WO2017038028A1 - Modeling device - Google Patents

Modeling device Download PDF

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Publication number
WO2017038028A1
WO2017038028A1 PCT/JP2016/003722 JP2016003722W WO2017038028A1 WO 2017038028 A1 WO2017038028 A1 WO 2017038028A1 JP 2016003722 W JP2016003722 W JP 2016003722W WO 2017038028 A1 WO2017038028 A1 WO 2017038028A1
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WO
WIPO (PCT)
Prior art keywords
modeling device
compression
laminate
stage
compression member
Prior art date
Application number
PCT/JP2016/003722
Other languages
French (fr)
Inventor
Toshihiro Ogata
Original Assignee
Canon Kabushiki Kaisha
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Filing date
Publication date
Application filed by Canon Kabushiki Kaisha filed Critical Canon Kabushiki Kaisha
Publication of WO2017038028A1 publication Critical patent/WO2017038028A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/141Processes of additive manufacturing using only solid materials
    • B29C64/147Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/188Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B29C64/194Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03GELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
    • G03G15/00Apparatus for electrographic processes using a charge pattern
    • G03G15/22Apparatus for electrographic processes using a charge pattern involving the combination of more than one step according to groups G03G13/02 - G03G13/20
    • G03G15/221Machines other than electrographic copiers, e.g. electrophotographic cameras, electrostatic typewriters
    • G03G15/224Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing

Definitions

  • the present disclosure relates to a modeling device, and specifically relates to a laminate modeling device that molds a three-dimensional object by laminating sheet layers that each include a mold material and a support material.
  • AM additive manufacturing
  • RP rapid prototyping
  • the AM technique is a technique of molding a three-dimensional object.
  • three-dimensional object shape data is sliced and divided into multiple layers, and lamination layers according to the pieces of sliced shape data is formed with a mold material.
  • Each of the formed lamination layers formed by the mold material is sequentially laminated and fixed such that a three-dimensional object is molded.
  • AM technique does not require any mold and is capable of molding complex shapes; accordingly, AM technique is used in prototyping a component, manufacturing a single article or articles in small lots.
  • the AM technique is a method in which a material is laminated in parts, compared with conventional processing methods, the AM technique has shortcomings in areas such as productivity, accuracy, and the limitations in the material that can be used in manufacturing the components.
  • 2D slice images formed of thermoplastic resin powder are developed using the electrophotographic method and are transferred onto a conveying belt. Subsequently, the slice images are heated and melted on the conveying belt and the slice images formed into sheets are laminated on a laminate, sheet by sheet, each as a sheet layer and are fixed to each other by performing pressure adhesion.
  • Each sheet layer includes a mold material formed of thermoplastic resin powder and a support material of the thermoplastic resin powder.
  • thermoplastic resin powder can be dealt with by adjusting the heating condition of the device.
  • modeling devices employing the electrophotographic method are being developed and technical development that overcomes the shortcomings and that can accurately laminate and fix the sheet layers is in need.
  • PTL 1 discloses a modeling device that employs the electrophotographic method, and there is a description therein on a fixing member. According to PTL 1, in a state in which an intermediate transfer body is stopped, a heater is lowered together with the intermediate transfer body and is stopped for a preset time to melt and fix the powder thereon.
  • stage and the heater employing a lifting and lowering member that is supported by ball splines and the like, such that the stage and the heater are structured so as to be capable of moving horizontally.
  • a technique that assures a plate, a belt, and a Z stage to be parallel to each other with a mechanical configuration in order to laminate the sheet material, which is formed by heating and melting a powder material, on a lamination base mounted on the Z stage or on an intermediate molded object.
  • thermoplastic base powder that has been set to a melting temperature using a heater is supplied to a build platform from upstream of the device, and the base powder is melted and transferred to the build platform using a presser plate. It is described that the build platform and the presser plate include a mechanism that can move in a Z-axis direction.
  • the compression member, the belt, and the Z stage cannot maintain the parallel relationship at all times, and upon occurrence of deviation in the parallel relationship, the compression member fails to compress at a uniform pressure.
  • the present disclosure provides a modeling device that forms a stable mold in which no lamination defect occurs.
  • a modeling device is a modeling device of a three dimensional object formed by laminating a plurality of layers, the modeling device includes a stage on which a laminate in which the plurality of layers are laminated is mounted, a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage, an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other, and a pressure applying member that applies compression force that compresses the laminate to the compression member.
  • the laminate can be compressed in a state in which the compression surface of the compression member is equalized in a parallel manner, the laminate can be compressed uniformly.
  • Fig. 1 is a schematic diagram of a three-dimensional object modeling device of a first embodiment of the present disclosure.
  • Fig. 2 is a diagram illustrating a laminating and compressing member of the first embodiment of the present disclosure.
  • Fig. 3 is a diagram illustrating a laminating and compressing member of a second embodiment of the present disclosure.
  • Fig. 4 is a diagram illustrating a laminating and compressing member of a third embodiment of the present disclosure.
  • the present disclosure is a modeling device of a three dimensional object formed by laminating a plurality of layers, the modeling device including a stage on which a laminate in which the plurality of layers are laminated is mounted, a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage, an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other, and a pressure applying member that applies compression force that compresses the laminate to the compression member.
  • the present disclosure can be suitably used in a so-called sheet laminating modeling device that forms a laminate by laminating sheet layers each including thermoplastic mold materials and thermoplastic support materials, and in the following embodiments, description of sheet laminating modeling devices will be described in detail.
  • Fig. 1 is a schematic diagram of a three-dimensional object modeling device of a first embodiment of the present disclosure.
  • the three-dimensional object modeling device of the present embodiment includes a layer forming member (001).
  • the layer forming member (001) is a member that forms an image in a form of a sheet layer, which is constituted by thermoplastic resin powder, on an intermediate transfer drum (002) using an electrophotographic method.
  • the sheet layer is a sheet-shaped mold image that includes a thermoplastic resin powder for molding that becomes a molded portion, and a support material of the thermoplastic resin powder that holds the mold material during laminating and that is removed after the molding.
  • a calculation member (not shown), such as a computer, first forms pieces of sliced shape data that are pieces of data of sliced and divided three-dimensional object shape data.
  • the three-dimensional object modeling device reads out the created sliced shape data and transmits the data to the layer forming member (001).
  • the layer forming member (001) forms a sheet layer, that is a 2D slice image (003), on the intermediate transfer drum (002). With the above, the sheet layer is developed into a mold image.
  • the 2D slice image (003) that has been developed at the intermediate transfer drum (002) is then transferred onto a conveying belt (009), serving as a conveyance member, upon rotation of the drum.
  • the intermediate transfer drum (002) is provided with a drum cleaner (004) that cleans the material that has not been transferred.
  • the 2D slice image (003) that has been transferred onto the conveying belt (009) is conveyed in a direction of the arrow illustrated in the drawing and reaches a position where the 2D slice image (003) comes into contact with a heating and conveying roller (008) that includes a heater 007.
  • the 2D slice image (003) that has been transferred onto the conveying belt is heated during the course of passing through the heating and conveying roller (008), is melted, turns into a thin membrane-like sheet layer from powder, and is conveyed to a laminating portion.
  • a heat insulating material (006) is disposed around the heating and conveying roller (008).
  • sheet layers are adhesively laminated layer by layer on an intermediate laminate on a stage (013).
  • the stage (013) is lifted to hold the laminate and the conveying belt with a compression member (010) such that the sheet layers are compressed and laminated.
  • the sheet layers may be directly laminated on the stage (013); however, disposing a lamination base (012) formed of resin or the like on the stage and molding the laminate on the lamination base (012) enable the laminate to be handled more easily in the succeeding process and, thus, are more desirable.
  • the stage (013) is lowered and the conveying belt (009) and the laminate are separated from each other.
  • the present embodiment may be configured such that the material that has not been laminated and that remains on the conveying belt (009) is removed from the belt with a cleaner (014) provided on the transfer backup roller (005).
  • a laminating and compressing member (015) is capable of uniformly compressing the entire surface of the laminate (011) even when there is deviation in the parallel relationship between the compression surface (the surface A) of the compression member (010), the conveying belt (009), the surface (the surface B) of the laminate, and, further, a surface of the lamination base (012).
  • Fig. 2 is a diagram illustrating the laminating and compressing member (015) of the laminating portion of the first embodiment of the present disclosure.
  • the laminating and compressing member (015) is constituted by the stage (013) that is a member that lifts and lowers the position of the laminate, the compression member (010), a self-aligning bearing (018) that is the equalizing mechanism that sets the compression member (010) to extend in a parallel manner along the laminate when pushing the sheet layer adhered to the conveying belt (009) against the laminate, and a pressure applying member (017) that adjusts the pushing force of the compression member against the laminate.
  • the compression member (010) includes the compression surface (the surface A) that holds and compresses the laminate (011) on the stage (013) with the stage, and may be configured of a metal plate material.
  • the present embodiment since the next sheet layer (021) is sequentially conveyed above the laminate with the conveying belt (009), the present embodiment is configured such that the compression member compresses the laminate with the conveying belt in between.
  • the equalizing mechanism is a mechanism that is configured so that the compression surface (the surface A) of the compression member is inclined, and that allows the compression surface (the surface A) to become inclined so as to become parallel with the surface (the surface B) to which the laminate is compressed when the laminate is compressed with the pressure applying member (017).
  • Such an equalizing mechanism includes a universal joint, a self-aligning bearing, and the like and, desirably, is a self-aligning bearing.
  • the equalizing mechanism (018) is directly provided on the compression member that opposes the laminate and at a position that faces the compression surface of the compression member; accordingly, there is no need to provide an adjustment member on the stage side. With the above, the positional relationship on the laminate side is not given away and deterioration in the lamination accuracy can be prevented from occurring.
  • the pressure applying member (017) is a member that apply force such that the compression surface becomes parallel to the compressed surface of the laminate when the compression member compresses the laminate.
  • the pressure applying member (017) is desirably a single or a plurality of mechanical springs, air springs, or the like, and, desirably, the spring force and the rotation point of the equalizing mechanism coincide each other.
  • arrangement is such that the center of the bearing and the position of the center of gravity of the spring force coincide each other and, further, the spring force or the spring resultant force acts in a thrust direction of the self-aligning bearing.
  • the compression member (010) desirably includes a cooling member so that the adhesion temperature can be adjusted.
  • the cooling member provided in the compression member includes a water cooling member, an air cooling member, a Peltier element, or the like; however, as illustrated in Fig. 2, it is desirable that the cooling member is a plurality of cooling pipes (019) disposed in the compression member.
  • the heating temperature melting the ABS resin is 200 degrees or higher and is about 230°C.
  • the laminate is cooled to between 80°C to 40°C before the next layer is laminated.
  • a continuous and stable molding can be performed without any lamination defect occurring and, even when there is deviation in the parallel relationship between the compression member, the belt, and the surface of the lamination base, the compression member and the belt can be made to extend along the compression surface of the laminate or the surface of the lamination base.
  • the stage (013) is a member that lifts and lowers the laminate in a thickness direction (a Z direction) of the cross section of the sheet layer, and pushes the sheet layer against the compression member through the lamination base.
  • the laminate is cooled with the compression member such that the laminate is adjusted to have the adhesion temperature.
  • the equalizing mechanism that sets the compression member parallel to the lamination base, and the pressure applying member that adjusts the pressing force of the compression member against the lamination base are included, the compression member and the belt are made parallel with respect to the surface of the lamination base; accordingly, the compression member and the belt that extend along the surface of the lamination base compress the laminate with a uniform pressure.
  • the adjustment mechanism operates such that the compression member and the belt are made to extend along the surface of the lamination base when deviation occurs in the parallel relationship between the compression member, the parallel relationship between the three components described above can be assured during cooling and compressing. Accordingly, the entire surface of the sheet layer can be compressed in a uniform manner and, as a result, the sheet layer becoming lifted with respect to the lamination base or the intermediate molded object and the material not being laminated and being left on the belt do not occur, and the entire surface of the sheet layer can be uniformly laminated. In other words, the robustness of the lamination process can be increased.
  • the adjustment mechanism that uniformly compresses the entire surface of the sheet layer operating in each lamination will result in laminating continuously and stably under a uniform compression condition in all of the lamination; accordingly, the molding becomes highly accurate.
  • the laminate is laminated on the lamination base, such as a resin plate or the like, rather than directly laminating the lamination on the Z stage.
  • the surface of the lamination base may be a reference for the compressed surface, and when the compression member (010), the belt (009), and the surface of the lamination base (012) are not parallel with respect to each other, the equalizing mechanism of the laminating and compressing member (015) may desirably be made to operate.
  • a direct acting guide (016) is disposed on the direct acting shaft (020) that transmits elastic force of the coil spring, so as to move up and down in accordance with the displacement of the coil spring (017).
  • the equalizing mechanism (018) is actuated and the compression surface (the surface A) of the compression member (010) is inclined and the compression surface (the surface A) that is separated by the thickness of the belt (009) becomes parallel to the surface of the lamination base (012) or the lamination surface (the surface B) of the intermediate molded object (011).
  • the compression member (010) includes the cooling pipes (019) serving as a cooling member that has a small diameter and that is branched into a plurality of pipes.
  • the plurality of cooling pipes (019) are disposed so as to penetrate the compression member (010).
  • the cooling pipes (019) are connected to a coolant circulation device at a lateral side of the compression member (010) through a hose (not shown).
  • the displacement and the bending tension of the hose are desirably adjusted with a spring or the like such that the hose does not affect the operation of the equalizing mechanism (018) and such that the moment at the rotation center of the equalizing mechanism (018) is balanced.
  • a configuration in which the hose is disposed after the length and the like of the hose is adjusted so that the hose functions as a member restricting the rotation of the compression member (010) is also desirable.
  • a rotation prevention pin or the like that has a strong restraining force may be provided as a member that restricts an in-plane rotation at the bearing of the equalizing material.
  • a thin thermally conductive rubber (022) that is an elastic body can be disposed on the surface of the compression surface of the compression member.
  • the sheet layer can be made to extend along minute in-plane projections and recesses of the lamination surface.
  • the thickness of the thermally conductive rubber is desirably 0.1 mm or larger or 2.0 mm or smaller and, more desirably, is 0.5 mm or larger or 1.5 mm or smaller.
  • the thin thermally conductive rubber (022) may be disposed on the compression surface to adjust the minute projections and recesses.
  • Fig. 3 is a diagram illustrating a laminating portion and a laminating and compressing member (015) of a second embodiment of the present disclosure.
  • the configuration of the device is the same as the three-dimensional object modeling device illustrated in Fig. 1 and only the configuration of the laminating and compressing member (015) is different.
  • a first point that is different from the laminating and compressing member (015) of the first embodiment is that a plurality of elastic bodies, serving as a pressure applying member (017) are disposed so as to be connected to the compression member.
  • the resultant force of the plurality of elastic body coincides with the rotation center of the equalizing mechanism (018) and acts in the thrust direction.
  • the laminating and compressing member (015) includes a compression member lifting and lowering means (023), and that the compression member (010) is lowered during lamination so as to coincide with the surface of the belt.
  • Fig. 4 is a diagram illustrating a laminating portion and a laminating and compressing member (015) of a third embodiment of the present disclosure.
  • the configuration of the device is the same as the three-dimensional object modeling device illustrated in Fig. 1 and only the laminating and compressing member (015) is different.
  • a first point that is different from the first and second embodiments is that an air spring (025) is used as the pressure applying member (015).
  • the advantage in using the air spring (025) is that when the compression surface (the surface A) of the compression member (010) and the belt (009) extend in a parallel manner along the surface of the lamination base (012) or the compressed surface (the surface B) of the intermediate molded object (011) that is a laminate, even if the air spring is inclined, the compression can be performed in a uniform manner.
  • a second point that is different is that the pressure applied to the laminate is variable.
  • a pressure adjustment member (024) is connected to the air spring (025), and by adjusting the pressure of the compressed air sent from a tank (not shown), adjustment to a pressure optimum for the material of the sheet layer and the sheet area can be made.
  • a restriction member (026) such as a plate, serving as a displacement restriction member that restricts the inclination or the displacement of the compression member (010) may be advantageously disposed.
  • Such a restriction member (026) can be applied to a configuration other than an air spring.
  • the compression member (010) and the belt (009) extends in a parallel manner along the surface of the lamination base (012) or the intermediate molded object (011).
  • the entire surface of the sheet layer (021) can be compressed in a uniform manner and, as a result, the sheet layer (021) becoming lifted with respect to the lamination base (012) or the intermediate molded object (011) and the material not being laminated and being left on the belt (009) do not occur, and the entire surface of the sheet layer (021) can be uniformly laminated.
  • the adjustment mechanism that uniformly compresses the entire surface of the sheet layer operating in each lamination will result in laminating continuously and stably under a uniform compression condition in all of the lamination; accordingly, the molding becomes highly accurate.

Abstract

An object of the present disclosure is to provide a modeling device that forms a stable mold in which no lamination defect occurs. The modeling device of a three-dimensional object formed by laminating a plurality of layers, the modeling device includes a stage on which a laminate in which the plurality of layers are laminated is mounted, a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage, an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other, and a pressure applying member that applies compression force that compresses the laminate to the compression member.

Description

MODELING DEVICE
The present disclosure relates to a modeling device, and specifically relates to a laminate modeling device that molds a three-dimensional object by laminating sheet layers that each include a mold material and a support material.
Molding techniques that are called additive manufacturing (AM), 3D printing, rapid prototyping (RP), and the like are known.
The AM technique is a technique of molding a three-dimensional object. In the AM technique, three-dimensional object shape data is sliced and divided into multiple layers, and lamination layers according to the pieces of sliced shape data is formed with a mold material. Each of the formed lamination layers formed by the mold material is sequentially laminated and fixed such that a three-dimensional object is molded.
AM technique does not require any mold and is capable of molding complex shapes; accordingly, AM technique is used in prototyping a component, manufacturing a single article or articles in small lots.
However, since the AM technique is a method in which a material is laminated in parts, compared with conventional processing methods, the AM technique has shortcomings in areas such as productivity, accuracy, and the limitations in the material that can be used in manufacturing the components.
As a method to overcome the above shortcomings, a laminate modeling device that employs an electrophotographic method, which is one of the methods called sheet lamination (SL) in which sheet-shaped materials are stacked and are adhesively laminated, has been proposed.
In detail, with the divided and sliced shape data, 2D slice images formed of thermoplastic resin powder are developed using the electrophotographic method and are transferred onto a conveying belt. Subsequently, the slice images are heated and melted on the conveying belt and the slice images formed into sheets are laminated on a laminate, sheet by sheet, each as a sheet layer and are fixed to each other by performing pressure adhesion.
Each sheet layer includes a mold material formed of thermoplastic resin powder and a support material of the thermoplastic resin powder.
Since it is a molding method in which the surfaces of the developed sheet layers are stacked, compared with methods of conventional AM techniques that perform lamination in a partial manner, the above is advantageous regarding the shortcoming in productivity.
Furthermore, since a material including small grain size particles can be used in the electrophotographic method, a sheet with a thickness of about 10 μm can be laminated. Accordingly, compared with fused deposition modeling, the above is advantageous regarding the shortcoming of accuracy. Furthermore, regarding the shortcoming regarding the selection of the material, various thermoplastic resin powder can be dealt with by adjusting the heating condition of the device.
Having the above advantages, modeling devices employing the electrophotographic method are being developed and technical development that overcomes the shortcomings and that can accurately laminate and fix the sheet layers is in need.
PTL 1 discloses a modeling device that employs the electrophotographic method, and there is a description therein on a fixing member. According to PTL 1, in a state in which an intermediate transfer body is stopped, a heater is lowered together with the intermediate transfer body and is stopped for a preset time to melt and fix the powder thereon.
Furthermore, there is a description of a stage and the heater employing a lifting and lowering member that is supported by ball splines and the like, such that the stage and the heater are structured so as to be capable of moving horizontally.
Furthermore, in PTL 1, a technique is disclosed that assures a plate, a belt, and a Z stage to be parallel to each other with a mechanical configuration in order to laminate the sheet material, which is formed by heating and melting a powder material, on a lamination base mounted on the Z stage or on an intermediate molded object.
In PTL 2, in a modeling device that employs the electrophotographic method, thermoplastic base powder that has been set to a melting temperature using a heater is supplied to a build platform from upstream of the device, and the base powder is melted and transferred to the build platform using a presser plate. It is described that the build platform and the presser plate include a mechanism that can move in a Z-axis direction.
However, in a device that directly performs lamination on the Z stage, a continuous and stable lamination cannot be performed just with the initial adjustment. This is because deviation occurs in the parallel relationship between the compression member, the belt, and the Z stage due to (1) when lamination proceeds, the stage becomes bent by the weight of the molded object, (2) when heating and cooling are performed for fusing, affected by the thermal deformation of each component, the positions of the compression member, the belt, and the Z stage change, (3) by performing compression, the stage, a guide, and the like change with time, and (4) there is a variation in thickness within a same single sheet due to instability in the process on the upstream side.
In other words, in the above Literatures, the compression member, the belt, and the Z stage cannot maintain the parallel relationship at all times, and upon occurrence of deviation in the parallel relationship, the compression member fails to compress at a uniform pressure.
If uniform compression cannot be performed, sufficient adhesion of the succeeding sheet layer after the lamination on the laminate cannot be performed. If adhesion is insufficient, the material that cannot be laminated remains on the belt and the molding turns out to be a failure. In a device that forms a laminate through sequential lamination and fixing, when adhesion of even a single layer is insufficient, the probability of the entire molded laminate becoming a failure increases.
Japanese Patent Laid-Open No. 2003-53849 ([0037] to [0042]) PCT Japanese Translation Patent Publication No. 2014-533210 ([0030] to [0037])
As described above, when a compression that is not uniform is performed on the laminate, the adhesion of the laminate does not go well and the ultimate mold becomes a failure.
The present disclosure provides a modeling device that forms a stable mold in which no lamination defect occurs.
A modeling device according to the present disclosure is a modeling device of a three dimensional object formed by laminating a plurality of layers, the modeling device includes a stage on which a laminate in which the plurality of layers are laminated is mounted, a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage, an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other, and a pressure applying member that applies compression force that compresses the laminate to the compression member.
In the present disclosure, since the laminate can be compressed in a state in which the compression surface of the compression member is equalized in a parallel manner, the laminate can be compressed uniformly.
Further features of the present invention will become apparent from the following description of embodiments with reference to the attached drawings.
Fig. 1 is a schematic diagram of a three-dimensional object modeling device of a first embodiment of the present disclosure. Fig. 2 is a diagram illustrating a laminating and compressing member of the first embodiment of the present disclosure. Fig. 3 is a diagram illustrating a laminating and compressing member of a second embodiment of the present disclosure. Fig. 4 is a diagram illustrating a laminating and compressing member of a third embodiment of the present disclosure.
The present disclosure is a modeling device of a three dimensional object formed by laminating a plurality of layers, the modeling device including a stage on which a laminate in which the plurality of layers are laminated is mounted, a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage, an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other, and a pressure applying member that applies compression force that compresses the laminate to the compression member.
The present disclosure can be suitably used in a so-called sheet laminating modeling device that forms a laminate by laminating sheet layers each including thermoplastic mold materials and thermoplastic support materials, and in the following embodiments, description of sheet laminating modeling devices will be described in detail.
Hereinafter, preferable embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.
First Embodiment
Fig. 1 is a schematic diagram of a three-dimensional object modeling device of a first embodiment of the present disclosure.
As illustrated in Fig. 1, the three-dimensional object modeling device of the present embodiment includes a layer forming member (001).
The layer forming member (001) is a member that forms an image in a form of a sheet layer, which is constituted by thermoplastic resin powder, on an intermediate transfer drum (002) using an electrophotographic method.
The sheet layer is a sheet-shaped mold image that includes a thermoplastic resin powder for molding that becomes a molded portion, and a support material of the thermoplastic resin powder that holds the mold material during laminating and that is removed after the molding.
A calculation member (not shown), such as a computer, first forms pieces of sliced shape data that are pieces of data of sliced and divided three-dimensional object shape data.
The three-dimensional object modeling device reads out the created sliced shape data and transmits the data to the layer forming member (001).
According to the data, the layer forming member (001) forms a sheet layer, that is a 2D slice image (003), on the intermediate transfer drum (002). With the above, the sheet layer is developed into a mold image.
The 2D slice image (003) that has been developed at the intermediate transfer drum (002) is then transferred onto a conveying belt (009), serving as a conveyance member, upon rotation of the drum.
The intermediate transfer drum (002) is provided with a drum cleaner (004) that cleans the material that has not been transferred.
The 2D slice image (003) that has been transferred onto the conveying belt (009) is conveyed in a direction of the arrow illustrated in the drawing and reaches a position where the 2D slice image (003) comes into contact with a heating and conveying roller (008) that includes a heater 007.
A process of forming the material into a sheet and a process of laminating sheet layers will be described in detail next.
The 2D slice image (003) that has been transferred onto the conveying belt is heated during the course of passing through the heating and conveying roller (008), is melted, turns into a thin membrane-like sheet layer from powder, and is conveyed to a laminating portion.
A heat insulating material (006) is disposed around the heating and conveying roller (008).
In the laminating portion, sheet layers are adhesively laminated layer by layer on an intermediate laminate on a stage (013). The stage (013) is lifted to hold the laminate and the conveying belt with a compression member (010) such that the sheet layers are compressed and laminated.
The sheet layers may be directly laminated on the stage (013); however, disposing a lamination base (012) formed of resin or the like on the stage and molding the laminate on the lamination base (012) enable the laminate to be handled more easily in the succeeding process and, thus, are more desirable.
Upon contact between the compression member (010) and the belt, the temperatures of the sheet layers held by the belt are reduced and each sheet layer is laminated with a layer thereunder such that the sheet layers are laminated.
After the laminating, the stage (013) is lowered and the conveying belt (009) and the laminate are separated from each other.
The present embodiment may be configured such that the material that has not been laminated and that remains on the conveying belt (009) is removed from the belt with a cleaner (014) provided on the transfer backup roller (005).
With an action of an adjustment mechanism (an equalizing mechanism) that makes a compression surface (a surface A) of the compression member (010) extend in a parallel manner along a surface (a surface B) of the laminate with the conveying belt (009) in between, a laminating and compressing member (015) is capable of uniformly compressing the entire surface of the laminate (011) even when there is deviation in the parallel relationship between the compression surface (the surface A) of the compression member (010), the conveying belt (009), the surface (the surface B) of the laminate, and, further, a surface of the lamination base (012).
Accordingly, cases such as the sheet layer (021) becoming lifted with respect to the lamination base (012) or the laminate (011), which is an intermediate molded object, and the material not being laminated and being left on the conveying belt (009) can be decreased, and the entire surface of the sheet layer (021) can be uniformly laminated and fixed.
Fig. 2 is a diagram illustrating the laminating and compressing member (015) of the laminating portion of the first embodiment of the present disclosure.
The laminating and compressing member (015) is constituted by the stage (013) that is a member that lifts and lowers the position of the laminate, the compression member (010), a self-aligning bearing (018) that is the equalizing mechanism that sets the compression member (010) to extend in a parallel manner along the laminate when pushing the sheet layer adhered to the conveying belt (009) against the laminate, and a pressure applying member (017) that adjusts the pushing force of the compression member against the laminate.
The compression member (010) includes the compression surface (the surface A) that holds and compresses the laminate (011) on the stage (013) with the stage, and may be configured of a metal plate material.
In the present embodiment, since the next sheet layer (021) is sequentially conveyed above the laminate with the conveying belt (009), the present embodiment is configured such that the compression member compresses the laminate with the conveying belt in between.
The equalizing mechanism is a mechanism that is configured so that the compression surface (the surface A) of the compression member is inclined, and that allows the compression surface (the surface A) to become inclined so as to become parallel with the surface (the surface B) to which the laminate is compressed when the laminate is compressed with the pressure applying member (017).
Such an equalizing mechanism includes a universal joint, a self-aligning bearing, and the like and, desirably, is a self-aligning bearing.
The equalizing mechanism (018) is directly provided on the compression member that opposes the laminate and at a position that faces the compression surface of the compression member; accordingly, there is no need to provide an adjustment member on the stage side. With the above, the positional relationship on the laminate side is not given away and deterioration in the lamination accuracy can be prevented from occurring.
The pressure applying member (017) is a member that apply force such that the compression surface becomes parallel to the compressed surface of the laminate when the compression member compresses the laminate.
The pressure applying member (017) is desirably a single or a plurality of mechanical springs, air springs, or the like, and, desirably, the spring force and the rotation point of the equalizing mechanism coincide each other.
Specifically, when a self-aligning bearing is used, desirably, arrangement is such that the center of the bearing and the position of the center of gravity of the spring force coincide each other and, further, the spring force or the spring resultant force acts in a thrust direction of the self-aligning bearing.
The compression member (010) desirably includes a cooling member so that the adhesion temperature can be adjusted. In such a case, the cooling member provided in the compression member includes a water cooling member, an air cooling member, a Peltier element, or the like; however, as illustrated in Fig. 2, it is desirable that the cooling member is a plurality of cooling pipes (019) disposed in the compression member.
As a specific example, when an ABS resin is used as the thermoplastic resin powder used in the sheet layer, the heating temperature melting the ABS resin is 200 degrees or higher and is about 230°C. Conversely, it is desirable that the laminate is cooled to between 80°C to 40°C before the next layer is laminated.
With the configuration described above, a continuous and stable molding can be performed without any lamination defect occurring and, even when there is deviation in the parallel relationship between the compression member, the belt, and the surface of the lamination base, the compression member and the belt can be made to extend along the compression surface of the laminate or the surface of the lamination base.
The stage (013) is a member that lifts and lowers the laminate in a thickness direction (a Z direction) of the cross section of the sheet layer, and pushes the sheet layer against the compression member through the lamination base. The laminate is cooled with the compression member such that the laminate is adjusted to have the adhesion temperature.
In such a case, since the equalizing mechanism that sets the compression member parallel to the lamination base, and the pressure applying member that adjusts the pressing force of the compression member against the lamination base are included, the compression member and the belt are made parallel with respect to the surface of the lamination base; accordingly, the compression member and the belt that extend along the surface of the lamination base compress the laminate with a uniform pressure.
Since the adjustment mechanism operates such that the compression member and the belt are made to extend along the surface of the lamination base when deviation occurs in the parallel relationship between the compression member, the parallel relationship between the three components described above can be assured during cooling and compressing. Accordingly, the entire surface of the sheet layer can be compressed in a uniform manner and, as a result, the sheet layer becoming lifted with respect to the lamination base or the intermediate molded object and the material not being laminated and being left on the belt do not occur, and the entire surface of the sheet layer can be uniformly laminated. In other words, the robustness of the lamination process can be increased. The adjustment mechanism that uniformly compresses the entire surface of the sheet layer operating in each lamination will result in laminating continuously and stably under a uniform compression condition in all of the lamination; accordingly, the molding becomes highly accurate.
Furthermore, when considering the ease of maintenance of the actual device, it is desirable that the laminate is laminated on the lamination base, such as a resin plate or the like, rather than directly laminating the lamination on the Z stage.
In such a case, since the compressed surface of the laminate is parallel to the surface of the lamination base, the surface of the lamination base may be a reference for the compressed surface, and when the compression member (010), the belt (009), and the surface of the lamination base (012) are not parallel with respect to each other, the equalizing mechanism of the laminating and compressing member (015) may desirably be made to operate.
The detailed operation is as follows. When the stage (013) is lifted, the conveying belt (009) and the compression member (010) are pushed upwards. In the above, the coil spring (017) serving as a pressure applying member is compressed, and with the elastic force thereof, compression force acts on the conveying belt (009) on which the sheet layer is held and on the surface of the lamination base (012) or the lamination surface of the intermediate molded object (011) forming an adhered state such that adhesive lamination is performed.
A direct acting guide (016) is disposed on the direct acting shaft (020) that transmits elastic force of the coil spring, so as to move up and down in accordance with the displacement of the coil spring (017).
When the compression member (010), the belt (009), the surface of the lamination base (012) or the lamination surface of the intermediate molded object (011) are not parallel to each other, the equalizing mechanism (018) is actuated and the compression surface (the surface A) of the compression member (010) is inclined and the compression surface (the surface A) that is separated by the thickness of the belt (009) becomes parallel to the surface of the lamination base (012) or the lamination surface (the surface B) of the intermediate molded object (011).
The compression member (010) includes the cooling pipes (019) serving as a cooling member that has a small diameter and that is branched into a plurality of pipes. The plurality of cooling pipes (019) are disposed so as to penetrate the compression member (010). The cooling pipes (019) are connected to a coolant circulation device at a lateral side of the compression member (010) through a hose (not shown).
It is desirable that there is a balance in the moment at the rotation center of the equalizing mechanism (018) with the plurality of cooling pipes (019), and it is desirable that a bending tension adjustment member that adjusts the bending tension of the cooling pipes is included. Specifically, the displacement and the bending tension of the hose are desirably adjusted with a spring or the like such that the hose does not affect the operation of the equalizing mechanism (018) and such that the moment at the rotation center of the equalizing mechanism (018) is balanced. In particular, a configuration in which the hose is disposed after the length and the like of the hose is adjusted so that the hose functions as a member restricting the rotation of the compression member (010) is also desirable.
Furthermore, a rotation prevention pin or the like that has a strong restraining force may be provided as a member that restricts an in-plane rotation at the bearing of the equalizing material.
Furthermore, a thin thermally conductive rubber (022) that is an elastic body can be disposed on the surface of the compression surface of the compression member. With the above, the sheet layer can be made to extend along minute in-plane projections and recesses of the lamination surface.
However, when a thick rubber with a few millimeters in thickness is disposed, the cooling efficiency of even the thermally conductive rubber (022) deceases significantly, and there are cases in which the in-plane cannot be compressed at a uniform pressure when compressing, a rubber elastic deformation surface is created causing the accuracy of the lamination surface to decrease, and the like.
The thickness of the thermally conductive rubber is desirably 0.1 mm or larger or 2.0 mm or smaller and, more desirably, is 0.5 mm or larger or 1.5 mm or smaller.
In other words, as illustrated in Fig. 2, while using the laminating and compressing member (015) that is capable of adjusting a large amount of inclination, the thin thermally conductive rubber (022) may be disposed on the compression surface to adjust the minute projections and recesses.
Second Embodiment
Fig. 3 is a diagram illustrating a laminating portion and a laminating and compressing member (015) of a second embodiment of the present disclosure.
The configuration of the device is the same as the three-dimensional object modeling device illustrated in Fig. 1 and only the configuration of the laminating and compressing member (015) is different.
A first point that is different from the laminating and compressing member (015) of the first embodiment is that a plurality of elastic bodies, serving as a pressure applying member (017) are disposed so as to be connected to the compression member. The resultant force of the plurality of elastic body coincides with the rotation center of the equalizing mechanism (018) and acts in the thrust direction.
In such a configuration, when the compression surface becomes inclined, since the displacement of the plurality of pressure applying members that are disposed is different, there is a slight in-plane pressure distribution. On the other hand, due to a moment rigidity of the equalizing mechanism (018), an abrupt inclination of the compression member (010) caused by a slight parallel variation in the course of the lamination becomes easily created.
A second point that is different is that the laminating and compressing member (015) includes a compression member lifting and lowering means (023), and that the compression member (010) is lowered during lamination so as to coincide with the surface of the belt.
With the lowering of the compression member (010), lamination can be performed while the deformation of the belt during lamination is suppressed further.
Third Embodiment
Fig. 4 is a diagram illustrating a laminating portion and a laminating and compressing member (015) of a third embodiment of the present disclosure.
The configuration of the device is the same as the three-dimensional object modeling device illustrated in Fig. 1 and only the laminating and compressing member (015) is different.
A first point that is different from the first and second embodiments is that an air spring (025) is used as the pressure applying member (015).
The advantage in using the air spring (025) is that when the compression surface (the surface A) of the compression member (010) and the belt (009) extend in a parallel manner along the surface of the lamination base (012) or the compressed surface (the surface B) of the intermediate molded object (011) that is a laminate, even if the air spring is inclined, the compression can be performed in a uniform manner.
In the case of a mechanical spring, when the displacement of a plurality of springs is different, then the acting force is different. When the acting force is different, there will be a difference in force, and the difference in force causes a difference in the distribution of pressure on the compression surface.
On the other hand, in the air spring, since a uniform pressure is applied to the entire surface on which the internal pressure acts, the inclination of the air spring does not hinder the uniform compression.
A second point that is different is that the pressure applied to the laminate is variable.
A pressure adjustment member (024) is connected to the air spring (025), and by adjusting the pressure of the compressed air sent from a tank (not shown), adjustment to a pressure optimum for the material of the sheet layer and the sheet area can be made.
Furthermore, as illustrated in Fig. 4, a restriction member (026), such as a plate, serving as a displacement restriction member that restricts the inclination or the displacement of the compression member (010) may be advantageously disposed. With the above, it will be possible to restrict the compression member (010) from inclining to or out of a range in which parallel adjustment can be performed, or the air spring can be restricted from being displaced to or out of its usable range.
Such a restriction member (026) can be applied to a configuration other than an air spring.
With the above, when the laminating and compressing member (015) is operated, the compression member (010) and the belt (009) extends in a parallel manner along the surface of the lamination base (012) or the intermediate molded object (011).
Accordingly, the entire surface of the sheet layer (021) can be compressed in a uniform manner and, as a result, the sheet layer (021) becoming lifted with respect to the lamination base (012) or the intermediate molded object (011) and the material not being laminated and being left on the belt (009) do not occur, and the entire surface of the sheet layer (021) can be uniformly laminated.
Accordingly, the robustness of the lamination process can be increased. The adjustment mechanism that uniformly compresses the entire surface of the sheet layer operating in each lamination will result in laminating continuously and stably under a uniform compression condition in all of the lamination; accordingly, the molding becomes highly accurate.
While preferable embodiments of the present disclosure have been described above, the present disclosure is not limited to the various embodiments and may be deformed and modified within the scope of the gist of the disclosure.
While the present invention has been described with reference to embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2015-171198, filed August 31, 2015 which is hereby incorporated by reference herein in its entirety.

Claims (20)

  1. A modeling device of a three-dimensional object formed by laminating a plurality of layers, the modeling device comprising:
    a stage on which a laminate in which the plurality of layers are laminated is mounted;
    a compression member that includes a compression surface that compresses the laminate on the stage by holding the laminate with the stage;
    an equalizing mechanism of the compression member, the compression surface being inclined such that the compression surface and an opposing surface of the laminate is parallel to each other; and
    a pressure applying member that applies compression force that compresses the laminate to the compression member.
  2. The modeling device according to Claim 1, wherein the compression member includes a cooling member.
  3. The modeling device according to Claim 1 or 2, further comprising:
    a conveyance member that conveys the layer onto the stage, the conveyance member sequentially conveying a next layer onto the laminate.
  4. The modeling device according to Claim 3, wherein the conveyance member is a conveying belt, and the compression member compresses the laminate with the conveying belt in between.
  5. The modeling device according to any one of Claims 1 to 4, wherein the layer is a sheet layer that includes thermoplastic mold materials and thermoplastic support materials.
  6. The modeling device according to any one of Claims 1 to 5, wherein the equalizing mechanism is a mechanism that, when the laminate is compressed with the pressure applying member, allows the compression surface to be inclined and become parallel to a surface of the laminate that is compressed.
  7. The modeling device according to any one of Claims 1 to 6, wherein the equalizing mechanism is a self-aligning bearing.
  8. The modeling device according to Claim 7, wherein the pressure applying member is a single or a plurality of mechanical springs, and spring force or spring resultant force coincides with a center of the self-aligning bearing.
  9. The modeling device according to Claim 7, wherein the pressure applying member is an air spring, and spring force coincides with a center of the self-aligning bearing.
  10. The modeling device according to Claim 8 or 9, wherein the spring force or a spring resultant force acts in a thrust direction of the self-aligning bearing.
  11. The modeling device according to Claim 9 or 10, further comprising a pressure adjustment member of the air spring.
  12. The modeling device according to Claim 2, wherein the cooling member includes a plurality of cooling pipes disposed in the compression member.
  13. The modeling device according to Claim 12, wherein the plurality of cooling pipes are disposed so as to penetrate the compression member, and a balance is achieved in a moment created by the plurality of cooling pipes at a rotation center of the equalizing mechanism.
  14. The modeling device according to Claim 13, further comprising a bending tension adjustment member that adjusts the bending tension of the cooling pipes.
  15. The modeling device according to Claim 14, wherein the bending tension adjustment member is a spring.
  16. The modeling device according to any one of Claims 1 to 15, wherein the compression surface includes an elastic body.
  17. The modeling device according to any one of Claims 1 to 16, wherein the equalizing mechanism is provided at a position that faces the compression surface of the compression member.
  18. The modeling device according to any one of Claims 1 to 17, wherein the compression member includes a member that restricts an in-plane rotation at the bearing of the equalizing mechanism.
  19. The modeling device according to any one of Claims 1 to 18, further comprising an inclination restriction member that restricts the compression member from inclining with respect to the stage or the opposing surface of the laminate.
  20. The modeling device according to any one of Claims 1 to 19, wherein the pressure applying member includes a displacement restriction member that restricts displacement of the compression member.
PCT/JP2016/003722 2015-08-31 2016-08-12 Modeling device WO2017038028A1 (en)

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JP2015171198A JP2017047572A (en) 2015-08-31 2015-08-31 Shaping apparatus

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US11597168B2 (en) 2018-10-05 2023-03-07 Fukui Prefectural Government Thin-layer tape automated lamination method and device

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JP2010028039A (en) * 2008-07-24 2010-02-04 Dainippon Printing Co Ltd Printer
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