PRODUCTION METHOD FOR THREE-DIMENSIONALLY SHAPED MOLDED OBJECT

• Main Authors: ABE SATOSHI, MATSUMOTO ISAMU, TAKENAMI MASATAKA
• Format: Patent
• Language: English; Korean
• Published: 26.05.2015
• Subjects: ADDITIVE MANUFACTURING TECHNOLOGY; ADDITIVE MANUFACTURING, i.e. MANUFACTURING OFTHREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVEAGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING,STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; CASTING; MAKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; PERFORMING OPERATIONS; POWDER METALLURGY; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; TRANSPORTING; WORKING METALLIC POWDER; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

"공구 절손 트러블(tool breakage trouble)" 등의 문제를 감소시키는 것이 가능한 분말 소결 적층법을 제공하는 것. 본 발명의 제조 방법은, (i) 분말층의 소정 개소에 광빔을 조사하여 상기 소정 개소의 분말을 소결 또는 용융 고화시켜 고화층을 형성하는 단계, 및 (ii) 얻어진 고화층 상에 새로운 분말층을 형성하고, 그 새로운 분말층의 소정 개소에 광빔을 조사하여 다른 고화층을 형성하는 단계에 의해 분말층 형성 및 고화층 형성을 반복하여 행하고, 고화층 및/또는 3차원 형상 조형물이 얻어진 후에 있어서 고화층 및/또는 3차원 형상 조형물의 표면에 절삭 공구로 표면 절삭 처리를 행하는 단계를 적어도 1회 포함하고, 표면 절삭 처리에 앞서서는, 고화층 및/또는 3차원 형상 조형물 주위의 분말을 흡인 노즐에 의해 제거하고, 흡인 제거에 있어서는, 절삭 공구의 절삭 가능 최하 레벨을 고려하여 3차원 형상 조형물 주위의 분말을 국소적으로 제거하고, 또한 흡인 노즐의 이동 궤적이, (a) 절삭 공구의 공구 최하 레벨에 위치하는 고화층 단면의 윤곽 A, (b) 가장 가까이에 형성된 고화층의 상면의 윤곽 B, 및 (c) 고화층의 적층 방향을 향해 윤곽 A와 윤곽 B를 동일 평면에 투영하는 것을 상정했을 때, 투영한 윤곽 A가 이루는 폐쇄 영역(A')으로부터 투영한 윤곽 B가 이루는 폐쇄 영역(B')을 제거하여 얻어지는 영역 C에 따른 궤적으로 되도록 흡인 노즐을 이동 조작시켜 분말을 국소적으로 제거하는 것을 특징으로 하는, 3차원 형상 조형물의 제조 방법이다. There is provided a selective laser sintering method capable of reducing the trouble in chipping or breakage of the machining tool and the like. The manufacturing method according to an embodiment of the present invention is a method for manufacturing a three-dimensional shaped object by repetition of a powder-layer forming and a solidified-layer forming, the repetition comprising the steps of (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof, and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein the method includes at least one step of a surface-machining process for machining a surface of the solidified layer and/or the shaped object by a machining tool at a point in time after the formation of the solidified layer and/or the manufacturing of the shaped object, wherein a suction removal of the powder located around the solidified layer and/or the shaped object is performed by a suction nozzle prior to the surface-machining process, such that the powder is locally removed in consideration of a lowermost machinable level of the machining tool, wherein the suction nozzle during the local removal of the powder is operated under such a condition that a movement path of the suction nozzle is a path along (a) a contour "A" of a cross section of the solidified layer positioned at the lowermost machinable level of the machining tool, (b) a contour "B" of an upper surface of the solidified layer formed most immediately before the suction removal, and (c) a region "C" obtained by subtracting a closed region "B' " from a closed region "A' ", the closed regions "A' " and "B' " being respectively obtained by a planar projection of the contours "A" and "B" with respect to the same plane, the planar projection being provided in a stacking direction of the solidified layers.