JP4889266B2 - Three-dimensional shaped object and manufacturing method thereof - Google Patents

Three-dimensional shaped object and manufacturing method thereof Download PDF

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JP4889266B2
JP4889266B2 JP2005255781A JP2005255781A JP4889266B2 JP 4889266 B2 JP4889266 B2 JP 4889266B2 JP 2005255781 A JP2005255781 A JP 2005255781A JP 2005255781 A JP2005255781 A JP 2005255781A JP 4889266 B2 JP4889266 B2 JP 4889266B2
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density region
sintered
base
low density
dimensional shaped
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JP2007070655A (en
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愼一 篠原
知実 田中
崇 鶴田
賢二 西谷
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Panasonic Corp
Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • 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
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Plasma & Fusion (AREA)
  • Ceramic Engineering (AREA)
  • Optics & Photonics (AREA)
  • Powder Metallurgy (AREA)

Description

本発明は粉末材料の選択的焼結によって形成される３次元形状造形物およびその製造方法に関するものである。   The present invention relates to a three-dimensional shaped article formed by selective sintering of a powder material and a method for producing the same.

３次元形状造形物の製造方法としては、例えば特許文献１に記載されているものがある。この方法は、図４（ａ）（ｂ）（ｃ）に示すように、焼結用テーブル６００に下部構成材となる基台１００を設置し、この基台１００上に無機質あるいは有機質の粉末材料１０２からなる粉末層１０３を形成し、その所定部に光ビーム（レーザービーム）Ｌを照射して焼結することで焼結部１０１ａを形成し、その後に、新たな粉末層１０３を形成し、その所定部に光ビームＬを照射して焼結することで、先の焼結部１０１ａと一体となった焼結部１０１ｂを形成する、というステップを繰り返すことにより、粉末材料１０２から焼結部１０１を一層ずつ積層的に形成して３次元形状造形物を製造するもので、複雑な３次元形状造形物も短時間で製造することができる。   As a manufacturing method of a three-dimensional shaped object, for example, there is one described in Patent Document 1. In this method, as shown in FIGS. 4 (a), (b), and (c), a base 100 as a lower constituent material is installed on a sintering table 600, and an inorganic or organic powder material is formed on the base 100. A powder layer 103 made of 102 is formed, and a predetermined portion thereof is irradiated with a light beam (laser beam) L and sintered to form a sintered portion 101a. Thereafter, a new powder layer 103 is formed, By repeating the step of forming the sintered part 101b integrated with the previous sintered part 101a by irradiating the predetermined part with the light beam L and sintering, the sintered part is made from the powder material 102. 101 is formed one layer at a time to produce a three-dimensional shaped object, and a complicated three-dimensional shaped object can also be produced in a short time.

強度を確保するために焼結密度を高くするとガス焼けなどの問題が発生するため、ガス抜き機能を付加したものもある。図５に示すように、基台１００に予め、焼結部１０１で覆われる表面で開口するガス抜き穴１００ａなどを加工して内部を多孔質材料で埋め込んでおき、焼結部１０１を形成する際に、ガス抜き穴１０１ａ上の下層の焼結部１０１はそれ以外の部分よりも焼結密度を低くして多孔質材料に似せることで、ガス抜き構造が形成されている。
特開２００３‐００１７１５公報 If the sintering density is increased to ensure strength, problems such as gas burning will occur, and some have added a degassing function. As shown in FIG. 5, the base 100 is previously processed with a gas vent hole 100 a opened on the surface covered with the sintered portion 101, and the inside is filled with a porous material, thereby forming the sintered portion 101. At this time, the lower portion of the sintered portion 101 on the vent hole 101a has a lower sintering density than the other portions so as to resemble a porous material, thereby forming a vent structure.
JP 2003-001715 A

しかしながら、ガス抜き機能を付加した３次元形状造形物は、上記したようにガス抜き部分の焼結密度を低くして多孔質材料に似せていることから、そのガス抜き部分の強度が他の部分より劣る。そのため射出成形金型の入子として用いるには剛性や耐久性が不十分なことがあり、成形ショット数の多い金型には金型部品として活用しにくいという問題がある。   However, since the three-dimensional shaped object to which the degassing function is added is similar to the porous material by lowering the sintering density of the degassing part as described above, the strength of the degassing part is different from that of the other part. Inferior. Therefore, there is a problem that rigidity and durability are insufficient for use as an insert of an injection mold, and it is difficult to use as a mold part for a mold having a large number of molding shots.

本発明は上記問題を解決するもので、ガス抜き機能を有しつつ、成形ショット数の多い金型にも金型部品として活用できる強度を有した３次元形状造形物を形成することを目的とする。   The present invention solves the above-described problem, and has an object to form a three-dimensional shaped article having a strength that can be used as a mold part even in a mold having a large number of molding shots while having a gas venting function. To do.

上記課題を解決するために本発明は、基台上で、無機質あるいは有機質の粉末材料の層を形成し、その粉末材料の層の所定部を光ビームの照射によって焼結させてその面内に焼結密度が高い高密度領域と、それよりも低い焼結密度を有する多孔質な低密度領域とを設けた焼結層を形成することを繰り返すことにより、複数の焼結層を一体化させて３次元形状造形物を製造する方法であって、ガス抜き部分を設けた前記基台の上に、前記ガス抜き部分を覆うように設けられた前記低密度領域と前記高密度領域とを有する前記基台側の焼結層を複数形成し、前記基台側の複数の焼結層の上に隣接して、高密度領域と低密度領域とを有する前記基台と反対側の焼結層を複数形成し、隣接する前記焼結層の内、前記基台側の焼結層における低密度領域の面積は、前記基台と反対側の焼結層の低密度領域の面積より大きいものである。低密度領域を分散させることで、同一面積をたとえば１箇所に集中させる場合に較べて強度が高まるので、ガス抜き機能、強度を併せ持たせ得るだけでなく、ガス抜きの範囲や輪郭は１つの低密度領域を基本に自由に設定できるようになり、これにより光ビームの照射時間の短縮を図ることも可能となる。 In order to solve the above-mentioned problems, the present invention forms a layer of an inorganic or organic powder material on a base, and sinters a predetermined portion of the powder material layer by irradiation with a light beam so as to be in the plane. By repeating the formation of a sintered layer provided with a high density region having a high sintered density and a porous low density region having a lower sintered density, a plurality of sintered layers can be integrated. A method for manufacturing a three-dimensional shaped object comprising the low density region and the high density region provided on the base on which the gas venting portion is provided so as to cover the gas venting portion. A plurality of sintered layers on the base side are formed, and adjacent to the plurality of sintered layers on the base side, a sintered layer on the side opposite to the base having a high density region and a low density region. the forming a plurality, of the sintered layer adjacent the low density region in the sintering layer of the base side Area, is greater than the area of the low density region of the opposite side of the sintered layer and the base. By dispersing the low density region, the strength is increased as compared with the case where the same area is concentrated in one place, for example. Based on the low density region, it can be freely set, and this makes it possible to shorten the irradiation time of the light beam.

隣接する焼結層の内、焼結用テーブル側の焼結層に、焼結用テーブルと反対側の焼結層の低密度領域の面積より面積が大きい低密度領域を設けてもよく、これにより、光ビームの照射時間のさらなる短縮を図ることができる。   Of the adjacent sintered layers, the sintered layer on the side of the sintering table may be provided with a low density region having a larger area than the area of the low density region of the sintered layer on the opposite side of the sintering table. Thus, the irradiation time of the light beam can be further shortened.

上記方法により製造される３次元形状造形物、すなわち、高密度領域とガス抜き部分を覆うように形成された低密度領域とを備えたガス抜き部分を設けた基台側の複数の焼結層と、前記基台側の複数の焼結層の上に隣接して形成されて前記高密度領域と前記低密度領域とを備えた前記基台と反対側の複数の焼結層とで構成し、隣接する前記焼結層の内、前記基台側の焼結層における低密度領域の面積は、前記基台と反対側の焼結層の低密度領域の面積より大きい３次元形状造形物も本発明を構成する。 A plurality of three-dimensional shaped objects manufactured by the above method, that is, a plurality of sintered layers on the base side provided with a degassing portion provided with a high-density region and a low-density region formed so as to cover the degassing portion And a plurality of sintered layers on the side opposite to the base, which is formed adjacent to the plurality of sintered layers on the base side and includes the high density region and the low density region. Among the adjacent sintered layers, the area of the low density region in the sintered layer on the base side is larger than the area of the low density region of the sintered layer on the opposite side of the base, This constitutes the present invention.

本発明方法によれば、ガス抜き機能と、ショット数の多い射出成形金型の金型部品などとしても使用可能な強度とを併せ持つ３次元形状造形物が得られる。ガス抜きの設定範囲や輪郭は、１つの低密度領域の大きさを基準に自由に設定することができる。低密度領域を多くすることで光ビームの照射時間を短縮することもできる。   According to the method of the present invention, a three-dimensional shaped object having both a gas venting function and a strength that can be used as a mold part of an injection mold having a large number of shots can be obtained. The degassing setting range and contour can be freely set based on the size of one low density region. By increasing the low density region, the irradiation time of the light beam can be shortened.

以下に本発明を実施する為の最良の形態について、図面を参照しながら説明する。
図１は本発明の一実施形態における３次元形状造形物の外観斜視図である。基台１００と、それを覆った焼結部１０１とで構成されている。焼結部１０１は、複数の焼結層が一体化された積層構造（後述する）を有するとともに、強度を確保するための高密度領域４０１とガス抜きのための多孔質な低密度領域４０２とが表面に格子状に、つまり縦横に複数個ずつ、分布している。 The best mode for carrying out the present invention will be described below with reference to the drawings.
FIG. 1 is an external perspective view of a three-dimensional shaped object in one embodiment of the present invention. It comprises a base 100 and a sintered part 101 covering it. The sintered portion 101 has a laminated structure (to be described later) in which a plurality of sintered layers are integrated, a high-density region 401 for ensuring strength, and a porous low-density region 402 for degassing. Are distributed in a lattice pattern on the surface, that is, a plurality of vertical and horizontal.

図２はこの３次元形状造形物を製造するための製造装置の一例を示しており、焼結用テーブル６００と、この焼結用テーブル６００を昇降させる昇降台６０１、焼結用テーブル６００上に粉末材料を供給する粉末供給装置６０２、焼結用テーブル６００上に偏光装置６０３を介して照射する光ビームＬを発生する光ビーム照射装置６０４、これらを制御する制御装置６０５で構成されている。粉末供給装置６０２はブレード６０６を有している。   FIG. 2 shows an example of a manufacturing apparatus for manufacturing the three-dimensional shaped object. On the sintering table 600, a lifting table 601 for raising and lowering the sintering table 600, and the sintering table 600. It comprises a powder supply device 602 for supplying a powder material, a light beam irradiation device 604 for generating a light beam L to be irradiated on a sintering table 600 via a polarizing device 603, and a control device 605 for controlling them. The powder supply device 602 has a blade 606.

上記した３次元形状造形物を製造する方法を説明する。
図３（ａ）に示すように、３次元形状造形物における下部構造の全てもしくは一部となる基台１００を焼結用テーブル６００上にセットする。この基台１００はその表面上で粉末材料を焼結させる時に焼結物と一体化するものであれば、どのような材料で形成されたものであってもよいが、予め所要の加工を済ませたものを用いる。ここでは焼結部１０１で覆われる表面で開口したガス抜き穴１００ａを加工したものを用いた。ガス抜き穴１００ａは多孔質材料で埋め込んでもよい。 A method for manufacturing the above-described three-dimensional shaped object will be described.
As shown in FIG. 3A, the base 100 that is all or part of the lower structure in the three-dimensional shaped object is set on the sintering table 600. The base 100 may be formed of any material as long as it is integrated with the sintered product when the powder material is sintered on the surface thereof, but the necessary processing is completed in advance. Use the same thing. Here, what processed the vent hole 100a opened on the surface covered with the sintered part 101 was used. The vent hole 100a may be filled with a porous material.

次に、図３（ｂ）に示すように、焼結用テーブル６００上に粉末材料１０２を供給しつつその表面をブレード６０６によってならして、基台１００上にΔｔの厚みの粉末層１０３を形成する。次に、図３（ｃ）に示すように、光ビームＬを所定の領域に対して照射して粉末層１０３を焼結させ、基台１００と一体化した焼結部１０１ａを形成する。その際には光ビーム照射装置６０４からの光ビームＬは偏光装置６０３により偏光して粉末層１０３に照射する。またその際に制御装置６０５によって偏光装置６０３を制御することで光ビームＬの照射位置を移動させる。粉末材料１０２は、金属、プラスチック、重合体、セラミックス、またはこれらが複合された無機質あるいは有機質の粉末材料であってよい。   Next, as shown in FIG. 3B, while supplying the powder material 102 onto the sintering table 600, the surface thereof is leveled by the blade 606, and the powder layer 103 having a thickness of Δt is formed on the base 100. Form. Next, as shown in FIG. 3C, the light layer L is irradiated to a predetermined region to sinter the powder layer 103, thereby forming a sintered portion 101 a integrated with the base 100. At that time, the light beam L from the light beam irradiation device 604 is polarized by the polarizing device 603 and applied to the powder layer 103. At that time, the irradiation position of the light beam L is moved by controlling the polarizing device 603 by the control device 605. The powder material 102 may be a metal, plastic, polymer, ceramic, or an inorganic or organic powder material in which these are combined.

その後に、図３（ｄ）に示すように、さらに粉末層１０３を形成し、その粉末層１０３を焼結して下層の焼結部１０１ａと一体化した焼結部１０１ｂを形成する、ということを繰り返して順次に積層していき、所望の３次元形状に近づけていく。その際には、順次に形成される焼結部１０１ａ，１０１ｂ，・・・の所定範囲の表面形状に沿うように光ビームＬの照射位置を移動させる。   After that, as shown in FIG. 3D, the powder layer 103 is further formed, and the powder layer 103 is sintered to form a sintered portion 101b integrated with the lower sintered portion 101a. Are repeatedly stacked in order to bring it closer to the desired three-dimensional shape. At that time, the irradiation position of the light beam L is moved so as to follow the surface shape of a predetermined range of the sintered portions 101a, 101b,.

なお焼結の際に、焼結部１０１ａ，１０１ｂ，・・・の面内（基台１００の表面方向）における焼結密度を調整する。これは、制御装置６０５より、光ビーム照射装置６０４の出力を制御して光ビームＬの強度を変更するか、あるいは偏光装置６０３の動作を制御して光ビームＬの走査速度（照射位置の移動速度）を変更することによる。光ビームＬの強度が大きいほど、また光ビームＬの走査速度が遅いほど、焼結密度が大きくなる。ここでは、光ビーム照射装置６０４の出力は一定に保ち、偏光装置６０３を通じて光ビームＬの走査速度を変更することにより、気孔率０.１％という高密度領域と、気孔率１０％という多孔質な低密度領域とが形成される条件を設定する。このように条件を設定した上で焼結を開始する。   During sintering, the sintering density in the plane of the sintered portions 101a, 101b,... (Surface direction of the base 100) is adjusted. This is because the controller 605 controls the output of the light beam irradiation device 604 to change the intensity of the light beam L, or controls the operation of the polarizing device 603 to control the scanning speed of the light beam L (movement of the irradiation position). By changing the (speed). The greater the intensity of the light beam L and the slower the scanning speed of the light beam L, the greater the sintering density. Here, the output of the light beam irradiation device 604 is kept constant, and by changing the scanning speed of the light beam L through the polarizing device 603, a high-density region with a porosity of 0.1% and a porous material with a porosity of 10%. A condition for forming a low density region is set. Sintering is started after setting the conditions in this way.

焼結による積層の初期の段階では、ガス抜きを設定する範囲（上述した低密度領域の分布範囲）の全体に対して光ビームＬの走査速度を速くすることで、図３（ｅ）に示すように、当該範囲にわたる低密度領域４０２を形成し、それ以外の部分は高密度領域４０１とする。ここでは低密度領域４０２を、基台１００のガス抜き穴１０１ａを覆うように中央に大きく矩形に形成し、それ以外の部分、すなわち周縁部のみに高密度領域４０１を配置している。このことにより、面積の広い低密度領域４０２が一般に用いられている多孔質材料に似ることになり、ガス抜き性能が向上する。また光ビームＬの照射時間についても、最初から高密度領域４０１と低密度領域４０２とを格子状に形成するのを目指すのに比べて、光ビームの走査速度が速い低密度領域４０２を広くとれることから、照射時間を短縮することができる。   In the initial stage of lamination by sintering, the scanning speed of the light beam L is increased with respect to the entire range in which gas venting is set (the above-described distribution range of the low density region), as shown in FIG. As described above, the low density region 402 over the range is formed, and the other part is the high density region 401. Here, the low-density region 402 is formed in a large rectangle at the center so as to cover the gas vent hole 101a of the base 100, and the high-density region 401 is disposed only at the other portion, that is, the peripheral portion. As a result, the low-density region 402 having a large area resembles a commonly used porous material, and the gas venting performance is improved. Also, with respect to the irradiation time of the light beam L, the low-density region 402 having a high scanning speed of the light beam can be widened as compared to aiming to form the high-density region 401 and the low-density region 402 in a lattice shape from the beginning. Therefore, the irradiation time can be shortened.

ある程度の厚みまで積層されたら、光ビームＬの走査速度を制御装置６０５と偏光装置６０３により切り替えて、図３（ｆ）に示すように、高密度領域４０１と複数の低密度領域４０２とを混在させる。ここでは、低密度領域４０２を線状かつ並列に形成し、それ以外は高密度領域４０１としたものを図示しているが、上述した高密度領域４０１と低密度領域４０２とが格子状に配置されたものを簡略化して示したものである（もちろん、図示したような線状の分布を有するものであってもよい）。低密度領域４０２は先に形成した低密度領域４０２の上に配置する。焼結部１０１の最終的な厚みは、３次元形状造形物に要求される強度を、先に周縁部のみに形成した高密度領域４０１とここで形成した高密度領域４０１とによって確保できる厚みとする。これはシミュレーションによって決定する。   When the layers are laminated to a certain thickness, the scanning speed of the light beam L is switched by the control device 605 and the polarizing device 603, and as shown in FIG. 3 (f), the high density region 401 and a plurality of low density regions 402 are mixed. Let Here, the low-density region 402 is formed linearly and in parallel, and the other is a high-density region 401, but the high-density region 401 and the low-density region 402 described above are arranged in a lattice pattern. This is a simplified illustration (of course, it may have a linear distribution as shown). The low density region 402 is disposed on the previously formed low density region 402. The final thickness of the sintered portion 101 is a thickness that can ensure the strength required for the three-dimensional shaped object by the high-density region 401 formed only in the peripheral portion and the high-density region 401 formed here. To do. This is determined by simulation.

所定の厚みの焼結部１０１が形成されたら、焼結用テーブル６００から基台１００を取り外すとともに未焼結で残った粉末材料１０２を除去することにより、目的とした３次元形状造形物を得る。   When the sintered portion 101 having a predetermined thickness is formed, the target 100 is removed by removing the base 100 from the sintering table 600 and removing the unsintered powder material 102. .

以上のようにして、基台１００を下部構造とし、積層された焼結部１０１を上部構造とし、かつ焼結部１０１の表面にガス抜きの為の低密度領域４０２と高密度領域４０１とが格子状等に形成された３次元形状造形物を得ることができる。かかる３次元形状造形物を、粉末材料１０２として、鉄系粉末を５０質量％以上含み、残部がニッケルおよびニッケル系合金からなる粉末合金である粉末材料を用いて、家電製品の筐体を形成する樹脂射出成型金型、その金型部品のなかでも可動側の入子として製造したところ、強度、ガス抜き機能とも、良好な結果が得られた。   As described above, the base 100 has a lower structure, the laminated sintered portion 101 has an upper structure, and a low density region 402 and a high density region 401 for degassing are formed on the surface of the sintered portion 101. A three-dimensional shaped article formed in a lattice shape or the like can be obtained. Using such a three-dimensional shaped object as a powder material 102, a housing for home appliances is formed using a powder material containing 50 mass% or more of iron-based powder and the balance being a powder alloy made of nickel and a nickel-based alloy. When a resin injection mold and its mold parts were manufactured as a movable side insert, good results were obtained in both strength and degassing function.

なおこの３次元形状造形物では、上述したように内部（下層）に低密度領域４０２を１箇所のみ、強度が確保できる限界まで広く設けることで照射時間の短縮を図ったが、内部も高密度領域４０１と低密度領域４０２とを格子状等に形成するようにしても構わない。   In this three-dimensional shaped object, as described above, the irradiation time was shortened by providing only one low density region 402 in the inside (lower layer) to the limit where the strength can be secured. The region 401 and the low density region 402 may be formed in a lattice shape or the like.

また基台１００にて下部構造を構成したが、全構造を焼結部１０１にて構成してもよく、その場合も同様の効果を得ることができる。
また高密度領域４０１および低密度領域４０２の形状を長方形またはそれが繋がった枠状等の形状とすることで、３次元形状造形物と光ビームＬの制御プログラムの製作負荷の軽減を図ったが、どのような形でも同様の効果を得ることはできる。ガス抜きの設定範囲や輪郭は、１つの低密度領域４０２の大きさを基準に自由に設定することができる。 Moreover, although the lower structure was comprised in the base 100, the whole structure may be comprised in the sintered part 101, and the same effect can be acquired also in that case.
In addition, the load of the control program for the three-dimensional shaped object and the light beam L has been reduced by making the shape of the high-density region 401 and the low-density region 402 a shape such as a rectangle or a frame shape connected to the rectangle. The same effect can be obtained in any form. The degassing setting range and contour can be freely set based on the size of one low density region 402.

本発明方法によれば、ガス抜き機能と強度とを併せ持った３次元形状造形物を製造することができ、ショット数の多い射出成形金型の金型部品などの製造にも有用である。   According to the method of the present invention, it is possible to produce a three-dimensional shaped article having both a gas venting function and strength, and it is also useful for producing a mold part of an injection mold having a large number of shots.

本発明の一実施形態における３次元形状造形物の外観斜視図External perspective view of three-dimensional shaped object in one embodiment of the present invention 図１の３次元形状造形物を製造するための従来よりある製造装置の構造図Structural drawing of a conventional manufacturing apparatus for manufacturing the three-dimensional shaped object of FIG. 図１の３次元形状造形物の製造方法を説明する工程断面図Process sectional drawing explaining the manufacturing method of the three-dimensional shape molded article of FIG. 従来の３次元形状造形物の製造方法を説明する工程断面図Process sectional drawing explaining the manufacturing method of the conventional three-dimensional shape molded article ガス抜き機能を付加した３次元形状造形物の製造方法を示す断面図Sectional drawing which shows the manufacturing method of the three-dimensional shape modeling thing which added the gas venting function

符号の説明Explanation of symbols

１００ 基台
１００ａ ガス抜き用穴
１０１ 焼結部
１０２ 粉末材料
１０３ 粉末層
４０１ 高密度領域
４０２ 低密度領域
６００ 焼結用テーブル
Ｌ 光ビーム DESCRIPTION OF SYMBOLS 100 Base 100a Degassing hole 101 Sintering part 102 Powder material 103 Powder layer 401 High density area 402 Low density area 600 Sintering table L Light beam

Claims (4)

基台上で、無機質あるいは有機質の粉末材料の層を形成し、
その粉末材料の層の所定部を光ビームの照射によって焼結させてその面内に焼結密度が高い高密度領域と、それよりも低い焼結密度を有する多孔質な低密度領域とを設けた焼結層を形成することを繰り返すことにより、複数の焼結層を一体化させて３次元形状造形物を製造する方法であって、
ガス抜き部分を設けた前記基台の上に、前記ガス抜き部分を覆うように設けられた前記低密度領域と前記高密度領域とを有する前記基台側の焼結層を複数形成し、
前記基台側の複数の焼結層の上に隣接して、高密度領域と低密度領域とを有する前記基台と反対側の焼結層を複数形成し、
隣接する前記焼結層の内、前記基台側の焼結層における低密度領域の面積は、前記基台と反対側の焼結層の低密度領域の面積より大きい
３次元形状造形物の製造方法。 Form a layer of inorganic or organic powder material on the base,
A predetermined portion of the powder material layer is sintered by irradiation with a light beam to provide a high density region having a high sintering density and a porous low density region having a lower sintering density in the plane. A method of manufacturing a three-dimensional shaped object by integrating a plurality of sintered layers by repeating forming a sintered layer,
A plurality of the base-side sintered layers having the low density region and the high density region provided so as to cover the gas vent portion are formed on the base having the gas vent portion,
Adjacent on the plurality of sintered layers on the base side, forming a plurality of sintered layers on the side opposite to the base having a high density region and a low density region,
Production of a three-dimensional shaped object in which the area of the low density region in the sintered layer on the base side among the adjacent sintered layers is larger than the area of the low density region in the sintered layer on the side opposite to the base Method. 前記基台と反対側の焼結層は、高密度領域と低密度領域とが格子状に分布されるように形成される
請求項１記載の３次元形状造形物の製造方法。 The method for producing a three-dimensional shaped article according to claim 1, wherein the sintered layer on the side opposite to the base is formed so that the high density region and the low density region are distributed in a lattice shape. 前記基台の前記ガス抜き部分は複数であり、
前記基台側の焼結層の低密度領域は、前記複数のガス抜き部分を覆い、繋がった一つの低密度領域である
請求項１または請求項２のいずれかに記載の３次元形状造形物の製造方法。 The gas vent portion of the base is plural,
3. The three-dimensional shaped object according to claim 1, wherein the low-density region of the sintered layer on the base side is one low-density region that covers and connects the plurality of gas vent portions. Manufacturing method. 複数の焼結層が一体化されてなる積層構造を有し、前記焼結層の面内に焼結密度が高い高密度領域とそれよりも低い焼結密度を有する多孔質な低密度領域とを備えた３次元形状造形物であって、
前記高密度領域とガス抜き部分を覆うように形成された前記低密度領域とを備えたガス抜き部分を設けた基台側の複数の焼結層と、
前記基台側の複数の焼結層の上に隣接して形成されて前記高密度領域と前記低密度領域とを備えた前記基台と反対側の複数の焼結層とで構成し、
隣接する前記焼結層の内、前記基台側の焼結層における低密度領域の面積は、前記基台と反対側の焼結層の低密度領域の面積より大きい
３次元形状造形物。 A laminated structure in which a plurality of sintered layers are integrated, and a high density region having a high sintered density and a porous low density region having a sintered density lower than that in the plane of the sintered layer; A three-dimensional shaped object comprising
A plurality of sintered layers on the base side provided with a degassing portion comprising the high density region and the low density region formed so as to cover the degassing portion;
A plurality of sintered layers on the opposite side of the base including the high-density region and the low-density region formed adjacent to the plurality of sintered layers on the base side,
Among the adjacent sintered layers, a three-dimensional shaped article in which the area of the low density region in the sintered layer on the base side is larger than the area of the low density region in the sintered layer on the side opposite to the base .
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