Three-dimensional deposition device and three-dimensional deposition method

A three-dimensional deposition device and a three-dimensional deposition method used to highly accurately manufacture a three-dimensional object are provided. A three-dimensional deposition device for forming a three-dimensional shape by depositing a formed layer on a base unit includes: a powder supply unit which supplies a powder material; a light irradiation unit which irradiates the powder material with a light beam so that at least a part of the powder material irradiated with the light beam is sintered or melted and solidified to form the formed layer; a heating unit which selectively heats an area having passed through a position irradiated with the light beam in the base unit or the formed layer or an area not having passed through the position irradiated with the light beam; and a control device which controls operations of the powder supply unit, the light irradiation unit, and the heating unit.

FIELD

The present invention relates to a three-dimensional deposition device and a three-dimensional deposition method used to manufacture a three-dimensional object by deposition.

BACKGROUND

As a technology of manufacturing a three-dimensional object, there is known a deposition shaping technology of manufacturing a three-dimensional object by irradiating a metallic powder material with a light beam. For example, Patent Literature 1 discloses a method in which a powder layer formed of a metallic powder material is irradiated with a light beam so that a sintered layer is formed and this process is repeated so that a plurality of sintered layers are integrally deposited to thereby form a three-dimensional object. Further, Patent Literature 2 discloses a device which includes a separable conical nozzle having a center opening used to output a laser beam and powdered metal. Here, a work is irradiated with a laser as a processing target to form a thin liquefied metal reserved part and powdered metal is supplied to that position to form padding.

CITATION LIST

Patent Literature

SUMMARY

Technical Problem

Incidentally, there has been a demand to manufacture the three-dimensional object with high accuracy in the deposition shaping technology of manufacturing the three-dimensional object.

An object of the invention is to provide a three-dimensional deposition device and a three-dimensional deposition method used to manufacture a three-dimensional object with high accuracy.

Solution to Problem

To solve the problem and achieve the object above, a three-dimensional deposition device of this invention forms a three-dimensional shape by depositing a formed layer on a base unit, includes: a powder supply unit which supplies a powder material; a light irradiation unit which irradiates the powder material with a light beam so that at least a part of the powder material irradiated with the light beam is sintered or melted and solidified to form the formed layer; a heating unit which selectively heats an area having passed through a position irradiated with the light beam in the base unit or the formed layer or an area not having passed through the position irradiated with the light beam; and a control device which controls operations of the powder supply unit, the light irradiation unit, and the heating unit.

It is preferable that in the three-dimensional deposition device, the powder supply unit injects the powder material toward the base unit, and the light irradiation unit irradiates the powder material feeding from the powder supply unit toward the base unit with a light beam so that the powder material is melted and the melted powder material is solidified on the base unit to thereby form the formed layer.

It is preferable that in the three-dimensional deposition device, the powder supply unit is concentrically disposed on an outer periphery of the light irradiation unit and is formed so that a powder passage causing the powder material to flow therethrough is formed between an inner tube surrounding a path through which the light beam of the light irradiation unit pass and an outer tube covering the inner tube.

It is preferable that the three-dimensional deposition device includes a movement mechanism that relatively moves the light irradiation unit and the powder supply unit with respect to the base unit, wherein the control device determines a path through which the light irradiation unit and the powder supply unit pass with respect to the base unit by the movement mechanism.

It is preferable in the three-dimensional deposition device that the heating unit includes a light source unit which outputs a light beam, and a heating operation is performed by irradiation with the light beam output from the light source unit.

It is preferable that in the three-dimensional deposition device, the light beam is a laser beam.

It is preferable that in the three-dimensional deposition device, the heating unit includes an irradiation position adjustment mechanism including a mirror which reflects the light beam output from the light source unit and an angle adjustment mechanism which adjusts an angle of the mirror.

It is preferable that in the three-dimensional deposition device, the light source unit includes a semiconductor laser which outputs a laser beam, a light concentrating unit which concentrates the laser beam output from the semiconductor laser, and an optical fiber to which the laser beam concentrated by the light concentrating unit is incident.

It is preferable that in the three-dimensional deposition device, the light source unit includes a plurality of the semiconductor lasers and a plurality of the light concentrating units, and the laser beams which are output from the semiconductor lasers and are concentrated by the light concentrating units are incident to one optical fiber.

It is preferable that in the three-dimensional deposition device, the semiconductor laser is a vertical emission type semiconductor laser.

It is preferable that in the three-dimensional deposition device, the plurality of semiconductor lasers are provided, and the light concentrating unit includes a collimating lens which is disposed at each of the plurality of semiconductor lasers and a multiplexing unit which multiplexes the laser beams collimated by the plurality of collimating lenses and causes the laser beam to be incident to the optical fiber.

It is preferable that the three-dimensional deposition device includes a temperature detection unit which detects a temperature and a temperature distribution of a surface of the formed layer, wherein the control device controls a heating operation of the heating unit in response to a measurement result of the temperature of the surface of the formed layer obtained by the temperature detection unit.

It is preferable that in the three-dimensional deposition device, the control device controls the heating operation of the heating unit based on the measurement result of the temperature of the surface of the formed layer obtained by the temperature detection unit and characteristics of the base unit and the formed layer.

It is preferable that the three-dimensional deposition device includes a plasma emission detection unit which detects a plasma emission state of the surface of the formed layer, wherein the control device controls the heating operation of the heating unit in response to a measurement result obtained by the plasma emission detection unit.

It is preferable that the three-dimensional deposition device includes a reflected light detection unit which detects reflected light from the surface of the formed layer, wherein the control device controls the heating operation of the heating unit in response to a measurement result obtained by the reflected light detection unit.

It is preferable that in the three-dimensional deposition device, the heating unit heats the area having passed through the position irradiated with the light beam.

It is preferable that in the three-dimensional deposition device, the heating unit heats the area not having passed through the position irradiated with the light beam.

It is preferable that the three-dimensional deposition device includes a switching mechanism which switches relative positions of the light irradiation unit and the heating unit, wherein the control device controls the relative positions of the light irradiation unit and the heating unit by the switching mechanism in response to relative movement directions of the light irradiation unit, the heating unit, and the base unit and a information whether an area to be heated by the heating unit is the area having passed through the position irradiated with the light beam in the base unit or the formed layer or the area not having passed through the position irradiated with the light beam.

To solve the problem and achieve the object above, a three-dimensional deposition method of this invention forms a three-dimensional object by depositing a formed layer on a base unit, includes: a deposition step of melting a powder material by irradiating the powder material with a light beam while injecting the powder material toward the base unit, solidifying the melted powder material on the base unit to form a formed layer on the base unit, and depositing the formed layer; and a heating step of selectively heating by irradiating, with a light beam, an area having passed through a position irradiated with the light beam in the base unit or the formed layer or an area not having passed through the position irradiated with the light beam.

Advantageous Effects of Invention

According to the invention, since an mechanism for depositing a three-dimensional object and a heating unit are provided, it is possible to provide a novel device and a novel method capable of selectively heating an area having passed through a position irradiated with a light beam or an area not having passed through the position irradiated with the light beam. Accordingly, it is possible to manufacture the three-dimensional object with high accuracy.

DESCRIPTION OF EMBODIMENTS

Hereinafter, preferred embodiments of the invention will be described in detail with reference to the accompanying drawings. Further, the invention is not limited to the embodiment. Then, when there are a plurality of embodiments, a combination of the embodiments may be employed.

FIG. 1is a schematic diagram illustrating a three-dimensional deposition device1of the embodiment. Here, in the embodiment, one direction within a horizontal plane will be set as an X-axis direction, a direction orthogonal to the X-axis direction within the horizontal plane will be set as a Y-axis direction, and a direction (a vertical direction) orthogonal to each of the X-axis direction and the Y-axis direction will be set as a Z-axis direction.

The three-dimensional deposition device1illustrated inFIG. 1is a device that manufactures a three-dimensional object on a base unit100. The base unit100is a base member on which the three-dimensional object is formed. The base unit100is carried to a predetermined position of the three-dimensional deposition device1so that the three-dimensional object is formed on a surface thereof. The base unit100of the embodiment is a plate-shaped member. Further, the base unit100is not limited thereto. As the base unit100, a base member of the three-dimensional object may be used or a member adding the three-dimensional object may be used. A member corresponding to a component or a product, by forming the three-dimensional object at a predetermined position, may be used as the base unit100.

The three-dimensional deposition device1includes a three-dimensional deposition chamber2, a spare chamber3, a deposition head accommodation chamber4, a machining unit accommodation chamber5, a bed10, a table unit11, a deposition head12, a machining unit13, a control device20, a heating head31, a machining measurement unit32, a tool exchange unit33, a nozzle exchange unit34, a powder introduction unit35, an air discharge unit37, a gas introduction unit38, a powder collection unit39, a temperature detection unit120, and a weight detection unit130.

The three-dimensional deposition chamber2is a casing (a chamber) in which a part other than a designed communication part such as a connection pipe is sealed from the outside. The designed communication part is provided with a valve that switches a sealed state and an opened state. If necessary, the three-dimensional deposition chamber2can be sealed. The three-dimensional deposition chamber2includes therein the bed10, the table unit11, the deposition head12, a part of the machining unit13, a part of the heating head31, the machining measurement unit32, the tool exchange unit33, and the nozzle exchange unit34.

The spare chamber3is provided adjacent to the three-dimensional deposition chamber2. In the spare chamber3, a part other than a designed communication part such as a connection pipe is sealed from the outside. The spare chamber3is formed as a decompression chamber that connects the outside and the three-dimensional deposition chamber2to each other. A base movement unit36is provided inside the spare chamber3. Here, for example, an airtight door6is provided at the connection part with the three-dimensional deposition chamber2in the spare chamber3. Further, the spare chamber3is connected to the outside by the airtight door7. Further, the spare chamber3is provided with an air discharge unit25which discharges air from the spare chamber3. When the door7is opened, a necessary member can be carried into the spare chamber3from the outside. Further, when the door6is opened, a member can be carried between the spare chamber3and the three-dimensional deposition chamber2.

The deposition head accommodation chamber4is provided at an upper face of the three-dimensional deposition chamber2in the Z-axis direction. The deposition head accommodation chamber4is supported by a Z-axis slide unit4ato be movable in the Z-axis direction (an arrow102) with respect to the three-dimensional deposition chamber2. A lower face of the deposition head accommodation chamber4in the Z-axis direction is connected to the three-dimensional deposition chamber2by a bellows18. The bellows18connects the lower face of the deposition head accommodation chamber4in the Z-axis direction to the three-dimensional deposition chamber2so that the lower face of the deposition head accommodation chamber4in the Z-axis direction is formed as a part of the three-dimensional deposition chamber2. Further, the three-dimensional deposition chamber2is formed so that an opening is formed in an area surrounded by the bellows18. A space surrounded by the bellows18and the lower face of the deposition head accommodation chamber4in the Z-axis direction is connected to the three-dimensional deposition chamber2and is sealed along with the three-dimensional deposition chamber2. The deposition head accommodation chamber4supports the deposition head12, a shape measurement unit30, and the heating head31. Further, the deposition head accommodation chamber4is formed so that a part including a nozzle23of the deposition head12and a part including a front end24of the heating head31protrude toward the three-dimensional deposition chamber2from the lower face in the Z-axis direction.

When the deposition head accommodation chamber4moves in the Z-axis direction by the Z-axis slide unit4a, the deposition head12, the shape measurement unit30, and the heating head31held therein are moved in the Z-axis direction. Further, the deposition head accommodation chamber4is connected to the three-dimensional deposition chamber2through the bellows18. The bellows18is deformed in accordance with the movement in the Z-axis direction and thus a sealed state between the three-dimensional deposition chamber2and the deposition head accommodation chamber4can be kept.

The machining unit accommodation chamber5is provided at the upper face of the three-dimensional deposition chamber2in the Z-axis direction. Further, the machining unit accommodation chamber5is disposed adjacent to the deposition head accommodation chamber4. The machining unit accommodation chamber5is supported by a Z-axis slide unit5ato be movable in the Z-axis direction (a direction of an arrow104) with respect to the three-dimensional deposition chamber2. A lower face of the machining unit accommodation chamber5in the Z-axis direction is connected to the three-dimensional deposition chamber2by a bellows19. The bellows19connects the lower face of the machining unit accommodation chamber5in the Z-axis direction to the three-dimensional deposition chamber2so that the lower face of the machining unit accommodation chamber5in the Z-axis direction is formed as a part of the three-dimensional deposition chamber2. Further, the three-dimensional deposition chamber2is formed so that an opening is formed in an area surrounded by the bellows19. A space surrounded by the lower face of the machining unit accommodation chamber5in the Z-axis direction and the bellows19is connected to the three-dimensional deposition chamber2and is sealed along with the three-dimensional deposition chamber2. The machining unit accommodation chamber5supports the machining unit13. Further, the machining unit accommodation chamber5is formed so that a part including a tool22of the machining unit13protrudes toward the three-dimensional deposition chamber2from the lower face in the Z-axis direction.

When the machining unit accommodation chamber5moves in the Z-axis direction by the Z-axis slide unit5a, the machining unit13held therein is moved in the Z-axis direction. Further, the machining unit accommodation chamber5is connected to the three-dimensional deposition chamber2through the bellows19. The bellows19is deformed in accordance with the movement in the Z-axis direction and thus a sealed state between the three-dimensional deposition chamber2and the machining unit accommodation chamber5can be kept.

The bed10is provided at a bottom in the three-dimensional deposition chamber2in the Z-axis direction. The bed10supports the table unit11. Various wirings, pipes, or driving assemblies are disposed on the bed10.

The table unit11is disposed on an upper face of the bed10and supports the base unit100. The table unit11includes a Y-axis slide unit15, an X-axis slide unit16, and a rotation table unit17. The table unit11has the base unit100attached thereto and moves the base unit100on the bed10.

The Y-axis slide unit15moves the X-axis slide unit16in the Y-axis direction (a direction of an arrow106) with respect to the bed10. The X-axis slide unit16is fixed to a member corresponding to a movable part of the Y-axis slide unit15. The X-axis slide unit16moves the rotation table unit17in the X-axis direction (a direction of an arrow108) with respect to the Y-axis slide unit15. The rotation table unit17is fixed to a member corresponding to a movable part of the X-axis slide unit16and supports the base unit100. The rotation table unit17is, for example, an inclined circular table and includes a fixing base17a, a rotation table17b, an inclination table17c, and a rotation table17d. The fixing base17ais fixed to a member corresponding to a movable part of the X-axis slide unit16. The rotation table17bis supported by the fixing base17a. The rotation table17brotates about a rotation shaft110which is a rotation axis and is parallel to the Z-axis direction. The inclination table17cis supported by the rotation table17b. The inclination table17crotates about a rotation shaft112which is an axis and is orthogonal to a face supporting the rotation table17b. The rotation table17dis supported by the inclination table17c. The rotation table17drotates about a rotation shaft114which is an axis and is orthogonal to a surface supporting the inclination table17c. The rotation table17dis used to fix the base unit100. In this way, the rotation table unit17can rotate the base unit100about three orthogonal axes by rotating the components thereof about the rotation shafts110,112, and114. The table unit11moves the base unit100fixed to the rotation table unit17in the Y-axis direction and the X-axis direction by the Y-axis slide unit15and the X-axis slide unit16. Further, the table unit11rotates the base unit100about three orthogonal axes by rotating the components thereof about the rotation shafts110,112, and114by the rotation table unit17. The table unit11may further move the base unit100in the Z-axis direction.

The deposition head12injects a powder material toward the base unit100, irradiates the powder material injected onto the base unit with a laser beam to melt the powder, and solidifies the melted powder on the base unit100to form a formed layer. The powder which is introduced into the deposition head12is powder which is used as a raw material of the three-dimensional object. In the embodiment, for example, a metal material such as iron, copper, aluminum, or titanium can be used as the powder. As the powder, a material such as ceramic other than the metal material may be used. The deposition head12is provided at a position facing the upper face of the bed10in the Z-axis direction. The deposition head12faces the table unit11. A lower part of the deposition head12in the Z-axis direction is provided with the nozzle23. The nozzle23is attached to a main body46of the deposition head12.

First, the nozzle23will be described with reference toFIG. 2.FIG. 2is a cross-sectional view illustrating an example of the nozzle23of the deposition head12. As illustrated inFIG. 2, the nozzle23is a double tube including an outer tube41and an inner tube42inserted into the outer tube41. The outer tube41is a tubular member and is formed so that a diameter decreases as it goes toward a front end (the downside in the Z-axis direction). The inner tube42is inserted into the outer tube41. The inner tube42is also a tubular member and has a shape in which a diameter decreases as it goes toward a front end (the downside in the Z-axis direction). In the nozzle23, a gap between an inner periphery of the outer tube41and an outer periphery of the inner tube42is formed as a powder passage43through which a powder material (powder) P passes. An inner peripheral face side of the inner tube42is formed as a laser path44through which a laser beam passes. Here, the main body46to which the nozzle23is attached is a double tube similarly to the nozzle23and the powder passage43and the laser path44are formed in this way. In the deposition head12, the powder passage43is disposed to surround the laser path44. In the embodiment, the powder passage43is formed as a powder injection unit which injects powder. In the deposition head12, the powder P which is introduced from the powder introduction unit35flows through the powder passage43. The powder P is injected from a nozzle injection opening45which is an opening at an end side between the outer tube41and the inner tube42.

Further, the deposition head12includes a light source47, an optical fiber48, and a light concentrating unit49. The light source47outputs a laser beam L. The optical fiber48guides a laser beam L output from the light source47to the laser path44. The light concentrating unit49is disposed at the laser path44and is disposed at the optical path of the laser beam L output from the optical fiber48. The light concentrating unit49concentrates a laser beam L output from the optical fiber48. The laser beam L which is concentrated by the light concentrating unit49is output from the end of the inner tube42.

The three-dimensional deposition device1includes a focal position adjustment unit140. The focal position adjustment unit140moves the light concentrating unit49in a direction in which the laser beam L travels. The focal position adjustment unit140can adjust a focal position of the laser beam L by moving a position of the light concentrating unit49in a direction in which the laser beam L travels. Additionally, a mechanism that adjusts a focal distance of the light concentrating unit49can be used as the focal position adjustment unit140. Further, in the three-dimensional deposition device1, the Z-axis slide unit4ais also used as one of the focal position adjustment units. The Z-axis slide unit4amoves along with a focal position P1of the laser beam L and a powder material injection position (for example, a focal position P2of the injected powder material). The focal position adjustment unit140can also move the focal position P1of the laser beam L to the focal position P2to which the powder material is injected. The three-dimensional deposition device1can switch a control target in response to an adjustment target.

The deposition head12injects the powder P from the powder passage43and outputs the laser beam L from the laser path44. The powder P injected from the deposition head12enters an area irradiated with the laser beam L output from the deposition head12. The powder P is heated by the laser beam L. The powder P irradiated with the laser beam L is melted and reaches the base unit100. The powder P which reaches the base unit100in a melted state is cooled and solidified. Accordingly, a formed layer is formed on the base unit100.

Here, the deposition head12of the embodiment guides the laser beam L output from the light source47by the optical fiber48, but an optical member other than the optical fiber may be used to guide the laser beam. Further, the light concentrating unit49may be provided at one of or both the main body46and the nozzle23. Since the deposition head12of the embodiment can be processed effectively, the powder passage43ejecting the powder P and the laser path44irradiated with the laser beam L are provided coaxially. However, the deposition head12is not limited thereto. The deposition head12may be formed so that an assembly for injecting the powder P and an assembly for emitting the laser beam L are provided as separate members. The deposition head12of the embodiment irradiates a powder material with a laser beam, but may emit a light beam other than the laser beam as long as the powder material can be melted or sintered.

Next, a supply path of the powder material of the deposition head12will be described in more detail.FIG. 3is a schematic diagram illustrating a schematic configuration of a structure that supplies the powder material of the deposition head.FIG. 4is a development diagram illustrating a schematic configuration of a branch tube and a distribution unit of the deposition head.FIG. 5is a perspective view illustrating a schematic configuration of a structure that supplies the powder material in the periphery of the nozzle of the deposition head.FIG. 6is a schematic diagram illustrating a schematic configuration of a mixing unit.FIG. 7is an explanatory diagram illustrating a change in cross-section of the mixing unit. As illustrated inFIG. 3, the powder material is supplied from the powder introduction unit35to the deposition head12through a powder supply tube150. The deposition head12includes a distribution unit152and a plurality of branch tubes154as a mechanism that supplies the supplied powder material to the powder passage43.

The distribution unit (distributor)152equalizes the powder supplied from the powder supply tube150and supplies the powder to the branch tube154. The plurality of branch tubes154are tubes which connect the distribution unit152and the powder passage43to each other and supply the powder P supplied from the distribution unit152to the powder passage43. In the deposition head12of the embodiment, as illustrated inFIG. 5, three branch tubes154are disposed equally, that is, at an interval of 120° in a circumferential direction.

A mixing unit156is provided inside the branch tube154. The mixing unit156is an mechanism that equalizes the powder P flowing through the branch tube154inside the branch tube154and includes a plurality of stirring plates156a. The stirring plate156ais twisted about an axial direction of the branch tube154along a flow direction of the branch tube154. Further, the stirring plates156awhich are adjacent to each other in the flow direction are twisted in the opposite directions. Accordingly, a flow of a fluid passing through the mixing unit156changes in response to an axial position of the branch tube154. Thus, a stirring operation is promoted. Further, in the embodiment, three branch tubes154are provided, but the number is not particularly limited. It is desirable to equally dispose the branch tubes154at a predetermined angular interval in the circumferential direction.

Further, the deposition head12is formed so that a flow straightening device158is provided in the powder passage43. The flow straightening device158straightens a flow of the powder material supplied from three branch tubes154. Accordingly, the deposition head12can arrange the flow of the powder material injected from the powder passage43and thus supply the powder material to a desired position with high accuracy.

The machining unit13is used to machine, for example, a formed layer or the like. As illustrated in FIG.1, the machining unit13is provided at a position facing the upper face of the bed10in the Z-axis direction and faces the table unit11. The tool22is attached to a lower part of the machining unit13in the Z-axis direction. Additionally, the machining unit13may be provided in the movable range of the base unit100using the table unit11above the bed10in the Z-axis direction. Here, the arrangement position is not limited to the position of the embodiment.

FIG. 6is a schematic diagram illustrating a configuration of the control device20. The control device20is electrically connected to the components of the three-dimensional deposition device1and controls the operations of the components of the three-dimensional deposition device1. The control device20is provided at the outside of the three-dimensional deposition chamber2or the spare chamber3. The control device20includes, as illustrated inFIG. 6, an input unit51, a controller52, a storage unit53, an output unit54, and a communication unit55. The components of the input unit51, the controller52, the storage unit53, the output unit54, and the communication unit55are electrically connected to one another.

The input unit51is, for example, an operation panel. An operator inputs information or an instruction to the input unit51. The controller52includes, for example, a CPU (Central Processing Unit) and a memory. The controller52outputs an instruction for controlling the operations of the components of the three-dimensional deposition device1to the components of the three-dimensional deposition device1. Further, information is input to the controller52from the components of the three-dimensional deposition device1. The storage unit53is, for example, a storage device such as a RAM (Random Access Memory) or a ROM (Read Only Memory). The storage unit53stores an operation program for the three-dimensional deposition device1controlling the operations of the components by the controller52executing the program, information of the three-dimensional deposition device1, or design information of the three-dimensional object. The output unit54is, for example, a display. The output unit54displays, for example, information of the components of the three-dimensional deposition device1. The communication unit55exchanges information with, for example, a communication line such as the Internet or a LAN (Local Area Network) by communicating with the communication line. Additionally, the control device20may include at least the controller52and the storage unit53. The control device20may output an instruction to the components of the three-dimensional deposition device1if the controller52and the storage unit53are provided.

The shape measurement unit30is fixed to the deposition head accommodation chamber4. The shape measurement unit30is disposed adjacent to the deposition head12. The shape measurement unit30measures a surface shape of the formed layer formed on the base unit100. As the shape measurement unit30, for example, a 3D scanner or a device measuring a relative distance can be used. For example, the shape measurement unit30performs scanning the surface of the formed layer on the base unit100by a laser beam to calculate position information (distance of arrow160) of the surface of the formed layer from reflected light. The shape measurement unit then measures the surface shape of the formed layer. Further, in the embodiment, the shape measurement unit30is attached to the deposition head accommodation chamber4. However, the shape measurement unit30may be attached to a different position as long as the surface shape of the formed layer formed on the base unit100can be measured.

FIG. 7is a schematic diagram illustrating a schematic configuration of components provided in the deposition head accommodation chamber. The heating head31heats the base unit100, the formed layer on the base unit100, the melted powder P, or the like. As illustrated inFIGS. 1 and 7, the heating head31is disposed adjacent to the deposition head12and selectively heats an upstream part (a part before processed) of an area to be processed by the deposition head12or a downstream part (a part after processed) of an area to be processed by the deposition head12thereof. The heating head31is fixed to the deposition head accommodation chamber4. The heating head31is disposed adjacent to the deposition head12. The heating head31heats the base unit100, the formed layer, the melted powder P (a molten body A), the solid body B, and the like by emitting a laser beam162thereto. Since the heating head31heats the formed layer or the melted powder P, a temperature of the formed layer or the melted powder P can be controlled. Therefore, it is possible to suppress an abrupt decrease in temperature of the formed layer or the melted powder P or to form an atmosphere (a high-temperature environment) in which the powder P is easily melted. Further, the heating head31can heat the formed layer or the base unit100before the molten body A is adhered, that is, before the formed layer is formed by the deposition head12.

An example of the heating head31will be described with reference toFIGS. 8 to 10.FIG. 8is a schematic diagram illustrating a schematic configuration of the heating head.FIG. 9is a schematic diagram illustrating a schematic configuration of a light source unit of the heating head.FIG. 10is a perspective view illustrating a schematic configuration of the heating head. The heating head31includes a light source unit502and a heating position adjustment mechanism504.

The light source unit502outputs the laser beam162used to heat the formed layer or the base unit100. As illustrated inFIG. 9, the light source unit502includes two semiconductor lasers540, two light concentrating units542, and an optical fiber544. Two semiconductor lasers540respectively output the laser beam. The light concentrating unit542is provided in each of the semiconductor lasers540and concentrates the laser output from the semiconductor laser540. The laser beam which is concentrated by each of two light concentrating units542is incident to the optical fiber544. The optical fiber544outputs the laser beam incident thereto toward the heating position adjustment mechanism504.

The light source unit502concentrates the light which is incident from two semiconductor lasers540by the light concentrating unit542and causes the light to be incident to one optical fiber544. Accordingly, the laser beam162obtained by multiplexing (joining) the laser beams output from two semiconductor lasers540is output from the light source unit502. Further, in the embodiment, the laser beams of two semiconductor lasers540are joined. However, the number of the semiconductor lasers is not limited to two and may be one to three or more. The light source unit502can increase the output of the laser beam162when the number of the semiconductor lasers is increased.

The heating position adjustment mechanism504includes a mirror512and a galvano mirror514. The heating position adjustment mechanism504irradiates an area532of the base unit100with the laser beam by reflecting the laser beam162output from the light source unit502through the mirror512and reflecting the laser beam through the galvano mirror514so that a direction is changed. The galvano mirror514includes a mirror520and an angular position adjustment mechanism522which rotates the mirror520about a rotation axis521to change a direction of the mirror520. When the galvano mirror514rotates the mirror520about the rotation axis521, a position irradiated with the laser beam162on a surface of the base unit100can be moved in a direction of the mirror520as illustrated inFIG. 10. In the embodiment, the position irradiated with the laser beam162can be moved in a range of the area532. The heating position adjustment mechanism504can perform a laser beam scanning operation by rotating the mirror520at a predetermined speed pattern in the galvano mirror514. The heating position adjustment mechanism504performs a laser beam scanning operation in a direction orthogonal to a direction of an arrow528which is the relative movement directions of the base unit100or the formed layer and the heating head31. Accordingly, the area532is formed so that a direction orthogonal to the arrow528becomes a longitudinal direction. Further, a direction in which the laser beam is moved by the heating position adjustment mechanism504is not limited thereto and may be set to an arbitrary direction if necessary. The heating position adjustment mechanism504can adjust the laser beam movement direction by adjusting, for example, a direction of the rotation axis521of the galvano mirror514.

The heating head31heats the base unit100or the formed layer in the area532by moving the laser beam162output from the light source unit502through the heating position adjustment mechanism504. The heating head31can adjust a heating position of the base unit100with high accuracy by moving the laser beam irradiation position and thus perform a heating operation with high accuracy.

The heating head31can output a laser beam having a short wavelength by using the semiconductor laser540as a laser beam source and thus increase an energy absorption degree for the base unit100, the formed layer, and the like. Accordingly, a heating operation can be performed effectively. Since the heating operation can be performed effectively, an oscillator can be decreased in size and thus the light source unit502can be decreased in size. Further, in the above-described embodiment, since a decrease in size of the device can be realized, the light source unit502is disposed inside a casing of the heating head31, but may be disposed outside the casing.

Here, it is desirable that the light source unit of the heating head use a vertical cavity surface emitting laser (VCSEL) outputting a beam in a direction perpendicular to a substrate face as a laser beam source.

FIG. 11is a schematic diagram illustrating a schematic configuration of another example of the light source unit of the heating head. A light source unit502aincludes two semiconductor lasers540a, a multiplexing unit550, and the optical fiber544. The multiplexing unit550includes two collimating lenses551, a diffraction grating552, and a light concentrating unit554. Each of two semiconductor lasers540aoutputs a laser beam. The semiconductor laser540ais a vertical cavity surface emitting laser. The collimating lens551is provided in each semiconductor laser540aand collimates the laser output from the semiconductor laser540a. The laser beam which is collimated by two collimating lenses551is incident to the diffraction grating552. The diffraction grating552diffracts at least one of the laser beams incident from two different directions to obtain the laser beam in the same direction. The light concentrating unit554concentrates the laser beam having passed through the diffraction grating552and causes the laser beam to be incident to the optical fiber544. The laser beam which is concentrated by the light concentrating unit554is incident to the optical fiber544. The optical fiber544outputs the incident laser beam toward the heating position adjustment mechanism504.

Since the light source unit502auses the vertical cavity surface emitting laser, the light source unit can be further decreased in size. Further, in the above-described embodiment, the laser beam is incident to the optical fiber, but the optical fiber may not be used.

Further, the heating head of the above-described embodiment can perform a scanning operation in one axis direction, but the heating head enables the laser beam is scanned in a multi-axis direction.FIG. 12is a schematic diagram illustrating a schematic configuration of another example of the heating head. A heating head31aillustrated inFIG. 12includes the light source unit502and a heating position adjustment mechanism504a. The heating position adjustment mechanism504aincludes a galvano mirror512ainstead of the mirror512of the heating position adjustment mechanism504.

The heating position adjustment mechanism504aincludes the galvano mirror512aand the galvano mirror514. The heating position adjustment mechanism504airradiates the area532of the base unit100with the laser beam by reflecting the laser beam162output from the light source unit502through the galvano mirror512aand reflecting the laser beam through the galvano mirror514so that a direction is changed. The galvano mirror512aincludes a mirror560and an angular position adjustment mechanism562which rotates the mirror560about a rotation axis564so that a direction of the mirror560is changed. Here, the rotation axis564is an axis different from the rotation axis521. When the galvano mirror512arotates the mirror562about the rotation axis564, a position of the laser beam162reaching the galvano mirror520can be moved by a direction of the mirror560as illustrated inFIG. 12.

The heating position adjustment mechanism504achanges the position of the laser beam reaching the mirror520by rotating the mirror560of the galvano mirror512a, and changes the position of the laser beam reaching the base unit100by rotating the mirror520of the galvano mirror514. The heating position adjustment mechanism504athen can move a position of the laser beam reaching the base unit100two-dimensionally. In this way, the heating head31acan adjust an irradiation position of the laser beam162in two dimensions by moving the irradiation position on the surface of the base unit100in a two-axis direction. Accordingly, the heating head31acan adjust a heating position on the base unit100with higher accuracy and thus perform a heating operation with higher accuracy.

Further, the heating head31aof the embodiment heats a target area by emitting the laser beam thereto, but the invention is not limited thereto. As long as the heating head31acan selectively heat the heating area, light other than a laser beam, for example, a light beam of infrared light may be used to heat the heating area or the heating area may be irradiated with an electromagnetic wave to heat the heating area.

The temperature detection unit120is disposed near the heating head31. As illustrated inFIG. 7, the temperature detection unit120measures a temperature by outputting a measurement wave164to a area including a position irradiated with the laser beam L and an area irradiated with the laser beam162output from the heating head31. As the temperature detection unit120, various temperature sensors that measure a temperature of a surface provided with a formed layer can be used.

The weight detection unit130detects a weight of the base unit100attached to the rotation table17dof the rotation table unit17. A load cell can be used as the weight detection unit130.

The machining measurement unit32measures a position of a front end56of the tool22of the machining unit13.FIG. 13is a schematic diagram illustrating an example of the machining measurement unit32. As illustrated inFIG. 13, the machining measurement unit32includes a light source unit57and an image capturing unit58. In the machining measurement unit32, the front end56of the tool22of the machining unit13is located between the light source unit57and the image capturing unit58. The light source unit57is, for example, an LED. The image capturing unit58is, for example, a CCD (Charge Coupled Device) camera. The machining measurement unit32irradiates the image capturing unit58with light LI from the light source unit57while the front end56of the tool22is disposed between the light source unit57and the image capturing unit58. The machining measurement unit32then acquires an image by the image capturing unit58. Accordingly, it is possible to acquire an image in which light is interrupted by the front end56of the tool22. The machining measurement unit32can acquire a shape and a position of the front end56by analyzing the image acquired by the image capturing unit58and specifically detecting a boundary between a light incident position and a non-light incident position. The control device20detects an accurate position of the front end56of the tool22attached to the machining unit13based on the acquired position of the front end56of the tool22and a position of the machining unit13(a position of the machining unit accommodation chamber5). Additionally, the machining measurement unit32is not limited to this configuration as long as measuring the position of the front end56of the machining unit13. For example, the front end may be measured by a laser beam.

The tool exchange unit33is disposed inside the three-dimensional deposition chamber2. The tool exchange unit33exchanges the tool22attached to the machining unit13. The tool exchange unit33moves a part which does not grip the tool22to a position facing the machining unit13. Subsequently, the tool exchange unit33moves a part which does not grip the tool22to a position facing the machining unit13. Subsequently, the tool exchange unit separates the tool22attached to the machining unit13. Then, the tool exchange unit moves a part which grips a different tool22to be attached to the machining unit13to a position facing the machining unit13and attaches the different tool22to the machining unit13. In this way, the tool exchange unit33can exchange the tool22of the machining unit13by attaching or separating the tool22of the machining unit13. Additionally, the tool exchange unit33is not limited to this configuration as long as the tool22of the machining unit13can be exchanged.

The nozzle exchange unit34is disposed inside the three-dimensional deposition chamber2. The nozzle exchange unit34exchanges the nozzle23attached to the deposition head12. The nozzle exchange unit34can use the same structure as that of the tool exchange unit33.

The powder introduction unit35introduces a powder material which becomes a raw material of a three-dimensional object to the deposition head12.FIGS. 14A and 14Bare schematic diagrams illustrating examples of the powder introduction unit. As illustrated inFIG. 14A, in the embodiment, the powder P is managed while being enclosed in a cartridge83. That is, the powder is shipped while being enclosed in the cartridge83in accordance with, for example, the type of material. The cartridge83is provided with a material display part84. The material display part84is, for example, a display which indicates powder information such as a material type. The material display part84is not limited to information which can be checked by eyes and may be an IC chip or a two-dimensional code or mark. This information can be acquired by a reader. The material display part84is not limited thereto as long as the type of powder can be displayed. The material display part84can indicate, for example, powder information necessary for manufacturing the three-dimensional object such as a particle size, a weight, purity of powder or an oxide coating of powder other than the type of powder. Further, the material display part84may include information which indicates whether the powder is a regular product.

The powder introduction unit35includes a powder storage unit81and a powder identification unit82. The powder storage unit81is, for example, a box-shaped member and accommodates the cartridge83therein. The powder storage unit81is connected to a carrying air supply part which carries out the powder or a carrying path through which the powder is carried to the deposition head12. The powder storage unit81introduces the powder stored in the cartridge83into the deposition head12when the cartridge83is accommodated therein. When the powder identification unit82detects a state where the cartridge83is accommodated in the powder storage unit81, the material display part84of the cartridge83is read so that the information of the powder stored in the cartridge83is read. The powder introduction unit35can supply known powder to the deposition head12by acquiring the powder information by the powder identification unit82.

Here, the powder introduction unit35may supply a powder which is not managed while being enclosed in the cartridge83to the deposition head12.FIG. 14Billustrates a powder introduction unit35A in which the powder is not enclosed in the cartridge83. The powder introduction unit35A includes a powder storage unit81A, a powder identification unit82A, and a powder guide tube89which connects the powder storage unit81A and the powder identification unit82A to each other. The powder storage unit81A is, for example, a box-shaped member and stores the powder P therein. The powder identification unit82A analyzes the powder supplied through the powder guide tube89and measures the powder information necessary for manufacturing the three-dimensional object such as a particle size, a weight, purity of powder or an oxide coating of powder. As the powder identification unit82A, a spectral analysis device which identifies a powder material by a spectral analysis, a particle size analysis device which measures a powder particle size by a particle size analysis, and a weight measurement device which measures a powder weight can be used. The powder identification unit82A measures powder purity from, for example, the type, the particle size, and the weight of the powder measured as described above. Further, the powder identification unit82A measures the oxide coating of the powder by, for example, conductivity. The powder introduction unit35A also can supply known powder to the deposition head12by acquiring the powder information by the powder identification unit82A.

The base movement unit36is disposed in the spare chamber3. The base movement unit36moves a base unit100afrom the inside of the spare chamber3into the three-dimensional deposition chamber2and moves the base unit100inside the three-dimensional deposition chamber2into the spare chamber3. The base unit100awhich is carried into the spare chamber3from the outside is attached to the base movement unit36. The base movement unit36carries the base unit100aattached thereto from the spare chamber3into the three-dimensional deposition chamber2. More specifically, the base movement unit36moves the base unit100aattached to the base movement unit36into the three-dimensional deposition chamber2so that the base unit is attached to the rotation table unit17. The base movement unit36moves the base unit100by, for example, a robot arm or an orthogonal carrying device.

The air discharge unit37is, for example, a vacuum pump and discharges air inside the three-dimensional deposition chamber2. The gas introduction unit38introduces a gas having a predetermined element, for example, an inert gas such as argon and nitrogen into the three-dimensional deposition chamber2. The three-dimensional deposition device1discharges the air of the three-dimensional deposition chamber2by the air discharge unit37and introduces a gas into the three-dimensional deposition chamber2by the gas introduction unit38. Accordingly, the three-dimensional deposition device1can form a desired gas atmosphere inside the three-dimensional deposition chamber2. Here, in the embodiment, the gas introduction unit38is provided below the air discharge unit37in the Z-axis direction. When the three-dimensional deposition device1uses argon having a specific weight higher than that of a gas such as oxygen in air as an introduction gas while the gas introduction unit38is provided below the air discharge unit37in the Z-axis direction, an argon gas can be appropriately charged into the three-dimensional deposition chamber2. Additionally, when the introduction gas is set as a gas lighter than air, a pipe may be disposed in an opposite way.

The powder collection unit39collects the powder P which is injected from the nozzle injection opening45of the deposition head12and is not used to form a formed layer. The powder collection unit39suctions the air inside the three-dimensional deposition chamber2and collects the powder P included in the air. The powder P which is injected from the deposition head12is melted and solidified by the laser beam L so that a formed layer is formed. However, since a part of the powder P is not irradiated with, for example, the laser beam L, there is a case where the powder is left inside the three-dimensional deposition chamber2. Further, chips which are cut by the machining unit13and are discharged from the formed layer are left in the three-dimensional deposition chamber2. The powder collection unit39collects the powder P or chips left in the three-dimensional deposition chamber2. The powder collection unit39may include an assembly such as a brush which mechanically collects the powder.

FIG. 15is a schematic diagram illustrating an example of the powder collection unit39. As illustrated inFIG. 15, the powder collection unit39includes an introduction part85, a cyclone part86, a gas discharge part87, and a powder discharge part88. The introduction part85is, for example, a tubular member and one end thereof is connected to, for example, the inside of the three-dimensional deposition chamber2. The cyclone part86is, for example, a hollow truncated conical member and is formed so that a diameter decreases as it goes downward in, for example, the vertical direction. The other end of the introduction part85is connected to the cyclone part86in a tangential direction of an outer periphery of the cyclone part86. The gas discharge part87is a tubular member and one end thereof is connected to an upper end of the cyclone part86in the vertical direction. The powder discharge part88is a tubular member and one end thereof is connected to a lower end of the cyclone part86in the vertical direction.

For example, a pump which suctions a gas is connected to the other end of the gas discharge part87. Thus, the gas discharge part87suctions a gas from the cyclone part86to form a negative pressure in the cyclone part86. Since the cyclone part86has a negative pressure, the introduction part85suctions a gas from the three-dimensional deposition chamber2. The introduction part85suctions the powder P which is not used to form the formed layer along with the gas inside the three-dimensional deposition chamber2. The introduction part85is connected to the cyclone part86in the tangential direction of the outer periphery of the cyclone part86. Thus, the gas and the powder P which are suctioned to the introduction part85turn along an inner periphery of the cyclone part86. Since the powder P has a specific weight higher than that of the gas, the powder is centrifugally separated outward in a radiation direction at the inner periphery of the cyclone part86. The powder P is directed toward the lower powder discharge part88in an extension direction by the own weight and is discharged from the powder discharge part88. Further, the gas is discharged by the gas discharge part87.

The powder collection unit39collects the powder P which is not used to form the formed layer in this way. Further, the powder collection unit39of the embodiment may separately collect the powder P in accordance with each specific weight. For example, since the powder having a low specific weight has a small weight, the powder is not directed toward the powder discharge part88and is suctioned to the gas discharge part87. Thus, the powder collection unit39can separately collect the powder P in accordance with the specific weight. Additionally, the powder collection unit39is not limited to such a configuration as long as the powder P which is not used to form the formed layer can be collected.

Next, a three-dimensional object manufacturing method using the three-dimensional deposition device1will be described.FIG. 16is a schematic diagram illustrating the three-dimensional object manufacturing method by the three-dimensional deposition device1according to the embodiment. The manufacturing method illustrated inFIG. 16can be performed by the control to the operations of the components of the control device20. In the embodiment, a case will be described in which a three-dimensional object is manufactured on a pedestal91. The pedestal91is, for example, a metallic plate-shaped member, but the shape and the material thereof may be arbitrarily set as long as the three-dimensional object is formed thereon. The pedestal91is attached on the base unit100. The base unit100is fixed to the rotation table unit17of the table unit11along with the pedestal91. Additionally, the pedestal91can be set as the base unit100.

As illustrated in step S1, the control device20moves the base unit100so that the pedestal91of the base unit100is disposed below the deposition head12in the Z-axis direction by the table unit11.

Next, as illustrated in step S2, the control device20introduces the powder from the powder introduction unit35into the deposition head12and emits the laser beam L while injecting the powder P from the deposition head12along with the gas. The powder P has a predetermined convergence diameter and is injected toward the pedestal91of the base unit100. The laser beam L is emitted to the powder P with a predetermined spot diameter between the deposition head12and the pedestal91. Here, the position of the spot diameter of the laser beam L in the Z-axis direction with respect to the position of the convergence diameter of the powder P in the Z-axis direction and the spot diameter at the position of the convergence diameter of the powder P in the Z-axis direction can be controlled by, for example, the movement of the position of the light concentrating unit49.

As illustrated in step S3, the control device20injects the powder P from the deposition head12while emitting the laser beam L so that the powder P is melted by the irradiation with the laser beam L. The melted powder P which is a molten body A falls downward in the Z-axis direction toward the pedestal91of the base unit100.

The molten body A which falls downward in the Z-axis direction reaches a predetermined position of the pedestal91of the base unit100. The molten body A on the pedestal91is cooled at a predetermined position on the pedestal91by, for example, heat radiation. As illustrated in step S4, the cooled molten body A is solidified as a solid body B on the pedestal91.

The control device20forms the solid body B on the base unit100by the deposition head12according to a sequence from step S2to step S4while moving the base unit100to a predetermined position by the table unit11. When these sequences are repeated, as illustrated in step S5, the solid body B forms a formed layer92having a predetermined shape on the pedestal91.

As illustrated in step S6, the control device20moves the pedestal91of the base unit100by the table unit11so that the formed layer92formed on the pedestal91is disposed below the machining unit13in the Z-axis direction. Further, the control device20performs a machining operation on the formed layer92by the machining unit13. The control device20determines whether to perform a machining operation by the machining unit13. If this machining operation is not necessary, the machining operation may not be performed. Thus, there is a case where the machining operation illustrated in step S6is not performed in accordance with the instruction of the control device20.

Next, as illustrated in step S7, the control device20moves the base unit100by the table unit11so that the formed layer92formed on the pedestal91is disposed below the deposition head12in the Z-axis direction. Then, the sequence from step S2to step S6is repeated so that a formed layer93is sequentially deposited on the formed layer92and thus the three-dimensional object is manufactured.

From the description above, the three-dimensional deposition device1according to the embodiment manufactures the three-dimensional object as below. The powder injection unit of the deposition head12injects the powder P toward the pedestal91of the base unit100. Further, the inner tube42of the deposition head12irradiates the powder P provided between the deposition head12and the pedestal91with the laser beam L. The powder P which is irradiated with the laser beam L is melted and solidified on the pedestal91of the base unit100and thus the formed layer92is formed. The three-dimensional deposition device1sequentially deposits the formed layer93on the formed layer92and performs an appropriate machining operation on the formed layers92and93by the machining unit13to manufacture the three-dimensional object.

In the embodiment, the three-dimensional object is manufactured on the pedestal91, but the three-dimensional object may not be manufactured on the pedestal91. The three-dimensional object may be directly manufactured on, for example, the base unit100. Further, the three-dimensional deposition device1may perform so-called overlay welding by depositing a formed layer on an existing shaped material.

In the embodiment, the machining unit13is used to perform, for example, a machining operation on the surface of the formed layer92, but may perform a machining operation on the other part.FIGS. 17A to 17Care schematic diagrams illustrating a three-dimensional object manufacturing method by the three-dimensional deposition device1according to the embodiment.FIGS. 17A to 17Cillustrate a sequence of manufacturing a member99illustrated inFIG. 17Cby the three-dimensional deposition device1.

The member99includes a disc part95, a shaft part97, and a truncated conical part98. Further, the member99is formed so that a threaded hole96is formed in the disc part95. As illustrated inFIG. 17C, the disc part95is a disc-shaped member. The shaft part97is a shaft-shaped member that has a diameter smaller than that of the disc part95and extends from a center of one face of the disc part95. The threaded hole96is provided at the outside of the shaft part97of the disc part95. The truncated conical part98is provided at a front end of the shaft part97and is formed so that an outer diameter increases as it goes toward an opposite side to the disc part95. A long diameter of the truncated conical part98is equal to, for example, an outer diameter of the disc part95. That is, the threaded hole96is located at the inside of the long diameter of the truncated conical part98.

Next, a sequence of manufacturing the member99by the three-dimensional deposition device1will be described. As illustrated inFIG. 17A, the three-dimensional deposition device1forms the disc part95and the shaft part97by depositing the formed layer through the deposition head12. After the disc part95and the shaft part97are manufactured, the three-dimensional deposition device1forms the threaded hole96by the machining unit13as illustrated inFIG. 17B. After the threaded hole96is formed, the three-dimensional deposition device1forms the truncated conical part98on the shaft part97by depositing the formed layer through the deposition head12. The member99is manufactured in this way.

Here, a long diameter part of the truncated conical part98is located at the outside of the threaded hole96. In other words, an area above the threaded hole96is covered by the truncated conical part98. Thus, for example, when the member99is manufactured by a machining operation, a processing tool for the threaded hole96cannot be moved from an area above the truncated conical part98toward the disc part95. However, the three-dimensional deposition device1forms the threaded hole96before the truncated conical part98is manufactured. In this case, the area above the threaded hole96is not covered. Thus, the three-dimensional deposition device1can process the threaded hole96by moving the machining unit13along the Z-axis direction from above in the Z-axis direction. In this way, the machining unit13can easily perform a machining operation by adjusting timing for the formed layer forming operation and the machining operation.

Next, a detailed process of manufacturing the three-dimensional object by the three-dimensional deposition device1according to the embodiment will be described.FIG. 18is a flowchart illustrating a step of manufacturing the three-dimensional object by the three-dimensional deposition device1according to the embodiment. The control device20reads, for example, the three-dimensional object design information stored in the storage unit53.

Next, the control device20discharges air in the three-dimensional deposition chamber2by the air discharge unit37(step S11). Here, the three-dimensional deposition chamber2is separated from the spare chamber3while the door6is closed. Further, in the three-dimensional deposition chamber2, a part which communicates with the other external air is also closed and sealed. For example, the control device20discharges air from the air discharge unit37so that an oxygen concentration in the three-dimensional deposition chamber2is 100 ppm or less and desirably 10 ppm or less. The control device20can set an inert state by changing the oxygen concentration inside the three-dimensional deposition chamber2to 100 ppm or less and further reliably set an inert state by changing the oxygen concentration to 10 ppm or less.

Next, the base unit100with the pedestal91is attached to the base movement unit36inside the spare chamber3(step S12). Additionally, the three-dimensional deposition device1may perform a process in step S12prior to a process in step S11.

After the base movement unit36in the spare chamber3is attached, the control device20closes the door7of the spare chamber3and discharges air inside the spare chamber3by the air discharge unit25(step S13). The control device20discharges air by the air discharge unit25so that the oxygen concentration in the spare chamber3decreases. It is desirable that the oxygen concentration inside the spare chamber3be equal to, for example, the oxygen concentration inside the three-dimensional deposition chamber2.

When the air of the spare chamber3is completely discharged, the control device20opens the door6of the three-dimensional deposition chamber2and attaches the base unit100to the rotation table unit17inside the three-dimensional deposition chamber2by the base movement unit36(step S14). The base unit100is fixed to the rotation table unit17. After the base unit100is attached to the rotation table unit17, the control device20returns the base movement unit36into the spare chamber3and closes the door6.

After the base unit100is set to the rotation table unit17, the control device20introduces a gas into the three-dimensional deposition chamber2by the gas introduction unit38(step S15). The control device20forms an atmosphere of an introduction gas inside the three-dimensional deposition chamber2by the gas introduction unit38. In the embodiment, the gas which is introduced by the gas introduction unit38is an inert gas such as nitrogen or argon. The gas introduction unit38introduces the inert gas so that the residual oxygen concentration in the three-dimensional deposition chamber2becomes 100 ppm or less.

Further, the three-dimensional deposition device1may omit step S11, step S13, and step S15in accordance with the type of powder material. For example, when any problem does not occur in the quality of the three-dimensional object even by the oxidization of the powder material, these steps may be omitted so that the three-dimensional deposition chamber2and the spare chamber3have atmospheric air.

When the inert gas is completely introduced into the three-dimensional deposition chamber2, the control device20determines whether to perform a machining operation on the pedestal91of the base unit100(step S16). For example, the control device20measures a surface shape of the pedestal91by the shape measurement unit30. The control device20determines whether to perform a machining operation on the pedestal91based on a measurement result of the shape measurement unit30. For example, when surface roughness of the pedestal91is larger than a predetermined value, the control device20determines that the machining operation is performed on the pedestal91. Here, the determination on whether the machining operation needs to be performed on the pedestal91by the control device20is not limited thereto and may not be performed by the measurement result of the shape measurement unit30. The control device20may store, for example, information of the pedestal91in the storage unit53. The control device20may determine whether the pedestal91needs to be processed based on the information of the pedestal91and the three-dimensional object design information. The control device20may be set to process the pedestal91at all times.

When the control device20determines that the machining operation for the pedestal91is needed (Yes in step S16), the control device20performs the machining operation for the pedestal91at a predetermined condition by the machining unit13(step S17). The control device20determines a condition of the machining operation for the pedestal91based on, for example, the shape measurement result of the pedestal91obtained by the shape measurement unit30or the information of the pedestal91and the three-dimensional object design information.

When the control device20determines that the processing for the pedestal91is not needed (No in step S16) or the machining operation for the pedestal91is performed at a predetermined condition, the control device20determines the formed layer forming condition based on, for example, the three-dimensional object design information read from the storage unit53(step S18). For example, the formed layer forming condition is a condition necessary to form the formed layer and includes a shape of each formed layer, a type of powder P, an injection speed of the powder P, an injection pressure of the powder P, an irradiation condition of the laser beam L, a positional relation among a convergence diameter of the powder P, a spot diameter of the laser beam L, and a formed layer surface, a dimension and a temperature of the melted powder P in air, a dimension of a molten pool formed on a formed layer surface, a cooling speed, or a movement speed of the base unit100using the table unit11.

When the control device20determines the formed layer forming condition, the deposition head12injects the powder P toward the pedestal91on the base unit100and irradiates the base unit100with the laser beam L and the base unit100starts to be heated (step S19). Since the control device20emits the laser beam L while injecting the powder P, the powder P can be melted by the laser beam L and the melted powder P can be solidified. Thus, the solid body B is formed on the pedestal91. Further, the control device20irradiates the base unit100with the laser beam L from the heating head31so that the base unit100starts to be heated.

The control device20forms the formed layer92on the pedestal91by moving the base unit100using the table unit11while injecting the powder P and emitting the laser beam L (step S20). The control device20heats the formed layer92or a part to which the solid body B is not yet adhered by the heating head31.

After the formed layer92is formed, the control device20determines whether a machining operation for the formed layer92is needed (step S21). For example, the control device20causes the shape measurement unit30to measure the surface shape of the formed layer92. The control device20determines whether the machining operation for the formed layer92is needed based on the measurement result of the shape measurement unit30. For example, when the surface roughness of the formed layer92is larger than a predetermined value, the control device20determines that the machining operation for the formed layer92is performed. However, the determination reference of the necessity of the machining operation for the formed layer92is not limited thereto. For example, the control device20may determine whether the machining operation for the formed layer92is needed based on the three-dimensional object design information and the formed layer forming condition. For example, when the surface roughness of the formed layer92calculated from the formed layer forming condition is larger than the necessary surface roughness based on the three-dimensional object design information, the control device20may determine that the machining operation for the formed layer92is needed.

When the control device20determines that the machining operation for the formed layer92is not needed (No in step S21), a process proceeds to step S24. When the control device20determines that the machining operation for the formed layer92is needed (Yes in step S21), the control device20determines a processing condition of the machining operation for the formed layer92(step S22). For example, the control device20determines the processing condition based on the measurement result of the shape measurement unit30, or based on the three-dimensional object design information and the condition of forming the formed layer92, or the like. After the control device20determines the formed layer processing condition, the control device20performs the machining operation for the formed layer92by the machining unit13based on the determined processing condition (step S23).

When the control device20performs the machining operation for the formed layer92or determines that the machining operation for the formed layer92is not needed, the control device determines whether to further deposit the formed layer93on the formed layer92(step S24). The control device20determines whether to further deposit the formed layer93on the formed layer92based on, for example, the three-dimensional object design information read from the storage unit53.

When the control device20determines that the deposition of the formed layer93is needed (Yes in step S24), the process returns to step S18and the formed layer93is deposited on the formed layer92. When the control device20determines that the deposition of the formed layer93is not needed (No in step S24), the manufacture of the three-dimensional object is completed.

The three-dimensional deposition device1manufactures the three-dimensional object in this way. The three-dimensional deposition device1according to the embodiment manufactures the three-dimensional object by injecting the powder P through the deposition head12and irradiating the powder P with the laser beam L. Specifically, the three-dimensional deposition device1irradiates the laser beam L toward the powder P moving toward a target, melts the powder before the powder reaches the target, and adheres the molten body A to the target. Accordingly, it is possible to form the formed layer while decreasing the melting amount by the laser beam L or without melting the target. Accordingly, it is possible to reduce an influence of the laser beam with respect to the manufactured target or the formed layer and further deposit the solid body B on the manufactured target. From the description above, the three-dimensional deposition device1can manufacture the three-dimensional object with high accuracy.

Further, since the three-dimensional deposition device1heats the base unit or the formed layer by the heating head31while selecting a heating position, it is possible to further appropriately control the formed layer forming condition. For example, when an area having passed through a position irradiated with the laser beam in the formed layer, that is, an area where the formed layer is already formed heated by the heating head31, the strength of the formed layer can be adjusted. Accordingly, it is possible to control a state of the formed layer with high accuracy while adjusting the strength of the formed layer. Alternatively, when an area not having passed through a position irradiated with the laser beam, that is, the formed layer or the base unit where the molten body A is not adhered yet is heated by the heating head31, it is possible to suppress a problem in which an abrupt decrease in temperature when the molten body is adhered to the base unit and thus further reliably obtain the molten body from the powder. Accordingly, since the three-dimensional deposition device1can perform a highly accurate processing operation, it is possible to manufacture the three-dimensional object with high accuracy.

Further, the three-dimensional deposition device1can perform an appropriate machining operation on the formed layer92by the machining unit13. Thus, the three-dimensional deposition device1can manufacture the three-dimensional object with high accuracy. Further, in the above-described embodiment, the machining operation can be performed on the formed layer92or the base unit100by the machining unit13with high accuracy. However, the machining unit13may not be provided and the machining operation may not be performed.

Further, the base movement unit36moves the base unit100into the three-dimensional deposition chamber2. There is a case where air is discharged in the three-dimensional deposition chamber2. For example, even when the operator does not enter the three-dimensional deposition chamber2, the base movement unit36can move the base unit100in the three-dimensional deposition chamber2.

Here, it is desirable that the three-dimensional deposition device1determine the formed layer forming condition by the shape measurement unit30.FIG. 19is a flowchart illustrating an example of a step of determining the formed layer forming condition by the three-dimensional deposition device1according to the embodiment. The process ofFIG. 19can be performed as a part of the process in step S18ofFIG. 18. The control device20measures a shape of the formed layer92by the shape measurement unit30(step S31). The control device20may measure the shape of the formed layer92by the shape measurement unit30while forming the formed layer by the deposition head12. The shape measurement unit30can measure both a shape of a position where the solid body B is to be formed by the deposition head12and a shape of the solid body B formed at that position. That is, the shape measurement unit30can measure a surface shape before and after the formed layer92is formed. After the control device20measures the shape of the formed layer92, the control device20determines a condition of forming the formed layer92including a heating condition based on a measurement result of the shape measurement unit30(step S33).

Since the control device20determines the heating condition in response to a surface shape measurement result of the formed layer92obtained by the shape measurement unit30, it is possible to determine the heating amount in each position in response to the shape of the formed layer92and further appropriately heat each position. Accordingly, since it is possible to obtain a uniform temperature or a uniform change in temperature at each position, it is possible to perform a processing operation with higher accuracy.

Further, the control device20determines the formed layer forming condition in response to the surface shape measurement result of the formed layer92obtained by the shape measurement unit30and controls an operation of the deposition head12. Thus, the three-dimensional deposition device1can further appropriately form the formed layer by setting a uniform distance between the formed layer forming position and the deposition head12or the like. Further, the three-dimensional deposition device1can measure the shape of the formed layer92by the shape measurement unit30while forming the formed layer by the deposition head12. Thus, the three-dimensional deposition device1can determines the formed layer forming condition more appropriately and further highly accurately manufacture the three-dimensional object based on the further appropriate formed layer forming condition. Here, in the above-described embodiment, the processing operation using the deposition head12has been described, but a processing operation using the machining unit13can be performed in the same way. Further, the formed layer forming condition determined in the above-described embodiment may be changed in accordance with a position or may be constant.

It is desirable that the three-dimensional deposition device1determine, as the formed layer forming condition, the movement path of the deposition head12, that is, a relative relation between the movement of the table unit11and the Z-axis position of the deposition head12based on a detection result. Accordingly, it is possible to uniformly set the thickness of the deposited formed layer, the temperature of the solid part, and a deposition speed.

The three-dimensional deposition device1may determine a process operation based on a temperature distribution detected by the temperature detection unit120.FIG. 20is a flowchart illustrating an example of a step of determining the formed layer forming condition. The control device20detects a temperature distribution in the surface of the formed layer by the temperature detection unit120(step S42). The control device20can detect a temperature distribution in an entire area of the surface of the formed layer by the measurement of the temperature detection unit120while the base unit100is moved by the table unit11. The control device20may perform the measurement before the processing operation is performed by the deposition head12or may perform the measurement while the processing operation is performed by the deposition head12.

After the control device20detects a temperature distribution, the control device20detects a formed layer shape (a surface shape) by the shape measurement unit30(step S44). The surface shape and the temperature distribution in the formed layer may be detected at the same time.

After the control device20detects a shape of the formed layer, the control device20specifies a detection position for detecting a temperature by the temperature detection unit based on the shape and the temperature distribution of the formed layer (step S46) and then detects a temperature at the specified position (step S48). The control device20determines a formed layer forming condition including a heating condition based on the detected temperature (step S49) and ends the step.

The three-dimensional deposition device1can control a temperature or a change in temperature at each position by measuring a temperature at a specific position, for example, a position which is not easily cooled or easily warmed and determining a heating condition. The three-dimensional deposition device1thus can perform a further appropriate processing operation.

Further, the three-dimensional deposition device1can uniformly set the thickness of the deposited formed layer, the temperature of the solid part, and a deposition speed by determining a movement path of the deposition head12as a processing condition based on a temperature distribution and a shape, that is, by determining a processing condition including a temperature distribution. That is, a further uniform processing operation can be performed with the processing condition determined based on the position which is not easily cooled and easily warmed.

Further, in the example illustrated inFIG. 20, a temperature is detected again, but the formed layer forming condition including the heating condition may be determined without the processes in step S46and step S48. Since the three-dimensional deposition device1determines the heating condition based on the temperature distribution and the shape, it is possible to control a temperature or a change in temperature at each position with high accuracy.

Further, the three-dimensional deposition device1may determine a process operation by using a detection result of the weight detection unit130. For example, the three-dimensional deposition object may be evaluated by a change in weight caused by the formed object. Specifically, the density of the three-dimensional deposition object can be calculated by a change in size and weight and thus a void formed in the three-dimensional deposition object can be detected. Further, the three-dimensional deposition device1can detect a foreign matter attached to the base unit100, that is, an unmelted powder material or chips produced during a processing operation of the machining unit13based on the weight of the weight detection unit130. Accordingly, this measurement result can be used to control the operation of the powder collection unit39.

The three-dimensional deposition device may further include another detection unit that detects a parameter for controlling a forming condition.FIG. 21is a schematic diagram illustrating another example of the periphery of the deposition head of the three-dimensional deposition device. The three-dimensional deposition device illustrated inFIG. 21includes a temperature detection unit120a, a half mirror182, a plasma emission detection unit190, and a reflected light detection unit192in the periphery of the laser beam path of the deposition head. The half mirror182is disposed between the light source47and the light concentrating unit49. The half mirror182causes the laser beam directed from the light source47toward the light concentrating unit49to be transmitted therethrough and reflects the laser beam directed from the light concentrating unit49toward the light source47. That is, the half mirror182reflects the laser beam reflected by the base unit100or the formed layer in a predetermined direction.

The plasma emission detection unit190detects plasma which is generated by the irradiation of the laser beam L to the base unit100, the formed layer, or the supplied powder. The reflected light detection unit192detects the laser beam L reflected by the half mirror182. Further, the temperature detection unit120adetects a temperature based on a condition at the position of the laser beam reflected by the half mirror182.

Next, an example of a control which is performed by components will be described with reference toFIGS. 22 to 24.FIG. 22is a flowchart illustrating an example of a step of determining a formed layer forming condition, that is, a heating condition of the heating head. The processes fromFIGS. 22 to 24are desirably performed along with the processing operation of the deposition head, but may be performed when the forming condition is determined. The control device20detects a temperature by the temperature detection unit120a(step S102), determines a heating condition based on the detected temperature (result) (step S104), and ends the process. When the control device20determines the heating condition of the heating head31based on the detection result obtained by the temperature detection unit120a, it is possible to further uniformly set the temperature of the formed layer and to perform a highly accurate processing operation. Further, the same process can be performed even in the case of the temperature detection unit120.

FIG. 23is a flowchart illustrating an example of a step of determining the formed layer forming condition. The control device20detects a plasma emission state by the plasma emission detection unit190(step S112), determines a heating condition based on the detected plasma emission state (step S114), and ends the process. Even when the control device20determines the heating condition of the heating head31based on the detection result obtained by the plasma emission detection unit190, it is possible to further uniformly set the temperature of the formed layer and to perform a highly accurate processing operation. Here, the control device20can monitor the temperature of the focal position of the laser by detecting a plasma emission state by the plasma emission detection unit190. Since plasma generated when the injected powder is melted by a laser beam emitted thereto is detected, a powder melted state in the gas can be monitored.

FIG. 24is a flowchart illustrating an example of a step of determining the formed layer forming condition. The control device20detects reflected light by the reflected light detection unit192(step S122), determines a heating condition based on the detected reflected light (step S124), and ends the process. Even when the control device20determines the heating condition of the heating head31based on the detection result obtained by the reflected light detection unit192, it is possible to further uniformly set the temperature of the formed layer and to perform a highly accurate processing operation. Here, the control device20can monitor a temperature at a position to which the molten body A is adhered by detecting reflected light by the reflected light detection unit192.

Here, it is desirable that the three-dimensional deposition device1have a configuration in which the temperature detection unit120and the heating head31rotate about the Z axis with respect to the deposition head12. Accordingly, it is possible to uniformly set or change a relative position of the temperature detection unit120and the heating head31with respect to the deposition head12in response to the movement direction of the table unit11. Further, the three-dimensional deposition device1may have a configuration in which two pieces of the temperature detection units120and the heating heads31are provided with respect to the deposition head12and are disposed with the deposition head12interposed therebetween.

FIG. 25is a schematic diagram illustrating another example of the deposition head accommodation chamber. A deposition head accommodation chamber570illustrated inFIG. 25supports the deposition head12, the shape measurement unit30, and the heating head31. In the deposition head accommodation chamber570, a part that supports the deposition head12, the shape measurement unit30, and the heating head31becomes a switching mechanism580. The switching mechanism580includes a fixed part581, a movable part582, a rotation mechanism584, and a seal part586. The fixed part581is supported by the Z-axis slide unit4aand a bottom face thereof is connected to the bellows18. The movable part582is embedded in the fixed part581and is used to fix the deposition head12, the shape measurement unit30, and the heating head31. The rotation mechanism584rotates the movable part582about an axis590with respect to the fixed part581. The seal part586rotatably seals a gap between the fixed part581and the movable part582in a lower face in the vertical direction, that is, in a face exposed to the three-dimensional deposition chamber2.

When the switching mechanism580rotates the movable part582with respect to the fixed part581, the relative positions of the deposition head12and the heating head31supported by the movable part582can be switched. Accordingly, the switching mechanism580can switch a state where the deposition head12is located at the upstream side of the heating head31and a state where the deposition head12is located at the downstream side of the heating head31, in the relative movement directions of the deposition head12and the base unit100, that is, a direction in which the table unit11moves the base unit100. That is, when the base unit100moves in the same direction, an anteroposterior position of the deposition head12and the heating head31for the processing position can be switched when the movable part582is rotated by 180°. Accordingly, it is possible to switch a state where the heating head31heats the base unit100or the formed layer before passing by the deposition head12(a state before the formed layer is formed) or a state where the heating head heats the base unit100or the formed layer having passed by the deposition head12(a state after the formed layer is formed).

FIG. 26is a flowchart illustrating an example of a process operation of the three-dimensional deposition device. The control device20detects the relative movement directions of the deposition head12and the base unit100(step S170) and specifies a heating area of the heating head31(step S172). The heating area of the heating head31is set in the base unit100which is processed by the deposition head12and includes an area heating the base unit100or the formed layer on which the deposition head12has not passed yet and an area heating the base unit100or the formed layer on which the deposition head12has already passed.

The control device20determines whether the heating head31is at an appropriate position with respect to the deposition head12(step S174). That is, it is determined whether the heating head is located at the heating area based on the relative movement directions of the deposition head12and the base unit100, the heating area, and the current relative positions of the deposition head12and the heating head31.

When the control device20determines that the heating head31is located at an appropriate position with respect to the deposition head12(Yes in step S174), a process proceeds to step S178. When the control device20determines that the heating head31is not located at an appropriate position with respect to the deposition head12(No in step S174), the control device20switches the relative positions of the heating head31and the deposition head12by the switching mechanism580(step S176) and the process proceeds to step S178.

When it is Yes in step S174or the control device20performs a process in step S176, the control device20determines whether the relative movement directions of the deposition head12and the base unit100are changed (step S178). When the control device20determines that the movement direction is changed (Yes in step S178), the process returns to step S170. When the control device20determines that the movement direction is not changed (No in step S178), the control device20determines whether to finish the manufacturing process (step S179). When the control device20determines that the manufacturing process will not be finished (No in step S179), the process returns to step S178. Meanwhile, when the control device20determines that the manufacturing process will be finished (Yes in step S179), the process ends.

The three-dimensional deposition device1can set a relation of the deposition head and the heating head with respect to a processing position in response to a setting by performing the process illustrated inFIG. 26so that the relative positions of the deposition head and the heating head are switched in response to the relative movement directions of the deposition head and the base unit. Accordingly, it is possible to suppress a change in heating position of the heating head with respect to a position processed by the deposition head in accordance with the relative movement between the deposition head and the base unit. Accordingly, it is possible to perform a highly accurate processing operation.

While the embodiments of the invention have been described, the embodiments are not limited to the content of these embodiments. Further, the above-described components include a component which is easily supposed by the person skilled in the art, a component which has substantially the same configuration, and a component which is in a so-called equivalent scope. The above-described components can be appropriately combined with one another. Additionally, various omissions, substitutions, or modifications of the components can be made without departing from the spirit of the above-described embodiments. For example, the three-dimensional deposition device1is not limited to a configuration in which the deposition head12injects the powder P and irradiates the powder P with the laser beam L. The three-dimensional deposition device1may form a formed layer by supplying the powder P and irradiating the powder P with the laser beam L and may perform an appropriate machining operation on the formed layer. For example, the three-dimensional deposition device1may form the formed layer by forming a powder layer by a powder supply unit and irradiating a part of the powder layer with the laser beam L to sinter the powder.

REFERENCE SIGNS LIST