THREE DIMENSIONAL MODELING APPARATUS

A three-dimensional modeling apparatus models a three-dimensional object by lamination modeling in an air-tight process chamber. The three-dimensional modeling apparatus includes an elevation guide chamber provided adjacent to the process chamber, an elevation stage provided so as to be capable of being raised and lowered in the elevation guide chamber, and a communication pipe communicating between a space below the elevation stage in the elevation guide chamber and the process chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims the benefit of priority from Japanese Patent Application Serial No. 2015-244580 filed on Dec. 15, 2015 and Japanese Patent Application Serial No. 2015-244584 filed on Dec. 15, 2015, the contents of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a three-dimensional modeling apparatus, and in particular to a three-dimensional modeling apparatus for modeling a three-dimensional object using an elevation stage capable of elevation.

BACKGROUND

A three-dimensional modeling apparatus, which is also called a 3D printer, enables easy and quick modeling of parts having relatively complex structure, and more attention is being paid thereto. There have been proposed various methods of modeling with a three-dimensional modeling apparatus. For example, AM (Additive Manufacturing) technology has been employed in a wide range of three-dimensional modeling apparatuses.

One example of AM technology is the lamination modeling method, in which an elevation stage is lowered gradually while layers of a material are stacked thereon, thereby to produce a desired three-dimensional object. This method typically includes steps of applying a laser beam onto a powder material on the elevation stage for sintering, lowering the elevation stage, placing additional powder material on the lowered elevation stage, and applying a laser beam onto the additional powder material for sintering. These steps are repeated to gradually form layers of a three-dimensional object.

For example, Patent Literature 1 discloses an apparatus for producing a three-dimensional object by solidifying a powdery modeling material into layers. In this apparatus, a powder layer is placed on a modeling platform that can move vertically, and a laser beam is applied onto the powder layer for solidification of the powder. Then, the modeling platform is lowered, a new powder layer is placed on the modeling platform, and a laser beam is applied onto the new powder layer. Such a series of steps are repeated to produce a three-dimensional object.

In addition, Patent Literature 2 discloses a method of producing a metal article by lamination modeling with an electron beam, instead of a laser beam. In general, oxidation of a metal material during sintering causes brittleness of the produced object. In the method disclosed in Patent Literature 2, sintering proceeds in an atmosphere of an inert gas such as argon, nitrogen, etc., such that the oxidation of the metal during sintering can be prevented.

RELEVANT REFERENCES

List of Relevant Patent Literature

Patent Literature 1: Japanese Patent Application Publication No. 2013-526429

Patent Literature 2: Japanese Patent Application Publication No. 2015-525290

SUMMARY

Problems to be Solved by the Invention

As stated above, oxidation of a material during modeling is unfavorable for ensuring a desired strength of the three-dimensional object produced. Therefore, sintering of a material should preferably proceed in an environment filled with an inert gas and containing no oxygen (O2).

Since it cannot be visually determined whether oxygen is present in a modeling apparatus, the presence of oxygen need to be determined based on a sensing value of an oxygen sensor provided in the modeling apparatus. However, oxygen included in a locally accumulated air cannot be detected by an oxygen sensor. Therefore, oxygen included in the air accumulated in a position separated from the oxygen sensor (e.g., a position below the elevation stage) cannot be detected when the elevation stage is stopped, whereas when the elevation stage is being raised or lowered, oxygen may be diffused to cause oxidation of the material being sintered. In a large apparatus in particular, an elevation stage having a large area displaces a large volume of air, causing a large amount of oxygen to diffuse within a chamber swiftly.

Between the elevation guide chamber and the elevation stage raised and lowered in the elevation guide chamber, there is provided a sealing member for preventing the powder material placed on the elevation stage from falling down. Such a sealing member works favorably for preventing the powder material from falling down but does not completely block a gas such as oxygen. Even when the sealing member provides relatively high tightness, a gap may be produced between the elevation stage or the elevation guide chamber and the sealing member while the elevation stage is repeatedly raised and lowered, and the gap may cause leakage of oxygen.

To ensure that the material used for producing a three-dimensional object is not oxidized, an oxygen sensor may be installed in the modeling apparatus and, when the oxygen sensor senses an oxygen density equal to or greater than a predetermined threshold value during modeling, the modeling operation may be stopped automatically. In this case, the oxygen sensor may sense an oxygen density equal to or greater than a predetermined threshold value and stop the modeling operation at timings not intended by an operator. To handle such interruption of the modeling operation quickly, the operator needs to pay attention to the modeling apparatus constantly during the modeling operation, resulting in a very large load imparted to the operator.

As described above, the material may be oxidized when the elevation stage is raised or lowered and the accumulated oxygen is diffused. It is a possible option to circulate a large amount of inert gas within the modeling apparatus so as to discharge the inert gas more quickly than the oxygen diffuses. However, this method requires a large amount of inert gas and is wasteful.

Therefore, it is essential to prevent accumulation of oxygen in the modeling apparatus. There has been a demand for an apparatus that discharges oxygen efficiently.

The Inventors have found that a large amount of oxygen accumulates particularly in a space enclosed by the elevation stage and the elevation guide chamber (typically, a space below the elevation stage).

The present invention is intended to overcome the above problems, and one object thereof is to provide a three-dimensional modeling apparatus that can prevent oxidation of a material during modeling of a three-dimensional object.

Means for Solving the Problem

One aspect of the present invention relates to a three-dimensional modeling apparatus for modeling a three-dimensional object by lamination modeling in an air-tight process chamber, the three-dimensional modeling apparatus comprising: an elevation guide chamber provided adjacent to the process chamber; an elevation stage provided so as to be capable of being raised and lowered in the elevation guide chamber; and at least one communication pipe communicating between a space below the elevation stage in the elevation guide chamber and the process chamber.

The at least one communication pipe may communicate between a space below a movement range of the elevation stage in the elevation guide chamber and the process chamber.

The elevation stage may serve for modeling conducted thereon.

The at least one communication pipe may include a plurality of communication pipes,

The plurality of communication pipes may communicate with the process chamber via the same wall portion among a plurality of wall portions constituting the process chamber and communicate with the elevation guide chamber via the same wall portion among a plurality of wall portions constituting the elevation guide chamber.

The at least one communication pipe may include a curved channel.

The at least one communication pipe may communicate with the process chamber at a position closer to an oxygen sensor than to a gas supply unit, the oxygen sensor being configured to sense an oxygen density in the process chamber, the gas supply unit being configured to supply an inert gas to the process chamber.

The three-dimensional modeling apparatus may further include a drive chamber containing at least a part of an elevation drive unit configured to raise and lower the elevation stage, wherein the drive chamber may communicate with the elevation guide chamber via a communication aperture, and the at least one communication pipe may communicate between the drive chamber and the process chamber.

The three-dimensional modeling apparatus may further include a drive chamber containing at least a part of an elevation drive unit configured to raise and lower the elevation stage, wherein the at least one communication pipe may further communicate between the process chamber and the drive chamber

The at least one communication pipe may include a process chamber communication channel that communicates with the process chamber, elevation guide chamber communication channels that branch from the process chamber communication channel and communicate with the elevation guide chambers, and a drive chamber communication channel that branches from the process chamber communication channel and communicates with the drive chamber. The cross-sectional area of the drive chamber communication channel may be larger than that of the elevation guide chamber communication channel.

The at least one communication pipe may include a process chamber communication channel that communicates with the process chamber, elevation guide chamber communication channels that branch from the process chamber communication channel and communicate with the elevation guide chambers, and a drive chamber communication channel that branches from the process chamber communication channel and communicates with the drive chamber. The cross-sectional area of the drive chamber communication channel may be smaller than that of the process chamber communication channel.

The three-dimensional modeling apparatus may further include a drive chamber containing an elevation drive unit configured to raise and lower the elevation stage, and at least one communication aperture in a wall between the elevation guide chamber and the drive chamber, the at least one communication aperture communicating between the elevation guide chamber and the drive chamber.

The three-dimensional modeling apparatus may comprise a plurality of elevation units each including the elevation guide chamber and the elevation stage, and the at least one communication pipe may comprise a plurality of communication pipes that communicate between each of the elevation guide chambers of the plurality of elevation units and the process chamber.

The plurality of communication pipes may include a first communication pipe and a second communication pipe, and the first communication pipe may communicate with the elevation guide chamber at a position above the position where the second communication pipe communicates with the elevation guide chamber.

The first communication pipe may communicate with the process chamber at a position closer to an oxygen sensor than to a gas supply unit, the oxygen sensor being configured to sense an oxygen density in the process chamber, the gas supply unit being configured to supply an inert gas to the process chamber.

The cross-sectional area of the channel of the first communication pipe may be larger than that of the channel of the second communication pipe.

At least one of the first communication pipe and the second communication pipe may be provided with a channel adjusting unit that can adjust the cross-sectional area of the channel.

The three-dimensional modeling apparatus may comprise a plurality of elevation units each including the elevation guide chamber and the elevation stage, and the plurality of communication pipes communicate between at least one of the elevation guide chambers of the plurality of elevation units and the process chamber. The elevation guide chambers of the plurality of elevation units are arranged adjacent to each other, and any two elevation guide chambers arranged adjacent to each other communicate with each other via a communication hole.

The three-dimensional modeling apparatus comprises three or more elevation units arranged adjacent to each other, and any two of the three or more elevation guide chambers arranged adjacent to each other communicate with each other via a communication hole. The opening cross-sectional area of the communication hole that communicates between the elevation guide chamber to which the communication pipe may be connected and the elevation guide chamber to which the communication pipe may not be connected may be larger than the opening cross-sectional area of the communication hole that communicates between the elevation guide chambers to which the communication pipe may not be connected.

The three-dimensional modeling apparatus may further include a drive chamber containing at least a part of an elevation drive unit configured to raise and lower the elevation stage, and at least one communication aperture communicating between at least one of the plurality of elevation guide chambers and the drive chamber.

The three-dimensional modeling apparatus may comprise a plurality of elevation units each including the elevation guide chamber and the elevation stage, the at least one communication pipe may comprise a plurality of communication pipes, the plurality of communication pipes include a first communication pipe and a second communication pipe, the first communication pipe may communicate with the elevation guide chamber at a position above the position where the second communication pipe communicates with the elevation guide chamber, the plurality of communication pipes may communicate between at least one of the elevation guide chambers of the plurality of elevation units and the process chamber, and the plurality of elevation guide chambers may be arranged adjacent to each other, and any two elevation guide chambers arranged adjacent to each other may communicate with each other via a communication hole.

The first communication pipe may communicate with the process chamber at a position closer to an oxygen sensor than to a gas supply unit, the oxygen sensor being configured to sense an oxygen density in the process chamber, the gas supply unit being configured to supply an inert gas to the process chamber.

The cross-sectional area of the channel of the first communication pipe may be larger than that of the channel of the second communication pipe.

At least one of the first communication pipe and the second communication pipe may be provided with a channel adjusting unit that can adjust the cross-sectional area of the channel.

The plurality of elevation guide chambers may include a first elevation guide chamber, a second elevation guide chamber, and a third elevation guide chamber arranged between the first elevation guide chamber and the second elevation guide chamber. The first elevation guide chamber and the third elevation guide chamber may communicate with each other via a communication hole. The second elevation guide chamber and the third elevation guide chamber may communicate with each other via a communication hole. At least one of the first communication pipe and the second communication pipe may communicate between the first elevation guide chamber and the process chamber. The cross-sectional area of the communication hole that communicates between the second elevation guide chamber and the third elevation guide chamber may be larger than that of the communication hole that communicates between the first elevation guide chamber and the third elevation guide chamber.

The first communication pipe may communicate between the first elevation guide chamber and the process chamber.

The second communication pipe may communicate between the second elevation guide chamber and the process chamber.

In the three-dimensional modeling apparatus, the at least one communication pipe may include a plurality of branch pipes, the plurality of branch pipes being respectively connected to a plurality of connection openings provided in a wall portion of the elevation guide chamber at a plurality of different positions with respect to a vertical direction, each of the plurality of branch pipes is provided with a valve configured to open and close a channel, the three-dimensional modeling apparatus further comprises: an opening/closing control unit configured to open and close the valves in accordance with an elevation level of the elevation stage, and the opening/closing control unit controls the valves so as to close the channels of the branch pipes connected to the connection openings provided in a space above the elevation stage in the elevation guide chamber.

The opening/closing controller may control the channel adjusting units provided on the plurality of branch pipes such that when two or more branch pipes are opened to the space below the elevation stage in the elevation guide chamber, the channels of a predetermined number of branch pipes positioned relatively above among the two or more branch pipes may be opened, and the channels of the other branch pipes among the two or more branch pipes may be closed.

The three-dimensional modeling apparatus may include an elastic member provided below the elevation stage in the elevation guide chamber. The elastic member may be contracted and expanded in accordance with the elevation level of the elevation stage. The elastic member may include a hollow portion formed therein, a first open communication portion that communicates between the hollow portion and the elevation guide chamber, and a second open communication portion that communicates between the hollow portion and the communication pipe.

The three-dimensional modeling apparatus may further include an elastic member provided below the elevation stage in the elevation guide chamber. The elastic member may be attached to the elevation stage. The elastic member may be contracted and expanded in accordance with the elevation level of the elevation stage. The elastic member may include a hollow portion formed therein, a first open communication portion that communicates between the hollow portion and the elevation guide chamber, and a second open communication portion that communicates between the hollow portion and the communication aperture.

The three-dimensional modeling apparatus may further include a first gas supply unit configured to supply an inert gas to the process chamber, and a second gas supply unit configured to supply the inert gas to the elevation guide chamber.

The second gas supply unit may supply an inert gas to the elevation guide chamber provided in one end of the plurality of elevation guide chambers arranged adjacent to each other, and the communication pipe may communicate between the elevation guide chamber provided in the other end of the plurality of elevation guide chambers arranged adjacent to each other and the process chamber.

The communication pipe may be provided to the elevation guide chamber positioned off the line extending from the second gas supply unit in the direction of the blow of the inert gas from the second gas supply unit.

The second gas supply unit may be provided on the wall portion that forms the elevation guide chamber provided in one end. The communication pipe may be provided on the wall portion that forms the elevation guide chamber provided in the other end. The wall portion on which the second gas supply unit is formed and the wall portion on which the communication pipe is formed may not be in parallel with each other.

Any two elevation guide chambers arranged adjacent to each other may communicate with each other via a communication hole. The communication hole may be positioned off the line connecting the second gas supply unit with an opening of the communication pipe opened to the elevation guide chamber.

The cross-sectional area of the opening of the communication pipe opened to the elevation guide chamber may be larger than that of the gas supply aperture of the second gas supply unit.

Another aspect of the present invention relates to a three-dimensional modeling apparatus for modeling a three-dimensional object by lamination modeling in an air-tight process chamber, the three-dimensional modeling apparatus comprising: an elevation guide chamber provided adjacent to the process chamber; an elevation stage provided so as to be capable of being raised and lowered in the elevation guide chamber; an inert gas supply opening for supplying an inert gas to a space below the elevation stage in the elevation guide chamber, and a gas discharge opening for discharging gases in the space below the elevation stage in the elevation guide chamber.

The inert gas supply opening and the gas discharge opening may be opened to a space below a movement range of the elevation stage in the elevation guide chamber.

The elevation stage may serve for modeling conducted thereon.

The inert gas supply opening and the gas discharge opening may be positioned at different levels with respect to the vertical direction.

The three-dimensional modeling apparatus may comprise a plurality of elevation units each including the elevation guide chamber and the elevation stage, the inert gas supply opening and the gas discharge opening may be opened to at least one of the elevation guide chambers of the plurality of elevation units, and the plurality of elevation guide chambers may be arranged adjacent to each other, and any two elevation guide chambers arranged adjacent to each other may communicate with each other via a communication hole.

The inert gas supply opening may be opened to the elevation guide chamber provided in one end of the plurality of elevation guide chambers arranged adjacent to each other, and the gas discharge opening may be opened to the elevation guide chamber provided in the other end of the plurality of elevation guide chambers arranged adjacent to each other.

The inert gas supply opening may be opened to the space below the movement range of the elevation stage in the elevation guide chamber provided in one end, and the gas discharge opening may be opened to the space below the movement range of the elevation stage in the elevation guide chamber provided in the other end.

The inert gas supply opening may be provided in the wall portion that forms the elevation guide chamber provided in one end. The gas discharge opening may be provided in the wall portion that forms the elevation guide chamber provided in the other end. The wall portion in which the inert gas supply opening is formed and the wall portion in which the gas discharge opening is formed may not be in parallel with each other.

The three-dimensional modeling apparatus may further include a drive chamber containing an elevation drive unit configured to raise and lower the elevation stage, wherein the drive chamber may communicate with the elevation guide chamber via a communication aperture, and the inert gas supply opening may be opened to the elevation guide chamber, and the gas discharge opening may be opened to the drive chamber.

The three-dimensional modeling apparatus may comprise a plurality of elevation units each including the elevation guide chamber and the elevation stage, the elevation guide chambers of the plurality of elevation units may be arranged adjacent to each other, and any two elevation guide chambers arranged adjacent to each other may communicate with each other via a communication hole. The drive chamber may communicate with at least one of the plurality of elevation guide chambers via a communication hole, and the inert gas supply opening may be opened to at least one of the plurality of elevation guide chambers.

The wall portion of the elevation guide chamber in which the inert gas supply opening is formed and the wall portion of the drive chamber in which the gas discharge opening is formed may be in parallel with each other.

The plurality of elevation guide chambers may include a first elevation guide chamber, a second elevation guide chamber, and a third elevation guide chamber arranged between the first elevation guide chamber and the second elevation guide chamber. The first elevation guide chamber and the third elevation guide chamber may communicate with each other via a communication hole. The second elevation guide chamber and the third elevation guide chamber may communicate with each other via a communication hole. The inert gas supply opening may be opened to the second elevation guide chamber. The cross-sectional area of the communication hole that communicates between the first elevation guide chamber and the third elevation guide chamber may be larger than that of the communication hole that communicates between the second elevation guide chamber and the third elevation guide chamber.

The three-dimensional modeling apparatus may further comprise a drive chamber containing an elevation drive unit configured to raise and lower the elevation stage, wherein the inert gas supply opening may be opened to the drive chamber, the gas discharge opening may be opened to the elevation guide chamber, and the drive chamber and the elevation guide chamber may communicate with each other.

The inert gas supply opening may be provided to the elevation guide chamber positioned off the line extending from the gas discharge opening in the direction of opening of the gas discharge opening.

The communication holes may include a communication hole positioned off the line connecting the inert gas supply opening with the gas discharge opening.

The gas discharge opening may be connected to a gas collection unit configured to collect the gases, the gas collection unit serving as a recycling unit configured to recycle the inert gas.

According to an aspect of the present invention, the gas channel having at least a part thereof formed of the communication pipe may communicate between the process chamber on which a gas discharge unit is provided and the space below the elevation stage in the elevation guide chamber. Thus, it may be possible to guide the oxygen gas accumulating in the three-dimensional modeling apparatus (particularly in the space below the elevation stage) to the process chamber via the communication pipe and discharge the oxygen gas out of the three-dimensional modeling apparatus via the gas discharge unit, effectively preventing oxidation of the material of the three-dimensional object during modeling.

According to another aspect of the present invention, the inert gas may be supplied to the space below the elevation stage in the elevation guide chamber via the inert gas supply opening, and the gas containing oxygen may be discharged from the space via the gas discharge opening. Thus, it may be possible to discharge the oxygen gas accumulating in the three-dimensional modeling apparatus (particularly in the elevation guide chamber) out of the three-dimensional modeling apparatus, effectively preventing oxidation of the material of the three-dimensional object during modeling.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Embodiments of the present invention will now be described with reference to the attached drawings. In the attached drawings, some dimensions and aspect ratios are conveniently altered from actual values for emphasis. The terms and values used herein to specify a shape, a geometric condition, and an extent thereof are not bound to a strict meaning thereof but should be interpreted as covering a range achieving the same functionality. In addition, the terms “above” and “below” used herein are based on the vertical direction according to the direction of gravity.

First Embodiment

FIG. 1shows a three-dimensional modeling apparatus10according to a first mode.FIGS. 2A and 2Bshow the three-dimensional modeling apparatus10ofFIG. 1as viewed from a side thereof (see the arrow S inFIG. 1).FIG. 2Aincludes an example of a communication pipe24, andFIG. 2Bincludes another example of the communication pipe24. InFIG. 1, a process chamber12and elevation units16are schematically illustrated with the interior thereof as viewed from a side, so as to facilitate comprehension. Further, inFIG. 1, the communication pipe24shown with a dotted line may be provided outside the process chamber12and the elevation units16(seeFIG. 2AandFIG. 2B).

The three-dimensional modeling apparatus10according to this mode may conduct lamination modeling of a three-dimensional object5by sintering (solidifying) a powder material1such as titanium in the air-tight process chamber12, and may include the process chamber12, a plurality of elevation units16(three elevation units16in this mode) provided below the process chamber12, and a drive chamber32provided below the elevation units16. The powder material1may be a metal powder made of titanium, iron, stainless steel, aluminum, steel, or other alloys, a synthetic powder such as polyamide or polystyrene, polyether ether ketone (PEEK), synthetic coating sand, or a ceramic powder.

Each of the elevation units16may include an elevation guide chamber14provided adjacent to the process chamber12and an elevation stage15provided so as to be capable of being raised and lowered in the elevation guide chamber14. Each elevation stage15may be raised and lowered so as to slide on the surfaces of side walls that define the associated elevation guide chamber14. In each elevation guide chamber14, there may be provided a sealing member (not shown) between the surfaces of the side walls of the elevation guide chamber14and the associated elevation stage15, and the sealing member may block a gap therebetween. The sealing member may block the powder material1such that the powder material1may not pass the gap between the elevation guide chamber14and the elevation stage15. The sealing member may preferably prevent a gas such as oxygen from passing the gap between the elevation guide chamber14and the elevation stage15but may not necessarily provide strict air-tightness. Thus, each of the elevations guide chambers14may be partitioned by the associated elevation stage15into a space above the elevation stage15and a space below the elevation stage15.

The three elevation units16may be constituted by a dispenser unit, a collection unit, and a building unit provided between the dispenser unit and the collection unit. The dispenser unit may include a dispenser elevation guide chamber141(a first elevation guide chamber) and a dispenser elevation stage151, the building unit may include a building elevation guide chamber143(a third elevation guide chamber) and a building elevation stage153, and the collection unit may include a collection elevation guide chamber142(a second elevation guide chamber) and a collection elevation stage152.FIG. 1shows the dispenser unit, the building unit, and the collection unit arranged in this order from right to left. There may be provided partition walls28between the dispenser elevation guide chamber141and the building elevation guide chamber143and between the collection elevation guide chamber142and the building elevation guide chamber143. The dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142may be arranged adjacent to each other with the partition walls28therebetween.

Each of the elevation stages15(the dispenser elevation stage151, the collection elevation stage152, and the building elevation stage153) may be provided with an elevation drive unit18configured to raise and lower the elevation stages15. The elevation drive unit18may raise and lower the associated elevation stage15under the control by a controller36. The dispenser elevation stage151, the collection elevation stage152, and the building elevation stage153may be raised and lowered in association with each other.

The dispenser unit (the dispenser elevation guide chamber141and the dispenser elevation stage151) may provide a space for retaining the powder material1, and the powder material1used for modeling the three-dimensional object5may be placed on the dispenser elevation stage151. The building unit (the building elevation guide chamber143and the building elevation stage153) may conduct modeling of the three-dimensional object5, in which the powder material1placed on the building elevation stage153may be sintered with a laser beam emitted from an emission unit30to form the three-dimensional object5. The collection unit (the collection elevation guide chamber142and the collection elevation stage152) may provide a space for collecting an excess portion of the powder material1supplied to the building elevation guide chamber143, and the excess portion of the powder material1may be accumulated on the collection elevation stage152.

The process chamber12may contain an application unit26that can reciprocate horizontally above the dispenser elevation stage151, the building elevation stage153, and the collection elevation stage152. When the application unit26moves horizontally, the powder material1may be supplied from the dispenser elevation guide chamber141into the building elevation guide chamber143, and the excess portion of the powder material1may be pressed from above the building elevation guide chamber143into the collection elevation guide chamber142. More specifically, the first step to supply a required amount of powder material1into the building elevation guide chamber143may be to raise the dispenser elevation stage151, lower the building elevation stage153, and lower the collection elevation stage152. Then, the application unit26disposed above the dispenser elevation stage151may move horizontally to above the building elevation guide chamber143and the collection elevation guide chamber142. Thus, the topmost portion of the powder material1on the dispenser elevation stage151may be pressed toward the building elevation guide chamber143, and further powder material1may be supplied into the building elevation guide143. The excess portion of the powder material1that is not contained in the building elevation guide chamber143may be pressed toward the collection elevation guide chamber142and collected.

Thus, the operation of the application unit26and the elevation stages15(the dispenser elevation stage151, the collection elevation stage152, and the building elevation stage153) may be performed in cooperation with each other under the control by the controller36, such that an adequate amount of powder material1can be supplied into the building elevation stage153to form layers. The distances by which the dispenser elevation stage151is raised, the building elevation stage153is lowered, and the collection elevation stage152is lowered may preferably be set such that a slightly larger amount of powder material1than is required to be supplied to above the building elevation stage153is supplied from the dispenser elevation guide chamber141to above the building elevation stage153and the excess portion of the powder material1that is not contained in the building elevation guide chamber143is contained in the collection elevation guide chamber142. In addition, the distance by which the building elevation stage153is lowered may be set in accordance with the thickness of the layer of the powder material1to be sintered by application of a laser beam. By way of an example, it may be possible to lower the collection elevation stage152and the building elevation stage153by 0.1 mm and raise the dispenser elevation stage151by 0.2 mm for one stroke.

The process chamber12may also contain a gas supply unit20, a gas discharge unit22, an emission unit30, and an oxygen sensor34, in addition to the application unit26.

The gas supply unit20in this mode may include a first gas supply unit201,202for supplying an inert gas such as argon or nitrogen (particularly argon in this mode) to the process chamber12. In the example shown inFIG. 1, the first gas supply unit201,202may include a first blow unit201provided above the building unit (the building elevation guide chamber143and the building elevation stage153) and a second blow unit202provided between the building unit and the first blow unit201(that is, below the first blow unit201). The first blow unit201and the second blow unit202may blow an inert gas into the space above the building unit so as not to substantially impact the powder material1placed on the building elevation stage153and the three-dimensional object5. The specific configuration and the position of the gas supply unit20are not particularly limited but may be set such that an inert gas can be supplied to at least one of the process chamber12and the elevation guide chambers14.

The gas discharge unit22may communicate with the process chamber12and may be configured to discharge gases from the process chamber12out of the three-dimensional modeling apparatus10.

The emission unit30according to this mode may emit a laser beam onto the powder material1on an elevation stage15(the building elevation stage153in this example) to solidify the powder material1(sinter the powder material1in this example). In the example shown inFIG. 1, the emission unit30may be installed in the process chamber12above the building unit (the building elevation guide chamber143and the building elevation stage153). However, the position to install the emission unit30may not be particularly limited. The emission unit30may be installed in other positions within the process chamber12or installed outside the process chamber12, as long as it can appropriately emit a laser beam onto the powder material1on the building elevation stage153.

The oxygen sensor34may be installed in the process chamber12and may be configured to sense the oxygen density. The position to install the oxygen sensor34, which may not be particularly limited, may preferably be set based on the relationship between the specific weights of the inert gas supplied from the gas supply unit20and oxygen. For example, if the specific weight of oxygen is smaller than that of the inert gas, the oxygen sensor34may preferably be installed in a relatively high position within the process chamber12, and if the specific weight of oxygen is larger than that of the inert gas, the oxygen sensor34may preferably be installed in a relatively low position within the process chamber12. The position to install the oxygen sensor34may preferably be set such that the communication pipe24(described later) may be opened to (communicate with) the process chamber12at a position closer to the oxygen sensor34than to the position where the gas supply unit20(the first blow unit201and the second blow unit202in this example) supplies an inert gas in the process chamber12.

The communication pipe24may form at least a part of a gas channel C communicating between the process chamber12and the spaces in the elevation guide chambers14below the elevation stages15. The communication pipe24in this mode may connect to the process chamber12and the elevation guide chambers14(particularly the building elevation guide chamber143), communicate with the process chamber12via a process chamber opening24a, and communicate with the building elevation guide chamber143via an elevation chamber opening24b.

The shape of the gas channel C formed by the communication pipe24may not be particularly limited. For example, the cross section of the gas channel C formed by the communication pipe24may have a circular shape or a non-circular shape such as rectangular or polygonal shapes. As shown inFIG. 2A, the communication pipe24may include a channel bent at right angles without continuous change of curvature of the gas channel C, or as shown inFIG. 2B, the communication pipe24may include a curved channel in which the curvature of the gas channel C changes continuously or is constant. It may also be possible that the communication pipe24includes both “a channel without continuous change of curvature of the gas channel C” and “a curved channel.” When the communication pipe24includes a curved channel, the pressure loss may be reduced, and the gas (the inert gas, oxygen, etc.) can flow smoothly through the gas channel C formed by the communication pipe24. Also, the substance of the communication pipe24may not be particularly limited Typically, the communication pipe24may be formed of a stainless steel (SUS) but may be formed of other metals or resins. In the examples shown inFIGS. 1, 2A, and 2B, the communication pipe24may be mounted on a wall portion (for example, a back wall portion) on which the gas supply unit20(the first blow unit201and the second blow unit202) is installed. However, the position to mount the communication pipe24may not be particularly limited, and the communication pipe24may be mounted on other wall portions of the three-dimensional modeling apparatus10. Further, as shown inFIGS. 2A and 2B, the communication pipe24in this example may extend outside the wall portion of the three-dimensional modeling apparatus10, but may alternatively extend in the wall portion of the three-dimensional modeling apparatus10.

The positions at which the communication pipe24may be connected and opened to the process chamber12and the elevation guide chambers14may not be particularly limited, but the communication pipe24may preferably be connected and opened to the process chamber12near the oxygen sensor34. With this arrangement, the oxygen sensor34can appropriately sense the density of the oxygen gas flowing from the communication pipe24into the process chamber12. Also, the communication pipe24may preferably be connected and opened to the building elevation guide chamber143(the elevation guide chambers14) below a movement range R of the building elevation stage153(the elevation stages15). With this arrangement, the communication pipe24may communicate between the process chamber12and the space below the movement range R of the building elevation stage153in the building elevation guide chamber143.

The drive chamber32may contain at least a part of the elevation drive units18. For example, when an elevation drive unit18includes a projecting portion having one end thereof fixed to an associated elevation stage15(the dispenser elevation stage151, the collection elevation stage152, or the building elevation stage153) and capable of projecting by a varied distance, and a motor (for example, a stepping motor) for driving the projecting portion, the drive chamber32may contain the motor and a part of the other end of the projecting portion.

The controller36may be installed above the process chamber12. The controller36may control the units in the three-dimensional modeling apparatus10. For example, the controller36may control the elevation drive units18to raise or lower the elevation stages15, control the horizontal movement of the application unit26, control the laser beam emission of the emission unit30, and control supply of the inert gas from the gas supply unit20. In particular, the controller36in this mode may receive the sensing values from the oxygen sensor34and, when the oxygen sensor34senses an oxygen density higher than a threshold value, the controller36may stop the elevation operation of the elevation stages15, the horizontal movement of the application unit26, and the laser beam emission from the emission unit30, suspend modeling of the three-dimensional object5, and issue an error message to an operator visually or audibly.

As described above, in this mode, the communication pipe24may communicate between the process chamber12and the space below the building elevation stage153in the building elevation guide chamber143. Thus, the gas (which may be oxygen in particular but may also be nitrogen that should be discharged in an argon gas environment) accumulated in the space below the building elevation stage153can be efficiently guided to the process chamber12through the communication pipe24and discharged out of the process chamber12through the gas discharge unit22. Accordingly, the gas in the three-dimensional modeling apparatus10(particularly the space below the building elevation stage153in the building elevation guide chamber143) can be efficiently replaced with the inert gas, thereby to prevent the oxygen gas from accumulating in the space below the building elevation stage153.

Thus, the oxygen sensor34may no longer or seldom sense an oxygen density higher than a threshold value, and therefore, even in the case where modeling should be suspended when the oxygen sensor34senses an oxygen density higher than a threshold value, modeling may be no longer or seldom suspended unexpectedly.

Further, in this mode, the gas in the space below the building elevation stage153in the building elevation guide chamber143may be guided to the process chamber12through the communication pipe24. Accordingly, the oxygen density in the space below the building elevation stage153can be observed indirectly by the oxygen sensor34provided in the process chamber12, and therefore, there is no need of providing an oxygen sensor in the space below the building elevation stage153in the building elevation guide chamber143.

In this mode, the opening of the communication pipe24(the elevation chamber opening24b) may be provided below the movement range R of the building elevation stage153. Therefore, the oxygen gas accumulating in the building elevation guide chamber143(particularly the space below the building elevation stage153) can be efficiently discharged without narrowing the movement range R of the building elevation stage153.

When the gas channel C of the communication pipe24has a curved channel, the gas can flow smoothly in the gas channel C, and the oxygen gas accumulating in the space below the building elevation stage153in the building elevation guide chamber143can be discharged efficiently. In addition to oxygen, nitrogen included in the remaining air can also be discharged in the same manner. This may also apply to other modes described below.

FIG. 3shows a three-dimensional modeling apparatus10according to a second mode.FIG. 4shows the three-dimensional modeling apparatus10ofFIG. 3as viewed from a side thereof (see the arrow S inFIG. 3).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The communication pipe24in this mode may connect to the process chamber12and the drive chamber32, and communicate with the process chamber12via the process chamber opening24aand communicate with the drive chamber32via a drive chamber opening24c. The wall portion that may partition the elevation guide chambers14(the building elevation guide chamber143in this example) from the drive chamber32may include a plurality of communication apertures38, and the drive chamber32may communicate with the elevation guide chambers14(the building elevation guide chamber143) via these communication apertures38. The communication apertures38may preferably be provided in such positions as to communicate between the drive chamber32and the space below the movement range R of the associated elevation stages15(the building elevation stage153) in the elevation guide chambers14(the building elevation guide chamber143).

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

The gas channel C that may communicate the process chamber12and the building elevation guide chamber143(particularly the space below the building elevation stage153) may be constituted by the communication pipe24(including the process chamber opening24aand the elevation chamber opening24b), the drive chamber32, and the communication apertures38. Accordingly, the oxygen gas accumulating in the space below the building elevation stage153in the building elevation guide chamber143can be guided to the process chamber12through the gas channel C and discharged out of the three-dimensional modeling apparatus10through the gas discharge unit22.

In this mode, in addition to the oxygen gas accumulating in the elevation guide chambers14(the building elevation guide chamber143), the oxygen gas accumulating in the drive chamber32can be guided to the process chamber12and discharged out of the three-dimensional modeling apparatus10through the gas discharge unit22. Thus, it may be possible to discharge the oxygen gas from the three-dimensional modeling apparatus10more securely and fill the three-dimensional modeling apparatus10with the inert gas.

It may also be possible that only one communication aperture38be provided. When a plurality of communication apertures38are provided, these communication apertures38may have either the same or different opening areas (channel areas).

FIG. 5shows a three-dimensional modeling apparatus10according to a third mode.FIG. 6shows the three-dimensional modeling apparatus10ofFIG. 5as viewed from a side thereof (see the arrow S inFIG. 5).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The communication pipe24in this mode may communicate between the process chamber12and the elevation guide chambers14(the building elevation guide chamber143in this example) and further communicate between the process chamber12and the drive chamber32. More specifically, the communication pipe24in this mode may be connected and opened to each of the process chamber12, the elevation guide chambers14(the building elevation guide chamber143), and the drive chamber32. Therefore, the communication pipe24may include a process chamber communication channel C1that communicates with the process chamber12via the process chamber opening24a, an elevation guide chamber communication channel C2that branches from the process chamber communication channel C1and communicates with the elevation guide chambers14(the building elevation guide chamber143) via the elevation chamber opening24b, and a drive chamber communication channel C3that branches from the process chamber communication channel C1and communicates with the drive chamber32via the drive chamber opening24c.

The cross-sectional areas (the channel areas) of the process chamber communication channel C1, the elevation guide chamber communication channel C2, and the drive chamber communication channel C3may not be particularly limited. For example, when the cross-sectional area of the drive chamber communication channel C3is larger than that of the elevation guide chamber communication channel C2, the gases may flow in or out through the drive chamber communication channel C3more smoothly than through the elevation guide chamber communication channel C2, and therefore, it may be possible to efficiently facilitate inflow of the inert gas into the drive chamber32and discharge of the oxygen gas from the drive chamber32. When the cross-sectional area of the drive chamber communication channel C3is smaller than that of the process chamber communication channel C1, the gases may flow in or out through the process chamber communication channel C1more smoothly than through the drive chamber communication channel C3, and therefore, it may be possible to efficiently facilitate inflow of the inert gas into the elevation guide chambers14(the building elevation guide chamber143) and the drive chamber32and discharge of the oxygen gas from the elevation guide chambers14(the building elevation guide chamber143) and the drive chamber32. Further, when the cross-sectional areas of the channels are smaller in the order of the process chamber communication channel C1, the drive chamber communication channel C3, and the elevation guide chamber communication channel C2(that is, the sectional area of the process chamber communication channel C1>the sectional area of the drive chamber communication channel C3>the sectional area of the elevation guide chamber communication channel C2), it may be possible to maintain a good balance between the inflow of the inert gas from the process chamber12into the building elevation guide chamber143and the drive chamber32, and the outflow of the oxygen gas from the building elevation guide chamber143and the drive chamber32to the process chamber12. With this arrangement, the oxygen gas discharged from the drive chamber32may be prevented from flowing into the building elevation guide chamber143and may be delivered to the process chamber12.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, it may be possible to prevent the oxygen gas from accumulating in any of the elevation guide chambers14(the building elevation guide chamber143) and the drive chamber32, so as to discharge the oxygen gas from the three-dimensional modeling apparatus10more securely and fill the three-dimensional modeling apparatus10with the inert gas.

FIG. 7shows a three-dimensional modeling apparatus10according to a fourth mode.FIG. 8shows the three-dimensional modeling apparatus10ofFIG. 7as viewed from a side thereof (see the arrow S inFIG. 7).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the wall portion that may partition the elevation guide chambers14(the building elevation guide chamber143in this example) from the drive chamber32may include a plurality of communication apertures38, and the drive chamber32may communicate with the elevation guide chambers14(particularly the space below the building elevation stage153in the building elevation guide chamber143) via these communication apertures38.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, the communication apertures38may communicate between the drive chamber32and the elevation guide chambers14(the building elevation guide chamber143). Therefore, it may be possible to prevent the oxygen gas from accumulating in any of the elevation guide chambers14(the building elevation guide chamber143) and the drive chamber32more securely, so as to fill the three-dimensional modeling apparatus10with the inert gas.

In particular, when an inert gas having a larger specific weight than oxygen, such as argon, is used, the inert gas can efficiently flow into the drive chamber32via the communication apertures38. The plurality of communication apertures38may be divided into communication apertures38that communicate primarily the gas flowing from the building elevation guide chamber143to the drive chamber32and communication apertures38that communicate primarily the gas flowing from the drive chamber32to the building elevation guide chamber143, so as to efficiently discharge the oxygen gas and fill the inert gas.

FIG. 9shows a three-dimensional modeling apparatus10according to a fifth mode.FIG. 10shows the three-dimensional modeling apparatus10ofFIG. 9as viewed from a side thereof (see the arrow S inFIG. 9).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, a plurality of communication pipes (a first communication pipe24A, a second communication pipe24B, and a third communication pipe24C) may be provided. These communication pipes24A,24B, and24C may communicate between each of the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) and the process chamber12. More specifically, the first communication pipe24A may connect to the process chamber12and the dispenser elevation guide chamber141, and may communicate between the process chamber12and the dispenser elevation guide chamber141via the process chamber opening24aand the elevation chamber opening24b. The second communication pipe24B may connect to the process chamber12and the collection elevation guide chamber142, and may communicate between the process chamber12and the collection elevation guide chamber142via the process chamber opening24aand the elevation chamber opening24b. The third communication pipe24C may connect to the process chamber12and the building elevation guide chamber143, and may communicate between the process chamber12and the building elevation guide chamber143via the process chamber opening24aand the elevation chamber opening24b.

The positions of the process chamber openings24aand the elevation chamber openings24bfor the communication pipes24A,24B, and24C may not be particularly limited. As in the first mode described above, the process chamber openings24afor the communication pipes24A,24B, and24C may preferably be positioned closer to the oxygen sensor34than to the position where the gas supply unit20(the first blow unit201and the second blow unit202) supplies an inert gas in the process chamber12. The elevation chamber openings24bfor the communication pipes24A,24B, and24C may preferably be positioned below the movement range R of the associated one of the elevation stages15(the dispenser elevation stage151, the collection elevation stage152, and the building elevation stage153).

The plurality of communication pipes24A,24B, and24C in this mode may communicate with the process chamber12through the same wall portion among the plurality of wall portions constituting the process chamber12, and may communicate with the associated one of the elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) through the wall portions on the same side among the plurality of wall portions constituting the elevation guide chambers14.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, the oxygen gas accumulating in the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) can be efficiently discharged via the plurality of communication pipes24A,24B, and24C, the process chamber12, and the gas discharge unit22.

FIG. 11shows a three-dimensional modeling apparatus10according to a sixth mode.FIG. 12shows the three-dimensional modeling apparatus10ofFIG. 11as viewed from a side thereof (see the arrow S inFIG. 11).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the fifth mode described above (seeFIGS. 9 and 10) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, a plurality of communication apertures38may be provided to communicate between each of the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) and the drive chamber32. Each of the elevation guide chambers14may be provided with two communication apertures38, and thus six communication apertures may be provided in total.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the fifth mode described above.

In this mode, the oxygen gas accumulating in the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) can be discharged, and in addition, the oxygen gas accumulating in the drive chamber32can also be efficiently discharged via the communication apertures38, the elevation guide chambers14, the communication pipes24, the process chamber12, and the gas discharge unit22.

The communication apertures38may not necessarily communicate between all of the plurality of elevation guide chambers14and the drive chamber32but may be configured only to communicate between at least one of the plurality of elevation guide chambers14and the drive chamber32.

FIG. 13shows a three-dimensional modeling apparatus10according to a seventh mode.FIG. 14shows the three-dimensional modeling apparatus10ofFIG. 13as viewed from a side thereof (see the arrow S inFIG. 13).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, a plurality of communication pipes (two communication pipes in this example) including a first communication pipe24A and a second communication pipe24B may be provided. The first communication pipe24A and the second communication pipe24B may connect to the process chamber12via the process chamber openings24aand may also connect to the same elevation guide chamber14(the building elevation guide chamber143in this example) via the elevation chamber openings24b.

The position where the first communication pipe24A is opened to the building elevation guide chamber143(that is, the position of the elevation chamber opening24bfor the first communication pipe24A) may be above the position where the second communication pipe24B is opened to the building elevation guide chamber143(that is, the position of the elevation chamber opening24bfor the second communication pipe24B). The elevation chamber openings24bfor the first communication pipe24A and the second communication pipe24B may be positioned below the movement range R of the associated one of the elevation stages15(the building elevation stage153in this example). The position where the first communication pipe24A is opened to the process chamber12(that is, the position of the process chamber opening24afor the first communication pipe24A) may be above the position where the second communication pipe24B is opened to the process chamber12(that is, the position of the process chamber opening24afor the second communication pipe24B).

The process chamber opening24afor the first communication pipe24A may be opened to the process chamber12at a position closer to the oxygen sensor34than to the position where the gas supply unit20(the first blow unit201and the second blow unit202) supplies an inert gas in the process chamber12.

The cross-sectional areas of the channels in the first communication pipe24A and the second communication pipe24B may not be particularly limited. The cross-sectional area of the channel in the first communication pipe24A may be either larger or smaller than that of the channel in the second communication pipe24B. When the cross-sectional area of the channel in the first communication pipe24A is larger than that of the channel in the second communication pipe24B, the oxygen gas accumulating in the building elevation guide chamber143can be efficiently guided to the process chamber12via the first communication pipe24A, with the inert gas such as argon having a larger specific weight than oxygen. Conversely, when the cross-sectional area of the channel in the first communication pipe24A is smaller than that of the channel in the second communication pipe24B, the inert gas can be efficiently guided to the building elevation guide chamber143via the second communication pipe24B, with the inert gas such as nitrogen having a smaller specific weight than oxygen. As a result, the oxygen gas accumulating in the building elevation guide chamber143can be efficiently forced into the process chamber12.

Further, at least one of the first communication pipe24A and the second communication pipe24B may be provided with a channel adjusting unit40that can adjust the degree of opening of the channel (the channel area). As the channel adjusting unit40adjusts the channel area, the conditions for passing the gas through the first communication pipe24A and the second communication pipe24B can be altered flexibly, thereby to discharge the oxygen gas from the three-dimensional modeling apparatus10more efficiently.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, the oxygen gas accumulating in the elevation guide chambers14(the building elevation guide chamber143) can be efficiently discharged via the plurality of communication pipes (the first communication pipe24A and the second communication pipe24B). As in this mode, use of the plurality of communication pipes24A,24B, each having a small channel area, may provide a large channel area of the communication pipes in total. Further, use of the plurality of communication pipes24A,24B may increase the freedom in arrangement of the communication pipes, making it possible to discharge the oxygen gas from the building elevation guide chamber143efficiently and fill the building elevation guide chamber143with the inert gas.

The first communication pipe24A and the second communication pipe24B may be opened to the building elevation guide chamber143and the process chamber12at different positions, such that one of the first communication pipe24A and the second communication pipe24B may serve mainly as a supply line of the inert gas and the other may serve mainly as a discharge line of the oxygen gas, making it possible to efficiently discharge the oxygen gas and supply the inert gas.

Of the plurality of communication pipes24A,24B, the one positioned higher (the first communication pipe24A in this example) may have a channel area larger than that of the other positioned lower (the second communication pipe24B in this example), such that the oxygen gas can be discharged efficiently with the inert gas such as argon.

The plurality of communication pipes24A,24B may be provided on the same wall portion, such that these communication pipes24A,24B can be readily maintained.

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1, 2A, and 2B) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The communication pipe24in this mode may communicate between at least one of the plurality of elevation guide chambers14(one elevation guide chamber14(the dispenser elevation guide chamber141) in this example) and the process chamber12. Each of the partition walls28may have a communication hole42formed therein, and any two elevation guide chambers14arranged adjacent to each other (in this example, the dispenser elevation guide chamber141and the building elevation guide chamber143, or the collection elevation guide chamber142and the building elevation guide chamber143) may communicate with each other via the communication hole42.

Each of the communication holes42may be positioned below the movement ranges R of the elevation stages15to be raised and lowered in the elevation guide chambers14partitioned with the partition wall including the communication hole42(that is, the elevation guide chambers14adjacent to each other). The communication hole42provided between the dispenser elevation guide chamber141and the building elevation guide chamber143may be positioned below the movement ranges R of the dispenser elevation stage151and the building elevation stage153. The communication hole42provided between the collection elevation guide chamber142and the building elevation guide chamber143may be positioned below the movement ranges R of the collection elevation stage152and the building elevation stage153. In this mode, the communication hole42provided between the dispenser elevation guide chamber141and the building elevation guide chamber143and the communication hole42provided between the collection elevation guide chamber142and the building elevation guide chamber143may have the same opening cross-sectional area (channel area).

Each of the partition walls28between the dispenser elevation guide chamber141and the building elevation guide chamber143and between the collection elevation guide chamber142and the building elevation guide chamber143may include a plurality of communication holes42. That is, a plurality of communication holes42may be provided between the dispenser elevation guide chamber141and the building elevation guide chamber143, and a plurality of communication holes42may be provided between the collection elevation guide chamber142and the building elevation guide chamber143.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142may communicate with each other via the communication holes42. Therefore, the inert gas supplied from the communication pipe24to the dispenser elevation guide chamber141may be delivered to the building elevation guide chamber143and the collection elevation guide chamber142via the communication holes42. The oxygen gas accumulating in the building elevation guide chamber143and the collection elevation guide chamber142can be moved to the dispenser elevation guide chamber141via the communication holes42and discharged via the communication pipe24, the process chamber12, and the gas discharge unit22.

Therefore, in this mode, it may be possible to efficiently discharge the oxygen gas accumulating in the plurality of elevation guide chambers14and fill the three-dimensional modeling apparatus10with the inert gas, while minimizing the space for installation of the communication pipe24.

In the example shown inFIG. 15, the communication pipe24may be connected to the dispenser elevation guide chamber141, which may be positioned in one end of the plurality of elevation guide chambers14arranged adjacent to each other. Alternatively, it may also be possible that the communication pipe24be connected to other elevation guide chambers14(the collection elevation guide chamber142and/or the building elevation guide chamber143).

FIG. 16shows a three-dimensional modeling apparatus10according to a ninth mode.

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the eighth mode described above (seeFIG. 15) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the first communication hole42A provided between the dispenser elevation guide chamber141and the building elevation guide chamber143and the second communication hole42B provided between the collection elevation guide chamber142and the building elevation guide chamber143may have different opening cross-sectional areas (channel areas). In particular, the opening cross-sectional area of the first communication hole42A that communicates between the elevation guide chamber14(the dispenser elevation guide chamber141in this example) to which the communication pipe24may be connected and the elevation guide chamber14(the building elevation guide chamber143in this example) to which the communication pipe24may not be connected may be larger than the opening cross-sectional area of the second communication hole42B that communicates between the elevation guide chambers14(the collection elevation guide chamber142and the building elevation guide chamber143) to which the communication pipe24may not be connected.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the eighth mode described above.

In this mode, the inert gas delivered to the dispenser elevation guide chamber141from the communication pipe24can be readily supplied to the building elevation guide chamber143, and the oxygen gas accumulating in the building elevation guide chamber143can be efficiently discharged to the dispenser elevation guide chamber141.

It may also be possible to provide a plurality of first communication holes42A and/or a plurality of second communication holes42B. That is, a plurality of first communication holes42A may be provided in the partition wall28between the dispenser elevation guide chamber141and the building elevation guide chamber143, and a plurality of second communication holes42B may be provided in the partition wall42B between the collection elevation guide chamber142and the building elevation guide chamber143. In this arrangement, it may be possible that the opening cross-sectional area of one of the first communication holes42A is not larger than the opening cross-sectional area of one of the second communication holes42B. The same effect as in this mode can be expected when the sum of the opening cross-sectional areas of the one or more first communication holes42A provided between the dispenser elevation guide chamber141and the building elevation guide chamber143is larger than the sum of the opening cross-sectional areas of the one or more second communication holes42B provided between the collection elevation guide chamber142and the building elevation guide chamber143. Accordingly, even when the opening cross-sectional area of one of the first communication holes42A is not larger than the opening cross-sectional area of one of the second communication holes42B, the number of the first communication holes42A may be larger than the number of the second communication holes42B such that the sum of the opening cross-sectional areas of the first communication holes42A is larger than the sum of the opening cross-sectional areas of the second communication holes42B.

Further, the relationship between the opening cross-sectional areas of the first communication pipe24A and the second communication pipe24B may not be limited to the above examples. For example, the sum of the opening cross-sectional areas of the one or more first communication pipes24A may be smaller than the sum of the opening cross-sectional areas of the one or more second communication pipes24B.

FIG. 17shows a three-dimensional modeling apparatus10according to a tenth mode.

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the eighth mode described above (seeFIG. 15) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, a plurality of communication apertures38may be provided to communicate between at least one of the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142) (all the elevation guide chambers14in this example) and the drive chamber32. That is, a communication aperture38may be provided in each of the wall portion partitioning the dispenser elevation guide chamber141from the drive chamber32, the wall portion partitioning the building elevation guide chamber143from the drive chamber32, and the wall portion partitioning the collection elevation guide chamber142from the drive chamber32.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the eighth mode described above.

In this mode, in addition to the oxygen gas accumulating in the elevation guide chambers14, the oxygen gas accumulating in the drive chamber32can be guided to the process chamber12and discharged out of the three-dimensional modeling apparatus10through the gas discharge unit22.

It may also be possible that only one communication aperture38be provided. When a plurality of communication apertures38are provided, these communication apertures38may have either the same or different opening areas (channel areas). Further, it may be possible that the cross-sectional area of the first communication hole42A is not necessarily the same as that of the second communication hole42B.

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the eighth mode described above (seeFIG. 15) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, a plurality of communication pipes (two communication pipes in this example) including a first communication pipe24A and a second communication pipe24B may be provided. The first communication pipe24A and the second communication pipe24B may communicate between at least one of the plurality of elevation guide chambers14(the dispenser elevation guide chamber141in this example) and the process chamber12. The first communication pipe24A and the second communication pipe24B may communicate with the process chamber12through the same wall portion among the plurality of wall portions constituting the process chamber12, and may communicate with the associated one of the elevation guide chambers14(the dispenser elevation guide chamber141in this example) through the same wall portion among the plurality of wall portions constituting the elevation guide chamber14(the dispenser elevation guide chamber141). The first communication pipe24A and the second communication pipe24B may be provided on the same wall portion, so as to reduce the space for installation.

The position where the first communication pipe24A is opened to the elevation guide chamber14(the dispenser elevation guide chamber141) (that is, the position of the elevation chamber opening24bfor the first communication pipe24A) may be above the position where the second communication pipe24B is opened to the elevation guide chamber14(the dispenser elevation guide chamber141) (that is, the position of the elevation chamber opening24bfor the second communication pipe24B). The position where the first communication pipe24A is opened to the process chamber12(that is, the position of the process chamber opening24afor the first communication pipe24A) may be above the position where the second communication pipe24B is opened to the process chamber12(that is, the position of the process chamber opening24afor the second communication pipe24B).

The process chamber opening24afor the first communication pipe24A may be opened to the process chamber12at a position closer to the oxygen sensor34than to the position where the gas supply unit20(the first blow unit201and the second blow unit202) supplies an inert gas in the process chamber12. In this example, the process chamber opening24afor the second communication pipe24B may also be opened to the process chamber12at a position closer to the oxygen sensor34than to the position where the gas supply unit20(the first blow unit201and the second blow unit202) supplies an inert gas in the process chamber12.

The cross-sectional areas of the channels (the channel areas) in the first communication pipe24A and the second communication pipe24B may not be particularly limited. The cross-sectional area of the channel in the first communication pipe24A may be the same as or larger or smaller than that of the channel in the second communication pipe24B. Further, at least one of the first communication pipe24A and the second communication pipe24B may be provided with a channel adjusting unit40that can adjust the degree of opening of the channel (the channel area). For example, the channel area of the first communication pipe24A may be larger than that of the second communication pipe24B such that the conduit resistance of the first communication pipe24A is smaller.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the eighth mode described above.

In this mode, the oxygen gas accumulating in the elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142) can be efficiently discharged via the first communication pipe24A and the second communication pipe24B.

It may be possible that the cross-sectional area of the first communication hole42A is not necessarily the same as that of the second communication hole42B. For example, the cross-sectional area of the second communication hole42B that communicates between the collection elevation guide chamber142(the second elevation guide chamber) and the building elevation guide chamber143(the third elevation guide chamber) may be larger than the cross-sectional area of the first communication hole42A that communicates between the dispenser elevation guide chamber141(the first elevation guide chamber) and the building elevation guide chamber143. In this arrangement, the inert gas supplied to the dispenser elevation guide chamber141via the first communication pipe24A and the second communication pipe24B can be efficiently delivered to the collection elevation guide chamber142, and the oxygen gas accumulating not only in the dispenser elevation guide chambers141but also the collection elevation guide chamber142and the building elevation guide chamber143can be efficiently discharged. The cross-sectional areas (the channel areas) of the first communication hole42A and the second communication hole42B may be larger than the channel areas of the first communication pipe24A and the second communication pipe24B. Thus, the cross-sectional areas of the first communication hole42A and the second communication hole42B may be large, such that the gases may flow in or out smoothly between the elevation guide chambers14and the oxygen gas accumulating in the elevation guide chambers14can be replaced with the inert gas smoothly.

The first communication pipe24A and the second communication pipe24B may not necessarily connect to the same elevation guide chamber14(the dispenser elevation guide chamber141in the above example) but may connect to different elevation guide chambers14. For example, as shown inFIG. 19, one of the first communication pipe24A and the second communication pipe24B (the first communication pipe24A in the example shown inFIG. 19) may connect to the dispenser elevation guide chamber141and the process chamber12, and the other (the second communication pipe24B in the example shown inFIG. 19) may connect to the collection elevation guide chamber142and the process chamber12. In this arrangement, the collection elevation guide chamber142provided in one end of the plurality of elevation guide chambers14arranged in an array, and the dispenser elevation guide chamber141provided in the other end may connect to the process chamber12, and the elevation guide chambers14arranged adjacent to each other may communicate with each other via the communication holes42. This arrangement may enable smooth inflow of the inert gas into the elevation guide chambers14and smooth discharge of the oxygen gas from the elevation guide chambers14.

The first communication pipe24A and the second communication pipe24B may communicate with the process chamber12through different wall portions among the plurality of wall portions constituting the process chamber12, and may communicate with the associated one of the elevation guide chambers14(the dispenser elevation guide chamber141in this example) through the different wall portions among the plurality of wall portions constituting the elevation guide chamber14.

FIG. 20shows a three-dimensional modeling apparatus10according to a twelfth mode.FIG. 21shows the three-dimensional modeling apparatus10ofFIG. 20as viewed from a side thereof (see the arrow S inFIG. 20).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the third mode described above (seeFIGS. 5 and 6) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The communication pipe24in this mode may also include a process chamber communication channel C1that communicates with the process chamber12via the process chamber opening24a, elevation guide chamber communication channels C2that branch from the process chamber communication channel C1and communicate with the elevation guide chambers14(the building elevation guide chamber143in this example) via the elevation chamber opening24b, and a drive chamber communication channel C3that branches from the process chamber communication channel C1and communicates with the drive chamber32via the drive chamber opening24c. In this mode, a plurality of elevation guide chamber communication channels C2may be provided along the elevation direction of the elevation stage15(the building elevation stage153) (that is, the vertical direction). More specifically, the communication pipe24may have a plurality of branch pipes24D, and the plurality of branch pipes24D may respectively connect to a plurality of elevation chamber openings24b(connection openings) disposed in the wall portion of the elevation guide chamber14(the building elevation guide chamber143) at different positions with respect to the vertical direction.

Each of the plurality of branch pipes24D may be provided with a channel adjusting unit40(a valve portion) that adjust the operation of opening/closing the associated elevation guide chamber communication channel C2. The channel adjusting units40may include any device such as an electromagnetic valve and can adjust the degree of opening of the associated channel (the channel area) either stepwise or steplessly. The channel adjusting units40may adjust the degree of opening of the associated channel at least between the closed state where the elevation guide chamber communication channel C2is completely closed to block the gas flow and the open state where the elevation guide chamber communication channel C2is opened to allow the gas flow.

FIG. 22is a block diagram showing an example of functionality of a controller36according to the twelfth mode. The controller36according to this mode may include an elevation controller50and an opening/closing controller52(an opening/closing control unit), and the elevation controller50may include an elevation level capturing unit51.

The elevation controller50may control the elevation drive units18to adjust the elevation of the elevation stages15(the dispenser elevation stage151, the collection elevation stage152, and the building elevation stage153). The elevation level capturing unit51may capture elevation data indicating the elevation levels of the elevation stages15. The opening/closing controller52may control the operation of opening/closing the channel adjusting units40provided on the plurality of branch pipes24D, based on the elevation data captured by the elevation level capturing unit51. In this mode, the operation of opening/closing the channel adjusting units40may be controlled based on the elevation level of the building elevation stage153.

More specifically, the opening/closing controller52may control the channel adjusting units40provided on the plurality of branch pipes24D so as to close the elevation guide chamber communication channels C2of the branch pipes24D that are connected to the elevation chamber openings24bprovided in the space above the building elevation stage153in the building elevation guide chamber143. For example, inFIGS. 20 and 21, when the building elevation stage153is at the uppermost level thereof, and all the branch pipes24D are opened to the space below the building elevation stage153in the building elevation guide chamber143, all the channel adjusting units40may be opened. Conversely, when the building elevation stage153is lowered and at least one of the plurality of branch pipes24D is opened to the space above the building elevation stage153in the building elevation guide chamber143, the channel adjusting units40may be closed such that the elevation guide chamber communication channels C2of the branch pipes24D opened to the space above the building elevation stage153are closed. At least part of the channel adjusting units40provided on the branch pipes24D that are opened to the space below the building elevation stage153in the building elevation guide chamber143may be opened, and the gases such as the inert gas and the oxygen gas can flow through the elevation guide chamber communication channels C2of the branch pipes24D associated with the opened channel adjusting units40.

FIG. 23is a flowchart showing an example of operation of opening/closing a channel adjusting unit40performed by the controller36according to the twelfth mode.

First, the elevation level capturing unit51may capture the data indicating the elevation level of the elevation stage15(the building elevation stage153in this example) with respect to the vertical direction (S11inFIG. 23). The elevation level capturing unit51may send to the opening/closing controller52the data indicating the elevation level of the elevation stage15(the building elevation stage153).

The opening/closing controller52may specify the branch pipes24D that will be opened to the space above the elevation stage15(the building elevation stage153) after the next operation of raising/lowering the elevation stage15(the building elevation stage153), based on the data sent from the elevation level capturing unit51(S12). Then, the opening/closing controller52may control and close the channel adjusting units40provided on and associated with the specified branch pipes24D, so as to close the elevation guide chamber communication channels C2of the branch pipes24D opened to the space above the elevation stage15(the building elevation stage153) (S13). The specific timing to close the elevation guide chamber communication channels C2of the branch pipes24D via the channel adjusting units40may be at least prior to the timing when the elevation chamber openings24bof the branch pipes24D are positioned above the elevation stage15(the building elevation stage153).

When the above sequential process is performed as the elevation stage15(the building elevation stage153) is lowered, the branch pipes24D opened to the space above the elevation stage15(the building elevation stage153) may be closed to block the gas and the powder material1, irrespective of the elevation level of the elevation stage15(the building elevation stage153).

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the third mode described above.

In this mode, the powder material1placed on the building elevation stage153may be prevented from entering the communication pipe24(particularly the branch pipes24D), and the oxygen gas accumulating in the space below the building elevation stage153can be discharged efficiently. Also, the powder material1placed on the building elevation stage153may be prevented from being disturbed by the inert gas blown from the branch pipes24D via the elevation chamber openings24b.

The positions of the branch pipes24D with respect to the vertical direction may not be particularly limited, but when the building elevation stage153is at the uppermost level thereof, all the branch pipes24D may preferably be opened to the space below the building elevation stage153in the building elevation guide chamber143. Further, the branch pipe24D at the lowest position in the vertical direction (hereinafter also referred to as “the lowest branch pipe24D”) among the plurality of branch pipes24D may preferably be opened to the space below the movement range R of the building elevation stage153in the building elevation guide chamber143. In this arrangement, at least the lowest branch pipe24D may be opened to the space below the building elevation stage153in the building elevation guide chamber143, irrespective of the elevation level of the building elevation stage153. Therefore, the oxygen gas accumulating in the building elevation guide chamber143can be guided to the process chamber12via the lowest branch pipe24D. In this arrangement, the lowest branch pipe24D may not be provided with the channel adjusting unit40, and the elevation guide chamber communication channel C2formed by the lowest branch pipe24D may be constantly open and allow the inflow and outflow of the gases therethrough.

When a plurality of branch pipes24D are opened to the space below the building elevation stage153in the building elevation guide chamber143, it may be possible to open only a part of the plurality of branch pipes24D opened to the space below the building elevation stage153and close the other branch pipes24D. For example, the opening/closing controller52may control the channel adjusting units40provided on the plurality of branch pipes24D such that when two or more branch pipes24D are opened to the space below the elevation stage15(the building elevation stage153) in the elevation guide chamber14(the building elevation guide chamber143), the elevation guide chamber communication channels C2of a predetermined number of branch pipes24D positioned relatively above among the two or more branch pipes24D may be opened, and the channels of the other branch pipes24D among the two or more branch pipes24D may be closed. Thus, for example, when an inert gas having a larger specific weight than oxygen, such as argon, is used, it may be possible to efficiently discharge the oxygen gas accumulating in the building elevation guide chamber143and fill the inert gas into the building elevation guide chamber143.

FIG. 24shows a three-dimensional modeling apparatus10according to a thirteenth mode.FIG. 25shows the three-dimensional modeling apparatus10ofFIG. 24as viewed from a side thereof (see the arrow S inFIG. 24).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the first mode described above (seeFIGS. 1 and 2) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, an elastic member56may be provided below the elevation stage15(the building elevation stage153in this example) in the elevation guide chamber14(the building elevation guide chamber143). The elastic member56may be attached to the elevation stage15(the building elevation stage153), and may be contracted and expanded in accordance with the elevation level of the elevation stage15(the building elevation stage153). The elastic member56may typically be constituted by a bellow member or a flexible member having a high elasticity such as those made of rubber or resins, but may alternatively be made of other members.

The elastic member56may include a hollow portion57formed therein, a first open communication portion58that communicates between the hollow portion57and the elevation guide chamber14(the building elevation guide chamber143), and a second open communication portion59that communicates between the hollow portion57and the communication pipe24. The first open communication portion58in this example may be provided in a side wall portion of the elastic member56and above the second open communication portion59.

The first open communication portion58may preferably be provided closer to the elevation stage15(the building elevation stage153) than may be the second open communication portion59(particularly immediately below the building elevation stage153). The second open communication portion59in this example may be provided in a side wall of the elastic member56and may connect directly to the elevation chamber opening24bof the communication pipe24. Therefore, the channel formed by the communication pipe24and the hollow portion57in the elastic member56may communicate with each other via the elevation chamber opening24band the second open communication portion59.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the first mode described above.

In this mode, the gases may flow in or out between the process chamber12and the elevation guide chamber14(the building elevation guide chamber143) via the communication pipe24and the elastic member56. Therefore, it may be possible to fill the elevation guide chamber14(the building elevation guide chamber143) with the inert gas and efficiently discharge the oxygen gas accumulating in the elevation guide chamber14(the building elevation guide chamber143).

In particular, the first open communication portion58may be constantly positioned close to the elevation stage15(the building elevation stage153) irrespective of the elevation level of the elevation stage15(the building elevation stage153). Accordingly, for example, when an inert gas having a larger specific weight than oxygen, such as argon, is used, it may be possible to efficiently discharge, via the first open communication portion58and the hollow portion57, the oxygen gas accumulating in a relatively high region within the space below the elevation stage15(the building elevation stage153) in the elevation guide chamber14(the building elevation guide chamber143).

FIG. 26shows a three-dimensional modeling apparatus10according to a fourteenth mode.FIG. 27shows the three-dimensional modeling apparatus10ofFIG. 26as viewed from a side thereof (see the arrow S inFIG. 26).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the thirteenth mode described above (seeFIGS. 24 and 25) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The communication pipe24in this mode may be opened to the process chamber12and the drive chamber32, and communicate with the process chamber12and the drive chamber32. A communication aperture38may be provided in the wall portion between the elevation guide chamber14(the building elevation guide chamber143in this example) and the drive chamber32so as to communicate between the elevation guide chamber14(the building elevation guide chamber143) and the drive chamber32. The second open communication portion59may be provided between the hollow portion57and the communication aperture38so as to communicate between the hollow portion57of the elastic member56and the communication aperture38.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the thirteenth mode described above.

In this mode, the communication pipe24, the drive chamber32, the communication aperture38, and the elastic member56may constitute the gas channel C that communicate between the process chamber12and the elevation guide chamber14(the building elevation guide chamber143).

Therefore, in addition to the oxygen gas accumulating in the elevation guide chambers14(the building elevation guide chamber143), the oxygen gas accumulating in the drive chamber32can be guided to the process chamber12and discharged out of the three-dimensional modeling apparatus10through the gas discharge unit22.

FIG. 28shows a three-dimensional modeling apparatus10according to a fifteenth mode.FIG. 29shows the three-dimensional modeling apparatus10ofFIG. 28as viewed from a side thereof (see the arrow S inFIG. 28).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the eighth mode described above (seeFIG. 15) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

The gas supply unit20in this mode may include a second gas supply unit for supplying the inert gas into the elevation guide chamber14, in addition to the first gas supply unit (the first blow unit201and the second blow unit202). In the example shown inFIGS. 28 and 29, a third blow unit203serving as the second gas supply unit may be opened to the collection elevation guide chamber142provided in one end of the plurality of elevation guide chambers14arranged adjacent to each other. The communication pipe24may communicate between the dispenser elevation guide chamber141provided in the other end of the plurality of elevation guide chambers14arranged adjacent to each other and the process chamber12.

Therefore, the third blow unit203may be provided on the wall portion that forms the collection elevation guide chamber142, and the communication pipe24may be provided on the wall portion that forms the dispenser elevation guide chamber141. The wall portion on which the third blow unit203is formed and the wall portion on which the communication pipe24is formed may not be opposed to each other. That is, these wall portions may not be in parallel with each other. In the example shown inFIGS. 28 and 29, the direction of the wall portion on which the third blow unit203is formed and the direction of the wall portion on which the communication pipe24is formed may be perpendicular to each other, and the direction of opening of a gas supply aperture203aof the third blow unit203that blows the inert gas toward the collection elevation guide chamber142and the direction of opening of the elevation chamber opening24bof the communication pipe24may be perpendicular to each other.

As described above, in this mode, the elevation chamber opening24bof the communication pipe24that is opened to the dispenser elevation guide chamber141may not be in the line extending from the gas supply aperture203aof the third blow unit203in the direction of the blow of the inert gas from the gas supply aperture203a. That is, the elevation chamber opening24bmay be off the line extending in the direction of the blow of the inert gas from the gas supply aperture203a.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the eighth mode described above.

In this mode, the inert gas may be supplied directly from the third blow unit203to the elevation guide chamber14(the collection elevation guide chamber142). Thus, it may be possible to fill the elevation guide chamber14with the inert gas and discharge the oxygen gas from the elevation guide chamber14more efficiently. In particular, when the inert gas is blown from the third blow unit203at a high pressure and supplied directly into the elevation guide chamber14(the collection elevation guide chamber142), it may be possible to diffuse the inert gas swiftly and prevent the oxygen gas from accumulating in the elevation guide chamber14(the collection elevation guide chamber142) efficiently. In addition, the elevation guide chambers14adjacent to each other may communicate with each other via the communication holes42. Therefore, the inert gas supplied into one elevation guide chamber14(the collection elevation guide chamber142) can be efficiently delivered to all the elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142) to discharge the oxygen gas quickly.

Of the two elevation guide chambers14that may be positioned in both ends of the array of the elevation guide chambers14, that is, the dispenser elevation guide chamber141and the collection elevation guide chamber142, one (the collection elevation guide chamber142in this example) may be provided with the third blow unit203, and the other (the dispenser elevation guide chamber141in this example) may be provided with the communication pipe24. In this arrangement, the inert gas can be delivered smoothly to all the elevation guide chambers14, and the oxygen gas can be efficiently discharged from the elevation guide chamber14positioned in the middle (the building elevation guide chamber143in this example), in addition to the elevation guide chambers14positioned in the both ends.

In this mode, the communication pipe24may communicate between the elevation guide chamber14(the dispenser elevation guide chamber141) and the process chamber12, and the gases may be discharged exclusively via the gas discharge unit22provided on the process chamber12. The gases in the elevation guide chambers14may be guided to the process chamber12via the communication pipe24. Accordingly, the oxygen density in the spaces below the elevation stages15of the elevation guide chambers14can be observed indirectly by the oxygen sensor34provided in the process chamber12, and therefore, there is no need of providing an oxygen sensor in the spaces below the elevation stages15.

The cross-sectional area of the elevation chamber opening24bof the communication pipe24that is opened to the dispenser elevation guide chamber141and the cross-sectional area of the gas supply aperture203aof the third blow unit203that blows the inert gas into the collection elevation guide chamber142may not be particularly limited. For example, the cross-sectional area of the elevation chamber opening24bmay be larger than that of the gas supply opening203a. In this arrangement, the oxygen gas accumulating in the elevation guide chambers14(the dispenser elevation guide chamber141, the collection elevation guide chamber142, and the building elevation guide chamber143) can be efficiently delivered to the process chamber12via the elevation chamber opening24band the communication pipe24and discharged from the gas discharge unit22.

FIG. 30shows a three-dimensional modeling apparatus10according to a sixteenth mode.FIG. 31shows the three-dimensional modeling apparatus10ofFIG. 30as viewed from a side thereof (see the arrow S inFIG. 30).

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the fifteenth mode described above (seeFIGS. 28 and 29) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the wall portion of the collection elevation guide chamber142on which the third blow unit203is formed and the wall portion of the dispenser elevation guide chamber141on which the communication pipe24is formed may be opposed to each other. That is, the gas supply aperture203aof the third blow unit203and the elevation chamber opening24bof the communication pipe24may be respectively provided on the wall portions opposed to each other.

In this mode, the gas supply aperture203aof the third blow unit203and the elevation chamber opening24bof the communication pipe24may be offset from each other.

More specifically, the elevation chamber opening24bof the communication pipe24may not be in the line extending from the gas supply aperture203aof the third blow unit203in the direction of the blow of the inert gas from the gas supply aperture203a, but may be offset from this line in the elevation guide chamber14(the dispenser elevation guide chamber141). The projection of the gas supply aperture203awith respect to the direction of the gas supply aperture203a(the direction of the blow of the inert gas) may be offset and separated from the projection of the elevation chamber opening24bwith respect to the direction of the gas supply aperture203a(the direction of the blow of the inert gas). The directions in which the gas supply aperture203aand the elevation chamber opening24bare offset may not be particularly limited. In the example shown inFIGS. 30 and 31, the gas supply aperture203aand the elevation chamber opening24bmay be offset from each other in a horizontal direction that is perpendicular to the vertical direction.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the fifteenth mode described above.

In this mode, the inert gas supplied from the gas supply aperture203aof the third blow unit203can be effectively prevented from being delivered to the process chamber12via the elevation chamber opening24bof the communication pipe24before the inert gas spreads throughout the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142). Therefore, it may be possible to efficiently fill the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142) with the inert gas and efficiently discharge the oxygen gas accumulating in the plurality of elevation guide chambers14.

In the three-dimensional modeling apparatus10according to this mode, the same or similar elements as in the three-dimensional modeling apparatus10according to the sixteenth mode described above (seeFIGS. 30 and 31) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the first communication hole42A provided between the dispenser elevation guide chamber141and the building elevation guide chamber143and the second communication hole42B provided between the collection elevation guide chamber142and the building elevation guide chamber143may be offset from each other. More specifically, the line extending from the first communication hole42A in the direction in which the first communication hole42A faces (the direction of opening) may be misaligned with the line extending from the second communication hole42B in the direction in which the second communication hole42B faces (the direction of opening). Therefore, the projection of the first communication hole42A with respect to the direction of opening of the first communication hole42A (the left-right direction inFIG. 32) may be separated from the projection of the second communication hole42B with respect to the same direction. The directions in which the first communication hole42A and the second communication hole42B are offset may not be particularly limited. In the example shown inFIG. 32, the first communication hole24A and the second communication hole42B may be offset from each other in the vertical direction.

In this mode, the gas supply aperture203aand the elevation chamber opening24bmay be respectively provided in the wall portions opposed to each other, and the gas supply aperture203amay be provided in the line extending from the elevation chamber opening24bin the direction in which the elevation chamber opening24bfaces. In this mode, the plurality of communication holes (the first communication hole42A and the second communication hole42B) may include a communication hole (the first communication hole42A in the example shown inFIG. 32) that is separated from the line connecting the gas supply aperture203aof the third blow unit203that blows the inert gas into the collection election guide chamber142with the elevation chamber opening24bof the communication pipe24that is opened to the dispenser elevation guide chamber141.

In other respects, the three-dimensional modeling apparatus10according to this mode may be the same as that of the sixteenth mode described above.

In this mode, the inert gas supplied from the gas supply aperture203aof the third blow unit203can be effectively prevented from being delivered to the process chamber12via the elevation chamber opening24bof the communication pipe24before the inert gas spreads throughout the plurality of elevation guide chambers14(the dispenser elevation guide chamber141, the building elevation guide chamber143, and the collection elevation guide chamber142).

The present invention is not limited to the modes and variations described above and is susceptible of various modification. Also, any parts or the entirety of the above modes and variations may be combined with each other.

For example, in the above modes, three elevation units16(the dispenser unit, the building unit, and the collection unit) may be provided. Alternatively, the three-dimensional modeling apparatus10may include only one or two elevation units16or include four or more elevation units16. Accordingly, in the three-dimensional modeling apparatus10, for example, the collection elevation guide chamber142may not contain the collection elevation stage152of the collection unit.

The positions of the communication pipe24and the third blow unit203may be modified as necessary. For example, the communication pipe24may be opened to other elevation guide chambers14(the dispenser elevation guide chamber141and/or the collection elevation guide chamber142) in addition to, or instead of, the building elevation guide chamber143. Further, the third blow unit203may supply the inert gas to other elevation guide chambers14(the dispenser elevation guide chamber141and/or the building elevation guide chamber143) in addition to, or instead of, the collection elevation guide chamber142.

In the above modes, the powder material1may be solidified (sintered) with a laser beam, but the means for solidifying the powder material1is not particularly limited. For example, the emission unit30may emit an electron beam, and the powder material1may solidify when irradiated with the electron beam emitted from the emission unit30.

The present invention is not limited to the above modes and variations but may include various aspects modified variously as could be conceived by those skilled in the art, and the effects produced by the present invention are not limited to those described above. Accordingly, addition, modification, and partial deletion of the elements described in the specification or recited in the claims can be made within the technical idea and the purport of the present invention.

Second Embodiment

FIG. 33shows a three-dimensional modeling apparatus310according to a first mode.FIG. 34schematically shows the three-dimensional modeling apparatus310ofFIG. 33as viewed from a side thereof (see the arrow S inFIG. 33). InFIG. 33, a process chamber312and elevation units316are schematically illustrated with the interior thereof as viewed from a side, so as to facilitate comprehension.

The three-dimensional modeling apparatus310according to this mode may conduct lamination modeling of a three-dimensional object305by sintering (solidifying) a powder material301such as titanium in the air-tight process chamber312, and may include the process chamber312, a plurality of elevation units316(three elevation units316in this mode) provided below the process chamber312, and a drive chamber332provided below the elevation units316. The powder material301may be a metal powder made of titanium, iron, stainless steel, aluminum, steel, or other alloys, a synthetic powder such as polyamide or polystyrene, polyether ether ketone (PEEK), synthetic coating sand, or a ceramic powder.

Each of the elevation units316may include an elevation guide chamber314provided adjacent to the process chamber312and an elevation stage15provided so as to be capable of being raised and lowered in the elevation guide chamber314. Each elevation stage315may be raised and lowered so as to slide on the surfaces of side walls that define the associated elevation guide chamber314. In each elevation guide chamber314, there may be provided a sealing member (not shown) between the surfaces of the side walls of the elevation guide chamber314and the associated elevation stage315, and the sealing member may block a gap therebetween. The sealing member may block the powder material301such that the powder material301may not pass the gap between the elevation guide chamber314and the elevation stage315. The sealing member may preferably prevent a gas such as oxygen from passing the gap between the elevation guide chamber314and the elevation stage315but may not necessarily provide strict air-tightness. Thus, each of the elevations guide chambers314may be partitioned by the associated elevation stage315into a space above the elevation stage315and a space below the elevation stage315.

The three elevation units316may be constituted by a dispenser unit, a collection unit, and a building unit provided between the dispenser unit and the collection unit. The dispenser unit may include a dispenser elevation guide chamber441(a first elevation guide chamber) and a dispenser elevation stage451, the building unit may include a building elevation guide chamber443(a third elevation guide chamber) and a building elevation stage453, and the collection unit may include a collection elevation guide chamber442(a second elevation guide chamber) and a collection elevation stage452.FIG. 33shows the dispenser unit, the building unit, and the collection unit arranged in this order from right to left. There may be provided partition walls328between the dispenser elevation guide chamber441and the building elevation guide chamber443and between the collection elevation guide chamber442and the building elevation guide chamber443. The dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442may be arranged adjacent to each other with the partition walls328therebetween.

Each of the elevation stages315(the dispenser elevation stage451, the collection elevation stage452, and the building elevation stage453) may be provided with an elevation drive unit318configured to raise and lower the elevation stages315. The elevation drive unit318may raise and lower the associated elevation stage315under the control by a controller336. The dispenser elevation stage451, the collection elevation stage452, and the building elevation stage453may be raised and lowered in association with each other.

The dispenser unit (the dispenser elevation guide chamber441and the dispenser elevation stage451) may provide a space for retaining the powder material301, and the powder material301used for modeling the three-dimensional object305may be placed on the dispenser elevation stage451. The building unit (the building elevation guide chamber443and the building elevation stage453) may conduct modeling of the three-dimensional object305. The building elevation stage453may serve for modeling conducted thereon. The powder material301placed on the building elevation stage453may be sintered with a laser beam emitted from an emission unit330to form the three-dimensional object305. The collection unit (the collection elevation guide chamber442and the collection elevation stage452) may provide a space for collecting an excess portion of the powder material301supplied to the building elevation guide chamber443, and the excess portion of the powder material301may be accumulated on the collection elevation stage452.

The process chamber312may contain an application unit326that can reciprocate horizontally above the dispenser elevation stage451, the building elevation stage453, and the collection elevation stage452. When the application unit326moves horizontally, the powder material301may be supplied from the dispenser elevation guide chamber441into the building elevation guide chamber443, and the excess portion of the powder material301may be pressed from above the building elevation guide chamber443into the collection elevation guide chamber442. More specifically, the first step to supply a required amount of powder material301into the building elevation guide chamber443may be to raise the dispenser elevation stage451, lower the building elevation stage453, and lower the collection elevation stage452. Then, the application unit326disposed above the dispenser elevation stage451may move horizontally to above the building elevation guide chamber443and the collection elevation guide chamber442. Thus, the topmost portion of the powder material301on the dispenser elevation stage451may be pressed toward the building elevation guide chamber443, and further powder material301may be supplied into the building elevation guide443. The excess portion of the powder material301that is not contained in the building elevation guide chamber443may be pressed toward and contained in the collection elevation guide chamber442.

Thus, the operation of the application unit326and the elevation stages315(the dispenser elevation stage451, the collection elevation stage452, and the building elevation stage453) may be performed in cooperation with each other under the control by the controller336, such that an adequate amount of powder material301can be supplied into the building elevation stage453to form layers. The distances by which the dispenser elevation stage451is raised, the building elevation stage453is lowered, and the collection elevation stage452is lowered may preferably be set such that a slightly larger amount of powder material301than is required to be supplied to above the building elevation stage453is supplied from the dispenser elevation guide chamber441to above the building elevation stage453and the excess portion of the powder material301that is not contained in the building elevation guide chamber443is contained in the collection elevation guide chamber442. In addition, the distance by which the building elevation stage453is lowered may be set in accordance with the thickness of the layer of the powder material301to be sintered by application of a laser beam. By way of an example, it may be possible to lower the collection elevation stage452and the building elevation stage453by 0.1 mm and raise the dispenser elevation stage451by 0.2 mm for one stroke.

The process chamber312may also contain a gas supply unit320, a gas discharge unit322, an emission unit330, and an oxygen sensor334, in addition to the application unit326.

The gas supply unit320in this mode may include a first gas supply unit501,502for supplying an inert gas such as argon or nitrogen (particularly argon in this mode) to the process chamber312. In the example shown inFIG. 33, the first gas supply unit501,502may include a first blow unit501provided above the building unit (the building elevation guide chamber443and the building elevation stage453) and a second blow unit502provided between the building unit and the first blow unit501(that is, below the first blow unit501). The first blow unit501and the second blow unit502may blow an inert gas into the space above the building unit so as not to substantially impact the powder material301placed on the building elevation stage453and the three-dimensional object305. The specific configuration and the position of the gas supply unit320are not particularly limited but may be set such that an inert gas can be supplied to at least one of the process chamber312and the elevation guide chambers314.

The gas discharge unit322may communicate with the process chamber312and may be configured to discharge gases from the process chamber312out of the three-dimensional modeling apparatus310.

The emission unit330according to this mode may emit a laser beam onto the powder material301on an elevation stage315(the building elevation stage153in this example) to solidify the powder material301(sinter the powder material301in this example). In the example shown inFIG. 33, the emission unit330may be installed in the process chamber312above the building unit (the building elevation guide chamber443and the building elevation stage453). However, the position to install the emission unit330may not be particularly limited. The emission unit330may be installed in other positions within the process chamber312or installed outside the process chamber312, as long as it can appropriately emit a laser beam onto the powder material301on the building elevation stage453.

The oxygen sensor334may be installed in the process chamber312and may be configured to sense the oxygen density. The position to install the oxygen sensor334, which may not be particularly limited, may preferably be set based on the relationship between the specific weights of the inert gas supplied from the gas supply unit320and oxygen. For example, if the specific weight of oxygen is smaller than that of the inert gas, the oxygen sensor334may preferably be installed in a relatively high position within the process chamber312, and if the specific weight of oxygen is larger than that of the inert gas, the oxygen sensor334may preferably be installed in a relatively low position within the process chamber312.

In the wall portion that forms the elevation guide chamber314(the building elevation guide chamber443in this example), there may be provided an inert gas supply opening354and a gas discharge opening355.

The inert gas supply opening354and the gas discharge opening355may be opened to (communicate with) a space below the movement range R of the elevation stage315(the building elevation stage453) in the elevation guide chamber314(the building elevation guide chamber443). The inert gas supply opening354may communicate with a space below the associated elevation stage315(the building elevation stage453in this example) in the elevation guide chamber314(the building elevation guide chamber443) and may connect with an inert gas supply pipe344that extends from an inert gas supply unit346configured to deliver the inert gas. Accordingly, the inert gas supply pipe344may function as the gas supply unit320along with the first blow unit501and the second blow unit502and serve as the second gas supply unit. The gas discharge opening355may communicate with a space below the elevation stage315(the building elevation stage453) in the elevation guide chamber314(the building elevation guide chamber443) and may connect with a gas discharge pipe345that extends from a gas collection unit347configured to collect the gases.

In this mode, the gas collection unit347may serve as a recycling unit for recycling the inert gas. The discharge gas may be delivered to the gas collection unit347from the gas discharge unit322as well as from the elevation guide chamber314(the building elevation guide chamber443). The recycling process is not particularly limited. For example, the gas collection unit347may extract a desired inert gas from the collected gas or free the collected gas from gaseous, liquid, and/or solid impurities other than the inert gas contained in the collected gas.

The inert gas supply opening354and the gas discharge opening355may be positioned at different levels with respect to the vertical direction. In this example, the gas discharge opening355may be positioned above the inert gas supply opening354.

The drive chamber332may contain at least a part of the elevation drive units318. For example, when an elevation drive unit318includes a projecting portion having one end thereof fixed to an associated elevation stage315(the dispenser elevation stage451, the collection elevation stage452, or the building elevation stage453) and capable of projecting by a varied distance, and a motor (for example, a stepping motor) for driving the projecting portion, the drive chamber332may contain the motor and a part of the other end of the projecting portion.

The controller336may be installed above the process chamber312. The controller336may control the units in the three-dimensional modeling apparatus310. For example, the controller336may control the elevation drive units318to raise or lower the elevation stages315, control the horizontal movement of the application unit326, control the laser beam emission of the emission unit330, and control supply of the inert gas from the gas supply unit320. In particular, the controller336in this mode may receive the sensing values from the oxygen sensor334and, when the oxygen sensor334senses an oxygen density higher than a threshold value, the controller336may stop the elevation operation of the elevation stages315, the horizontal movement of the application unit326, and the laser beam emission from the emission unit330, suspend modeling of the three-dimensional object305, and issue an error message to an operator visually or audibly.

As described above, in this mode, the inert gas supply unit346may supply the inert gas to the space below the building elevation stage453in the building elevation guide chamber443via the inert gas supply pipe344and the inert gas supply opening354. The gas that contains oxygen accumulating in this space may be collected from the space into the gas collection unit347via the gas discharge opening355and the gas discharge pipe345. Thus, it may be possible to discharge the oxygen gas accumulating in the three-dimensional modeling apparatus310(particularly in the building elevation guide chamber443) out of the three-dimensional modeling apparatus310and effectively prevent oxidation of the material of the three-dimensional object305during modeling. In particular, the inert gas may be supplied directly to the space below the building elevation stage453in the building elevation guide chamber443, and therefore, the inert gas can be supplied to the space at a high pressure to diffuse the inert gas effectively. Thus, the oxygen gas accumulating in the space below the building elevation stage453in the building elevation guide chamber443can be quickly discharged to the gas collection unit347via the gas discharge opening355and the inert gas supply opening354. Additionally, the nitrogen gas may also be discharged in the argon gas environment.

The oxygen gas accumulating in the space above the building elevation stage453in the building elevation guide chamber443and the process chamber312may be discharged from the gas discharge unit322due to the effect of the inert gas supplied from the first blow unit501and the second blow unit502.

The inert gas supply opening354and the gas discharge opening355may be positioned below the movement range R of the building elevation stage453. Therefore, the oxygen gas accumulating in the building elevation guide chamber443(particularly the space below the building elevation stage453) can be efficiently discharged without narrowing the movement range R of the building elevation stage453and irrespective of the elevation level of the building elevation stage453. In addition to oxygen, nitrogen included in the remaining air can also be discharged in the same manner. This may also apply to other modes described below.

In the three-dimensional modeling apparatus310of this mode, the oxygen sensor334may no longer or seldom sense an oxygen density higher than a threshold value, and therefore, even in the case where modeling should be suspended when the oxygen sensor334senses an oxygen density higher than a threshold value, modeling may be no longer or seldom suspended unexpectedly.

The inert gas supply opening354and the gas discharge opening355may be positioned at different levels with respect to the vertical direction, and therefore, the gas flow can be smoothened in the building elevation guide chamber443, and the supply of the inert gas and the discharge of the oxygen gas can be efficient. In particular, the gas discharge opening355may be positioned above the inert gas supply opening354, such that when argon, having a larger specific weight than oxygen, is used as an inert gas, the oxygen gas may tend to be present above the inert gas and can be efficiently delivered to the gas collection unit347via the gas discharge opening355and the gas discharge pipe345.

The gas collection unit347may recycle the inert gas for effective reuse of the inert gas. The inert gas recycled in the gas collection unit347may be returned into the three-dimensional modeling apparatus310(the process chamber312and/or the elevation guide chamber314) or may be used for other applications.

FIG. 35shows a three-dimensional modeling apparatus310according to a second mode.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the first mode described above (seeFIGS. 33 and 34) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the inert gas supply opening354and the gas discharge opening355may be opened to at least one of the plurality of elevation guide chambers314(the dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442) (the dispenser elevation guide chamber441and the collection elevation guide chamber442in this example). More specifically, the inert gas supply opening354may be opened to the dispenser elevation guide chamber441, which may be provided in one end of the plurality of elevation guide chambers314arranged adjacent to each other. The gas discharge opening355may be opened to the collection elevation guide chamber442, which may be provided in the other end of the plurality of elevation guide chambers314arranged adjacent to each other. The inert gas supply opening354may be opened to the space below the movement range R of the dispenser elevation stage451in the dispenser elevation guide chamber441, and the gas discharge opening355may be opened to the space below the movement range R of the collection elevation stage452in the collection elevation guide chamber442.

The wall portion that forms the dispenser elevation guide chamber441and includes the inert gas supply opening354and the wall portion that forms the collection elevation guide chamber442and includes the gas discharge unit355may not be opposed to each other. That is, these wall portions may not be in parallel with each other. More specifically, in the example shown inFIG. 35, the inert gas supply opening354may be provided in the wall portion facing in the direction of depth of the drawing, while the gas discharge opening355may be provided in the wall portion facing in the left-right direction of the drawing.

Any two elevation guide chambers314arranged adjacent to each other (in this example, the dispenser elevation guide chamber441and the building elevation guide chamber443, or the collection elevation guide chamber442and the building elevation guide chamber443) may communicate with each other via the communication hole342. The cross-sectional areas of the openings (hereinafter also referred to as “opening cross-sectional areas”) of the communication holes342may not be particularly limited. All the communication holes342may have the same opening cross-sectional areas, or alternatively, the communication hole342that communicates between the dispenser elevation guide chamber441and the building elevation guide chamber443and the communication hole342that communicates between the collection elevation guide chamber442and the building elevation guide chamber443may have different opening cross-sectional areas. The number of communication holes342that communicate between the dispenser elevation guide chamber441and the building elevation guide chamber443and the number of communication holes342that communicate between the collection elevation guide chamber442and the building elevation guide chamber443may also not be particularly limited. Each of the partition walls328may include one or more communication holes342.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the first mode described above.

In this mode, the inert gas supplied from the inert gas supply unit346to the dispenser elevation guide chamber441via the inert gas supply pipe344and the inert gas supply opening354may be diffused into the building elevation guide chamber443and the collection elevation guide chamber442via the communication holes342. As the inert gas flows in, the oxygen gas accumulating in the dispenser elevation guide chamber441and the building elevation guide chamber443may be moved and delivered to the collection elevation guide chamber442, and collected into the gas collection unit347via the gas discharge opening355and the gas discharge pipe345. Therefore, it may be possible to discharge the oxygen gas from all the elevation guide chambers314(the dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442) and fill all the elevation guide chambers314with the inert gas.

In particular, the inert gas supply opening354and the gas discharge opening355may be respectively opened to the dispenser elevation guide chamber441and the collection elevation guide chamber442, which may be disposed in the opposite ends of the array of the elevation guide chambers314. Thus, the inert gas can flow from the dispenser elevation guide chamber441to the collection elevation guide chamber442, such that the inert gas may be supplied to the building elevation guide chamber443disposed between the dispenser elevation guide chamber441and the collection elevation guide chamber442. Accordingly, the oxygen gas can be discharged from other elevation guide chambers314(the dispenser elevation guide chamber441and the building elevation guide chamber443) as well as from the collection elevation guide chamber442to which the gas discharge opening355is opened.

The inert gas supply opening354and the gas discharge opening355may be provided in the wall portions that are not opposed to or in parallel with each other, and therefore, the inert gas supplied from the inert gas supply opening354may be diffused efficiently in the elevation guide chambers314(the dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442). Thus, the oxygen gas can be prevented from accumulating in the elevation guide chambers314and discharged from the elevation guide chambers314efficiently.

FIG. 36shows a three-dimensional modeling apparatus310according to a third mode.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the first mode described above (seeFIGS. 33 and 34) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the inert gas supply opening354may be opened to the elevation guide chamber314(the collection elevation guide chamber442in this example), and the gas discharge opening355may be opened to the drive chamber332.

The wall portion of the elevation guide chamber314(the collection elevation guide chamber442) in which the inert gas supply opening354is formed and the wall portion of the drive chamber332in which the gas discharge opening355is formed may face in the same direction. That is, these wall portions may be in parallel with each other. In the example shown inFIG. 36, the inert gas supply opening354and the gas discharge opening355may be provided in the wall portions facing in the left-right direction of the drawing.

Any two elevation guide chambers314arranged adjacent to each other (in this example, the dispenser elevation guide chamber441and the building elevation guide chamber443, or the collection elevation guide chamber442and the building elevation guide chamber443) may communicate with each other via the communication hole342. The opening cross-sectional areas of the communication holes342may not be particularly limited. All the communication holes342may have the same opening cross-sectional areas, or alternatively, the communication hole342that communicates between the dispenser elevation guide chamber441and the building elevation guide chamber443and the communication hole342that communicates between the collection elevation guide chamber442and the building elevation guide chamber443may have different opening cross-sectional areas. The number of communication holes342that communicate between the dispenser elevation guide chamber441and the building elevation guide chamber443and the number of communication holes342that communicate between the collection elevation guide chamber442and the building elevation guide chamber443may also not be particularly limited. Each of the partition walls328may include one or more communication holes342.

The drive chamber332may communicate with at least one of the plurality of elevation guide chambers314(the dispenser elevation guide chamber441in this example) via the communication apertures338. That is, one or more communication apertures338that allow gas flow may be provided in the wall portion partitioning the dispenser elevation guide chamber441from the drive chamber332. The opening cross-sectional areas of the communication apertures338are not particularly limited. When a plurality of communication apertures338are provided, these communication apertures338may have either the same or different opening cross-sectional areas. Thus, in this three-dimensional modeling apparatus310, the communication apertures338may be opened to the dispenser elevation guide chamber441in one end of the array of the elevation guide chambers314, and the inert gas supply opening354may be opened to the collection elevation guide chamber442in the other end.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the first mode described above.

In this mode, the inert gas may be supplied directly to the elevation guide chamber314(the collection elevation guide chamber442in this example). Thus, it may be possible to fill the elevation guide chamber314with the inert gas and discharge the oxygen gas from the elevation guide chamber314quickly. In this mode, the inert gas supplied to the collection elevation guide chamber442via the inert gas supply opening354may be discharged from the gas discharge opening355via the building elevation guide chamber443, the dispenser elevation guide chamber441, and the drive chamber332. Accordingly, it may be possible to discharge the oxygen gas accumulating in all the elevation guide chambers314and the drive chamber332and make sure that the oxygen gas is prevented from accumulating in the three-dimensional modeling apparatus310.

The inert gas supply opening354may be opened to at least one of the plurality of elevation guide chambers314. The inert gas supply opening354may be opened to an elevation guide chamber314other than the collection elevation guide chamber442, or may be opened to two or three elevation guide chambers314.

The communication apertures338may communicate between any one of the plurality of elevation guide chambers314and the drive chamber332and may not necessarily communicate between the dispenser elevation guide chamber441and the drive chamber332. The plurality of communication apertures338may be provided so as to communicate between a plurality of elevation guide chambers314and the drive chamber332. Accordingly, the communication apertures338may be provided in any one or more wall portions among the wall portion that partitions the dispenser elevation guide chamber441from the drive chamber332, the wall portion that partitions the building elevation guide chamber443from the drive chamber332, and the wall portion that partitions the collection elevation guide chamber442from the drive chamber332.

FIG. 37shows a three-dimensional modeling apparatus310according to a fourth mode.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the third mode described above (seeFIG. 36) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the first communication hole342A provided between the dispenser elevation guide chamber441and the building elevation guide chamber443and the second communication hole342B provided between the collection elevation guide chamber442and the building elevation guide chamber443may have different opening cross-sectional areas (channel areas). The cross-sectional area of the first communication hole342A that communicates between the elevation guide chambers314(the dispenser elevation guide chamber441and the building elevation guide chamber443in this example) having no inert gas supply opening354may be larger than the cross-sectional area of the second communication hole342B that communicates between the elevation guide chamber314(the collection elevation guide chamber442in this example) having the inert gas supply opening354and the elevation guide chamber314(the building elevation guide chamber443in this example) having no inert gas supply opening354.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the third mode described above.

Since the dispenser elevation guide chamber441is remote from the inert gas supply opening354, the inert gas may be supplied to the dispenser elevation guide chamber441at a relatively low pressure. However, in this mode, the inert gas can be supplied to the dispenser elevation guide chamber441via the first communication hole342A having a large cross-sectional area. Therefore, it may be possible to generate a gas flow through the collection elevation guide chamber442, the building elevation guide chamber443, the dispenser elevation guide chamber441, and the drive chamber332and discharge the oxygen gas accumulating in the elevation guide chambers314and the drive chamber332.

It may also be possible to provide a plurality of first communication holes342A and/or a plurality of second communication holes342B. That is, a plurality of first communication holes342A may be provided in the partition wall328between the dispenser elevation guide chamber441and the building elevation guide chamber443, and a plurality of second communication holes342B may be provided in the partition wall328between the collection elevation guide chamber442and the building elevation guide chamber443. In this arrangement, it may be possible that the opening cross-sectional area of one of the first communication holes342A is not larger than the opening cross-sectional area of one of the second communication holes342B. The same effect as in this mode can be expected when the sum of the opening cross-sectional areas of the one or more first communication holes342A provided between the dispenser elevation guide chamber441and the building elevation guide chamber443is larger than the sum of the opening cross-sectional areas of the one or more second communication holes342B provided between the collection elevation guide chamber442and the building elevation guide chamber443. Accordingly, even when the opening cross-sectional area of one of the first communication holes342A is not larger than the opening cross-sectional area of one of the second communication holes342B, the number of the first communication holes342A may be larger than the number of the second communication holes342B such that the sum of the opening cross-sectional areas of the first communication holes342A is larger than the sum of the opening cross-sectional areas of the second communication holes342B.

Further, the relationship between the opening cross-sectional areas of the first communication pipe324A and the second communication pipe324B may not be limited to the above examples. For example, the sum of the opening cross-sectional areas of the one or more first communication pipes324A may be smaller than the sum of the opening cross-sectional areas of the one or more second communication pipes324B.

FIG. 38shows a three-dimensional modeling apparatus310according to a fifth mode.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the second mode described above (seeFIG. 36) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the inert gas supply opening354may be opened to the drive chamber332, the gas discharge opening355may be opened to the elevation guide chamber314(the collection elevation guide chamber442in this example), and the drive chamber332and the elevation guide chamber314(the collection elevation guide chamber442in this example) may communicate with each other via the dispenser elevation guide chamber441, the building elevation guide chamber443, and the communication hole342.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the third mode described above.

In this mode, the inert gas supplied via the inert gas supply opening354may move through the drive chamber332, the dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442and flow out through the gas discharge unit355. Therefore, in this mode, it may also be possible to fill the elevation guide chambers314and the drive chamber332with the inert gas and efficiently discharge the oxygen gas accumulating in the elevation guide chambers314and the drive chamber332.

FIG. 39shows a three-dimensional modeling apparatus310according to a sixth mode.FIG. 40shows the three-dimensional modeling apparatus310ofFIG. 39as viewed from a side thereof (see the arrow S inFIG. 39). InFIG. 40, the inert gas supply opening354is shown, but the inert gas supply pipe344and the inert gas supply unit346connected to the inert gas supply opening354are omitted, so as to facilitate comprehension.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the second mode described above (seeFIG. 35) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the wall portion of the dispenser elevation guide chamber441in which the inert gas supply opening354is formed and the wall portion of the collection elevation guide chamber442in which the gas discharge opening355is formed may be opposed to each other. That is, the inert gas supply opening354and the gas discharge opening355may be respectively provided in the wall portions opposed to each other.

In this mode, the inert gas supply opening354and the gas discharge opening355may be offset from each other. More specifically, the inert gas supply opening354may not be in the line extending from the gas discharge opening355in the direction of opening of the gas discharge opening355, but may be offset from this line in the elevation guide chamber314(the dispenser elevation guide chamber441). Accordingly, the projection of the inert gas supply opening354with respect to the direction of the inert gas supply opening354(the direction of opening of the inert gas supply opening354(the left right direction inFIG. 39and the direction of depth inFIG. 40)) may be offset and separated from the projection of the gas discharge opening355with respect to the same direction. The direction in which the inert gas supply opening354and the gas discharge opening355are offset from each other is not particularly limited. In the example shown inFIGS. 39 and 40, the inert gas supply opening354and the gas discharge opening355may be offset from each other in a horizontal direction that is perpendicular to the vertical direction.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the third mode described above.

In this mode, the gas discharge opening355may not be in the line extending from the inert gas supply opening354in the direction of the blow of the inert gas from the inert gas supply opening354. Accordingly, the inert gas supplied via the inert gas supply opening354can be effectively prevented from being discharged via the gas discharge opening355before the inert gas spreads throughout the plurality of elevation guide chambers314. Therefore, it may be possible to efficiently fill the plurality of elevation guide chambers314with the inert gas and efficiently discharge the oxygen gas accumulating in the plurality of elevation guide chambers314.

FIG. 41shows a three-dimensional modeling apparatus310according to a seventh mode.

In the three-dimensional modeling apparatus310according to this mode, the same or similar elements as in the three-dimensional modeling apparatus310according to the sixth mode described above (seeFIGS. 39 and 40) will be denoted by the same reference numerals and detailed descriptions thereof will be omitted.

In this mode, the first communication hole342A provided between the dispenser elevation guide chamber441and the building elevation guide chamber443and the second communication hole342B provided between the collection elevation guide chamber442and the building elevation guide chamber443may be offset from each other. More specifically, the line extending from the first communication hole342A in the direction in which the first communication hole342A faces (the direction of opening) may be misaligned with the line extending from the second communication hole342B in the direction in which the second communication hole342B faces (the direction of opening). Therefore, the projection of the first communication hole342A with respect to the direction of opening of the first communication hole342A (the left-right direction inFIG. 41) may be separated from the projection of the second communication hole342B with respect to the same direction. The direction in which the first communication hole342A and the second communication hole342B are offset from each other is not particularly limited. In the example shown inFIG. 41, the first communication hole342A and the second communication hole342B may be offset from each other in the vertical direction.

In this mode, the inert gas supply opening354and the gas discharge opening355may be respectively provided in the wall portions opposed to each other, and the gas discharge opening355may be provided in the line extending from the inert gas supply opening354in the direction in which the inert gas supply opening354faces (the direction of opening). In this mode, the plurality of communication holes (the first communication hole342A and the second communication hole342B) may include a communication hole (the first communication hole342A in the example shown inFIG. 41) that is separated and offset from the line connecting the inert gas supply opening354with the gas discharge opening355.

In other respects, the three-dimensional modeling apparatus310according to this mode may be the same as that of the sixth mode described above.

In this mode, the first communication hole342A that may communicate between the dispenser elevation guide chamber441and the building elevation guide chamber443may be separated from the line extending from the inert gas supply opening354in the direction of the blow of the inert gas from the inert gas supply opening354(the first communication hole342A may be offset from the inert gas supply opening354). Accordingly, the inert gas supplied via the inert gas supply opening354can be effectively prevented from being delivered to the process chamber312via the elevation chamber opening324bof the communication pipe324before the inert gas spreads throughout the plurality of elevation guide chambers314.

The present invention is not limited to the modes and variations described above and is susceptible of various modification. Also, any parts or the entirety of the above modes and variations may be combined with each other.

For example, in the above modes, three elevation units316(the dispenser unit, the building unit, and the collection unit) may be provided. Alternatively, the three-dimensional modeling apparatus310may include only one or two elevation units316or include four or more elevation units316. Accordingly, in the three-dimensional modeling apparatus310, for example, the collection elevation guide chamber442may not contain the collection elevation stage452of the collection unit.

The positions of the inert gas supply opening354and the gas discharge opening355may be modified as necessary. For example, the inert gas supply opening354and the gas discharge opening355may be opened to one or more of the plurality of elevation guide chambers314(the dispenser elevation guide chamber441, the building elevation guide chamber443, and the collection elevation guide chamber442).

In the above modes, the powder material301may be solidified (sintered) with a laser beam, but the means for solidifying the powder material301is not particularly limited. For example, the emission unit330may emit an electron beam, and the powder material301may solidify when irradiated with the electron beam emitted from the emission unit330.

The present invention is not limited to the above embodiments and variations but may include various aspects modified variously as could be conceived by those skilled in the art, and the effects produced by the present invention are not limited to those described above. Accordingly, addition, modification, and partial deletion of the elements described in the specification or recited in the claims can be made within the technical idea and the purport of the present invention.