface) 10a of the drum 10 from below. That is, the drum 10 is supported by the three guide rollers 5, 6 and 7 sandwiching the wall of the drum 10. As described above, the drum 10 is supported by the guide rollers 5, 6, and 7, thereby eliminating the need for a bearing.

  The guide rollers 5, 6 and 7 are drums at a predetermined height position in the Z-axis direction so as to form a slit region S (see FIG. 6) described later between the stage side and the outer peripheral surface 10a of the drum 10. 10 is supported. That is, a linear region along the X-axis direction (first direction) that is the surface of the modeling stage 15 and the lowermost portion of the outer peripheral surface 10a of the drum 10 (the portion of the drum 10 that is closest to the stage). A slit region S is formed by facing A1. The linear area A1 is a part of the outer peripheral surface 10a of the drum 10 and can be regarded as a substantially flat surface.

  The width of the linear region A1 in the Y-axis direction (second direction) is 0.1 to 1 mm, and the spot diameter of laser light emitted from the irradiation unit 30 described later is 1 to 100 μm. It is. However, the width and the spot diameter of the linear region A1 can be appropriately changed depending on the size of the drum, the size of the modeled object, the modeling accuracy, and can take values other than those ranges.

  As shown in FIG. 3, for example, one guide roller 5 among the three guide rollers 5, 6, and 7 is driven by a roller motor 8. Thereby, the drum 10 is rotated by the guide roller. Note that two or more of the guide rollers 5, 6 and 7 may be driven by a motor.

  The arrangement of these three guide rollers 5, 6 and 7 is not limited to the form shown in FIG. 1, and can be changed as appropriate.

  A supply nozzle 26 that has a long shape along the X axis and supplies the photocurable material R to the drum 10 is provided between the side walls 2. The supply nozzle 26 is disposed, for example, at the lower part of the drum 10 and at a position away from the linear area A1 which is the lowermost part of the drum 10. As the supply nozzle 26, a nozzle having a plurality of holes (not shown) for discharging the photocurable material R along its longitudinal direction is used. Alternatively, as the supply nozzle 26, a slit coat type nozzle having a slit provided along the longitudinal direction thereof may be used. The plurality of holes or slits open toward the side where the drum 10 is disposed.

  The supply nozzle 26 is connected to, for example, a pump, a pipe, an open / close valve (not shown) for introducing the photocurable material R into the supply nozzle 26.

  As shown in FIG. 1, the three-dimensional modeling apparatus 100 includes a lifting mechanism (a part of a moving mechanism) 14 that supports the modeling stage 15 and moves the modeling stage 15 up and down with respect to the moving base 11. The elevating mechanism 14 controls the distance between the modeling stage 15 and the linear area A <b> 1 of the drum 10 by elevating the modeling stage 15 with the elevating motor 19. The uppermost position of the modeling stage 15 by the elevating mechanism 14 is a position where the linear region A1 of the drum 10 is substantially disposed. The modeling stage 15 has a circular shape in the horizontal plane (in the XY plane), but is not limited to a circular shape, and may be a rectangular shape or other shapes. As the photocurable material R, an ultraviolet curable resin is typically used.

  As shown in FIG. 1, the three-dimensional modeling apparatus 100 includes an irradiation unit 30 that irradiates a photocurable material R supplied from a supply nozzle 26 with laser light as energy rays. On the rear side of the three-dimensional modeling apparatus 100, two support columns 3 are erected from the base 1, and the beam material 4 is bridged between the two support columns 3. It is provided so as to pass through the inside. The irradiation unit 30 is disposed inside the drum 10 and can be moved to the X axis by an X axis moving mechanism 60 provided on the beam member 4. The X-axis movement mechanism 60 includes an X-axis movement motor 63 (see FIG. 3), a rail plate 62 having a guide rail 62a fixed to the beam member 4, and a movable plate 61 movably attached to the rail plate 62. Have The X-axis moving mechanism 60 functions as a scanning mechanism that scans laser light in the X-axis direction.

  The irradiation unit 30 is fixed to a movable plate 61, and includes a laser light source 31, an objective lens holder 32 disposed immediately below the laser light source 31, and an objective lens 34 held by the objective lens holder 32 (FIGS. 2 and 3). And a fixed plate 33 that supports the laser light source 31 and the objective lens holder 32 and fixes them to the movable plate 61.

  The irradiation unit 30 stops the spot diameter of the laser beam emitted from the laser light source 31 using the objective lens 34, and the light in the slit region S or the slit region S and the vicinity thereof through the wall of the drum 10. Focus on curable material R. That is, typically, the objective lens 34 is disposed at a position on the optical axis such that the focal point of the laser light matches at least the photocurable material R in the slit region S.

  The elevating mechanism 14, the Y-axis moving mechanism 70, and the X-axis moving mechanism 60 shown in FIG. 3 can be realized by, for example, a ball screw driving mechanism, a rack and pinion driving mechanism, a belt driving mechanism, or a fluid pressure cylinder driving mechanism. it can.

  The three-dimensional modeling apparatus 100 includes a lifting motor controller 51 that controls driving of the lifting motor 19, a roller motor controller 54 that controls driving of the roller motor 8, and a Y-axis moving motor controller that controls driving of the Y-axis moving motor 72. 53, an X-axis movement motor controller 55 for controlling the drive of the X-axis movement motor 63 is provided. The three-dimensional modeling apparatus 100 includes a laser power controller 52 that controls the power of laser light emitted from the laser light source 31. The operation of each of these controllers is comprehensively controlled by the host computer 50. Although not shown, the three-dimensional modeling apparatus 100 also includes a controller connected to the supply nozzle 26 and a controller for driving the open / close valve.

  The host computer and each controller include a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), and the like. Instead of the CPU, a DSP (Digital Signal Processor), a PLD (Programmable Logic Device) (for example, an FPGA (Field Programmable Gate Array)), an ASIC (Application Specific Integrated Circuit), or the like may be used. Typically, each controller is connected to each other by wire, but at least one of these controllers may be connected to a control system in the three-dimensional modeling apparatus 100 by radio. Each controller may be configured by hardware.

(Operation of 3D modeling equipment)
Next, the operation of the three-dimensional modeling apparatus 100 configured as described above will be described. 4A to 4C are diagrams sequentially illustrating the operation.

  FIG. 4A shows a stationary state of the three-dimensional modeling apparatus 100, and shows a state where the moving base 11 is in the initial position. Before actually performing modeling, the thickness of one layer of the cured layer that is the photocurable material R is set via the host computer. And the height position of the modeling stage 15 when the modeling stage 15 comes into contact with the linear region A1 which is the lowest part of the drum 10 by driving the lifting mechanism 14 according to the control of the lifting motor controller 51, for example, Set as the origin in the Z-axis direction.

  Note that the position of the modeling stage 15 in the Y-axis direction at the time of setting the origin can be set as appropriate.

  When the origin is set, the modeling stage 15 is lowered by a preset thickness of one layer of the photocurable material R.

  After the modeling stage 15 is lowered, the modeling stage 15 is moved to a modeling start position which is a predetermined position as shown in FIG. This modeling start position is a position in the direction along the Y axis of the modeling stage 15 such that the slit region S between the modeling stage 15 and the linear region A1 of the drum 10 can be formed. If this modeling start position is the position of the modeling stage 15 at which the slit region S can be formed, the setting can be appropriately changed depending on the size of the modeled object to be formed in the Y-axis direction.

  When the modeling stage 15 is located at the modeling start position, the photocurable material R is supplied from the supply nozzle 26 to the lower surface side of the drum 10. As already described above, for example, an ultraviolet curable resin is used as the photocurable material R. Hereinafter, this is referred to as a resin liquid R for convenience.

  When the resin liquid R is thus transferred to the drum 10, the roller motor drives the guide roller 5 based on the control of the roller motor controller 54. As a result, the drum 10 rotates to a position where the portion of the drum 10 to which the resin liquid R adheres is located at the lowermost portion of the drum 10. Then, the rotation of the drum 10 is stopped. FIG. 6 shows an enlarged view of the slit region S and the surrounding area at this time. From this state, irradiation of the resin liquid R with laser light, that is, exposure is started.

  Depending on the type of the resin liquid R, the resin liquid R may be transmitted through the drum 10 by its own weight, so that the space between the lower surface of the drum 10 including the slit region S and the surface of the modeling stage 15 may be satisfied. When the resin liquid R is transmitted through the outer peripheral surface 10a of the drum 10 by its own weight, the rotation of the drum 10 is unnecessary.

  And the irradiation unit 30 irradiates a laser beam. Laser light generated from the laser light source 31 passes through the objective lens 34 and enters the resin liquid R in the slit region S through the drum 10. The irradiation unit 30 moves in the direction along the X axis under the control of the X axis moving motor controller 55, and based on the data for one column in the X axis direction in one layer of the modeling target, the laser power controller Under the control of 52, the resin liquid R is selectively exposed.

  Specifically, the laser power controller 52 generates a laser power modulation signal in accordance with the data for one column and sends it to the laser light source 31, so that one column in the X-axis direction in one layer. The minute resin liquid R is selectively exposed and cured. At least the resin liquid R in the slit region S is exposed. During exposure by laser light irradiation, the drum 10 is stopped.

  As the laser light, one having an ultraviolet wavelength region is used. The thickness of one layer of the shaped object is 1 μm to 100 μm, but is not limited to this range and can be set as appropriate.

  When the exposure for one row along the X-axis direction of the resin liquid R is completed, the laser beam irradiation operation is stopped, and the modeling stage 15 is moved backward in the direction along the Y-axis by the Y-axis moving mechanism 70 (FIG. 4). A predetermined pitch is moved to the right side in (B). Then, selective exposure for the next one row (one row adjacent to the first row) in the first layer is performed in the same manner as described above.

  As shown in FIG. 4C, the three-dimensional modeling apparatus 100 repeats the scan irradiation of the laser beam along the X-axis direction and the step feed along the Y-axis direction of the modeling stage 15 as described above. In addition, a selectively cured layer of the resin liquid R for one layer, that is, a modeled object for one layer is formed. In this way, exposure processing for one layer is performed according to the so-called raster scan procedure. The pitch of the intermittent movement of the modeling stage 15 in the direction along the Y axis depends on the spot diameter of the laser beam, that is, on the resolution when forming the modeled object. Can be set as appropriate.

  FIG. 7 is an enlarged view of the resin liquid R and the cured layer on the modeling stage 15 shown in FIG. In FIG. 7, the hardened layer R1 for one layer is represented by black. As shown in FIG. 7, an uncured resin liquid R adheres to the drum 10 on the right side, which is downstream from the slit region S, and also on the formed cured layer R1. An uncured resin liquid R adheres, but this is not a problem. This will be described later.

  Here, when the exposure for one row along the X-axis direction is completed and the modeling stage 15 (and the moving base 11) moves in the direction along the Y-axis by the Y-axis moving mechanism 70, the drum 10 and the modeling stage The drum 10 is dragged by the frictional force with the 15 side and rotates counterclockwise in FIGS. Alternatively, at this time, the drum 10 may be rotated by driving the roller motor 8 of the guide roller 5.

  When the exposure for one row of the resin liquid R is completed and the modeling stage 15 moves by a predetermined pitch, the drum 10 is positioned on the Z axis on the downstream side of the slit region S (for example, on the right side of the slit region S in FIG. 6). The modeling stage 15 moves so as to move away from the modeling stage 15 in the direction. Thereby, the hardened layer R1 (hardened layer adhering to the outer peripheral surface 10a of the drum 10) immediately after being formed can be peeled cleanly from the drum 10.

  Moreover, in the conventional regulated liquid level method, it was also a problem that the flatness of the molded article deteriorated due to distortion of the film or the glass surface. On the other hand, in this embodiment, the shape of the outer peripheral surface 10a of the drum 10 is a curved surface (cylindrical surface), and the liquid level is regulated by the linear region A1. Therefore, even if the contraction force when the resin liquid R is cured is applied to the drum 10, the drum 10 is hardly deformed or distorted, and the deformation of the drum 10 due to the viscosity of the resin liquid R before exposure can be prevented. . Thereby, the flatness of hardened layer R1 can be raised and the thickness can be controlled with high accuracy.

  According to the inventor's experiment, when the curved surface (for example, the outer peripheral surface 10a of the drum 10) is compared with the flat surface (for example, the surface of the modeling stage 15), the adhesion of the cured resin layer to the curved surface. Is weaker than in the case of a flat surface. Therefore, it has been confirmed that a cured resin layer remains on the flat surface. In this experiment, such a result is obtained when the curved surface and the flat surface are made of the same material.

  In addition, if a hardened layer for one layer is formed on the modeling stage 15 first, the adhesive force to the hardened layer, which is the same material as the resin material from the next second layer, is the outer periphery of the drum 10. It becomes stronger than the adhesion to the surface 10a. In experiments, it has been confirmed that even when the radius of curvature of the glass regulating body is 1 m, the hardened layer is peeled off sufficiently cleanly.

  Therefore, in this embodiment, the cured layer can be reliably peeled off from the drum.

  When the exposure to the resin liquid R for one layer is completed, the modeling stage 15 is lowered by the thickness of one layer of the hardened layer R1. Then, the movable base 11 and the modeling stage 15 return again from the position shown in FIG. 4C to the modeling start position shown in FIG. In this case, the moving base 11 and the modeling stage 15 may return to the modeling start position while the modeling stage 15 is lowered.

  When the exposure to the resin liquid R for one layer is completed and the modeling stage 15 is lowered, the guide roller 5 is driven to rotate the drum 10 by a predetermined angle counterclockwise in FIGS. . As a result, the outer peripheral surface 10a of the new drum 10 to which the resin liquid R is not attached faces the modeling stage 15 side. Excess resin liquid R adhering to the outer peripheral surface 10a of the drum 10 is periodically removed by a cleaning device (not shown).

  In the second layer modeling process (exposure process), the uncured resin liquid R remaining on the first cured layer R1 is exposed by the same operation as the first layer. A second hardened layer R1 is formed. In this way, the resin liquid R is supplied to the drum 10 so as to be periodically replenished while the shaped objects are stacked in the Z-axis direction.

  However, of course, the resin liquid R may be replenished every time one layer of the forming process, or in a shorter cycle, or always.

  In the above description, the drum 10 is rotated by a predetermined angle after the exposure processing for one layer is completed. However, when the accuracy of the shape of the modeled object is not required by the user, even if the exposure to the resin liquid R for one layer is completed and the excessive resin liquid R is attached to the outer peripheral surface 10a of the drum 10, the drum 10 A plurality of layers may be formed without rotating a predetermined angle.

  As shown in FIGS. 5A to 5C, the operation shown in FIG. 4 is performed on the modeled object in a state where the modeled object having an arbitrary thickness is formed as described above. Further, a hardened layer R1 for one layer is formed by the same operation.

  The three-dimensional modeling apparatus 100 may form an anchor pattern as follows. FIG. 8 is a diagram showing a pattern of exposure processing for one layer viewed in the Z-axis direction. In this example, at the start and end of the scan along the X-axis direction of the irradiation unit 30, the laser beam is irradiated so as to form the anchor pattern Rb as a part of the modeled object. That is, this shaped article (cured layer R1) has a main body Ra and an anchor pattern Rb formed around the main body Ra.

  By forming the anchor pattern Rb in this way, it is possible to suppress an adverse effect on the modeling accuracy due to a change in scan speed at the rising and falling of the irradiation unit 30. Thereby, the exposure processing of the edge portion Re in the X-axis direction of the main body Ra formed inside these anchor patterns Rb can be made uniform in the Y-axis direction. Thereby, the edge part Re of the main body Ra can be formed with high accuracy.

  The anchor pattern Rb in the example shown in FIG. 8 is formed to be, for example, a straight line along the Y-axis direction. However, the shape along the Y-axis direction of the anchor pattern Rb does not necessarily have to be a straight line shape, is a parenthesis shape (for example, <>), a zigzag shape, or according to the outer shape of the modeled object. It may be a shape. The length of the anchor pattern Rb in the X-axis direction can be set as appropriate.

  As described above, in the present embodiment, the thickness of each layer of the modeled object can be maintained to be accurately constant. Moreover, this can improve the uniformity of the flat surface of the cured layer R1 for each layer.

  In the present embodiment, as described above, since the modeling stage 15 moves so that the drum 10 moves away from the modeling stage 15 in the Z-axis direction, the cured layer R1 of resin can be peeled cleanly from the drum 10. .

  In the present embodiment, since the liquid surface of the resin liquid R is regulated by the linear region A1, even if a resin material having a high viscosity is used, a modeled object can be formed with an accurate layer thickness. A wider range of choices.

  In the conventional regulated liquid level method, time is required for the process of peeling the modeled object from the film or glass surface. However, in the present embodiment, the modeled object is peeled off from the drum 10 during step feeding in the direction along the Y axis of the modeling stage 15 during the exposure process. That is, the time required for forming the shaped article can be shortened because the time zone for the exposure process and the peeling process for one layer overlap.

  In the present embodiment, in the linear region A1 of the drum 10, the drum 10 as the restricting body is intermittently peeled off from the modeling stage 15 side by a minute amount (every step feed along the Y-axis direction). )Occur. Therefore, the peeling force is weak and damage to the hardened layer R1 can be prevented. That is, the hardened layer R1 is easily peeled off from the regulating body. Further, since the peeling force is so weak, the hardened layer R1 does not peel off from the modeling stage 15.

  In the present embodiment, the lowermost part of the outer peripheral surface 10a of the drum 10 is a linear area A1, and a slit area S serving as an exposure area is formed between the area A1 and the modeling stage 15 side. That is, by forming the drum 10 that is the restricting body into a cylindrical shape, the function of the restricting body can be provided with a simple shape.

  In the present embodiment, the irradiation unit 30 is disposed in the drum 10. Thereby, the merit of forming the drum 10 in a cylindrical shape increases. Further, the three-dimensional modeling apparatus 100 can be reduced in size as compared with the case where the irradiation unit 30 is disposed outside the drum 10.

[Second Embodiment]
FIG. 9 is a side view showing the main part of the three-dimensional modeling apparatus according to the second embodiment of the present invention. In the following description, the same members, functions, etc. included in the three-dimensional modeling apparatus 100 according to the embodiment shown in FIG. 1 will be simplified or omitted, and different points will be mainly described.

  The three-dimensional modeling apparatus 200 shown in FIG. 9 includes a plate member 20 having a curved surface formed as a regulating body instead of the above-described drum. The plate member 20 is typically a part of a cylindrical body. The plate member 20 has a lower surface 20 a facing the modeling stage 15 side supported by, for example, a plurality of guide rollers 45 and 46, and an upper surface 20 b pressed by the guide roller 47. An irradiation unit 30 is disposed on the upper surface 20 b side of the plate member 20.

  At least one of these guide rollers 45 to 47 may be driven, or all the guide rollers may not be driven.

  In the lowermost part of the lower surface 20a facing the modeling stage 15 side of the plate material 20 thus provided, a linear region A1 that can be regarded as a substantially flat surface, and the modeling stage 15 side (the hardened layer R1 on the modeling stage 15) ), A slit region S is formed.

  When the drum 10 that is a cylindrical body is used as in the first embodiment, by increasing the diameter of the cylinder, the curvature of the outer peripheral surface is reduced, and the linear region A1 that can be regarded as a plane is formed. The area can be increased. However, when the diameter of the cylinder is increased, the three-dimensional modeling apparatus is also enlarged. Therefore, by forming the regulating body in a plate shape as in the present embodiment, the area of the linear region A1 that can be regarded as a flat surface is increased while suppressing the enlargement of the three-dimensional modeling apparatus 200. Can do.

  The plate material is not limited to a form that is a part of a cylindrical body, and the shape viewed from the side as shown in FIG. 9 may be formed in a shape along a part of a quadratic curve such as an ellipse or a hyperbola. Good.

[Third Embodiment]
FIGS. 10A and 10B are a side view and a front view, respectively, showing the main part of the three-dimensional modeling apparatus according to the third embodiment of the present invention.

  The regulation body of the three-dimensional modeling apparatus 210 according to the present embodiment is a semi-cylindrical body 40 that is a part of a cylindrical body. That is, both the semi-cylindrical body 40 and the plate member 20 according to the second embodiment are part of the cylindrical body, and the operational effects are the same except that the curvature of the outer peripheral surface thereof is different.

  The irradiation unit 80 of the three-dimensional modeling apparatus 210 according to this embodiment includes a laser light source 31 and a condenser lens 134. The condenser lens 134 has a function of condensing laser light. The laser light from the irradiation unit 80 is scanned along the X-axis direction on the resin liquid R by the galvano mirror 35 of the galvano scan mechanism. The galvanometer mirror can be rotated by a predetermined angle around a rotation axis along the Y-axis direction by a motor or an actuator (not shown) for scanning in the X-axis direction.

  By using such a galvano scan mechanism, the scan speed in the X-axis direction can be increased compared to the scan mechanism of the irradiation unit 30 according to the first embodiment.

  Moreover, the three-dimensional modeling apparatus 210 according to the present embodiment has the following operational effects. When the regulation body is formed in a cylindrical shape, an irradiation unit 30 is provided inside the drum 10 as in the three-dimensional modeling apparatus 100 shown in FIG. 1, and in this case, there is a restriction on the optical path length of the laser light. However, as in this embodiment, if the semi-cylindrical body 40 has a shape without a cylinder, the restriction on the optical path length of the laser light can be eliminated.

  The irradiation unit 80 and the galvanometer mirror 35 may be applied to the three-dimensional modeling apparatus 200 shown in FIG.

  Instead of the galvanometer mirror 35, a rotating polygon mirror may be provided.

  In the example shown in FIG. 10A, the semi-cylindrical body 40 is provided in such a posture that the cylindrical body is cut obliquely, but the cut surface may be substantially parallel (horizontal) to the XY plane. It is not limited to horizontal and any angle is acceptable.

  The regulating body is not limited to a semi-cylindrical shape, and the angle at which the regulating body is cut off is not limited.

[Fourth Embodiment]
FIG. 11 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the fourth embodiment of the present invention.

  The three-dimensional modeling apparatus 300 according to the present embodiment includes a Y-axis moving mechanism 70 and a Z-axis moving mechanism 17 as moving mechanisms that move the modeling stage 15. The Y-axis moving mechanism 70 moves the modeling stage 15 along the vertical direction. The Z-axis moving mechanism 17 moves the Y-axis moving mechanism 70 toward and away from the drum 10. In other words, the Z-axis moving mechanism 17 moves the Y-axis moving mechanism 70 horizontally to move the modeling stage 15 closer to and away from the drum 10. In the description of this embodiment, the vertical direction is the Y-axis direction, and the separation / contact direction (horizontal direction) of the modeling stage 15 with respect to the drum 10 is the Z-axis direction.

  As the Z-axis moving mechanism, the Z-axis moving mechanism 17 directly moves the modeling stage 15 in the Z-axis direction, instead of moving the modeling stage 15 in the Z-axis direction via the Y-axis moving mechanism 70. It may be a configuration.

  The Z-axis moving mechanism 17 only needs to have the same structure as the lifting mechanism described in the above embodiment. The same applies to the Y-axis moving mechanism 70. The three-dimensional modeling apparatus 300 according to the present embodiment also includes the irradiation unit 30 and the X-axis moving mechanism 60 (see FIG. 1) as in the above embodiment. In this case, the irradiation unit 30 emits laser light in the horizontal direction toward the stage.

  A supply nozzle 26 for supplying a resin liquid is provided at a predetermined position on the outer peripheral surface 10 a side of the drum 10. The predetermined position is in the vicinity of the drum 10 and above the linear area A1 in the position where the distance between the outer peripheral surface 10a of the drum 10 and the surface of the modeling stage 15 is closest in the Y-axis direction. Provided.

  A cleaning unit 27 is disposed in the vicinity of the drum 10 and below the linear region A1. The cleaning unit 27 includes a cleaning nozzle 28 that supplies a cleaning liquid (cleaning material) to a modeled object formed on the modeling stage 15, and an air blow nozzle 29 that ejects air toward the modeled object, for example. The cleaning nozzle 28 and the air blow nozzle 29 have a long shape along the X-axis direction, and these are arranged side by side along the Y-axis direction. The upper and lower positions of the cleaning nozzle 28 and the air blow nozzle 29 may be reversed.

  Further, a cleaning unit 37 having the same structure as that of the cleaning unit 27 is also arranged on the drum 10. The cleaning nozzle 38 supplies cleaning liquid to the outer peripheral surface 10 a of the drum 10, and the air blow nozzle 39 ejects air toward the outer peripheral surface of the drum 10.

  As the cleaning liquid discharged from the cleaning nozzles 28 and 38, for example, ethanol or methanol is used. From the air blow nozzles 29 and 39, other gases such as an inert gas may be ejected instead of air.

  A waste liquid tank 18 is provided in the lower part of the drum 10, and excess material (resin liquid), cleaning liquid, and the like are stored in the waste liquid tank 18.

  The operation of the three-dimensional modeling apparatus 300 configured as described above will be described. The following is a description of the operation for one layer of the shaped object.

  When the resin liquid is supplied from the supply nozzle 26 to the outer peripheral surface 10a of the drum 10, a guide roller (not shown) that supports the drum 10 is driven, and for example, the drum 10 rotates clockwise by a predetermined angle in FIG. When the drum 10 rotates, the resin liquid adhering to the drum 10 moves to a slit region formed between the linear region A1 of the drum 10 and the modeling stage 15 side. Alternatively, the resin liquid adhering to the drum 10 may be supplied to the slit region along the outer peripheral surface 10a by its own weight.

  The resin liquid is held in the slit region by its own surface tension.

  The resin in the slit region S is scanned while the irradiation unit 30 is scanned along the X-axis direction, and the modeling stage 15 is moved stepwise downward from the state shown in FIG. 11 along the Y-axis direction. The liquid is irradiated with laser light. Thereby, hardened layer R1 is formed.

  As shown in FIG. 12, the modeling stage 15 moves downward until the entire hardened layer R1 is positioned below the linear region A1 of the drum 10. Then, the cleaning liquid and air are supplied from the cleaning unit 27 to the cured layer R1, and, for example, the remaining resin liquid remaining on the cured layer R1 is removed. Further, cleaning liquid and air are supplied from the cleaning unit 37 to the drum 10, and excess resin liquid adhering to the outer peripheral surface of the drum 10 is also removed.

  By repeating the process for one layer of such a modeled object a predetermined number of times, a modeled object is formed.

  In the present embodiment, surplus material can be flowed downward from the hardened layer R1 by gravity, so that the surface of the hardened layer R1 can be cleanly removed, so that highly accurate modeling is possible.

  The timing of cleaning by the cleaning units 27 and 37 may be for each layer of the modeled object, may be for each of a plurality of layers, or may be always during the modeling process, and is arbitrary. Since the cleaning liquid flows down, the air blow nozzle is not essential in the fourth embodiment.

[Fifth Embodiment]
FIGS. 13A to 13F are views showing the main part of a three-dimensional modeling apparatus according to the fifth embodiment of the present invention.

  The three-dimensional modeling apparatus 310 includes a color nozzle unit 48 instead of the supply nozzle 26 of the three-dimensional modeling apparatus 300 according to the fourth embodiment. Other than that, the 3D modeling apparatus 310 has substantially the same configuration as the 3D modeling apparatus 300.

  The color nozzle unit 48 includes a nozzle 48R that supplies a resin solution dyed red, a nozzle 48G that supplies a resin solution dyed green, and a nozzle 48B that supplies a resin solution dyed blue. That is, the three-dimensional modeling apparatus 310 can form a full-color modeled object. The arrangement of these nozzles 48R, 48G, and 48B can be changed as appropriate.

  As shown in FIG. 13A, the red resin liquid is supplied from the nozzle 48R to the slit area, and the irradiation unit 30 (see FIG. 11) moves in the X-axis direction while the red resin liquid supplied to the slit area Irradiate with laser light. Further, when the modeling stage 15 is moved in the Y-axis direction by step feed, one red cured layer R1 (R) is formed. Then, as shown in FIG. 13B, the excess red resin liquid is removed by the cleaning unit 27.

  Similarly to FIGS. 13A and 13B, in FIGS. 13C and 13D, the cured layer R1 (G) made of the green resin liquid is formed in the same layer as the cured layer R1 (R) made of the red resin liquid. It is formed. Similarly, as shown in FIGS. 13E and 13F, a hardened layer R1 (B) made of a blue resin liquid is formed in the same layer as the hardened layers R1 (R) and R1 (G). Is done. Thereby, a cured layer for one layer is formed. In FIGS. 13A to 13F, not all hardened layers having the same color are present in the X-axis direction, and red, green, and blue hardened layers are also present in the X-axis direction.

  Since the spot diameter of the laser beam by the irradiation unit can be set as appropriate, according to the resolution of the irradiation of the laser beam, it is possible to form a colored colored object ranging from low to high. it can. For example, if the spot diameter of the laser beam is about 10 μm, high-definition color coloring can be performed.

  As described above, in the present embodiment, since the modeling stage 15 moves in the vertical direction, it is easy to remove the surplus material. Therefore, it is easy to remove these surplus materials for each layer. For each layer, it becomes easy to form a shaped object having a different color.

  According to this embodiment, since it can color with the color to the inside of a molded article, the cross section when a user cuts a molded article, for example, is also colored. Therefore, this embodiment is advantageous even when it is desired to express the cross-sectional structure of the modeled object.

  In the present embodiment, cyan, magenta, and yellow (CMY) resin liquids may be used instead of the RGB resin liquids.

  In addition to RGB or CMY, it is also possible to form a molded article having colored portions on the inside or outer surface of a transparent object by additionally using a transparent resin liquid.

  In addition to RGB or CMY, white resin liquid can be additionally used to make white the base color of the modeled object. Thereby, the modeling thing colored more vividly is realizable.

  Instead of RGB or CMY, gray scale shaped objects may be formed using white and black resin liquids.

  Alternatively, in addition to a form in which a plurality of materials having different colors are used, a plurality of materials having different physical properties may be used. Different physical properties are forms in which hardness, density, light absorption, viscosity, conductivity, magnetic (non-magnetic), etc. are different. Of course, the method using these plural materials is not limited to the case where the cleaning is performed by the cleaning unit 27 for each layer, and can also be applied to the first to third embodiments.

[Sixth Embodiment]
FIG. 14 is a diagram for explaining a sixth embodiment of the present invention.

  In this embodiment, the slit coat nozzle 26 is used as a supply nozzle for supplying a resin material. In addition, a thixotropic material is used as the resin material. As the regulating body, any of the above-described drum 10, plate member 20, semi-cylindrical body 40 and the like may be used as long as it has a linear region A1.

  The thixotropic resin liquid R2 is supplied from the slit coat nozzle 26, and an overhanging thin film is formed as shown.

  Conventionally, as a method for forming a shaped article having an overhang-like portion, for example, a photo-curing resin material to which a light absorber is added is used, and the photo-curing resin material is cured by adjusting the intensity of laser light to be irradiated. There was a way to limit the depth to do. However, with this method, the depth of curing cannot be strictly controlled, and the surface roughness of the overhanging portion cannot be controlled at all.

  In the present embodiment, by using the thixotropic material R2, it is possible to form a highly accurate overhang portion R3 that does not depend on the curing depth. In the present embodiment, an overhanging thin film can be formed by using the slit coat type nozzle 26.

  In particular, by using a regulating body having a linear region A1, the peeling force of the shaped article from the regulating body (drum 10) becomes very weak as described above, so that the stress applied to the shaped article is very high. It becomes small, and it becomes an overhang-like and thin part can be formed now.

  The film thickness of the overhanging portion R3 may be set smaller than the thickness of the wall of the drum 10.

  It may be set so that the intensity of the laser beam when forming the overhanging portion R3 is stronger than the intensity of the laser beam when forming the cured layer (lower cured layer R1) other than the overhanging portion R3. . Thereby, the resin liquid of overhanging part R3 can be hardened reliably.

  The material of the hardened layer (lower hardened layer R1) other than the overhanging portion R3 may be different from the material of the overhanging portion R3. In this case, it is only necessary to provide supply nozzles for supplying these materials. For example, the fourth embodiment or the fifth embodiment may be applied to the sixth embodiment.

  The thixotropic material R2 may be applied to the first to fifth embodiments.

  A gel-like material formed in a film shape is wound around the outer peripheral surface 10a of the drum 10 in place of the thixotropic material R2, and the gel-like material is exposed to form an overhang portion R3. Good.

  FIGS. 15A to 15C are diagrams illustrating an example of a modeled object having an overhang-like portion. This shaped object is applied to, for example, a microchannel.

  As shown in FIG. 15B, a lid member 103 is formed as a thin film of an overhanging portion on the cured layer 102 that forms the flow channel 101 formed as shown in FIG. 15A. Then, as shown in FIG. 15C, a hardened layer 105 that forms the flow path 104 is further formed on the lid member 103. Thus, in this embodiment, the micro flow path which has a three-dimensional flow path can be formed as a molded article. In such a micro flow path, a passive electric circuit (capacitor, inductor, resistance, etc.) can be constructed by flowing a plating solution through the flow path and plating the flow path. Similarly, the strength can be increased by plating.

[Seventh Embodiment]
16 and 17 are views showing main parts of the three-dimensional modeling apparatus according to the seventh embodiment of the present invention.

  The three-dimensional modeling apparatus 320 according to the present embodiment has a drum position control mechanism. The drum position control mechanism controls the position of the drum 10 as a regulating body in the optical axis direction (Z-axis direction) of laser light. The three-dimensional modeling apparatus 320 shown in FIG. 16 is a type of apparatus in which the modeling stage 15 moves in the vertical direction as shown in FIG.

  Laser light from the irradiation unit 130 is irradiated onto a modeling stage (not shown) through the drum 10. Therefore, in order to maintain the focus state of the laser light, the position of the drum 10 in the Z-axis direction needs to be set to a predetermined position. Therefore, the drum position control mechanism controls the position of the drum 10 to maintain the focus state of the laser beam, and the film thickness of the resin material is controlled with high accuracy by controlling the position of the drum 10.

  In FIG. 16, the drum 10 is supported by four guide rollers 56 and 57 (the guide rollers 56 and 57 are also arranged in the X-axis direction of the paper surface of FIG. 16).

  Of the four guide rollers, two guide rollers 56 are connected to an actuator 65 (see FIG. 17) using a piezo that can move the position of the guide rollers along the Z-axis direction.

  The irradiation unit 130 includes a laser light source 131, a mirror 133, an objective lens 34, a beam sampler 132, a condenser lens 135, and a photodetector 136. The beam sampler 132 samples a part of the laser light emitted from the laser light source 131. The condenser lens 135 collects the light emitted from the beam sampler 132 in the photodetector 136.

  The photodetector 136 converts the obtained intensity distribution state into an electrical signal and outputs the signal to the focus controller 64. The focus controller 64 controls the driving of the actuator 65 based on the input intensity distribution signal so as to maintain the focus state of the laser beam, for example. In this case, the guide roller 56, the actuator 65, and the focus controller 64 function as a control mechanism. By driving the actuator 65, the guide roller 56 moves along the Z-axis direction, and thereby the position of the drum 10 in the Z-axis direction is controlled.

  Such a drum position control mechanism can also be applied to a three-dimensional modeling apparatus having a modeling stage that moves horizontally as in the first to third and sixth embodiments.

  Note that the focus controller 64 may control not only the driving of the actuator 65 but also the driving of the Z-axis moving mechanism 17 (see FIG. 11 and the like) that moves the modeling stage 15 in the Z-axis direction.

[Eighth Embodiment]
FIG. 18 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the seventh embodiment of the present invention.

  The three-dimensional modeling apparatus 330 according to the present embodiment includes a slope 59. Along the slope 59, a first set 41 provided on the upper side and a second set 42 provided on the lower side are arranged. Each of the first set 41 and the second set 42 includes a drum 10, an irradiation unit 30, an X axis moving mechanism (not shown) that scans the irradiation unit 30, a supply nozzle 26, and a cleaning unit 27. As described above, the cleaning unit 27 includes the cleaning nozzle 28 and the air blow nozzle 29.

  The difference between the first set 41 and the second set 42 is that the material supplied by each supply nozzle 26 is different. The difference in material is at least one of color and physical properties as described above.

  The three-dimensional modeling apparatus 330 includes an oblique movement mechanism 58 that moves the modeling stage 15 and the lifting mechanism 14 that moves the modeling stage 15 up and down along the slope 59. The angle of the slope 59 with respect to the horizontal plane is, for example, 30 to 70 degrees, but is not limited to this range. In this case, the elevating mechanism 14 raises and lowers the modeling stage 15 in a direction substantially perpendicular to the inclined surface 59 (modeling lamination direction).

  The operation of the three-dimensional modeling apparatus 330 configured as described above will be described.

  First, as shown in FIG. 18, the modeling stage 15 descends along the slope 59 from the initial position waiting on the upper side, and exposure and cleaning processes are performed in the first set 41. The exposure process and the cleaning process are as described in FIGS. Excess resin liquid and cleaning liquid that flow down during the exposure process and the cleaning process are disposed of in a waste liquid tank (not shown) through a waste liquid path disposed along the slope 59.

  When the exposure and cleaning process in the first set 41 is completed, the modeling stage 15 is further lowered, and the exposure and cleaning process is performed in the second set 42. In this second set, a layer having the same height as the hardened layer formed in the first set 41 (height in the lifting direction in the lifting mechanism 14) is formed, that is, the first set 41 and The processing is performed without changing the height of the modeling stage 15 with the second set 42.

  When the exposure and cleaning process in the second set 42 is completed, the modeling stage 15 repeats the process from the first set 41.

  As described above, in the present embodiment, the modeling stage 15 moves along the slope 59 and the modeling process is performed with different materials in the two sets 41 and 42. Here, in the exposure and cleaning process in the first set 41, excess resin liquid and cleaning liquid flow down in the vertical direction due to gravity, so that the resin liquid and cleaning liquid scatter and adhere to the second set 42. There is nothing wrong. This is an advantage of using the slope 59.

  Thereby, modeling processing is performed with two types of materials while being cleaned by the cleaning unit 27 for each layer. As a result, similarly to the embodiment shown in FIG. 13, a shaped article including two types of materials can be formed with high accuracy.

  When the fifth embodiment shown in FIG. 13 is compared with this embodiment, in the fifth embodiment, the modeling stage 15 needs to return to the initial position every time one kind of resin liquid is supplied. The advantage of this embodiment is that it is not necessary. However, compared with the 3D modeling apparatus 330 according to the present embodiment, the 3D modeling apparatus 310 according to the fifth embodiment can reduce the size of the apparatus, such as the footprint of the apparatus, and reduce the number of parts. It has a merit that can be.

  In the above description, two sets 41 and 42 are provided, but three or more sets may be provided and three or more types of materials may be supplied.

  In the above description, the two sets 41 and 42 are formed with the same height of the hardened layer using different materials, but the two sets 41 and 42 may be formed of the same material with different heights of the hardened layer.

  In the present embodiment, the slope 59 is provided, but a set of a plurality of drums 10 and the like may be arranged along a horizontal plane.

  The irradiation unit 30 may not be provided for each of the first set 41 and the second set 42. In that case, for example, instead of the drum 10 as the restricting body, the plate member 20 shown in FIG. 9 or the semi-cylindrical body 40 shown in FIG. 10 is used, and the irradiation unit 30 is moved between the sets 41 and 42. Just do it.

[Ninth Embodiment]
FIG. 19 is a diagram illustrating a main part of a three-dimensional modeling apparatus according to the ninth embodiment of the present invention.

  The three-dimensional modeling apparatus 340 according to the present embodiment includes a Y-axis moving mechanism 36 that moves the modeling stage 15 and the Z-axis moving mechanism 16 along the Y-axis direction that is the vertical direction. Further, the first set 43 and the second set 44 are arranged along the Y-axis direction.

  The first set 43 includes the drum 10, the irradiation unit 30, the supply nozzle 26, and an X axis movement mechanism (not shown). The second set 44 includes a cleaning unit 27 in addition to the elements included in the first set 43. Each supply nozzle 26 of the two sets 43 and 44 supplies a different kind of material.

  The operation of the three-dimensional modeling apparatus 340 configured as described above will be described.

  The modeling stage 15 descends from the expected position of the modeling stage 15 as shown in the figure, and exposure processing is performed by the first set 43. When the exposure processing by the first set 43 is completed, the Z-axis moving mechanism 16 retracts a predetermined distance along the Z-axis direction before or while the modeling stage 15 is lowered. In order to prevent the hardened layer R <b> 1 formed by the first set 43 from interfering with the second set 44, the modeling stage 15 is retracted by such a predetermined distance.

  When the modeling stage 15 is lowered to a position where the formed hardened layer R1 can be cleaned by the cleaning unit 27, the hardened layer R1 is cleaned by the cleaning unit 27, and excess resin liquid and cleaning liquid are discarded in the waste liquid tank 18. Is done.

  When the cleaning process by the cleaning unit 27 is completed, the modeling stage 15 is raised to a position where the exposure process by the second set 44 is possible. Then, the modeling stage 15 returns by the distance previously retracted along the Z-axis direction. In the second set 44, a resin liquid of a different type from the resin liquid supplied in the first set 43 is supplied, and the same layer as the layer processed in the first set 43 (the same in the stacking direction). The exposure process is performed on the layer having a height.

  When the exposure processing in the second set 44 is completed, the modeling stage 15 is lowered to a position where the formed hardened layer R1 can be cleaned by the cleaning unit 27. Then, the hardened layer R <b> 1 is cleaned by the cleaning unit 27, and excess resin liquid and cleaning liquid are discarded in the waste liquid tank 18.

  The above operation is repeated for each cured layer.

  As described above, also in the present embodiment, a plurality of different materials can be supplied, and the hardened layer R1 is cleaned cleanly by the cleaning unit, so that a shaped object having a plurality of materials can be formed with high accuracy. Can do.

[Other Embodiments]
The embodiment according to the present invention is not limited to the embodiment described above, and other various embodiments are realized.

  In each of the above embodiments, the modeling stage 15 has a structure that moves in two axes, the Y and Z axes. In addition to the two axes, a rotation mechanism for rotating the modeling stage 15 may be provided around the stacking direction (Z-axis direction) of the hardened layer. For example, in the case of laser beam scanning only in the X-axis direction (constant direction), depending on the conditions of the modeling process, the modeled object may be deformed (sink or warped) after being removed from the modeling stage 15. is there. However, the laser beam can be scanned in a desired direction by the rotation mechanism. For example, such a deformation of the modeled object can be prevented by forming the modeled object while the modeling stage rotates by a predetermined angle for each layer, for each of a plurality of layers, or at random. The predetermined angle is, for example, an angle such as 30 °, 90 °, 180 °, a combination thereof, or a random angle.

  In each said embodiment, the protective film may be provided in the surface (for example, outer peripheral surface 10a of the drum 10) of a control body. Specifically, a protective film is wound around the surface of the regulation body. Thereby, instead of washing | cleaning the surface of a regulation body, the surface of a regulation body can be cleaned by removing a protective film regularly. Alternatively, a protective film such as Teflon may be formed in advance on the surface of the regulating body so that the resin liquid or the like hardly remains. In that case, the surface can be cleaned, for example, by simple cleaning or gas blowing.

  As the protective film, a material that transmits energy rays is used. If the protective film is a light transmissive material, for example, polycarbonate, polyethylene, polyvinyl chloride, or the like is used.

  In each of the above embodiments, the number of laser beams of the irradiation unit is one, but a plurality of laser beams may be used. For example, the irradiation mechanism is controlled by the control unit so that the irradiation period of the energy beam to the material includes a period in which at least two of the plurality of laser beams are simultaneously irradiated. Typically, all laser beams are irradiated substantially simultaneously. As a result, a wide range of exposure processing can be performed on the material at a time, so that the time required for the modeling processing can be shortened. In the case of this example, a plurality of laser light sources may be provided, or n (n is an integer greater than or equal to 1) light sources may be used, and the laser beam may be divided into a plurality to form n + 1 or more laser beams. .

  In the above description, for example, a resin liquid colored in color is used when forming a model colored in color. Instead of this resin liquid, a material in which a colored filler is mixed with the resin liquid may be used. For example, it is possible to use a material in which colored fine particles having a diameter smaller than the minimum stacking thickness of the modeled object are mixed in the resin liquid. As fine particles, glass, resin, metal powder, starch, gypsum, salt, sugar or the like is used.

  Alternatively, a filler such as transparent or white can be used as the filler and can be colored with a dye.

  If the laminate thickness of the modeled object is sufficiently thin, a full-color modeled object can be formed even with one color per layer.

  The material of the modeled object is not limited to a photocurable material, and a material that is cured by thermal energy, an electron beam, or ultrasonic waves may be used. Moreover, the energy beam irradiated from an irradiation unit can also be suitably changed according to material. Examples of energy rays include ultraviolet rays, infrared rays, visible light, electron beams, heat rays, and ultrasonic waves. The heat ray may be infrared rays, and in this case, the curing process is performed by spot heating with an infrared laser. A heat ray, an ultrasonic wave, etc. should just be used when forming a molded article with comparatively low modeling precision.

  In the above embodiment, the guide roller 5 or the like is given as an example of a mechanism that rotatably supports the regulating body (the drum 10, the plate member 20, the semi-cylindrical body 40, and the like). However, a bearing may be used instead of the guide roller. In that case, the regulating body may be supported by a support member having a rotating shaft, and a bearing may be connected to the rotating shaft.

  In the said embodiment, although the modeling stage 15 was made into the form which moves to a Y-axis direction, the form to which a control body and an irradiation unit move to a Y-axis direction may be sufficient.

  When the drum 10 is used as the restricting body, a restricting body having a solid (solid) structure may be used when high modeling accuracy is not required.

  As shown in FIG. 9, a plate member having a flat surface may be used instead of the plate member 20 having a curved surface as a restricting body, and the plate member may be supported so as to be bent by its own weight. As the support mechanism, a guide roller as shown in FIG. 9 can be used.

  In the three-dimensional modeling apparatus according to each of the above embodiments, a roller or a squeegee may be provided in order to remove excess resin liquid in the cured layer. This may be provided instead of the cleaning unit 27.

  In the first and second embodiments, a cleaning unit for removing excess resin liquid may be provided as in the fourth embodiment (see FIGS. 11 and 12). In that case, the cleaning nozzle may not be provided, and only the air blow nozzle may be provided.

  At least two of the features of each embodiment may be combined. For example, the plate member 20 or the semi-cylindrical body 40 may be applied to each of the fourth to ninth embodiments or the embodiments described in [Other Embodiments]. In addition, it is obvious to those skilled in the art to appropriately combine these characteristic portions.

S: Slit area A1: Linear area R: Resin liquid (material)
R1, 102, 105 ... hardened layer Rb ... anchor pattern Ra ... shaped body R2 ... thixotropic material R3 ... overhang-like portion 5-7, 45-47, 56, 57 ... guide roller 10 ... drum 10a ... outer peripheral surface (surface)
DESCRIPTION OF SYMBOLS 14 ... Elevating mechanism 15 ... Modeling stage 17, 16 ... Z-axis moving mechanism 20 ... Plate material 20a ... Lower surface 20b ... Upper surface 26 ... Supply nozzle, slit coat nozzle 28, 38 ... Cleaning nozzle 30, 80, 130 ... Irradiation unit 36, 70 ... Y axis moving mechanism 40 ... Semi-cylindrical body 41, 43 ... First set 42,44 ... Set 48 ... Color nozzle unit 50 ... Host computer 58 ... Moving mechanism 60 ... X axis moving mechanism 64 ... Focus controller 70 ... Y axis Moving mechanism 100, 200, 210, 300, 310, 320, 330, 340 ... 3D modeling apparatus

The present technology can have the following configurations.
(1)
Stage,
A regulating body that has a surface including a linear region along the first direction, and is arranged facing the stage so that the linear region of the surface is closest to the stage; and
A supply nozzle that supplies a material that is cured by energy of energy rays to a slit region that is a region between the stage side and the linear region;
An irradiation unit that irradiates the energy beam to the material supplied to the slit region by the supply nozzle via the regulator.
In order to form a cured layer of the material for one layer, the stage is moved relative to the regulator along a second direction different from the first direction, and the material is applied by the energy beam. In order to laminate | stack the said hardened layer, the three-dimensional modeling apparatus which comprises the moving mechanism which moves the said control body and the said stage relatively along the direction of the said lamination | stacking.
(2)
The three-dimensional modeling apparatus according to (1),
The regulating body is formed in a cylindrical shape,
The three-dimensional modeling apparatus, wherein the surface including the linear region is an outer circumferential surface of the cylindrical regulation body.
(3)
The three-dimensional modeling apparatus according to (2),
The irradiation unit is disposed inside the cylinder of the regulating body.
(4)
(2) or the three-dimensional modeling apparatus according to (3),
A three-dimensional modeling apparatus further comprising a plurality of guide rollers that rotatably support the regulating body.
(5)
The three-dimensional modeling apparatus according to (4),
A three-dimensional modeling apparatus further comprising a drive unit that drives at least one of the plurality of guide rollers.
(6)
The three-dimensional modeling apparatus according to (1),
The three-dimensional modeling apparatus, wherein the regulating body is formed in a plate shape whose surface is a curved surface.
(7)
It is the three-dimensional modeling apparatus according to any one of (1) to (6),
The moving mechanism relatively moves the regulating body and the stage along a direction including a vertical component.
(8)
It is the three-dimensional modeling apparatus according to any one of (1) to (7),
A three-dimensional modeling apparatus further comprising a cleaning nozzle for supplying a cleaning material to a modeled object formed on the stage.
(9)
It is the three-dimensional modeling apparatus according to any one of (1) to (8),
A plurality of the supply nozzles are provided, and the plurality of supply nozzles discharge different materials, respectively.
(10)
It is the three-dimensional modeling apparatus according to any one of (1) to (9),
The supply nozzle is a slit coat type nozzle.
(11)
It is the three-dimensional modeling apparatus according to any one of (1) to (10),
The supply nozzle supplies a thixotropic material as the material.
(12)
It is the three-dimensional modeling apparatus according to any one of (1) to (11),
A plurality of the regulation body and the supply nozzle are provided as a set of the regulation body and the supply nozzle, respectively.
The set of the plurality of regulation bodies and the supply nozzle is arranged along the second direction by the moving mechanism.
(13)
It is the three-dimensional modeling apparatus according to any one of (1) to (12),
The said irradiation unit irradiates an energy beam so that the anchor pattern arrange | positioned in the at least one part of the main body used as modeling object among the modeling objects and the circumference | surroundings of the said main body may be formed.
(14)
It is the three-dimensional modeling apparatus according to any one of (1) to (13),
The irradiation unit includes a generation source that generates the energy beam, and a detector that detects an intensity distribution of the energy beam generated from the generation source.
The three-dimensional modeling apparatus further includes a control mechanism that controls a relative position between the regulating body and the irradiation unit based on an intensity distribution of the energy rays detected by the detector.
(15)
It is the three-dimensional modeling apparatus according to any one of (1) to (14),
A three-dimensional modeling apparatus further comprising a rotation mechanism that rotates the stage around an axis along the stacking direction.
(16)
It is the three-dimensional modeling apparatus according to any one of (1) to (15),
A three-dimensional modeling apparatus further comprising a protective film provided on the surface of the regulating body.
(17)
It is the three-dimensional modeling apparatus according to any one of (1) to (16),
An irradiation mechanism for irradiating a plurality of energy beams as the energy rays;
The three-dimensional modeling apparatus includes a period in which the plurality of energy beams are simultaneously irradiated within an irradiation period of the energy beam on the material by the irradiation mechanism.
(18)
A regulating body having a stage and a surface including a linear region along the first direction, and arranged facing the stage so that the linear region of the surface is closest to the stage A manufacturing method using a three-dimensional modeling apparatus comprising:
Supply a material that hardens with energy of energy rays to a slit region that is a region between the stage side and the linear region,
Irradiating the material supplied to the slit region by the supply nozzle with the energy rays through the regulating body;
In order to form a cured layer of the material for one layer, the stage is moved relative to the regulating body along a second direction different from the first direction,
In order to laminate | stack the said hardened layer of the said material with the said energy beam, the said regulator and the said stage are moved relatively along the direction of the said lamination | stacking.
(19)
(18) A method for manufacturing a shaped article according to (18),
The regulating body is formed in a cylindrical shape,
The said surface including the said linear area | region is the outer peripheral surface of the said cylindrical-shaped said control body. The manufacturing method of a molded article.
(20)
(19) A manufacturing method of a shaped article according to
In the step of irradiating the energy beam, a method of manufacturing a shaped article in which the energy beam is irradiated from the inside of the cylinder of the regulating body.
(21)
(19) or (20), the method for producing a shaped article according to
The three-dimensional modeling apparatus includes a plurality of guide rollers that rotatably support the regulating body.
(22)
It is a manufacturing method of a modeling thing given in (21),
The three-dimensional modeling apparatus further includes a drive unit that drives at least one of the plurality of guide rollers.
(23)
(18) A method for manufacturing a shaped article according to (18),
The regulation body is formed in a plate shape whose surface is a curved surface.
(24)
It is a manufacturing method of a model given in any 1 paragraph among (18) to (23),
In the moving step, a method of manufacturing a shaped article that relatively moves the regulating body and the stage along a direction including a vertical component.
(25)
It is a manufacturing method of a model given in any 1 paragraph among (18) to (24),
A method of manufacturing a shaped article, wherein a cleaning material is supplied to the cured product each time one or more layers of the cured product are formed.
(26)
It is a manufacturing method of a model given in any 1 paragraph among (18) to (25),
A plurality of the supply nozzles are provided, and the plurality of supply nozzles discharge different materials, respectively.
(27)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (26),
The supply nozzle is a slit coat type nozzle.
(28)
It is a manufacturing method of a model given in any 1 paragraph among (18) to (27),
The supply nozzle supplies a thixotropic material as the material.
(29)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (28),
A plurality of the regulation body and the supply nozzle are provided as a set of the regulation body and the supply nozzle, respectively.
The set of the plurality of regulation bodies and the supply nozzles are arranged along the second direction.
(30)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (29),
In the irradiation step, a method of manufacturing a modeled object that irradiates energy rays so as to form a main body to be modeled in a modeled object and an anchor pattern arranged at least in a part of the periphery of the main body.
(31)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (30),
Detecting the intensity distribution of the energy rays;
A manufacturing method of a modeled object that controls a relative position between the regulating body and the irradiation unit based on the detected intensity distribution of the energy beam.
(32)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (31),
The irradiation step includes a step of irradiating an energy ray while the stage rotates around an axis along the stacking direction.
(33)
It is a manufacturing method of a modeling thing given in any 1 paragraph among (18) to (32),
The manufacturing method of the molded article which further comprises the protective film provided in the said surface of the said control body.
(34)
In any one of (18) to (33), there is provided a manufacturing method of a shaped article,
The three-dimensional modeling apparatus includes an irradiation mechanism that irradiates a plurality of energy beams as the energy rays,
The method of manufacturing a shaped article includes a period of simultaneous irradiation of the plurality of energy beams in the irradiation step of the energy beam to the material by the irradiation mechanism.

Claims (32)

Stage,
A regulating body that has a surface and is arranged to face the stage such that a part of the surface is closer to the stage than other regions;
An irradiation unit that irradiates an energy ray to a slit region that is a region between the stage side and a partial region of the surface;
A nozzle that supplies a material that is cured by energy of the energy ray to the slit region via the regulating body;
A three-dimensional modeling apparatus comprising: a moving mechanism that relatively moves the stage and the regulating body. The three-dimensional modeling apparatus according to claim 1,
The regulating body is formed in a cylindrical shape,
The three-dimensional modeling apparatus, wherein the surface including the partial region is an outer peripheral surface of the cylindrical regulation body. The three-dimensional modeling apparatus according to claim 2,
The irradiation unit is disposed inside the cylinder of the regulating body. The three-dimensional modeling apparatus according to any one of claims 1 to 3 ,
A three-dimensional modeling apparatus further comprising a plurality of guide rollers that rotatably support the regulating body. The three-dimensional modeling apparatus according to claim 4,
A three-dimensional modeling apparatus further comprising a drive unit that drives at least one of the plurality of guide rollers. The three-dimensional modeling apparatus according to claim 1,
The three-dimensional modeling apparatus, wherein the regulating body is formed in a plate shape whose surface is a curved surface. The three-dimensional modeling apparatus according to any one of claims 1 to 6,
The moving mechanism relatively moves the regulating body and the stage along a direction including a vertical component. The three-dimensional modeling apparatus according to any one of claims 1 to 7,
A three-dimensional modeling apparatus further comprising a cleaning nozzle for supplying a cleaning material to a modeled object formed on the stage. The three-dimensional modeling apparatus according to any one of claims 1 to 8,
The said irradiation unit irradiates an energy beam so that the anchor pattern arrange | positioned in the at least one part of the main body used as modeling object among the modeling objects and the circumference | surroundings of the said main body may be formed. The three-dimensional modeling apparatus according to any one of claims 1 to 9,
The irradiation unit includes a generation source that generates the energy beam, and a detector that detects an intensity distribution of the energy beam generated from the generation source.
The three-dimensional modeling apparatus further includes a control mechanism that controls a relative position between the regulating body and the irradiation unit based on an intensity distribution of the energy rays detected by the detector. The three-dimensional modeling apparatus according to any one of claims 1 to 10,
A three-dimensional modeling apparatus further comprising a rotation mechanism that rotates the stage around an axis along a stacking direction of a material that is cured by energy of the energy beam. The three-dimensional modeling apparatus according to any one of claims 1 to 11,
A three-dimensional modeling apparatus further comprising a protective film provided on the surface of the regulating body. The three-dimensional modeling apparatus according to any one of claims 1 to 12,
An irradiation mechanism for irradiating a plurality of energy beams as the energy rays;
The three-dimensional modeling apparatus includes a period in which the plurality of energy beams are simultaneously irradiated within an irradiation period of the energy beam with respect to the material cured by the energy of the energy beam by the irradiation mechanism.   The three-dimensional modeling apparatus according to claim 1,
  The nozzle is disposed at a position away from the slit region.
  3D modeling device.   The three-dimensional modeling apparatus according to claim 1,
  The stage is disposed obliquely with respect to a horizontal plane
  3D modeling device. In a manufacturing method by a three-dimensional modeling apparatus comprising a stage and a regulating body arranged to face the stage so that a part of the surface has a surface and is closer to the stage than other regions. There,
A material that is cured by the energy of energy rays is supplied to the slit region, which is a region between the stage side and a partial region of the surface, by the nozzle through the regulation body,
Irradiating the energy beam to the material supplied to the slit region via the regulating body,
A method of manufacturing a shaped article, wherein the stage and the regulating body are relatively moved when the material for the one layer is supplied. It is a manufacturing method of the modeling thing according to claim 16 ,
The regulating body is formed in a cylindrical shape,
The said surface including the said one part area | region is the outer peripheral surface of the said cylindrical-shaped said control body. The manufacturing method of a molded article. It is a manufacturing method of the modeling thing according to claim 17 ,
In the step of irradiating the energy beam, a method of manufacturing a shaped article in which the energy beam is irradiated from the inside of the cylinder of the regulating body. It is a manufacturing method of a modeling thing given in any 1 paragraph among Claims 16-18 ,
The three-dimensional modeling apparatus includes a plurality of guide rollers that rotatably support the regulating body. It is a manufacturing method of a modeling thing according to claim 19 ,
The three-dimensional modeling apparatus further includes a drive unit that drives at least one of the plurality of guide rollers. It is a manufacturing method of the modeling thing according to claim 16 ,
The regulation body is formed in a plate shape whose surface is a curved surface. The method of producing a molded article according to any one of the claims 16 21,
In the moving step, a method of manufacturing a shaped article that relatively moves the regulating body and the stage along a direction including a vertical component. The method of producing a molded article according to any one of the claims 16 22,
A method of manufacturing a shaped article, wherein a cleaning material is supplied to the cured product each time one or more layers of the cured product are formed. The method of producing a molded article according to any one of the claims 16 23,
In the step of supplying the material to the slit region,
A first material is supplied to any first layer, and a second material different from the first material is supplied to any second layer different from the first layer. Method. A method for producing a shaped article according to claim 16 to 24 ,
In the step of supplying the material to the slit region, a method of manufacturing a shaped article is provided in which a material having thixotropy is supplied as the material. The method of producing a molded article according to claims 16 to 1 wherein one of 25,
In the irradiation step, a method of manufacturing a modeled object that irradiates energy rays so as to form a main body to be modeled in a modeled object and an anchor pattern arranged at least in a part of the periphery of the main body. It is a manufacturing method of a modeling thing given in any 1 paragraph among Claims 16 to 26 ,
Detecting the intensity distribution of the energy rays;
A manufacturing method of a modeled object that controls a relative position between the regulation body and an irradiation unit that irradiates the energy beam based on the detected intensity distribution of the energy beam. It is a manufacturing method of a modeling thing given in any 1 paragraph among Claims 16 to 27 ,
The irradiation step includes a step of irradiating an energy beam while the stage rotates around an axis along a stacking direction of a material that is cured by the energy of the energy beam. The method of producing a molded article according to any one of the claims 16 28,
The manufacturing method of the molded article which further comprises the protective film provided in the said surface of the said control body. The method of producing a molded article according to any one of the claims 16 29,
The three-dimensional modeling apparatus includes an irradiation mechanism that irradiates a plurality of energy beams as the energy rays,
The method of manufacturing a shaped article includes a period of simultaneous irradiation of the plurality of energy beams in the irradiation step of the energy beam to the material by the irradiation mechanism.   It is a manufacturing method of the modeling thing according to claim 16,
  The nozzle is disposed at a position away from the slit region.
  Manufacturing method of a model.   It is a manufacturing method of the modeling thing according to claim 16,
  The stage is disposed obliquely with respect to a horizontal plane
  Manufacturing method of a model.