阅读说明：本技术 三维造型物的造型方法 (Method for molding three-dimensional object ) 是由 富田诚一 于 2019-11-19 设计创作，主要内容包括：本发明提供一种提高粉末使用效率和刮刀工作效率的三维造型物的造型方法,包括造型台上侧的粉末层的形成和由激光进行的烧结,采用：工序1,将刮刀移动距离设定为不到达腔室壁部的短距离；工序2,在基于由工序1设定的移动距离的移动区域内,确定将与刮刀移动方向正交的方向的两端侧连接的壁部层、或在包围预定进行烧结的区域的状态下对于粉末供给部侧的端部从该区域的两侧连接的线状的壁部层的位置；工序3,通过以由工序1设定的移动距离移动刮刀而形成粉末层；工序4,对于由工序3形成的粉末层,通过照射激光束或电子束而形成烧结层,并且在由工序2确定的壁部层的位置通过照射激光束或电子束而形成壁部层；工序5,反复进行工序3和4。(The invention provides a method for forming a three-dimensional shaped object, which improves the use efficiency of powder and the working efficiency of a scraper, comprises the formation of a powder layer on the upper side of a forming table and the sintering by laser, and adopts the following steps: step 1, setting the scraper moving distance to be a short distance which does not reach the wall of the chamber; a step 2 of determining the positions of wall layers connecting both ends in a direction orthogonal to the movement direction of the doctor blade, or linear wall layers connecting both sides of a region to be sintered to the end of the powder supply portion side while surrounding the region, within a movement region based on the movement distance set in the step 1; a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1; a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam; and 5, repeating the steps 3 and 4.)

1. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the thickness of the powder layer formed by the step 3 can be maintained in a laminated state at the end portion,

the position of the end portion of the powder layer formed in the step 3 on the opposite side of the powder supplying portion coincides with the position of the end portion of the wall layer formed in the step 4 at the position farthest from the powder supplying portion.

2. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the thickness of the powder layer formed by the step 3 can be maintained in a laminated state at the end portion,

the position of the end portion of the powder layer formed in the step 3 on the opposite side of the powder supplying portion coincides with the position of the end portion of the wall layer formed in the step 4 at the position farthest from the powder supplying portion.

3. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the entire region of the wall layer in step 2 is formed in a direction oblique to the moving direction of the doctor blade by gradually reducing the amount of powder supplied in both side regions in the frame of the doctor blade.

4. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the partial region of the wall layer in step 2 is formed in a direction oblique to the moving direction of the doctor blade by gradually reducing the amount of the powder supplied in the both side regions in the frame body of the doctor blade.

5. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the entire region of the wall layer in step 2 is formed into an elliptical or circular arc shape centered on the center position of the modeling table by gradually reducing the amount of powder supplied in the two side regions in the frame body of the doctor blade.

6. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the partial region of the wall layer in the step 2 is formed in an elliptical or circular arc shape centered on the center position of the modeling table by gradually reducing the amount of powder supplied in the two side regions in the frame body of the doctor blade.

7. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

after the sintering of the shaping region, the surface of the sintered layer and the vicinity thereof are cut so that the width between the end of the sintered layer farthest from the powder supply portion and the inner end of the wall layer closest to the powder supply portion becomes the cutting width of the surface of the sintered layer.

8. A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

after the sintering of the shaping region, the surface of the sintered layer and the vicinity thereof are cut so that the width between the end of the sintered layer farthest from the powder supply portion and the inner end of the wall layer closest to the powder supply portion becomes the cutting width of the surface of the sintered layer.

Technical Field

The present invention is directed to a three-dimensional shaped object shaping method based on the formation of a powder layer, in which the formation area of the powder layer is not set to the entire area on a shaping table corresponding to the total moving distance of a doctor blade, but is set to a short moving distance of the doctor blade, thereby setting the formation area of the powder layer to a partial area on the shaping table.

Background

Disclosure of Invention

The invention provides a method for forming a three-dimensional shaped object, which can avoid forming an excessive powder layer and can improve the working efficiency in the movement of a scraper.

To solve the above problems, the present invention includes the following basic technical components (1), (2), (3), (4), (5), (6), (7) and (8).

(1) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the thickness of the powder layer formed by the step 3 can be maintained in a laminated state at the end portion,

the position of the end portion of the powder layer formed in the step 3 on the opposite side of the powder supplying portion coincides with the position of the end portion of the wall layer formed in the step 4 at the position farthest from the powder supplying portion.

(2) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the thickness of the powder layer formed by the step 3 can be maintained in a laminated state at the end portion,

the position of the end portion of the powder layer formed in the step 3 on the opposite side of the powder supplying portion coincides with the position of the end portion of the wall layer formed in the step 4 at the position farthest from the powder supplying portion.

(3) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the entire region of the wall layer in step 2 is formed in a direction oblique to the moving direction of the doctor blade by gradually reducing the amount of powder supplied in both side regions in the frame of the doctor blade.

(4) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the partial region of the wall layer in step 2 is formed in a direction oblique to the moving direction of the doctor blade by gradually reducing the amount of the powder supplied in the both side regions in the frame body of the doctor blade.

(5) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the entire region of the wall layer in step 2 is formed into an elliptical or circular arc shape centered on the center position of the modeling table by gradually reducing the amount of powder supplied in the two side regions in the frame of the doctor blade.

(6) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

the partial region of the wall layer in the step 2 is formed in an elliptical or circular arc shape centered on the center position of the modeling table by gradually reducing the amount of powder supplied in the two side regions in the frame body of the doctor blade.

(7) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connecting both side ends in a direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

after the sintering of the shaping region, the surface of the sintered layer and the vicinity thereof are cut so that the width between the end of the sintered layer farthest from the powder supply portion and the inner end of the wall layer closest to the powder supply portion becomes the cutting width of the surface of the sintered layer.

(8) A method of forming a three-dimensional shaped object, comprising forming a powder layer by moving a doctor blade and scattering powder on an upper side of a forming table, and sintering a forming area by irradiating a laser beam or an electron beam, the method comprising the steps of:

a step 1 of setting a moving distance of the scraper moving in a linear direction after receiving the powder supplied by the powder supply part to be smaller than a total moving distance based on a wall of the chamber;

a step 2 of determining the position of a linear wall layer connected from both sides of a region to be sintered to the end portion on the powder supply portion side while surrounding the region, within a movement region of the doctor blade based on the movement distance set in the step 1;

a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1;

a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam;

a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached,

after the sintering of the shaping region, the surface of the sintered layer and the vicinity thereof are cut so that the width between the end of the sintered layer farthest from the powder supply portion and the inner end of the wall layer closest to the powder supply portion becomes the cutting width of the surface of the sintered layer.

In the present invention based on the basic technical configurations (1), (2), (3), (4), (5), (6), (7), and (8), the powder layer is formed as in step 3 at the movement distance of the doctor blade set as in step 1, and not only the sintered layer but also the wall layers positioned in sequence in step 2 are formed and stacked as in step 4, whereby the collapse of the area of the powder layer on the side opposite to the powder supply part can be prevented, and as a result, the formation of an extra powder layer can be avoided, and the operation efficiency of the doctor blade can be improved.

As described later, since the powder layer is rarely or not formed in the region where the sintered layer is not present on the outer side of the wall layer, that is, on the basis of the wall layer, it is possible to avoid a problem that a considerable amount of powder falls from the gap between the wall of the chamber and the end of the molding table.

Drawings

Fig. 1 is a plan view for explaining the features of the basic technical configurations (3) and (4), (a) shows a case of the basic technical configuration (3), and (b) shows a case of the basic technical configuration (4). Note that the white-frame arrow indicates the moving direction of the doctor blade, which is the same in the following plan view.

Fig. 2 is a plan view for explaining the features of the basic technical configurations (5) and (6), where (a) shows the case of the basic technical configuration (5) and (b) shows the case of the basic technical configuration (6).

Fig. 3 shows a flowchart for explaining the steps of the present invention, wherein (a) shows the cases of the basic technical configurations (1) (3) (5) (7), and (b) shows the cases of the basic technical configurations (2) (4) (6) (8). N in (a) and (b) represents the number of sintered layers formed by irradiation, and K in (a) represents the number of times of movement when a plurality of doctor blade movements are required to form one sintered layer.

Fig. 4 shows a state of stacking three-dimensional shaped objects in which steps 3 and 4 are repeated on the premise of steps 1 and 2 in the basic technical configurations (1) and (2), (a) is a side sectional view showing a state of stacking completed in the basic technical configurations (1) and (2), (b) is a plan view showing a state of stacking completed in the basic technical configuration (1), and (c) is a plan view showing a state of stacking completed in the basic technical configuration (2).

Fig. 5 is a side sectional view showing a configuration of a conventional technique, where (a) shows a state where a powder layer is laminated over the entire upper region on a modeling table, and (b) shows a state where the laminated powder layer is collapsed from the upper region in a case where the powder layers are sequentially formed on a powder supply portion side in a partial region on the modeling table.

Description of the reference numerals

1 moulding table

2 scraper

21 frame body

22 plate-shaped body

3 sintered layer

4 wall layers

5 powder supply part

6 walls of the chamber

10 powder

Detailed Description

In the above-described basic technical configurations (1), (2), (3), (4), (5), (6), (7), and (8), in order to mold a three-dimensional shaped object, it is necessary to form a powder layer by moving the doctor blade 2 and to form the sintered layer 3 in the molding region by irradiating a laser beam or an electron beam, which is the same as in the conventional technique.

Further, after the sintering, the sintered surface and its vicinity may be cut by a cutting tool, and the cutting step is necessary in the case of shaping a precise shape.

In the above-described basic technical configurations (1), (3), (5), and (7), as shown in the flowchart of fig. 3(a), the following steps are employed.

In step 1, the moving distance of the scraper moving in the linear direction after receiving the powder supplied by the powder supply part is set to be smaller than the total moving distance based on the wall of the chamber.

And a step 2 of determining the position of the linear wall layer connecting both side ends in the direction orthogonal to the moving direction of the doctor blade in the moving region of the doctor blade based on the moving distance set in the step 1.

And a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1.

And a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam.

And a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached.

In the basic technical configurations (2), (4), (6) and (8), as shown in the flowchart of fig. 3(b), the following steps are employed.

In step 1, the moving distance of the scraper moving in the linear direction after receiving the powder supplied by the powder supply part is set to be smaller than the total moving distance based on the wall of the chamber.

And a step 2 of determining the position of a linear wall layer connected from both sides of the region to be sintered to the end portion on the powder supply portion side while surrounding the region in the movement region of the doctor blade based on the movement distance set in the step 1.

And a step 3 of forming a powder layer by moving the doctor blade by the movement distance set in the step 1.

And a step 4 of forming a sintered layer by irradiating the powder layer formed in the step 3 with a laser beam or an electron beam, and forming a wall layer by irradiating the wall layer determined in the step 2 with a laser beam or an electron beam.

And a step 5 of repeating the step 3 and the step 4 until the top of the three-dimensional object is reached.

As is apparent from the above steps, the basic technical configurations (1), (3), (5), (7) are different from the basic technical configurations (2), (4), (6) and (8), and the shape of the wall layer 4 formed in a linear shape in the step 2 is different, and the other steps 1, 3 and 4 are the same.

Fig. 3(a) shows a state in which the sintered layer 3 is formed before the wall layer 4 and each powder layer is formed by a plurality of movements of the doctor blade 2, but such a state may be adopted in the basic technical configurations (2), (4), (6), and (8).

Similarly, fig. 3(b) shows a state in which the wall layer 4 is formed before the sintering layer 3 and the powder layer is formed by 1 time of movement of the doctor blade 2, but such a state may be adopted in the basic technical configurations (1), (3), (5), and (7).

By adopting the above-described steps, in the basic technical configurations (1), (2), (3), (4), (5), (6), (7) and (8), as shown in the side sectional view of fig. 4(a), the sintered layer 3 is not merely superimposed but the wall layer 4 is superimposed in the region where the powder layers formed in the above-described step 3 are stacked, as in the step 4, whereby the powder layers can be prevented from collapsing.

Further, by setting the moving distance of the doctor blade 2 to be smaller than the total moving distance based on the wall portion 6 of the chamber, that is, the moving distance of the doctor blade 2 in contact with or close to the wall portion 6, in the basic technical configurations (1), (2), (3), (4), (5), (6), (7), and (8), as shown in fig. 4(b) and 4(c), the forming region of the powder layer is set to be a partial region on the shaping table 1, whereby the work efficiency of forming the powder layer can be improved.

While the linear wall layers 4 are connected to both end sides in the direction perpendicular to the moving direction of the doctor blade 2 in step 2 of the basic technical configurations (1), (3), (5), and (7), the wall layers 4 formed in a linear shape are connected to the powder supply portion 5 side from both sides of the region in a state of surrounding the region to be sintered in step 2 of the basic technical configurations (2), (4), (6), and (8), and the shapes of the wall layers 4 are different between the two.

The shape of the wall layer 4 in the basic technical configurations (1), (3), (5), and (7) is simpler than the shape of the wall layer 4 in the basic technical configurations (2), (4), (6), and (8).

In contrast, in the case of the basic technical configurations (2), (4), (6), and (8), the powder layers outside the wall layer 4 surrounding the sintering region are not formed, and thus more efficient use of the powder layers can be achieved.

This point will be described later in the embodiment of fig. 4 (c).

The relationship between the position of the end of the powder layer and the position of the end of the wall layer 4 will be described, but in the basic technical configurations (1), (2), (3), (4), (5), (6), (7) and (8), an embodiment may be adopted in which the position of the end on the opposite side of the powder supply portion 5 in the powder layer formed in step 3 is located in the vicinity of the position of the end farthest from the position of the powder supply portion 5 in the wall layer 4 formed in step 4 (fig. 1(b) and fig. 2(b) show the case where the above-described embodiment is adopted).

In the case of such an embodiment, although the powder layers of the parts are sequentially stacked outside the wall layer 4 farther from the powder supply portion 5 and the end portions of the powder layers and the vicinity thereof are collapsed, the stacked state of the powder layers on the powder supply portion 5 side can be maintained by the stacking of the wall layer 4, and the collapse of a large number of powder layers that hinder the formation of the sintered layer 3 as shown in fig. 5(b) can be sufficiently avoided.

In the basic technical configurations (1) and (2), as shown in fig. 4(b) and (c) and fig. 1(a) and 2(a), the powder layer formed in step 3 has a thickness capable of maintaining a laminated state at the end portion, and the position of the end portion on the opposite side of the powder supply portion 5 in the powder layer formed in step 3 coincides with the position of the end portion farthest from the powder supply portion 5 in the wall layer 4 formed in step 4.

In the case of the basic technical configurations (1) and (2), the powder layer in the outer region of the wall layer 4 is not formed, and thus the stacking of the extra powder layers can be completely avoided.

However, in the lamination of the powder layers, it is necessary to select a thickness to such an extent that the end portions do not collapse.

Fig. 1(b) and 2(b) show a state in which a powder layer is formed in the vicinity of the outer end of the wall layer 4, and the technical configuration of the basic technical configuration (2) is not adopted in the basic technical configurations (4) and (6), and fig. 1(a) and 2(a) show a state in which the technical configuration of the basic technical configuration (1) is adopted in the basic technical configurations (3) and (5) because a powder layer is not formed at the outer end of the wall layer 4.

In the basic technical configurations (1), (2), (3), (4), (5), (6), (7), and (8), the powder layer is formed little or not outside the wall layer 4, and the wall layer 4 is separated from the wall 6 of the chamber, so that a problem that a considerable amount of the powder 10 falls from the gap between the wall 6 of the chamber and the end of the shaping table 1 can be avoided.

Further, in the case where the outer end of the wall layer 4 coincides with the end of the modeling table 1 and there is a predetermined gap between the end of the modeling table 1 and the wall 6 of the chamber, assuming that it is necessary or desirable to completely prevent the powder layer from falling, this can be solved by using the basic technical configuration (1) shown in fig. 1(a), 2(a), and 4(b) in a state where the powder layer is not formed in the outer region of the wall layer 4, and this is also the same in the case of the basic technical configuration (2) shown in fig. 4 (c).

The wall layers 4 are sequentially stacked as shown in fig. 4(a), and the thickness of the wall layers 4 in the horizontal direction is not particularly limited as long as the wall layers can be prevented from falling off to the outside of the adjacent powder layers, that is, from the powder supply portion 5 to the opposite side.

However, the thickness of 5mm or more is usually sufficient to prevent the above-mentioned falling-off in most three-dimensional moldings.

In the case of the basic technical configurations (2), (4), (6), and (8), as shown in fig. 1(b), 2(b), and 4(c), the following embodiments can be adopted: in a frame 21 of a doctor blade 2 receiving powder 10 from a powder supply portion 5, 2 plate-like bodies 22 are provided on both sides of a region including a maximum width in a sintered layer 3 with reference to a direction orthogonal to a moving direction of the doctor blade 2, the powder 10 is supplied from the powder supply portion 5 into the 2 plate-like bodies 22, and 2 wall portions 4 are formed by a process 4 along the moving direction of the 2 plate-like bodies 22, and the 2 wall portions 4 are connected by another wall portion 4.

In the case of the above embodiment, the stacking of the excessive powder layer can be reliably avoided even in the region in the direction orthogonal to the moving direction of the doctor blade 2.

In the wall layer 4, in the case of the basic technical configuration (1), as shown in fig. 4(b), the entire region may be formed in a straight line in the direction orthogonal to the moving region of the blade 2, or in the case of the basic technical configuration (2), as shown in fig. 4(c), a part of the region may be formed in a straight line in the direction orthogonal to the moving direction of the blade 2, and by forming the wall layer in such a straight line, a simple design can be achieved.

However, the basic technical configurations (1) and (2) are not limited to the formation of such a straight line.

The basic technical configuration (3) is characterized in that the entire area of the wall layer 4 is formed in a direction oblique to the moving direction of the blade 2 as shown in fig. 1(a), and the basic technical configuration (4) is characterized in that a partial area of the wall layer 4 is formed in a direction oblique to the moving direction of the blade 2 as shown in fig. 1 (b).

As in the basic technical configurations (3) and (4), by setting the wall layer 4 in a state of being inclined with respect to the moving direction of the doctor blade 2, the wall layer 4 can be formed in a state closer to the three-dimensional shaped object than in an orthogonal state.

As shown in fig. 1(a) and (b), in order to reduce the formation of the powder layer on the outer side of the wall layer 4 in the oblique state, that is, on the opposite side of the powder supply portion 5, the amount of the powder 10 supplied to the frame 21 of the doctor blade 2 in the elongated shape is gradually reduced.

The basic technical configuration (5) is, as shown in fig. 2(a), characterized in that the entire region of the wall layer 4 is formed in an elliptical arc shape or a circular arc shape centered on the center position of the modeling table 1, and the basic technical configuration (6) is, as shown in fig. 2(b), characterized in that a partial region of the wall layer 4 is formed in the elliptical arc shape or the circular arc shape (fig. 2(a) shows a case of a circular arc shape, and fig. 2(b) shows a case of an elliptical arc shape).

In the basic technical configurations (5) and (6), the wall layer 4 can be formed in a state close to the sintered layer 3 as in the basic technical configurations (3) and (4), and by adjusting to a state in which the amount of the powder 10 supplied in the both side regions in the frame body 21 of the doctor blade 2 formed into an elongated shape is gradually reduced as in the case of the basic technical configurations (3) and (4), a state in which an excessive powder layer is formed outside the wall layer 4 can be reduced as much as possible.

The basic technical constitutions (7) and (8) are characterized in that after the sintering of the shaping region, the surface of the sintered layer 3 and the vicinity thereof are cut, and the width between the position of the end portion of the sintered layer 3 on the side farthest from the powder supply portion 5 and the end portion of the wall layer 4 on the inner side closest to the powder supply portion 5 is made to be the cutting width of the surface of the sintered layer 3.

In the three-dimensional modeling, the cutting of the surface of the sintered layer 3 is not always performed, but in the case of a three-dimensional modeled object that needs to be cut, the most compact stacking area of the powder layers can be realized based on the widths of the basic technical configurations (7) and (8), and the most efficient movement of the doctor blade 2 can be achieved.

Industrial applicability

The invention can avoid the overlapping of redundant powder layers in all three-dimensional modeling object modeling methods, and realize the effective movement of a scraper. The present invention can be widely applied to all three-dimensional shaped object shaping methods using the movement of a doctor blade and the irradiation of a laser beam or an electron beam.