WO2018199041A1 - Method for producing three-dimensional formed object, and three-dimensional formed object - Google Patents

Abstract

Provided is a method for producing a three-dimensional formed object by alternately repeating powder layer formation and solidified layer formation. In this production method, a density change region, where the density of the three-dimensional formed object changes in a localized manner, is disposed on a surface section which includes an oblique face of the three-dimensional formed object, and in the density change region, the density is changed in accordance with the angle formed by the surface section including the oblique face and the lamination direction of solidified layers.

Description

Manufacturing method of three-dimensional shaped object and three-dimensional shaped object

The present disclosure relates to a method for manufacturing a three-dimensional shaped object and a three-dimensional shaped object. In more detail, this indication is related with the manufacturing method of the three-dimensional shape molded article which forms a solidified layer by light beam irradiation to a powder layer, and the three-dimensional shape molded article obtained by it.

A method for producing a three-dimensional shaped object by irradiating a powder material with a light beam (generally referred to as “powder bed fusion bonding method”) has been conventionally known. In this method, a three-dimensional shaped object is manufactured by alternately repeating powder layer formation and solidified layer formation based on the following steps (i) and (ii) (see Patent Document 1 or Patent Document 2). .
(I) A step of irradiating a predetermined portion of the powder layer with a light beam and sintering or melting and solidifying the powder at the predetermined portion to form a solidified layer.
(Ii) A step of forming a new powder layer on the obtained solidified layer and similarly irradiating a light beam to form a further solidified layer.

According to such a manufacturing technique, it becomes possible to manufacture a complicated three-dimensional shaped object in a short time. When an inorganic metal powder is used as the powder material, the obtained three-dimensional shaped object can be used as a mold. On the other hand, when organic resin powder is used as the powder material, the obtained three-dimensional shaped object can be used as various models.

Suppose that a metal powder is used as a powder material and a three-dimensional shaped object obtained thereby is used as a mold. As shown in FIG. 12, first, the squeezing blade 23 is moved to transfer the powder 19 to form a powder layer 22 having a predetermined thickness on the modeling plate 21 (see FIG. 12A). Next, the solidified layer 24 is formed from the powder layer by irradiating a predetermined portion of the powder layer with the light beam L (see FIG. 12B). Subsequently, a new powder layer is formed on the obtained solidified layer and irradiated with a light beam again to form a new solidified layer. When the powder layer formation and the solidified layer formation are alternately performed in this manner, the solidified layer 24 is laminated (see FIG. 12C), and finally a three-dimensional shape composed of the laminated solidified layers. A model can be obtained. Since the solidified layer 24 formed as the lowermost layer is in a state of being combined with the modeling plate 21, the three-dimensional modeled object and the modeling plate form an integrated object, and the integrated object can be used as a mold. it can.

Japanese National Patent Publication No. 1-502890 JP 2000-73108 A

When using a three-dimensional shaped object as a mold, a molding raw material in a molten state (hereinafter referred to as “mold side”) formed in a mold cavity space formed by combining so-called “core side” and “cavity side” molds. Also referred to as “molten raw material”. Specifically, the molten raw material is poured into a mold cavity space, and the molten raw material thus poured is cooled to obtain a molded product. That is, the molten raw material flows to fill the mold cavity space, and the molten raw material changes to a solidified state, thereby obtaining a molded product.

In the obtained molded product, linear traces may occur due to the flow of the molten raw material in the mold cavity space. That is, a so-called “weld line” occurs in the molded product. The weld line is undesirable in terms of the appearance of the molded product. Also, the weld line is not desirable in terms of the strength of the molded product. Therefore, in order to reduce the weld line, for example, the gas existing in the mold cavity space or the gas generated from the molten raw material is extracted to the outside during filling of the molten raw material (hereinafter also referred to as “gas venting”).

The inventor of the present application has found that there is a problem to be overcome in the conventional gas venting, and has found that it is necessary to take measures for that. Specifically, the present inventors have found that there are the following problems.

When a mold made of a three-dimensional modeled object is used, it is conceivable to provide a fine hole on the surface of the three-dimensional modeled object, and perform gas venting using the microhole region as a ventilation region. In such a ventilation region, the fine holes themselves function as gas passages. Therefore, it is preferable in terms of degassing. However, the surface of the molded product may be rough due to the fine holes. That is, when the ventilation region is provided on the mold surface, the ventilation region itself may adversely affect the surface of the molded product, and high-quality molding transfer may be difficult. This means that in the case of a mold provided with a ventilation region on the surface, the “gas release characteristics” and the “high-quality transfer characteristics” have a trade-off relationship. In particular, the inventor of the present application has found that when a mold surface including a ventilation region includes an “inclined surface”, a transfer characteristic peculiar to the surface is developed, and the roughness of the surface of the molded product may not be ignored.

The present invention has been made in view of such circumstances. That is, a main problem of the present invention is to provide a three-dimensional shaped article that is more suitable as a mold having a ventilation region.

In order to solve the above problems, in one embodiment of the present invention,
(I) a step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt-solidify the powder at the predetermined portion to form a solidified layer; and (ii) a new powder on the obtained solidified layer A method for producing a three-dimensional shaped article in which a powder layer and a solidified layer are alternately formed by a step of forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer Because
A density change region in which the density of the three-dimensional shaped object is locally different is provided on the surface portion including the inclined surface of the three-dimensional shaped object,
In the density change region, there is provided a method for manufacturing a three-dimensional shaped object, in which the density is locally varied according to the angle formed by the surface of the object including the inclined surface and the stacking direction of the solidified layer.

In one embodiment of the present invention, a three-dimensional shaped article obtained by the above manufacturing method is also provided. One aspect of the present invention is a three-dimensional shaped object composed of laminated solidified layers and having an inclined surface,
A density change region where the density of the three-dimensional shaped object is locally different is provided in the surface portion including the inclined surface,
In the density change region, the density is locally different depending on the angle formed by the surface of the model including the inclined surface with the stacking direction of the solidified layer.

According to one aspect of the present invention, a three-dimensional shaped object including a ventilation region can be obtained more suitably. More specifically, in one embodiment of the present invention, a three-dimensional shaped article can be obtained as a mold that suitably exhibits both “gas release characteristics” and “high-quality transfer characteristics”.

In particular, in a mold made of a three-dimensional shaped object according to one aspect of the present invention, even in a ventilation region having an “inclined surface”, high-quality transfer characteristics while ensuring a suitable “gas release characteristic” Can be obtained. That is, it is possible to reduce the roughness of the surface of the molded product while ensuring a suitable degassing characteristic.

Also, for example, when a cylindrical molded product is molded with a mold, a weld line is usually easily generated at the tip of the cylindrical molded product. In one aspect of the present invention, it is possible to provide a mold with a wider ventilation region for effectively reducing such weld lines.

Sectional drawing which represented typically the three-dimensional shaped object (three-dimensional shaped object which has an inclined surface as a "non-smooth surface") which concerns on 1 aspect of this invention. Sectional drawing which represented typically the three-dimensional modeled object (three-dimensional modeled object which has an inclined surface as a "smooth surface") concerning one mode of the present invention. Schematic diagram for explaining “Roughness of the surface of the molded product due to surface opening” Cross-sectional view of a three-dimensional shaped object for explaining the micropore structure in the density change region Sectional drawing of the three-dimensional shape molded article for demonstrating the aspect which provides a hollow path Cross-sectional view of a three-dimensional shaped object for explaining a mode in which “solidified portions of random fine holes” are provided in a hollow channel Perspective view partially showing a cylindrical molded product Perspective perspective view partially showing a mold for obtaining a cylindrical molded product Sectional drawing of the three-dimensional shape molded article for demonstrating an aspect provided with two hollow paths Sectional drawing of the three-dimensional shape molded article for demonstrating the aspect from which a density changes to an inner side direction Cross-sectional view of a three-dimensional shaped object for explaining a mode in which the outer peripheral portion is a random fine hole region or a high-density region Sectional drawing (FIG. 12 (a): powder layer formation, FIG. 12 (b): solidified layer formation, FIG. 12 (c)) schematically showing a process aspect of stereolithography combined processing in which the powder bed fusion bonding method is performed. : Stacking of solidified layers) The perspective view which showed the composition of the optical modeling compound processing machine typically Flow chart showing general operation of stereolithography combined processing machine

Hereinafter, an embodiment of the present invention will be described in more detail with reference to the drawings. The forms and dimensions of the various elements in the drawings are merely examples, and do not reflect actual forms and dimensions.

In this specification, “powder layer” means, for example, “a metal powder layer made of metal powder” or “a resin powder layer made of resin powder”. The “predetermined portion of the powder layer” substantially refers to the region of the three-dimensional shaped object to be manufactured. Therefore, by irradiating the powder existing at the predetermined location with a light beam, the powder is sintered or melted and solidified to form a three-dimensional shaped object. Further, “solidified layer” means “sintered layer” when the powder layer is a metal powder layer, and means “cured layer” when the powder layer is a resin powder layer. Incidentally, the metal powder used in one embodiment of the present invention is a powder mainly composed of iron-based powder, and in some cases, a group consisting of nickel powder, nickel-based alloy powder, copper powder, copper-based alloy powder, graphite powder, and the like. It may be a powder further comprising at least one selected from.

The “up and down” direction described directly or indirectly in the present specification is based on the positional relationship between the modeling plate and the three-dimensional modeled object when the three-dimensional modeled object is manufactured. Specifically, the side on which the three-dimensional shaped object is manufactured with reference to the modeling plate is defined as “upward”, and the opposite side is defined as “downward”. For convenience, it can be understood that the downward direction in the vertical direction (that is, the direction in which gravity acts) corresponds to “downward”, and the opposite direction corresponds to “upward”.

Furthermore, “cross-sectional view” used directly or indirectly in the present specification corresponds to a side view when the powder bed fusion bonding method is viewed from the side or viewed along the horizontal direction. For simplicity, it may be regarded as a cross-sectional view of the three-dimensional shaped object obtained when the three-dimensional shaped object is virtually cut off on a plane parallel to the stacking direction of the solidified layer.

[Powder bed fusion bonding method]
First, the powder bed fusion bonding method which is a premise of the manufacturing method according to one embodiment of the present invention will be described. In particular, an optical modeling composite processing in which a cutting process is additionally performed on a three-dimensional shaped object in the powder bed fusion bonding method will be exemplified. FIG. 12 schematically shows a process aspect of the optical modeling composite processing. FIG. 13 and FIG. 14 respectively show flowcharts of the main configuration and operation of the stereolithography combined processing machine capable of performing the powder bed fusion bonding method and the cutting process.

The stereolithography combined processing machine 1 includes a powder layer forming means 2, a light beam irradiation means 3, and a cutting means 4, as shown in FIG.

The powder layer forming means 2 is means for forming a powder layer by spreading a powder such as a metal powder or a resin powder with a predetermined thickness. The light beam irradiation means 3 is a means for irradiating a predetermined portion of the powder layer with the light beam L. The cutting means 4 is a means for cutting the side surface of the laminated solidified layer, that is, the surface of the three-dimensional shaped object.

The powder layer forming means 2 mainly comprises a powder table 25, a squeezing blade 23, a support table 20, and a modeling plate 21, as shown in FIG. The powder table 25 is a table that can be moved up and down in a powder material tank 28 whose outer periphery is surrounded by a wall 26. The squeezing blade 23 is a blade that can move in the horizontal direction to obtain the powder layer 22 by supplying the powder 19 on the powder table 25 onto the support table 20. The support table 20 is a table that can be moved up and down in a modeling tank 29 whose outer periphery is surrounded by a wall 27. The modeling plate 21 is a plate that is arranged on the support table 20 and serves as a base for a three-dimensional modeled object.

The light beam irradiation means 3 mainly includes a light beam oscillator 30 and a galvanometer mirror 31 as shown in FIG. The light beam oscillator 30 is a device that emits a light beam L. The galvanometer mirror 31 is means for scanning the emitted light beam L into the powder layer 22, that is, scanning means for the light beam L.

The cutting means 4 mainly includes an end mill 40 and a drive mechanism 41 as shown in FIG. The end mill 40 is a cutting tool for cutting the side surface of the laminated solidified layer, that is, the surface of the three-dimensional shaped object. The drive mechanism 41 is means for moving the end mill 40 to a desired location to be cut.

The operation of the stereolithography combined processing machine 1 will be described in detail. The operation of the optical modeling complex machine 1 includes a powder layer forming step (S1), a solidified layer forming step (S2), and a cutting step (S3) as shown in the flowchart of FIG. The powder layer forming step (S1) is a step for forming the powder layer 22. In the powder layer forming step (S1), first, the support table 20 is lowered by Δt (S11) so that the level difference between the upper surface of the modeling plate 21 and the upper end surface of the modeling tank 29 becomes Δt. Next, after raising the powder table 25 by Δt, the squeezing blade 23 is moved in the horizontal direction from the powder material tank 28 toward the modeling tank 29 as shown in FIG. Thereby, the powder 19 arranged on the powder table 25 can be transferred onto the modeling plate 21 (S12), and the powder layer 22 is formed (S13). Examples of the powder material for forming the powder layer 22 include “metal powder having an average particle diameter of about 5 μm to 100 μm” and “resin powder such as nylon, polypropylene, or ABS having an average particle diameter of about 30 μm to 100 μm”. it can. When the powder layer 22 is formed, the process proceeds to a solidified layer forming step (S2). The solidified layer forming step (S2) is a step of forming the solidified layer 24 by light beam irradiation. In the solidified layer forming step (S2), the light beam L is emitted from the light beam oscillator 30 (S21), and the light beam L is scanned to a predetermined location on the powder layer 22 by the galvano mirror 31 (S22). As a result, the powder at a predetermined location of the powder layer 22 is sintered or melted and solidified to form a solidified layer 24 as shown in FIG. 12B (S23). As the light beam L, a carbon dioxide laser, an Nd: YAG laser, a fiber laser, an ultraviolet ray, or the like may be used.

The powder layer forming step (S1) and the solidified layer forming step (S2) are alternately repeated. As a result, a plurality of solidified layers 24 are laminated as shown in FIG.

When the laminated solidified layer 24 reaches a predetermined thickness (S24), the process proceeds to the cutting step (S3). The cutting step (S3) is a step for cutting the side surface of the laminated solidified layer 24, that is, the surface of the three-dimensional shaped object. A cutting step is started by driving the end mill 40 (see FIG. 12C and FIG. 13) (S31). For example, when the end mill 40 has an effective blade length of 3 mm, a cutting process of 3 mm can be performed along the height direction of the three-dimensional shaped object. When the solidified layer 24 is laminated, the end mill 40 is driven. Specifically, a cutting process is performed on the side surface of the laminated solidified layer 24 while the end mill 40 is moved by the drive mechanism 41 (S32). At the end of such a cutting step (S3), it is determined whether or not a desired three-dimensional shaped object has been obtained (S33). When the desired three-dimensional shaped object is not yet obtained, the process returns to the powder layer forming step (S1). Thereafter, the powder layer forming step (S1) to the cutting step (S3) are repeatedly performed to further laminate the solidified layer and perform a cutting process, whereby a desired three-dimensional shaped object is finally obtained.

[Production method of the present invention]
The manufacturing method according to an aspect of the present invention is characterized by the formation of a solidified layer with respect to the above-described powder bed fusion bonding method. In particular, the density of the surface portion of the three-dimensional shaped object obtained by forming the solidified layer is characterized.

In the manufacturing method according to one aspect of the present invention, “density change regions” in which the density of the three-dimensional shaped object is locally different are provided on the surface portion including the inclined surface of the three-dimensional shaped object. In other words, a “density change region” in which the density of the three-dimensional shaped object changes along the surface portion including the inclined surface is provided in the three-dimensional shaped object. As shown in FIGS. 1 and 2, in the manufacture of the three-dimensional shaped object 100, the density changing region 150 is formed so as to have a thickness from the surface 110 of the object to the inside.

In particular, in the manufacturing method according to one aspect of the present invention, the density changes in accordance with “the angle formed by the surface of the model including the inclined surface with the stacking direction of the solidified layer (hereinafter also simply referred to as“ surface angle ”)”. The density of the region 150 is locally varied. In short, in the density change region 150, the density is locally varied according to the surface angle of the model surface 110. This means that when the three-dimensional shaped object 100 having an inclined surface is manufactured, the solidified layer is formed so that the density of the three-dimensional shaped object changes according to the surface angle of the three-dimensional object. . In the embodiment shown in FIG. 1, the surface vicinity region (150A, 150B, 150C) of the target according to the surface angle (for example, θ _A , θ _B , θ _{C as shown} ) including the inclined surface. The density of each is different from each other. Similarly, in the aspect shown in FIG. 2, depending on the surface angle (for example, θ _a , θ _b , θ _c , θ _d , θ _{e as shown} ) of the object surface 110 including the inclined surface, The densities of the surface vicinity regions (150a, 150b, 150c, 150d, 150e) are made different from each other. As can be seen from FIG. 1 and FIG. 2, in the present invention, “the angle formed by the surface of the surface portion including the inclined surface and the laminating direction of the solidified layer” (that is, “surface angle”) means the surface of the model and the solidified layer. Among the angles formed with the stacking direction, the angle on the side that forms an acute angle is particularly indicated. As will be described later, in one aspect of the present invention, the three-dimensional shaped article is formed so that the surface portion including the outermost surface of the three-dimensional shaped article has a density that gradually changes along the cross-sectional contour of the outermost surface. It is preferable to perform manufacture.

In this specification, the “surface portion including the inclined surface of the three-dimensional shaped object” means that the surface of the three-dimensional shaped object is a cross-sectional view of the three-dimensional shaped object as shown in FIGS. 1 and 2. It means substantially the surface portion of the shaped object in which the angle formed with the stacking direction of the solidified layer (ie, “surface angle”) is not constant. In addition, in this specification, the expression “providing a density change region in which the density of the three-dimensional shaped object is locally different on a surface portion including the inclined surface of the three-dimensional shaped object” is broadly defined for each local region. This means that density change regions having different densities are provided on the surface portion of the shaped object including the inclined surface. In a narrow sense, such an expression forms a density change region where the density varies locally according to the size of the surface angle of the three-dimensional shaped object when viewed in cross-section as shown in the figure. It means that the thickness is provided from the surface of the object. As can be understood from the above description, the “inclined surface” in the present specification refers to a surface of a molded object whose angle formed with respect to the stacking direction is not constant in a cross-sectional view of the three-dimensional shaped object. Particularly preferably, the angle is such that the angle gradually changes along the surface of the object to be modeled. In addition, such an inclined surface may have a form of “non-smooth surface” or “a plurality of sub-planes” as illustrated in FIG. 1, for example, or as illustrated in FIG. It may have the form of “smooth surface” or “curved surface”.

In addition, the expression “in the density changing region, in the density changing region, the density is locally changed according to the angle formed by the surface of the surface portion including the inclined surface and the stacking direction of the solidified layer” is used in the local expression in the density changing region. This means that the density change and the degree of surface inclination of the three-dimensional shaped object have a correlation with each other. In other words, it can be said that the surface portion forming the surface angle has a density corresponding to the size of the surface angle of the three-dimensional shaped object.

The size of the surface angle will be described in detail with reference to cross-sectional views of the three-dimensional shaped object shown in FIGS. When the angle formed by the surface of the three-dimensional shaped object with respect to the stacking direction of the solidified layer constituting the three-dimensional shaped object is smaller (that is, when the surface angle is small), the surface of the formed object is relatively steep. Thus, the degree of surface inclination becomes larger. In short, it can be said that the inclination degree is larger in such a case. On the other hand, when the angle formed by the surface of the three-dimensional shaped object with respect to the stacking direction of the solidified layer constituting the three-dimensional shaped object is larger (that is, when the surface angle is large), the surface of the formed object is relatively non- A steep surface is formed, and the degree of surface inclination becomes smaller. In short, it can be said that the inclination degree is smaller in such a case. In addition, as shown in FIG. 2, when the inclined surface of the three-dimensional shaped object is curved, a tangent line passing through the surface of the three-dimensional object in a cross-sectional view may be used as the “virtual surface”. That is, an angle formed by the “virtual surface” and the “stacking direction of the solidified layer” may be used as the surface angle.

In the manufacturing method according to one embodiment of the present invention, the density change region 150 preferably has a density change, but is preferably provided as a low density region as a whole. For example only, the density changing region 150 may be provided as a low density region having a solidification density of 40 to 90%. In such a case, the region other than the density change region 150 (for example, the region 155 located on the inner side of the density change region as shown in FIGS. 1 and 2) is a high density region (a region having a solidification density of 91 to 100%). ) May be provided. In other words, the density change region 150 forms a low density region with a solidification density of 40 to 90% as a whole, but the density in the low density region gradually changes according to the size of the surface angle. It is preferable to produce a product. A three-dimensional shaped object including such a density change region 150 can be more suitably used as a mold. Specifically, when the three-dimensional shaped object obtained by the manufacturing method according to one aspect of the present invention is used as a mold, the density change region 150 can be used as a “venting region”, and the gas venting characteristics as described later. And high-quality transfer characteristics can be suitably provided.

As can be seen from the above description, the “density change region” in the present invention refers to a region where the density differs at least one or more within the region. Such density changing regions may have different densities in the region, but the density in the region may be different from the density in other regions. In this regard, the density change region may be a low-density region having a lower density than regions other than the region. In such a case, a portion having a relatively high density with a large surface angle in the density change region may have a lower density than regions other than the density change region from a macroscopic viewpoint.

In particular, in one aspect of the present invention, both the generation of the weld line and the surface roughness of the molded product can be more effectively reduced even in the ventilation region provided in the surface portion including the “inclined surface”. This will be described in detail. For example, assume a ventilation region having a fine hole shape as shown in FIG. As can be seen from the illustrated embodiment, the surface opening of the micropores differs depending on the size of the surface angle in the ventilation region with an “inclined surface”, and as a result, the generation of weld lines and the roughness of the surface of the molded product are Will be affected. For example, it is assumed that the “angle formed by the surface of the molded article and the stacking direction of the solidified layer” is small. In such a case, since the surface opening of the fine hole is larger (see FIG. 3), the degassing efficiency is high and the generation of the weld line can be reduced, but the surface of the molded product tends to become rough due to the large surface opening (fine). This is because the surface opening with larger pores is easier for the raw material resin to enter the micropores through the opening). On the contrary, the case where “the angle formed by the surface of the molded article and the stacking direction of the solidified layer” is large is assumed. In such a case, since the surface opening of the fine hole is smaller (see FIG. 3), the roughness of the surface of the molded product can be reduced, but the gas venting efficiency can be reduced due to the small surface opening (more than the fine hole). This is because a small surface opening has a higher resistance when passing gas). In this respect, in one aspect of the present invention, it is possible to provide a ventilation region in which the density is locally changed according to the size of the surface angle, and the “size of the surface opening” is suitable for the degassing efficiency and the rough surface of the molded product. It can be made in view of both reduction in thickness.

In a preferred embodiment, the density is relatively increased as the surface angle is reduced in the density change region. That is, in the local surface portion where the surface angle is relatively small, the density of the three-dimensional shaped object is relatively increased. Thereby, even if it is a local part with a small surface angle and being generally worried about the roughness of the surface of a molded article, this roughness can be suppressed. Although not bound by a specific theory, it is presumed that the surface opening of the fine holes on the inclined surface can be made smaller as the density of the three-dimensional shaped object increases. For example, the local portion 150C having a relatively small surface angle in the density change region 150 may have a higher density than the local portion 150A having a relatively large surface angle. 2, for example, the local portion 150d or 150e having a relatively small surface angle in the density change region 150 is more than the local portion 150b or 150a having a relatively large surface angle. The density may be increased. By doing so, the surface opening size of the micropores in the local portion where the surface angle is relatively small (in short, the portion where the inclination degree is larger) does not need to be excessively large, and the raw material resin is fine at the time of molding. It becomes difficult to enter the hole, and the roughness of the surface of the molded product can be reduced.

In the manufacturing method according to one aspect of the present invention, the density in the density change region may be gradually changed along the surface portion including the inclined surface. In other words, the density change according to the surface angle may be referred to as “gradual change”. This means that the density of the local portion of the density change region is changed stepwise as the surface angle becomes smaller or larger. In short, this means that the density of the local portion of the density change region is changed stepwise as the degree of surface inclination increases or decreases. As an example based on the mode shown in FIG. 1, the density of such portions may be gradually increased with the local portions 150A → 150B → 150C where the surface angle becomes relatively small. The aspect shown in FIG. 2 is also the same, and the density of such portions may be gradually increased with local portions 150a → 150b → 150c → 150d → 150e where the surface angle becomes relatively small. This makes it easier to optimize both the degassing efficiency and the reduction in the surface roughness of the molded product for the entire ventilation region. In detail, the degassing efficiency can be improved mainly by lowering the resistance at the time of degassing in the portion where the density is relatively low. On the other hand, the reduction in the roughness of the surface of the molded product can be mainly brought about by a relatively high density in a portion where the surface angle is originally small and the roughness of the surface of the molded product is a concern. This is because the portion having a relatively high density has fewer voids into which the resin enters, and thus contributes to a reduction in the roughness of the surface of the molded product.

It should be noted that the region where the angle formed between the stacking direction of the solidified layer and the surface of the model is substantially 0 ° may be a high-density region having a solidification density of 91 to 100%, for example. In the embodiment shown in FIGS. 1 and 2, the surface area of “151” may be formed as a high density area. When a three-dimensional shaped object is used as a mold, an area where the angle between the solidified layer stacking direction and the surface of the object is substantially 0 ° is an area where occurrence of weld lines is not a concern. This is because it can be used to improve the structural strength of the three-dimensional shaped object. That is, it is possible to optimize both the improvement of the gas venting efficiency and the reduction of the roughness of the molded product surface while ensuring the strength necessary for the mold. As can be seen from FIG. 1 and FIG. 2, “an aspect in which a region having a surface angle of substantially 0 ° is a high-density region” is the outermost region (or inclined surface portion) in the horizontal direction of the three-dimensional shaped object. It is possible to correspond to an aspect in which at least a part of the peripheral region (inner side) is a “high-density region that cannot be vented”.

In a preferred embodiment, the density change region has a microporous structure. In other words, in the manufacturing method according to one aspect of the present invention, fine holes may be formed as a “density change region” of the three-dimensional shaped object. Since the fine holes form voids in the three-dimensional shaped object, when the three-dimensional shaped object is used as a mold, the fine holes serve as vent holes and can contribute to degassing. The “micropore” in the present specification refers to a hole having an average pore size on the order of microns, for example, an average pore size of about 10 to 150 μm (based on a cross-sectional image of a three-dimensional shaped object) Average pore size).

The microporous structure can be obtained by relatively lowering the irradiation energy of the light beam applied to the powder region when forming the solidified layer. For example, a region of a three-dimensional shaped object that does not have a micropore structure, that is, a high-density region (for example, a solidification density of 91 to 100%) is irradiated with a light beam having an irradiation energy density E of about 8 to 15 J / mm ^2. In contrast, in a density changing region having a fine pore structure (for example, a solidification density of 40 to 90%), it may be formed with a light beam having an irradiation energy density E of about 1 to 7 J / mm ² . Note that energy density E = laser output (W) / (scanning speed (mm / s) × scanning pitch (mm) (manufacturing conditions are, for example, powder layer thickness: 0.05 mm, laser type: CO _2. (Carbon dioxide) laser, spot diameter: 0.5 mm.) The above numerical range of the irradiation energy is merely an example, and may depend on the type of the powder material. It should be noted that the value of the irradiation energy density E can be appropriately changed depending on the type of powder material forming the powder layer.

The “solidification density (%)” referred to in the present specification substantially means a solidification cross-sectional density (occupation ratio of the solidification material) obtained by performing image processing on a cross-sectional photograph of a three-dimensional shaped object. The image processing software to be used is Scion Image ver. 4.0.2 (Scion freeware). After binarizing the cross-sectional image into a solidified part (white) and a hole part (black), By counting the total number of pixels Px _all and the number of pixels Px _white of the solidified portion (white), the solidified cross-sectional density ρ _S can be obtained by the following equation 1. When metal powder is used as the powder material, “solidification density” corresponds to “sintering density”.
[Formula 1]

In addition to (a) adjusting the irradiation energy (output energy) of the light beam, (b) adjusting the scanning speed of the light beam, (c) adjusting the scanning pitch of the light beam, d) It can also be performed by adjusting the condensing diameter of the light beam. For example, in order to lower the solidification density, (a) in addition to lowering the irradiation energy (output energy) of the light beam, (b) increasing the scanning speed of the light beam, (c) increasing the scanning pitch of the light beam. (D) This can also be achieved by increasing the light collection diameter of the light beam. Conversely, in order to increase the solidification density, in addition to (a) increasing the output energy of the light beam, (b) decreasing the scanning speed of the light beam, (c) narrowing the scanning pitch of the light beam, ( d) It can also be achieved by reducing the condensing diameter of the light beam. These (a) to (d) may be performed alone or in various combinations with each other.

The micropore structure provides micropores in the three-dimensional shaped object. Such micropores are preferably “row micropores”. That is, in the manufacturing method according to one embodiment of the present invention, it is desirable to form the row-shaped micropores 158 in which the voids form a row for the micropore structure 157 (see FIG. 4). As shown in FIG. 4, the columnar micropores 158 may have a form in which voids extend in a row along the stacking direction of the solidified layer. In the local portion of the density changing region where the row-like micro holes 158 are provided, the voids are continuously arranged in a row in a state where the seam is reduced or in a state where there is no seam, so that the resistance at the time of degassing is further reduced. It becomes easy to improve the "gas venting efficiency". The fine holes may be random holes. That is, as the fine holes 157, random fine holes 159 in which voids are randomly distributed may be provided (see FIG. 4). Since the random fine holes 159 have random gaps as shown in FIG. 4, the gas can be extracted from any direction, and the anisotropy in the degassing direction is reduced. On the other hand, the random micropores 159 may exhibit the property that the raw material resin does not easily enter the pores (not limited to a specific theory, but this is because the micropores extend long because they are random. It is thought that this is caused by the fact that the voids themselves are small, and that the resistance when the resin enters is increased because there are random small voids at random). Therefore, the random fine holes 159 can contribute to the prevention of the roughness of the surface of the molded product.

As can be seen from the form shown in FIG. 4, in the present invention, the structure including the row-like micro holes 158 and the random micro holes 159 is referred to as “vertical hole communication structure” and “micro-hole random arrangement structure”, respectively. You can also.

The columnar microholes 158 and the random microholes 159 can be obtained by appropriately adjusting various scanning conditions and / or irradiation energy conditions of the light beam when forming the solidified layer. Although not particularly limited, the columnar micropores 158 can be obtained by crossing the scanning path P of the light beam between the solidified layers in the formation of the solidified layers adjacent to each other in the stacking direction (the maximum in FIG. 4). See below). Such an aspect of “intersection of scanning paths” corresponds to an aspect in which light beam irradiation is performed so that the scanning paths P form “lattices” between adjacent solidification layers. On the other hand, the random fine holes 159 can be obtained by reducing the irradiation energy density by narrowing the laser scanning pitch and increasing the scanning speed relative to the row-like fine hole forming conditions.

As described above, in the structure provided with the random fine holes 159, since the raw material resin is difficult to enter the fine holes, the density changing region may be formed so as to make use of the characteristics. Specifically, random fine holes may be formed at locations where the surface angle is small. Thereby, even in a region where the surface angle is small and the roughness of the surface of the molded product is generally a concern, such roughness can be effectively suppressed with “random fine holes”. For example, in the embodiment shown in FIG. 1, random fine holes may be provided in the local portion 150 </ b> C having a relatively small surface angle in the density change region 150. Further, as exemplified by the mode shown in FIG. 2, random fine holes may be provided in, for example, the local portions 150e and / or 150d having a relatively small surface angle in the density change region 150. As a more specific example, random micropores may be provided in a surface portion having a relatively small surface angle, while row-like micropores may be provided in a surface portion having a relatively large surface angle. As a result, it is possible to suppress the roughness even in a local portion where the surface angle is small and generally the roughness of the surface of the molded product is a concern. On the other hand, the surface angle is provided at a location where the surface angle is large. Desired degassing can be achieved with the row of fine holes having low resistance when degassing.

In a preferred aspect, a hollow path communicating with the outside of the three-dimensional shaped object is provided inside the three-dimensional shaped object. That is, in the manufacturing method according to one embodiment of the present invention, it is preferable to form a hollow path that is in fluid communication with the outside. When a three-dimensional shaped object is used as a mold, the hollow path may be used as a ventilation path or a temperature control medium path. In the manufacturing method according to one embodiment of the present invention, the hollow path can be formed by setting a part of the region where the solidified layer is formed as a non-irradiated portion that is not irradiated with a light beam. In other words, the third order finally obtained by locally providing a “non-irradiated portion that is not irradiated with a light beam and is not solidified” within the solidified layer formation region (that is, the region where the three-dimensional shaped object is formed). A hollow path can be formed in the original shaped object.

When the hollow passage 160 is used as a ventilation passage, the hollow passage 160 and the fine pore structure 157 are preferably provided in fluid communication with each other (see FIG. 5). Thereby, “gas venting” when the three-dimensional shaped object 100 is used as a mold can be performed via the microporous structure 157 and the hollow path 160. The gas existing in the mold cavity space during filling of the molten raw material or the gas generated from the molten raw material is discharged from the fine hole structure 157 (that is, fine holes) on the mold surface to the outside of the mold cavity space. The air is finally discharged to the outside of the mold through the air passage 160. Since the hollow passage 160 is larger than the micropores of the microporous structure 157, the fluid resistance at the time of degassing can be reduced, and the “gas venting efficiency” can be easily improved.

The hollow channel used as the “ventilation channel” may be extended so as to cover the entire density changing region (for example, the hollow channel is extended so as to pass through all the local portions having different densities in the density changing region). You may let me) As shown in FIG. 5, at least a part of the hollow path 160 may extend along the inclined surface of the three-dimensional shaped object. That is, at least a part of the hollow path 160 may be extended along the “surface of the modeled object 110 including the inclined surface”. In such a case, the communication state between the fine pore structure 157 of the density change region 150 and the hollow path 160 can be more easily taken, and the fluid resistance at the time of degassing can be more effectively reduced. As can be seen from the cross-sectional view shown in FIG. 5, the extension of the hollow passage 160 may penetrate or cross the microporous structure 157 (preferably, the extension of the hollow passage 160 is The microporous structure 157 may be penetrated or crossed while being along the inclined surface). For example, in a cross-sectional view as shown in the drawing, the hollow path 160 is set so that the shortest separation distance between at least a part of the hollow path 160 and the “surface of the molded article 110 including the inclined surface” is substantially constant. May be extended.

As shown in FIG. 6, the hollow passage 160 used as a ventilation passage may include or include a “solidified portion 159 ′ composed of random fine holes” in a part thereof. The random micropores can pass the gas flow in either direction. Therefore, by arranging such random micropores locally in the hollow path, it is possible to improve the structural strength of the three-dimensional shaped object provided with the hollow path while ensuring a flowable state. .

The manufacturing method according to one embodiment of the present invention is suitably used for manufacturing a three-dimensional shaped object having an inclined surface (for example, a mold having an inclined surface). Although it is only one example to the last, in the manufacturing method which concerns on 1 aspect of this invention, you may manufacture the metal mold | die for obtaining "the molded article which has an inner surface and an outer surface" as a three-dimensional shape molded article. Although it is an example to the last, you may manufacture the metal mold | die for cylindrical molded articles, for example. More specifically, a three-dimensional shaped object may be manufactured in order to obtain a mold 300 (see FIG. 8) for forming a cylindrical molded product 200 as shown in FIG. As used herein, “cylindrical molded product” refers to a molded product having an overall appearance of “cylindrical shape”, one end forming an open end and the other end forming a closed end. pointing.

In the present invention, the mold may be a mold for the inner surface of a molded product (that is, a mold for the inner surface of the molded product). Speaking of a mold 300 as shown in FIG. 8, it corresponds to an inner surface mold for obtaining the inner surface of a cylindrical molded product. Such an inner surface mold may be a slide core.

In the case of the mold 300 as an “inner mold”, a density change region may be provided in a cavity surface portion (particularly, a surface portion including an inclined surface) for the inner surface of the molded product. As a preferred example, the tip portion 350 of the inner surface mold may be provided as a three-dimensional shaped object, and the region of the foremost surface 355 may be a density change region (see FIG. 8). In general, a weld line is likely to be generated at a tip portion (particularly an inner portion of a closed end) of an “molded product having an inner surface and an outer surface” such as the cylindrical molded product 200. In order to reduce such a weld line, an “inclined surface” is used. A vent area of "form" can be provided in the mold more extensively. That is, in one aspect of the present invention, it is possible to provide a wider ventilation region with respect to the mold cavity surface region where weld lines are particularly likely to occur, thereby reducing both the generation of weld lines and the surface roughness of the molded product. Can do.

[Three-dimensional shaped object of the present invention]
The three-dimensional shaped object according to one aspect of the present invention is obtained by the above-described manufacturing method. Therefore, the three-dimensional shaped object according to one aspect of the present invention is configured by laminating a solidified layer formed by light beam irradiation on a powder layer, and an inclined surface (that is, an outermost surface in an inclined form). It has. In particular, in the three-dimensional modeled object 100 according to one aspect of the present invention, the “density change region” 150 having locally different densities is provided on the modeled object surface 110 of the surface part including the inclined surface, and the density change is performed. The density in the region 150 is locally different depending on “an angle formed by the surface 110 of the surface portion including the inclined surface and the stacking direction of the solidified layer” (see FIGS. 1 and 2). In other words, the three-dimensional modeled object includes a density change region in which the density changes along the surface of the model, and the region has a density change corresponding to the degree of the surface inclination of the modeled object. .

Due to the presence of the density change region 150, the three-dimensional shaped article 100 according to one aspect of the present invention can be more suitably used as a mold. Specifically, when the three-dimensional shaped object 100 is used as a mold, the density change region 150 can be used as a “venting region”, and both the gas venting characteristics and the high-quality transfer characteristics are as described above. Can be advantageously provided.

In a preferred aspect of the three-dimensional shaped object, the density of the density change region gradually differs along the surface portion including the inclined surface. That is, in the density change region, the change corresponding to the degree of surface inclination is a gradual change. This means that the density of the local portion of the density change region changes stepwise as the surface angle of the shaped object decreases or increases. In short, it means that the density of the local portion of the density changing region is gradually changed as the inclination of the three-dimensional shaped object increases or decreases.

For example, in the three-dimensional shaped object 100 shown in FIG. 1, the density of the portion gradually increases with the local portions 150A → 150B → 150C where the surface angle becomes relatively small. The same applies to the three-dimensional shaped object 100 shown in FIG. 2, and the density of the portion gradually increases with the local portions 150a → 150b → 150c → 150d → 150e where the surface angle becomes relatively small. ing. When a three-dimensional shaped object having such a gradual density change is used as a mold, it is easier to optimize both the gas venting efficiency improvement and the surface roughness reduction of the molded product as the entire ventilation region. .

Preferably, in the density change region, the smaller the surface angle, the higher the density. In such a case, even in a region where the surface angle is small and generally the roughness of the surface of the molded product is a concern, such roughness can be suppressed. In the three-dimensional modeled object 100 shown in FIG. 1, the local portion 150B having a relatively small surface angle in the density change region 150 is 5 in comparison with the local portion 150A having a relatively large surface angle. A density of ˜40% higher (for example, a density of 5-30% or 5-20% higher), and the local portion 150C having a relatively small surface angle is set to 5 than the local portion 150B having a relatively large surface angle. The density may be ˜40% higher (eg 5-30% or 5-20% higher density). Further, in the three-dimensional shaped object 100 shown in FIG. 2, the local portion 150b having a relatively small surface angle in the density change region 150 is 5 to 30% higher in density than the local portion 150a having a relatively large surface angle. Similarly, the local portion 150c having a relatively small surface angle is made 5 to 30% higher in density than the local portion 150b having a relatively large surface angle. (Eg, 5-20% or 5-10% higher density). Furthermore, the local portion 150d having a relatively small surface angle has a density 5 to 30% higher than the local portion 150c having a relatively large surface angle (for example, a density 5 to 20% or 5 to 10% higher). Similarly, the local portion 150e having a relatively small surface angle may have a density that is 5 to 30% higher than the local portion 150d having a relatively large surface angle (for example, a density that is 5 to 20% or 5 to 10% higher). As good).

In a preferred embodiment of the three-dimensional shaped object, the density change region has a fine pore structure. When such a three-dimensional shaped article is used as a mold, the fine holes serve as vent holes and can contribute to degassing. The micropore structure 157 preferably includes “a row of micropores 158 in which the voids form a row” and / or “random pores 159 in which the voids are randomly distributed” (see FIG. 4).

As shown in FIG. 4, it is preferable that the columnar micropores 158 have a form in which voids extend in a row along the stacking direction of the solidified layer. In the density changing region in which the row-shaped fine holes 158 are provided, the voids are continuous in a row with a seam reduced or without a seam, so that the resistance at the time of degassing is further reduced, and the degassing efficiency is improved. It becomes easy to improve. On the other hand, in the density change region in which the random fine holes 159 are provided, as shown in FIG. 4, since the voids are distributed randomly, the gas can be extracted from any direction, and the anisotropy in the degassing direction is Reduced.

In view of the fact that the molten raw material does not easily enter random micropores and the roughness of the surface of the molded product is easily prevented, it is preferably a density change region in which random micropores are provided at local locations where the surface angle is relatively small. . Thereby, even in a region where the surface angle is small and the roughness of the surface of the molded product is generally concerned, such roughness can be more effectively suppressed by “random fine holes”. With regard to the three-dimensional shaped object 100 shown in FIG. 1, it is preferable that random fine holes 159 are provided in, for example, a local portion 150 </ b> C having a relatively small surface angle in the density change region 150. Similarly, in the three-dimensional shaped object 100 shown in FIG. 2, it is preferable that random fine holes 159 are provided in, for example, the local portions 150e and / or 150d having a relatively small surface angle in the density change region 150. . In such a case, row-shaped micropores are provided in local portions 150A and / or 150B (the embodiment of FIG. 1) or 150a, 150b and / or 150c (the embodiment of FIG. 2) having a relatively large surface angle in the density change region 150. It may be done.

In a preferred aspect, the three-dimensional shaped object has a hollow path inside, and the hollow path communicates with the outside of the three-dimensional shaped object. When the three-dimensional shaped object is used as a mold, the hollow path may be a ventilation path or a temperature control medium path. For example, as shown in FIG. 9, the three-dimensional shaped object 100 has at least two hollow paths (160A, 160B), one hollow path 160A forms a ventilation path, and the other hollow path 160B A temperature control medium path may be formed. The hollow channel 160A as the ventilation channel may have a diameter (more specifically, “cross-sectional dimension perpendicular to the gas flow direction”) of, for example, about 0.5 to 3 mm. On the other hand, the hollow path 160B as the temperature control medium path may have a diameter (more specifically, “a cross-sectional dimension orthogonal to the flow direction of the temperature control medium”) of, for example, about 3 to 15 mm.

When the three-dimensional shaped object 100 is used as a mold and the hollow path 160A is used as a ventilation path, it is preferable that the hollow path 160A and the microporous structure 157 are in fluid communication with each other. This is because a mold that can be preferably “degassed” is provided through the microporous structure 157 and the hollow passage 160A. The hollow passage 160A can be provided in a larger size than the fine hole, and the fluid resistance at the time of degassing can be reduced. Therefore, the gas from the mold cavity space can be efficiently discharged to the outside of the mold through the hollow passage 160A communicating with the fine hole structure 157 when the molten raw material is filled.

In the three-dimensional shaped object according to one aspect of the present invention, the hollow path serving as the ventilation path may extend so as to cover the entire density change region. For example, as shown in FIG. 5, it is preferable that at least a part of the hollow path 160 extends so as to follow the contour shape of the surface 110 of the three-dimensional shaped object 100. In this case, the fluid communication state between the fine pore structure 157 in the density change region and the hollow passage 160 can be more easily taken. Further, as shown in the cross-sectional view of FIG. 5, the hollow path 160 extends so that the shortest separation distance between at least a part of the hollow path 160 and the surface 110 of the three-dimensional shaped article 100 is substantially constant. You can do it. Similar to the extended form of the hollow path 160, the density changing region 150 may be provided along the surface 110 of the three-dimensional shaped object with a substantially constant thickness (see FIG. 5). In such a case, a relatively large number of high density regions 155 can be provided inside the density change region 150, and the three-dimensional shaped article 100 that is more preferable in terms of structural strength can be obtained. From the viewpoint of increasing the overall structural strength of the three-dimensional shaped object 100, as shown in FIG. 6, "solidified portion 159 'composed of random fine holes" is formed in a part of the hollow path 160 used as a ventilation path. It may be provided.

However, this is merely an example, and the three-dimensional shaped object may be a mold for obtaining “a molded article having an inner surface and an outer surface”. For example, the three-dimensional shaped object may be a mold for forming a cylindrical molded product 200 as shown in FIG. One specific example of such a mold is a mold 300 as shown in FIG. Examples of the tubular molded product 200 include water-based products (such as a shower head and a water discharge product) and piping products. In a preferred embodiment, the three-dimensional shaped object is a mold particularly for the inner surface of the molded product. A mold 300 illustrated in FIG. 8 is an inner surface mold for obtaining the inner surface of the tubular molded product 200. Such an inner surface mold may be a slide core.

When the three-dimensional shaped object is a mold for the inner surface of the molded product, a density change region is provided in a cavity surface portion (particularly a surface portion including an inclined surface) for the inner surface of the molded product. It is preferable. For example, when the three-dimensional shaped article is a mold for a cylindrical molded product, it is preferable that the density change region is a ventilation region in the mold. That is, in such a mold, the density changing region (particularly the density changing region having a fine pore structure) can be positively used for “gas venting” at the time of injection molding.

As shown in FIG. 8, it is preferable that the three-dimensionally shaped object forms a tip portion 350 of a mold 300 that becomes an “inner mold”. In addition, at least a part of the foremost surface 355 of the mold 300 may be a density change region. In such a mold 300, both the generation of weld lines and the surface roughness of the molded product can be more effectively reduced. This is because a weld line is likely to occur at the distal end portion (particularly, the inner distal end portion) of the cylindrical molded product, and the ventilation region for reducing the weld line can be made wider.

As shown in FIG. 8, in the mold 300 as the inner surface mold, the “temperature adjusting medium path and the rear side of the hollow path 160A (ventilation path) in fluid communication with the density change region of the micropore structure” The hollow path 160B "is preferably positioned. More specifically, as shown in the permeation diagram of FIG. 8, in this mold 300, the foremost extending portion of “hollow path 160B used as a temperature control medium path” is “hollow path 160A used as a vent path”. It is preferable that it is located in the back side rather than the foremost extension part. Thereby, more suitable temperature control can be achieved while performing “gas venting” from the front end surface of the mold 300.

In order to avoid duplication since other matters, such as a more detailed matter of the three-dimensional modeled object concerning one mode of the present invention, a further specific mode, etc. are explained in the above-mentioned [production method of the present invention]. The description is omitted.

As mentioned above, although embodiment of this indication was described, it is only a typical example of the application scope of this indication. Therefore, those skilled in the art will readily understand that the present invention is not limited to the embodiment described above, and various modifications can be made.

For example, in the above description, the aspect in which the density of the three-dimensional modeled object changes in the direction along the surface of the three-dimensional modeled object has been described, but the direction of density change is not limited to the “direction along the surface”. As shown in FIG. 10, the density of the three-dimensional shaped object 100 may change toward the inner side of the three-dimensional shaped object 100. In the form shown in FIG. 10, the density of 150A ′, 150B ′, 150C ′ positioned relatively inside is lower than that of 150A, 150B, 150C positioned relatively outside (surface side). Good. Preferably, the density gradually decreases from the surface toward the inside. In such an aspect, it becomes easier to optimize both the gas venting efficiency improvement and the reduction of the surface roughness of the molded product for the entire ventilation region.

Furthermore, as shown in FIG. 11, the outer peripheral portion 152 of the three-dimensional structure 100 is a random microhole area or a high-density area (91 regardless of the size of the surface angle of the three-dimensional structure 100. May be provided as a region having a solidification density of ˜100%. By appropriately utilizing such an aspect, the degree of freedom in designing a three-dimensional shaped object used as a mold is increased.

In the above description, the aspect of manufacturing a mold for the inner surface of a molded product as a three-dimensional shaped article having a “density change region” is mentioned, but the present invention is not necessarily limited thereto. In the present invention, a “density change region” may be provided for the outer surface mold of the molded product. That is, it is also conceivable to manufacture the outer mold for the molded product according to the present invention. This is particularly true when a two-layer molded product (two-color molded product) is obtained as a molded product. In the two-layer molding, the outer surface of the molded product of the first layer becomes a non-design surface, and a density change region is provided in a cavity surface portion (particularly a surface portion including an inclined surface) for such a non-design surface. A mold may be manufactured.

Various articles can be manufactured by carrying out the manufacturing method of the three-dimensional shaped object of the present disclosure. For example, when the three-dimensional shaped article is made of a metal material, the three-dimensional shaped article can be used as a mold such as a plastic injection mold, a press mold, a die casting mold, a casting mold, or a forging mold. it can. On the other hand, when the three-dimensional shaped article is made of a resin material, the three-dimensional shaped article can be used as a resin molded product.

Cross-reference of related applications

This application is based on the Paris Convention based on Japanese Patent Application No. 2017-085437 (Filing Date: April 24, 2017, Title of Invention: “Method for Manufacturing Three-Dimensional Shaped Model and Three-dimensional Shaped Model”). Claim priority. All the contents disclosed in the application are incorporated herein by this reference.

22 Powder layer 24 Solidified layer L Light beam 100 Three-dimensional shaped object 110 Surface 150 in the surface portion including the inclined surface Density change region 157 Micropore structure 158 Columnar micropore 159 Random micropore 160 Hollow path θ _A , θ _B , θ _C surface angle θ _a , θ _b , θ _c , θ _d , θ _e surface angle

Claims (16)

(I) a step of irradiating a predetermined portion of the powder layer with a light beam to sinter or melt solidify the powder at the predetermined portion to form a solidified layer; and (ii) a new powder on the obtained solidified layer A method for producing a three-dimensional shaped article in which a powder layer and a solidified layer are alternately formed by a step of forming a layer and irradiating a predetermined portion of the new powder layer with a light beam to form a further solidified layer Because
A density change region in which the density of the three-dimensional shaped object is locally different is provided on the surface portion including the inclined surface of the three-dimensional shaped object,
In the said density change area | region, the manufacturing method of the three-dimensional shape molded article which makes the said density differ locally according to the angle which the surface in the said surface part containing the said inclined surface forms with the lamination direction of the said solidification layer. The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the density of the density change region is gradually changed along the surface portion including the inclined surface. The method for producing a three-dimensional shaped object according to claim 1 or 2, wherein the density is relatively increased as the angle is reduced in the density change region. The method for producing a three-dimensional shaped article according to any one of claims 1 to 3, wherein the density change region has a fine pore structure. The method for producing a three-dimensional shaped article according to claim 4, wherein due to the micropore structure, row-like micropores in which voids form rows and / or random micropores in which voids are randomly distributed are formed. The method for manufacturing a three-dimensionally shaped object according to claim 5, wherein the random fine holes are formed at locations where the angle is relatively small in the surface portion including the inclined surface. The method for producing a three-dimensional shaped object according to any one of claims 1 to 6, wherein a hollow path communicating with the outside of the three-dimensional shaped object is provided inside the three-dimensional shaped object. The method for producing a three-dimensional shaped article according to claim 7, which is dependent on any one of claims 4 to 6, wherein the hollow path and the fine pore structure are provided in fluid communication with each other. The method for manufacturing a three-dimensional shaped article according to claim 7 or 8, wherein at least a part of the hollow path extends along the inclined surface of the three-dimensional shaped article. As the three-dimensional shaped object, a mold for the inner surface of the molded product is manufactured,
The method for manufacturing a three-dimensional shaped article according to any one of claims 1 to 9, wherein in the inner surface mold, the density changing region is provided in the surface portion for the inner surface of the molded product. It is a three-dimensional shaped object composed of a laminated solidified layer and having an inclined surface,
A density change region in which the density of the three-dimensional shaped object is locally different is provided on the surface portion including the inclined surface,
In the density change region, the three-dimensional shaped object in which the density is locally different according to an angle formed by a surface of the surface portion including the inclined surface with a stacking direction of the solidified layer. The three-dimensional shaped article according to claim 11, wherein the density of the density change region gradually varies along the surface portion including the inclined surface. The three-dimensional shaped object according to claim 11 or 12, wherein the density is relatively higher as the angle is smaller in the density change region. The density changing region has a microporous structure;
The three-dimensional shaped article according to any one of claims 11 to 13, wherein the micropore structure includes row-like micropores in which voids form a row and / or random micropores in which voids are randomly distributed. . A hollow path is provided inside the three-dimensional shape object, and the hollow path communicates with the outside of the three-dimensional shape object.
The three-dimensional shaped article according to claim 14, wherein the hollow path and the microporous structure are in fluid communication with each other. The three-dimensional shaped object is a mold for the inner surface of a molded product,
The three-dimensionally shaped article according to any one of claims 11 to 15, wherein in the inner surface mold, the density changing region is provided in the surface portion for the inner surface of the molded product.

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