GB2262817A - Making 3-d resin images - Google Patents
Making 3-d resin images Download PDFInfo
- Publication number
- GB2262817A GB2262817A GB9226599A GB9226599A GB2262817A GB 2262817 A GB2262817 A GB 2262817A GB 9226599 A GB9226599 A GB 9226599A GB 9226599 A GB9226599 A GB 9226599A GB 2262817 A GB2262817 A GB 2262817A
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- United Kingdom
- Prior art keywords
- wiper
- resin
- liquid
- liquid resin
- process according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 221
- 239000011347 resin Substances 0.000 title claims abstract description 221
- 239000007788 liquid Substances 0.000 claims abstract description 122
- 238000000034 method Methods 0.000 claims abstract description 32
- 230000005499 meniscus Effects 0.000 claims abstract description 16
- 239000000463 material Substances 0.000 claims description 9
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- 229920002050 silicone resin Polymers 0.000 claims description 3
- 238000010538 cationic polymerization reaction Methods 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 claims description 2
- 238000010526 radical polymerization reaction Methods 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 description 5
- 238000013461 design Methods 0.000 description 5
- 230000003287 optical effect Effects 0.000 description 5
- 239000004809 Teflon Substances 0.000 description 4
- 229920006362 Teflon® Polymers 0.000 description 4
- 238000007796 conventional method Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 239000002033 PVDF binder Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000001678 irradiating effect Effects 0.000 description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 2
- 230000002269 spontaneous effect Effects 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- 125000001153 fluoro group Chemical group F* 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000013307 optical fiber Substances 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
Classifications
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70416—2.5D lithography
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03H—HOLOGRAPHIC PROCESSES OR APPARATUS
- G03H1/00—Holographic processes or apparatus using light, infrared or ultraviolet waves for obtaining holograms or for obtaining an image from them; Details peculiar thereto
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/12—Spreading-out the material on a substrate, e.g. on the surface of a liquid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
- B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/0037—Production of three-dimensional images
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0072—Roughness, e.g. anti-slip
- B29K2995/0073—Roughness, e.g. anti-slip smooth
Landscapes
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Optics & Photonics (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
Abstract
A process for forming a three-dimensional image of resin by applying a light from laser (a) to a photo-curable, liquid resin (g) in a resin container (h) to form a cured resin layer (i) and repeating this step to putting a plurality of cured resin layers one on another. In this process, a wiper (4) on wiper array (k) is arranged above the resin container at such an inclination angle (6) that substantially no meniscus is caused and so that the flat plate is moved in a direction perpendicular to the lengthwise direction of the flat plate, thereby forming a liquid resin layer having a smooth face and a uniform thickness on the previously formed cured resin layer. By the above process, it is possible to put cured resin layers each having a precise thickness of 0.1 mm or less one on another and the resulting shaped article has a smooth surface. The wiper may be a single blade (Figs 3a and 3b), two blades (Fig 3c) or a blade (4) and a brush (5). <IMAGE>
Description
The present invention relates to a process and apparatus for forming a three-dimensional image of resin by applying a light to a photo-curable, liquid resin, more particularly, to a process and apparatus for forming a three-dimensional image of resin which comprises putting a plurality of resin layers one on another, wherein even when each of the layers has a small film thickness, the thickness of a film of liquid resin to form the layer can be made uniform.
Die molding is widely used in the production of shaped articles from synthetic resins. The die molding, however, has had such various problems that the cost for die production is very high and many steps are required to obtain a final product, i.e. a shaped article.
In order to solve the above problems which the die molding has, a process has recently been proposed for forming a desired three-dimensional image by applying a given light beam to a photo-curable resin to cure the resin (see Japanese Patent Application Kokai No. 6235966).
In this process, a three-dimensional shaped article of resin is produced by repeating the steps of applying a light to the given portions of the surface of a photo-curable, liquid resin to form a first cured layer of a desired shape, feeding the same photo-curable, liquid resin (uncured) onto the first cured resin layer, applying a light to the resin in the same manner to form a second cured resin layer to place the second cured resin layer on the first cured resin layer. In this case, as the light for curing the resin, a laser beam is used in view of the characteristics of the photo-curable, liquid resin to wavelength of light to which the resin is sensitive, the directivity and convergence of the laser beam, etc.
In the above process, in order to control the thickness of a cured resin layer to be newly formed on the cured resin layer formed previously, it is necessary to control the film thickness of a photo-curable, liquid resin (uncured) to be fed onto the previously cured resin layer. In a conventional method for controlling the film thickness of a liquid resin, a cured resin is sunk in a liquid resin down to a position deeper than the desired position, i.e. a position deeper than the thickness of the cured resin. The liquid resin is fed slowly onto the surface of the cured resin by spontaneous flow and the liquid face of resin becomes flat. Then, the cured resin is lifted up to the predetermined position.In this case, generally, the liquid face of resin is not flat and has a swell above a part or the whole of the upper surface of the cured resin; consequently, the thickness of the liquid resin on the cured resin is larger than the predetermined thickness. Subsequently, a wiper made of a flat plate which is arranged perpendicularly to the liquid face of resin, is moved to scratch off the excessive portion of the liquid resin on the cured resin to control the thickness of the liquid resin on the cured resin, to the desired thickness.
Further, Japanese Patent Application Kokai No.
61-114818 describes obtaining a liquid resin layer of a uniform thickness in the above method by moving a wiper made of a flat plate which is arranged perpendicularly to the face of liquid resin while the liquid resin is fed.
In the above method for controlling the film thickness of a liquid resin, there was no problem when cured resin layers of relatively large thickness (about 0.2 mm) were put one on another; however, it was found that when cured resin layers having a precise thickness of 0.1 mm or less were put one on another, there appeared a swell at the liquid face of resin, which was presumed to be due to the viscosity and surface tension of the liquid resin, and it was impossible to precisely put thin cured resin layers one on another.For example, when a wiper arranged perpendicularly to the liquid face of resin was used, the cured resin layers had step-by-step a lens-shaped swell corresponding to the swell of liquid resin before curing; and finally, the highest portion of the cured resin layers became higher than the liquid face of resin, whereby the wiper comes to contact with the highest portion. As a result, in some cases, it brought about the destruction of shaped article, or the stoppage of wiper movement and consequent failure in shaping.
Even when there was no wiper contact, the shaped article had no reliable precision in height.
In the above-mentioned known processes for forming three-dimensional image of resin by putting resin layers one on another, steps corresponding to the thicknesses of cured resin layers always appear at the curved surface or sloping surface of the formed threedimensional image of resin. Hence, in order to heighten the precision of the formed image, it is desirable that each cured resin layer has a thickness as small as possible. The smaller the thickness, the smoother the surface of the formed image becomes, whereby the polishing in the post-treatment step becomes easy or unnecessary. Thus, the above-mentioned swell is a very undesirable phenomenon.
An object of the present invention is to provide a process capable of forming a three-dimensional image of resin having a precise thickness, which has solved the above problems of prior art.
Another object of the present invention is to provide an apparatus which can be effectively used in the process.
Other objects and advantages of the present invention will become apparent from the following description and the accompanying drawings, in which Fig.
1 is a schematic perspective view showing the construction of an example of the apparatus for forming threedimensional image of resin according to the present invention; Fig. 2 is a sectional view of a typical example of the portion of a wiper used in the present invention that contacts with a liquid resin; Figs. 3(a)3(d) are sectional views of modifications of the said portion of the wiper; Figs. 4(a)-4(e) are schematic views explaining the smoothening of the liquid face of resin;
Figs. 5(a) and 5(b) are perspective views of a design model and a three-dimensional image formed by a conventional process, respectively; Figs. 6(a) and 6(b) are schematic views of a meniscus generated with a conventional wiper and a swell of liquid resin caused thereby, respectively; Figs. 7(a)-7(c) are views showing contact angles between wiper and liquid resin. In Figs.
1-7, a represents a laser oscillator, b represents a mirror, c represents a shutter, d represents a Z focus lens, e represents a mirror, f represents a lift, g represents a liquid resin, h represents a liquid resin tank, i represents a photo-cured article, j represents a laser beam, k represents a wiper, m represents a pump, 1 represents a cured resin, 2 represents a liquid resin, and 3 and 4 represent wipers, and 4A represents the vertical portion of the wiper.
According to the present invention, there is provided a process for forming a three-dimentional image of resin by applying a light to a photo-curable, liquid resin placed in a resin container, to form a cured resin layer of a desired shape at a given position and repeating this step to put a plurality of cured resin layers one on another, characterized in that above the resin container, a wiper is arranged at such an inclination angle to the liquid face of resin that substantially no meniscus is caused and the wiper is moved in a direction perpendicular to the lengthwise direction of the wiper prior to the application of a light, thereby forming a liquid resin layer having a smooth face and a uniform thickness on the previously formed cured resin layer.
The present invention further provides an apparatus for forming a three-dimensional image of resin, which comprises a liquid resin container, a means for sinking or lifting a cured resin layer, a means for applying a light to the surface of a liquid resin, a wiper and a means for moving the wiper, characterized in that the wiper is arranged above the liquid resin container at such an inclination angle to the liquid face of resin that substantially no meniscus is caused and so that the wiper can be moved by said moving means in a direction perpendicular to the lengthwise direction of the wiper.
The present invention is described in comparison with the prior art, referring to the accompanying drawings. Figs. 4(a)-4(e) are schematic views explaining a conventional method for controlling the film thickness of a liquid resin. In this conventional method, the cured resin 1 shown in Fig. 4(a) is sunk in a liquid resin 2, as shown in Fig. 4(b). In this case, the cured resin 1 is sunk deeper than a desired film thickness.
The liquid resin 2 is fed onto the cured resin 1 by spontaneous flow and the liquid face of resin above the cured resin becomes flat. Then, as shown in Fig. 4(c), the cured resin 1 is lifted to the predetermined position. In this case, generally, the liquid face of resin is not flat and has a swell above a part or the whole of the upper surface of the cured resin 1; hence, the film thickness of the liquid resin 2 on the cured resin 1 is larger than the predetermined one. Subsequently, a wiper 3 (a flat plate) arranged perpendicularly to the liquid face of resin is moved to scratch off the excessive liquid resin above the cured resin 1, as shown in Fig.
4(d), whereby the film thickness of the liquid resin 2 on the cured resin 1 is adjusted to the predetermined thickness as shown in Fig. 4(e).
Thorough investigation on the above phenomenon of swell has revealed that the swell is caused by a meniscus being caused owing to the contact angle between wiper and liquid resin to allow the liquid resin to adhere to the wiper. That is, as shown in Fig. 6(a), a meniscus is always caused when the wiper 3 is used which is arranged perpendicularly to the liquid face of the liquid resin 3, unless the combination of wiper and liquid resin is such that the contact angle is 900, and the level of the resin adhering to the wiper becomes higher than the liquid face of resin. This meniscus is moved together with the wiper 3 when the wiper 3 is moved, but, as shown in Fig. 6(b), a swell remains above the cured resin 1 even after the wiper 3 was left from the upper surface of the cured resin 1.
From the above fact, it has been found that if the meniscus is prevented from being caused, no swell is formed. Figs. 7(a)-7(c) show contact angles o between a wiper 3 and a liquid resin 2. When a combination of liquid resin and wiper has a contact angle 6 as shown in
Figs. 7(a)-7(c), a meniscus is caused when the wiper 3 is arranged perpendicularly to the liquid face of the liquid resin 2, as shown in Fig. 7(a), and consequently, the liquid resin is lifted at the meniscus portion.
Fig. 7(b) shows a contact angle of the liquid resin 2 placed on the wiper 3.
Meanwhile, as shown in Fig. 7(c) wherein the wiper 3 is slanted so that the angle between the wiper and the liquid face becomes equal to the contact angle 6, the liquid face becomes apparently horizontal at least on one side of the wiper and the liquid resin is not lifted on this side. Hence, when the wiper is moved in a direction opposite to said side of the wiper (where the liquid face is flat), the liquid face formed after the movement is flat and a uniform liquid resin film is obtained.
In the present process for forming a threedimensional image of resin by applying a light to a photo-curable, liquid resin contained in a resin container, to form a cured resin layer of the desired shape at the desired position and putting a plurality of the cured resin layers thus formed one on another, a wiper is arranged above said resin container at such an inclination angle to the liquid face of resin that substantially no meniscus is caused, and the wiper is moved in a direction perpendicular to the lengthwise direction of the wiper to form a liquid resin layer.
According to this method, it becomes possible to put resin layers having a precise thickness of 0.1 mm or less one on another.
The apparatus for forming a three-dimensional resin image according to the present invention comprises a liquid resin container, a means for sinking and lifting a cured resin layer, a means for irradiating and scanning the liquid face of a liquid resin with a laser beam, a wiper and a means for moving the wiper, and is characterized in that the wiper is arranged above the liquid resin container at such an inclination angle to the liquid face of resin that substantially no meniscus is caused and so that the wiper can be moved by said moving means in a direction perpendicular to the lengthwise direction of the wiper.
It is preferable that the wiper has a flat surface, that is, the wiper is a flat plate. The angle of the wiper to the liquid face of resin (i.e. the inclination angle of the wiper is varied depending upon the combination of the type of the resin and the material of the wiper and is preferably selected so as to be equal to the contact angle which is uniquely determined by said combination. The inclination angle may deviate slightly from the contact angle as long as substantially no meniscus is formed.
The inclination angle of the wiper is preferably 300 or more. When the inclination angle is less than 300, it may happen that the liquid resin adheres onto the slope of the wiper by some action and the resin falls gradually, giving adverse effects.
The material of the wiper preferably has a surface energy as low as possible. The lower the surface energy of the material, the higher the contact angle against the liquid resin, and hence, it becomes possible to make the inclination angle of the wiper larger.
Further, such a wiper has low wettability with the liquid resin and can prevent the adhesion of the liquid resin to the surface of the wiper. The specific material of the wiper is preferably a fluorine-containing polymer (e.g.
Teflon, polyvinylidene fluoride), a silicone resin, other materials (e.g. metal) coated with or laminated to either of said resins.
As to the structure of the wiper, the inclined wiper of the present invention may be used alone or in combination of two or more. When two or more wipers are used, the front wipers (front in the direction of moving of wiper) may be perpendicular wiper(s) or brush type wiper(s) as long as the last wiper is the inclined wiper of the present invention.
In the present invention, there is used an inclined wiper having such an inclination angle that substantially no meniscus is caused, so that it is possible to put cured resin layers having a precise thickness of 0.1 mm or less one on another and also possible to smoothen the surface of a shaped article. As a result, the shaped article has improved appearance; the polishing of the article in the post-treatment step is easy or unnecessary; a model can be produced faster; and the shaped article has an improved precision in the height direction.
The present invention is hereinafter described more specifically referring to the accompanying drawings.
Fig. 1 is a schematic perspective view showing the constitution of an example of apparatus of the present invention for forming a three-dimensional image.
This apparatus comprises an optical system capable of irradiating and scanning the liquid face of a photocurable liquid resin with a laser beam and a resin container system which contains a photo-curable, liquid resin and in which a cured resin layer can be sunk and lifted. A photo-curable liquid resin g is contained in a liquid resin tank h. To the tank h are fitted a lift for sinking and lifting a cured resin layer i in the liquid resin g, a wiper k and a pump m for returning the liquid resin which has overflowed, to the tank h.
The optical system comprises a laser oscillator a, mirrors b and e, a shutter c and a Z focus lens d. A laser beam i is focused on the liquid face of the liquid resin g by the optical system, and the laser beam j is scanned on the liquid face of liquid resin g by rotating the mirror e. In this case, a difference in optical paths arises between when the laser beam is applied to the liquid face perpendicularly and when the laser beam is applied obliquely at a certain angle, resulting in a difference in focal points. However, use of the Z focus lens d can correct the optical path difference and enables the focal point to be always controlled to the liquid face. This control of the focal point is also possible by using, in place of the Z focus lens, a correction lens which moves along the path of the laser beam.
In order to form a three-dimensional image, the three-dimensional image to be formed is sliced into thin pieces in, for example, a perpendicular direction; the sectional shapes of the thin pieces are memorized in a memory unit (not shown); the rotation of the mirror e is controlled by a control unit (not shown) such as computer or the like; then, a first cured resin layer of the desired shape is formed; and thereafter, the lift f is controlled to sink said cured resin layer in the liquid resin by the thickness of a cured resin layer to be formed next. Said memory unit and control unit may be the same as those used conventionally, and hence, they are not shown in Fig. 1. The wiper k is moved, when necessary, in a direction shown by an arrow mark in Fig.
1 or in its opposite direction, by a motor controlled by the same control unit. The driving system for the wiper may also be the same as used conventionally, and hence, it is not shown in Fig. 1.
As the apparatus for forming a threedimensional image, besides an apparatus wherein the scanning of a laser beam is conducted using a movable mirror as shown in Fig. 1, there may also be used, for example, an apparatus wherein scanning is conducted by moving an optical fiber using an NC table or an apparatus wherein exposure is conducted at one time using a mask such as liquid crystal shutter or the like.
The photo-curable, liquid resin used is not critical, and conventional photo-curable, liquid resins can be used. Specifically, there can be used photocurable resins of radical polymerization type such as urethane acrylate, epoxy acrylate and the like; photocurable resins utilizing photo-induced cationic polymerization of epoxy resin; and so forth.
Next, a description is made of the present process for forming a three-dimensional image of resin using a wiper. A sectional shape of the portion of the present wiper that comes into contact with the photocurable, liquid resin, is shown in Fig. 2. This shape is obtained by cutting the lower end of a thin flat plate so that the resulting end has an angle equal to the contact angle 6. The wiper 4 is moved while the lower end is in contact with the liquid face of the liquid resin. Figs.
3(a)-3(c) show other sectional shape examples of the portion of the wiper that comes into contact with the photo-curable, liquid resin. In the wiper of Fig. 3(a), a vertical portion 4A is provided on the upper side of the shape shown in Fig. 2; in the wiper of Fig. 3(b), one side is left as it is vertical; in the wiper of Fig.
3(c), the wiper of Fig. 3(a) is combined with a conventional vertical wiper 3; and in the wiper of Fig.
3(d), the wiper of Fig. 3(a) is combined with a brush 5.
In the wipers of Fig. 3(c) and Fig. 3(d), the vertical wiper 3 and the brush 5 are each provided in front of the wiper 4 in the direction of the moving of the wiper.
Example 1
A three-dimensional model was produced using an apparatus having the construction shown in Fig. 1. In the apparatus, the level of the liquid face of resin is controlled by an overflow method and is always kept constant by circulating a liquid resin with the circulation pump m. Using the apparatus, a model was produced which had the shape shown in Fig. 5(a), by putting cured resin layers each of 50 zm in thickness one on another.
In Fig. 5(a), the figures show dimensions in mm of the model.
The wiper used was made of a Teflon plate of 2 mm in thickness and had the shape shown in Fig. 3(a).
The photo-curable resin used was Desolite SCR-200 (manufactured by Japan Synthetic Rubber Co., Ltd.) which is a urethane acrylate type resin. Since the contact angle 6 between the resin and the wiper was 600, the inclination angle of the wiper was adjusted to 600.
The cured resin layers were put one on another in the same manner as shown in Figs. 4(a)-4(e). That is, after completion of the curing of the nth layer by laser beam application, the lift f was sunk by 1.5 mm and simultaneously the wiper k was moved in the direction opposite to the arrow mark shown in Fig. 1 to the end of the layer. Then, the system was allowed to stand for 5 seconds; the liquid resin was allowed to flow onto the nth layer; and the lift was lifted to the predetermined position (50 #m lower than the initial position).
Thereafter, the wiper was moved in the arrow mark direction to smoothen the liquid face. The system was again allowed to stand for 5 seconds, followed by laser beam application to the (n+l)th layer. The above procedure was repeated to complete the formation of a model.
During the formation of the model, the wiper was not contacted with the cured resin layers. The produced model had no swell as shown in Fig. 5(b) (prior art) and gave good appearance which was the same as that of the design model.
Comparative Example 1
A model shown in Fig. 5(a) was produced in the same manner as in Example 1, using a perpendicular wiper as shown in Fig. 6(a). The wiper was made of the same
Teflon plate as used in Example 1. It was observed during the formation of a model that the wiper contacted with each cured resin layer because some portions of the layer were thicker than the design values.
Hence, the produced model had swells as shown in Fig. 5(b).
Example 2
The model of Fig. 5(a) which consisted of layers each having a thickness of 20 pm was produced using, as a wiper, two flat plates as shown in Fig. 3(a) (one of the flat plates having an inclined portion and the other being a perpendicular flat plate). The flat plate having an inclined portion was made of the same
Teflon plate as used in Example 1, and the perpendicular flat plate was made of a polyethylene plate of 2 mm in thickness. The subsequent procedure was the same as in
Example 1, to produce a model. No contact was caused between the wiper and each cured resin layer during the formation of the model, and the produced model had the same shape as that of the design model.
Example 3
A model consisting of layers each having a thickness of 30 ;im was produced using, as a wiper, a combination of a flat plate having an inclined portion and a brush as shown in Fig. 3(d), in the same manner as in Example 1. In this Example, each of the cured resin layers was sunk by 30 ijm corresponding to the predetermined thickness of each layer without the cured resin layers having been first sunk deeper and then lifted to the predetermined position as in Example 1, to form each layer.
The flat plate having an inclined portion was made of a polyvinylidene fluoride plate of 1 mm in thickness. Since the contact angle between this plate and the liquid resin was 470, the inclination angle of the plate was adjusted to 470. The brush was made of wool and had a front wool portion of 20 mm in length.
No contact was observed between the wiper and each cured resin layer during the formation of the model, and the produced model had the same shape as that of the design model.
As described above, the present invention enables the cured resin layers having a precise thickness of 0.1 mm or less to be put one on another and can provide a shaped article having a smooth surface. As a result, the shaped article has improved appearance; the polishing of the article in the post-treatment step is easy or unnecessary; model production can be conducted faster; and the shaped article has an improved precision in the height direction.
Claims (17)
1. A process for forming a three-dimensional image of resin by applying a light to a photo-curable, liquid resin placed in a resin container, to form a cured resin layer of a desired shape at a given position and repeating this step to put a plurality of cured resin layers one on another, characterized in that above the resin container, a wiper is arranged at such an inclination angle to the liquid face of resin that substantially no meniscus is caused, and the wiper is moved in a direction perpendicular to the lengthwise direction of the wiper prior to the application of a light, thereby forming a liquid resin layer having a smooth face and a uniform thickness on the previously formed cured resin layer.
2. The process according to Claim 1, wherein the inclination angle of the wiper is 300 or more.
3. The process according to Claim 1, wherein the inclination angle of the wiper is equal to the contact angle between the wiper and the liquid resin.
4. The process according to Claim 1, wherein the photo-curable, liquid resin is a radical polymerization type photo-curable resin or a photo-curable resin utilizing the photo-induced cationic polymerization of epoxy resin.
5. The process according to Claim 1, wherein the photo-curable, liquid resin is urethane acrylate or epoxy acrylate.
6. The process according to Claim 1, wherein the thickness of the liquid resin layer is 0.1 mm or less.
7. The process according to Claim 1, wherein the thickness of the liquid resin layer is 20-50 Rm.
8. The process according to Claim 1, wherein the wiper is a flat plate made of a material having a low surface energy.
9. The process according to Claim 8, wherein the material having a low surface energy is a fluorinecontaining polymer, a silicone resin, a metal coated with or laminated to either of said resins.
10. The process according to Claim 1, wherein the light is a laser beam.
11. The process according to Claim 1, wherein the cured resin layer formed by light application is sunk in the liquid resin by a depth equal to the thickness of a cured resin layer to be formed next, then the liquid face of resin is smoothened with the wiper, and a light is thereafter applied to the liquid resin on the previously formed cured resin layer.
12. An apparatus for forming a three-dimensional image of resin, which comprises a liquid resin container, a means for sinking or lifting a cured resin layer, a means for applying a light to the surface of a liquid resin, a wiper and a means for moving the wiper, characterized in that the wiper is arranged above the liquid resin container at such an inclination angle that substantially no meniscus is caused and so that the wiper can be moved by said moving means in a direction perpendicular to the lengthwise direction of the wiper.
13. The apparatus according to Claim 12, wherein the inclination angle of the wiper is 300 or more.
14. The apparatus according to Claim 12, wherein the inclination angle of the wiper is equal to the contact angle between the wiper and the liquid resin.
15. The apparatus according to Claim 12, wherein the means for applying a light to the surface of a liquid resin is a means for applying a laser beam to the liquid resin which means comprises a laser oscillator, mirrors, a shutter, and a Z focus lens.
16. The apparatus according to Claim 12, wherein the wiper is a flat plate made of a material having a low surface energy.
17. The apparatus according to Claim 16, wherein the material having a low surface energy is a fluorinecontaining polymer, a silicone resin, a metal coated with or laminated to either of said resins.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP34680891A JP3173088B2 (en) | 1991-12-27 | 1991-12-27 | Optical stereoscopic image forming method and apparatus |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB9226599D0 GB9226599D0 (en) | 1993-02-17 |
| GB2262817A true GB2262817A (en) | 1993-06-30 |
| GB2262817B GB2262817B (en) | 1995-05-24 |
Family
ID=18385950
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9226599A Expired - Lifetime GB2262817B (en) | 1991-12-27 | 1992-12-21 | Process and apparatus for formation of 3-D image in resin |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP3173088B2 (en) |
| KR (1) | KR100241676B1 (en) |
| GB (1) | GB2262817B (en) |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4416901A1 (en) * | 1994-05-13 | 1995-11-16 | Eos Electro Optical Syst | Prodn of three=dimensional objects |
| DE4416988A1 (en) * | 1994-05-13 | 1995-11-16 | Eos Electro Optical Syst | Three=dimensional object mfr and process equipment |
| EP0739704A1 (en) * | 1995-04-25 | 1996-10-30 | EOS GmbH ELECTRO OPTICAL SYSTEMS | Device for producing an object using stereolithography |
| US5753171A (en) * | 1994-05-13 | 1998-05-19 | Eos Gmbh Electro Optical Systems | Method and apparatus for producing a three-dimensional object |
| US6251557B1 (en) | 1996-05-09 | 2001-06-26 | Dsm N.V. | Photosensitive resin composition for rapid prototyping and a process for the manufacture of 3-dimensional objects |
| US20130012086A1 (en) * | 2009-12-14 | 2013-01-10 | Gurit(Uk) Ltd | Repair of composite materials |
| DE102014108633A1 (en) * | 2014-06-18 | 2015-12-24 | Heraeus Kulzer Gmbh | "More efficient method for the production of three-dimensional objects by means of rapid prototyping" |
| EP3819100A1 (en) * | 2019-11-08 | 2021-05-12 | Ivoclar Vivadent AG | Method for the generative construction of shaped bodies by means of stereolithography |
| EP3784475A4 (en) * | 2018-10-26 | 2021-11-03 | Hewlett-Packard Development Company, L.P. | Three-dimensional printing |
| CN115431516A (en) * | 2022-08-03 | 2022-12-06 | 湖南大学 | Supplementary accessory that rotatory curved surface photocuring 3D printer of cooperation used |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3761759B2 (en) * | 2000-01-18 | 2006-03-29 | 株式会社アズマ工機 | Stereolithography apparatus and wiper apparatus |
| KR101548220B1 (en) * | 2014-10-20 | 2015-08-31 | (주)아이투스 인터내셔날 | 3D Printer |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4575330A (en) * | 1984-08-08 | 1986-03-11 | Uvp, Inc. | Apparatus for production of three-dimensional objects by stereolithography |
| JPH10114898A (en) * | 1996-07-24 | 1998-05-06 | Imaginative Res Assoc Inc | Instant foaming clear solution and gel |
-
1991
- 1991-12-27 JP JP34680891A patent/JP3173088B2/en not_active Expired - Lifetime
-
1992
- 1992-12-21 GB GB9226599A patent/GB2262817B/en not_active Expired - Lifetime
- 1992-12-26 KR KR1019920025600A patent/KR100241676B1/en not_active IP Right Cessation
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4575330A (en) * | 1984-08-08 | 1986-03-11 | Uvp, Inc. | Apparatus for production of three-dimensional objects by stereolithography |
| US4575330B1 (en) * | 1984-08-08 | 1989-12-19 | ||
| JPH10114898A (en) * | 1996-07-24 | 1998-05-06 | Imaginative Res Assoc Inc | Instant foaming clear solution and gel |
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4416988A1 (en) * | 1994-05-13 | 1995-11-16 | Eos Electro Optical Syst | Three=dimensional object mfr and process equipment |
| US5753171A (en) * | 1994-05-13 | 1998-05-19 | Eos Gmbh Electro Optical Systems | Method and apparatus for producing a three-dimensional object |
| DE4416901A1 (en) * | 1994-05-13 | 1995-11-16 | Eos Electro Optical Syst | Prodn of three=dimensional objects |
| EP0739704A1 (en) * | 1995-04-25 | 1996-10-30 | EOS GmbH ELECTRO OPTICAL SYSTEMS | Device for producing an object using stereolithography |
| US5665401A (en) * | 1995-04-25 | 1997-09-09 | Eos Gmbh Electro Optical Systems | Apparatus for producing an object using stereolithography |
| US5904889A (en) * | 1995-04-25 | 1999-05-18 | 3D Systems, Inc. | Apparatus and method for producing an object using stereolithography |
| US6251557B1 (en) | 1996-05-09 | 2001-06-26 | Dsm N.V. | Photosensitive resin composition for rapid prototyping and a process for the manufacture of 3-dimensional objects |
| US9381707B2 (en) * | 2009-12-14 | 2016-07-05 | Gurit (Uk) Ltd. | Repair of composite materials |
| US20130012086A1 (en) * | 2009-12-14 | 2013-01-10 | Gurit(Uk) Ltd | Repair of composite materials |
| DE102014108633A1 (en) * | 2014-06-18 | 2015-12-24 | Heraeus Kulzer Gmbh | "More efficient method for the production of three-dimensional objects by means of rapid prototyping" |
| DE102014108633B4 (en) | 2014-06-18 | 2024-02-08 | Kulzer Gmbh | Device and method for producing three-dimensional objects using rapid prototyping |
| DE102014108633B9 (en) | 2014-06-18 | 2024-07-04 | Kulzer Gmbh | Device and method for producing three-dimensional objects by rapid prototyping |
| EP3784475A4 (en) * | 2018-10-26 | 2021-11-03 | Hewlett-Packard Development Company, L.P. | Three-dimensional printing |
| EP3819100A1 (en) * | 2019-11-08 | 2021-05-12 | Ivoclar Vivadent AG | Method for the generative construction of shaped bodies by means of stereolithography |
| CN115431516A (en) * | 2022-08-03 | 2022-12-06 | 湖南大学 | Supplementary accessory that rotatory curved surface photocuring 3D printer of cooperation used |
| CN115431516B (en) * | 2022-08-03 | 2024-05-28 | 湖南大学 | Auxiliary accessory for cooperation of rotary curved surface photo-curing 3D printer |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9226599D0 (en) | 1993-02-17 |
| KR100241676B1 (en) | 2000-02-01 |
| JP3173088B2 (en) | 2001-06-04 |
| JPH05177718A (en) | 1993-07-20 |
| KR930013893A (en) | 1993-07-22 |
| GB2262817B (en) | 1995-05-24 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PE20 | Patent expired after termination of 20 years |
Expiry date: 20121220 |