Stack forming apparatus and manufacturing method of stack formation

A stack forming apparatus according to embodiments comprises a nozzle and a controller. The nozzle is configured to selectively inject more than one kind of material to a target and to apply laser light to the injected material to melt the material. The controller is configured to control the kind and supply amount of material to be supplied to the nozzle.

FIELD

Embodiments described herein relate to a stack forming apparatus and a manufacturing method of a stack formation.

BACKGROUND

Heretofore, a technique has been known as a method of manufacturing a stack formation. This technique repeats the step of forming a powder layer by a powder material made of a resin material or a metallic material and the step of applying, for example, light or laser light to a predetermined position of the powder layer to solidify a predetermined range of the powder layer, and stacks solidified layers to manufacture a stack formation having a three-dimensional shape.

DETAILED DESCRIPTION

According to one embodiment, a stack forming apparatus includes a nozzle and a controller. The nozzle is configured to selectively inject more than one kind of material to a target and to apply laser light to the injected material to melt the material. The controller is configured to control the kind and supply amount of material to be supplied to the nozzle.

Hereinafter, a stack forming apparatus1and a manufacturing method of a stack formation100according to a first embodiment will be described with reference toFIG. 1toFIG. 4.

FIG. 1is an explanatory diagram schematically showing the configuration of the stack forming apparatus1according to the first embodiment.FIG. 2is an explanatory diagram schematically showing the configurations of essential parts of the stack forming apparatus1; more specifically, the configurations of a nozzle33and a melting device45.FIG. 3is a perspective view showing the configuration of a galvano-scanner55of an optical device15used in the stack forming apparatus1.FIG. 4is an explanatory diagram showing an example of the manufacture of the stack formation100using the stack forming apparatus1.

As shown inFIG. 1, the stack forming apparatus1comprises a treatment tank11, a stage12, a moving device13, a nozzle device14, the optical device15, a measurement device16, and a controller17. The stack forming apparatus1is configured to stack layers of a material supplied by the nozzle device14on a target110provided on the stage12, and thereby enables the stack formation100having a predetermined shape to be formed.

The target110is, for example, a base110ahaving an upper surface on which the stack formation100is to be formed, or a layer110bwhich constitutes part of the stack formation100, and the target110is a target to which the material is supplied by the nozzle device14. The material is a powder resin material or a metallic material. Different kinds of metallic materials, for example, a first material121and a second material122are used.

The treatment tank11comprises a main chamber21, an auxiliary chamber22formed adjacent to the main chamber21, and a door23which can open and shut the main chamber21and airtightly close the main chamber21. The main chamber21is formed so that the stage12, the moving device13, part of the nozzle device14, and the measurement device16can be disposed therein. The main chamber21comprises a supply hole21ato supply inert gases such as nitrogen and argon, and a discharge hole21bto discharge the gasses in the main chamber21. The supply hole21aof the main chamber21is connected to a supply device which supplies the inert gases. The discharge hole21bis connected to a discharge device which discharges the gasses in the main chamber21.

The auxiliary chamber22is formed adjacent to the main chamber21. The auxiliary chamber22is formed so that the auxiliary chamber22can be spatially continuous with the main chamber21via the door23. For example, the stack formation100treated in the main chamber21is conveyed to the auxiliary chamber22. The auxiliary chamber22comprises a transfer device which carries, for example, the manufactured stack formation100and conveys the stack formation100from the main chamber21, and a conveying device24such as a conveying arm which sucks the stack formation100with, for example, a vacuum head and then conveys the stack formation100. The auxiliary chamber22is isolated from the main chamber21by the closing of the door23when the stack formation100is formed.

The stage12is formed so that the target110can be supported thereon. The moving device13is configured to be able to move the stage12in three axial directions.

The nozzle device14is configured to be able to selectively supply predetermined amounts of more than one kind of material to the target110on the stage12, and to be able to emit laser light200. More specifically, the nozzle device14comprises a first supply device31which can supply the first material121, a second supply device32which can supply the second material122, the nozzle33connected to the first supply device31, the second supply device32, and the optical device15, and supply pipes34which connect the first supply device31and the nozzle33as well as the second supply device32and the nozzle33.

For example, the first material121is a powder metallic material. The second material122is a powder metallic material different from the first material.

The first supply device31comprises a tank31ato store the first material121, and supply means31bfor supplying a predetermined amount of the first material121to the nozzle33from the tank31a. The first supply device31is configured to be able to supply the first material121in the tank31ato the nozzle33by using the inert gases of nitrogen and argon as carriers.

The second supply device32comprises a tank32ato store the second material122, and supply means32bfor supplying a predetermined amount of the second material122to the nozzle33from the tank32a. The second supply device32is configured to be able to supply the second material122in the tank32ato the nozzle33by using the inert gases of nitrogen and argon as carriers.

The nozzle33is connected to the first supply device31and the second supply device32via the supply pipes34. The nozzle33is connected to the optical device15via a cable210which can transmit the laser light200. The nozzle33is configured to be movable relative to the stage12.

The nozzle33comprises a cylindrical outer envelope35, an injection hole37which is provided in the outer envelope36and which injects the first material121and the second material122from its distal end, a light passage38which transmits the laser light200, and optical lenses39provided in the light passage38. For example, two nozzles33having the injection holes37different in diameter are provided. For example, the injection hole37of one of the nozzles33is formed with a diameter of 0.2 mm, and the injection hole37of the other nozzle33is formed with a diameter of 2.0 mm. The nozzles33are configured to be able to mix the first material121and the second material122in powder form supplied from the first supply device31and the second supply device32.

The nozzles33are configured to be able to mix therein the first material121and the second material122in powder form supplied from the first supply device31and the second supply device32, or to be able to respectively inject the first material121and the second material122from the injection holes37and mix the first material121and the second material122after the injection.

In the configuration described according to the present embodiment, for example, two injection holes37are provided, and one of the injection holes37is a first injection hole37aconnected to the first supply device31while the other is a second injection hole37bconnected to the second supply device32. As shown inFIG. 2, for example, the injection holes37are formed aslant relative to the axial center of the outer envelope36and the optical center of the laser light200to be emitted so that the first material121and the second material122conveyed by the gasses supplied from the first supply device31and the second supply device32intersect with each other at a predetermined distance from the injection holes37.

The light passage38is provided along the axial center of the outer envelope36. The optical lenses39are provided in, for example, the light passage38. Two optical lenses39are provided so that the laser light200from the cable210can be converted to parallel light and the parallel light, can be converged. The optical lenses39are configured to most converge at a predetermined position, more specifically, at the intersection of the first material121and the second material122that are injected from the injection holes37.

As shown inFIG. 1andFIG. 3, the optical device15comprises a light source41, and an optical system42connected to the light source41via the cable210. The light source41has a transmission element, and is a supply source of the laser light200which is configured to be able to emit the laser light200from the transmission element. The light source41is configured to be able to change a power density of the laser light to be emitted.

The optical system42is configured to be able to supply the laser light200emitted from the light source41to the nozzles33and to apply the laser light200to the first material121and the second material122injected to the target110. The optical system42is also configured to be able to apply the laser light200to the layer110bon the base110aand to the materials121and122.

More specifically, the optical system42comprises a first lens51, a second lens52, a third lens53, a fourth lens54, and the galvano-scanner55. The first lens51, the second lens52, the third lens53, and the fourth lens54are fixed to the optical system42. The optical system42may be configured to comprise an adjustment device which can move the first lens51, the second lens52, the third lens53, and the fourth lens54in two axial directions, more specifically, in directions that intersect at right angles with or intersect with an optical path.

The first lens51is configured to be able to convert the laser light200which has been brought in via the cable210to parallel light and to bring the converted laser light200to the galvano-scanner55. The same number of second lenses52as the nozzles33are provided. The second lens52is configured to be able to converge the laser light200emitted from the galvano-scanner55and to emit the laser light200to the nozzles33via the cable210.

The third lens53is configured to be able to converge the laser light200emitted from the galvano-scanner55and to emit the laser light200to the target110. The fourth lens54is configured to be able to converge the laser light200emitted from the galvano-scanner55and to emit the laser light200to the target110.

The galvano-scanner55is configured to be able to split the parallel light converted by the first lens51into the second lens52, the third lens53, and the fourth lens54. The galvano-scanner55comprises a first galvano-mirror57, a second galvano-mirror58, and a third galvano-mirror59. Each of the galvano-mirrors57,58, and59is configured to be able to vary the inclination angle and split the laser light200.

The first galvano-mirror57transmits some of the laser light200which has passed through the first lens51and thereby emits the laser light200to the second galvano-mirror58, and reflects the remainder of the laser light200and thereby emits the laser light200to the fourth lens54. The first galvano-mirror57is configured to be able to adjust, via the inclination angle thereof, the application position of the laser light200which has passed through the fourth lens54.

The second galvano-mirror58emits some of the laser light200to the third galvano-mirror59, and reflects and then emits the remainder of the laser light200to the third lens53. The second galvano-mirror58is configured to be able to adjust, via the inclination angle thereof, the application position of the laser light200which has passed through the third lens53.

The third galvano-mirror59emits some of the laser light200to one of the second lenses52, and emits the rest of the laser light200to the other second lens52.

This optical system42constitutes the melting device45which heats the first material121(123) and the second material122(123) supplied to the target110by the first galvano-mirror57, the second galvano-mirror58, and the third lens53to form and anneal the layer110b. The melting device45uses the laser light200to melt the first material121and the second material122supplied onto the base110afrom the nozzles33, and forms the layer110b.

The optical system42also constitutes a removing device46which uses the laser light200supplied by the first galvano-mirror57and the fourth lens54to remove unnecessary parts formed on the base110aand the layer110bby the first material121and the second material122.

The removing device46is configured to be able to remove parts of the stack formation100different from a predetermined shape; for example, scattered materials generated during the supply of the first material121and the second material122by the nozzles33or unnecessary parts generated during the formation of the layer110b. The removing device46is configured to be able to emit the laser light200having a power density that can remove the above-mentioned parts.

The measurement device16is configured to be able to measure the shape of the layer110band the shape of the formed stack formation100which are the shapes of the solidified materials on the base110a. The measurement device16is configured to be able to send information regarding the measured shape to the controller17.

For example, the measurement device16comprises a camera61, and an image processor62which performs image processing in accordance with information measured by the camera61. The measurement device16is configured to be able to measure, by, for example, an interference method or a light-section method, the shapes of the layer110band the stack formation100, that is, the shape of the material123which is the mixture of the first, material121and the second material122on the base110a.

The controller17is electrically connected to the moving device13, the conveying device24, the first supply device31, the second supply device32, the light source41, the galvano-scanner55, and the image processor62via a signal line220.

The controller17is configured to be able to move the stage12in three axial directions by controlling the moving device13. The controller17is configured to be able to convey the formed stack formation100to the auxiliary chamber22by controlling the conveying device24. The controller17is configured to be able to adjust the supply of the first material121and the supply amount of the first material121by controlling the first supply device31.

The controller17is configured to be able to adjust the supply of the second material122and the supply amount of the second material122by controlling the second supply device32. The controller17is configured to be able to adjust the power density of the laser light200emitted from the light source41by controlling the light source41. The controller17is configured to be able to adjust the inclination angles of the first galvano-mirror57, the second galvano-mirror58, and the third galvano-mirror59by controlling the galvano-scanner55. The controller17is configured to be able to move the nozzles33.

The controller17comprises a storage unit17a. The shape of the stack formation100to be formed is stored in the storage unit17aas a threshold. The ratio between the materials121and122in the layer110bof the stack formation100to be formed is also stored in the storage unit17a.

The controller17has the following functions (1) to (3).

(1) A function of selectively injecting the materials from the nozzles33.

(2) A function of judging the shape of the material on the base110a.

(3) A function of trimming the material on the base110a.

Now, these functions (1) to (3) are described.

The function (1) is a function of selectively injecting the first material121and the second material122from the nozzles33in accordance with the preset ratio between the first material121and the second material122in each layer110bof the stack formation100stored in the storage unit17a. More specifically, the function (1) controls the supply means31band32bof the first supply device31and the second supply device32, and adjusts the ratio between the first material121and the second material122set in the predetermined layer110bof the stack formation100when the layer110bis formed. The function (1) changes the ratio between the first material121and the second material122to form a slanted material, for example, when the stack formation100is partly formed by different materials or at a different ratio.

In more detail, for example, when one end side of the stack formation is only formed by the first material121and the other end side of the stack formation is only formed by the second material122, the first material alone is first supplied to stack the layer110bon the base110aand form a part which is formed by the first material121alone. The ratio between the first material and the second material is then changed by degrees up to the part formed by the second material122alone, and the ratio of the materials of the layer110bis changed so that the ratio between the first material and the second material is fifty percent at an intermediate position between the part formed by the first material121alone and the part formed by the second material122alone. Thus, the function (1) changes the ratio between the first material121and the second material122, and can thereby form a slanted material in which the ratio between the first material121and the second material122changes by degrees.

The function (2) is a function of using the measurement device16to measure the shape of the layer110bor the stack formation100formed by the first material121and the second material122injected from the nozzles33on the base110a, and comparing the shape with the threshold in the storage unit17ato judge whether a part which is different from the predetermined shape is formed. More specifically, the first material121and the second material122are injected from the nozzles33by the use of the gasses and melted by the laser light200, so that when the materials121and122are supplied onto the base110aand the layer110b, parts of the materials121and122may be scattered and a part which is different from the predetermined shape may be formed. The function (2) compares the shape measured by the measurement device16with the threshold stored in the storage unit17ato detect the scattered materials121and122, and judges whether the materials121and122are supplied to be formed into the predetermined shape. In other words, the function (2) is a function of judging whether the materials121and122are attached to the part which is different from the predetermined shape of the stack formation100and the stack formation100has a part projecting from the predetermined shape (threshold).

The function (3) is a function of removing the materials121and122having shapes different from the predetermined shape that are measured by the function (2) and thereby trimming the materials121and122supplied from the nozzles33into the predetermined shape. More specifically, when the materials121and122are scattered and attached to the part which is different from the predetermined shape in accordance with the function (2), the function (3) controls the light source41so that the laser light200emitted from the fourth lens54via the first galvano-mirror57has a power density that can evaporate the materials121and122. The function (3) then controls the first galvano-mirror57, and applies the laser light200to this part to evaporate the materials121and122and thereby trim the materials121and122into the predetermined shape.

Now, the manufacturing method of the stack formation100using the stack forming apparatus1is described with reference toFIG. 2andFIG. 4.

First, as shown inFIG. 4, the controller17controls the first supply device31and the second supply device32to spray predetermined amounts of the first material121and the second material122from the nozzles33within a predetermined range. More specifically, the first supply device31and the second supply device32are controlled by the controller17, and the first material121and/or the second material122in powder form are injected from the injection holes37at a predetermined ratio to produce a predetermined material for the layer110bto be formed. The laser light200is applied to melt the injected materials121and122.

Thus, as shown inFIG. 2, a predetermined amount of the melted material123is supplied within a range on the base110ain which the layer110bis to be formed. For example, when injected to the base110aor the layer110b, the material123is deformed into an aggregate of the material123in layer or thin film form, or cooled by the gas carrying the material123or cooled by heat liberation transferring the heat to the aggregate of the material123, and stacked in granular form into a granular aggregate.

The melting device45is then controlled to apply the laser light200to the aggregate of the material123on the base110a, and the aggregate of the material123is remelted into the layer110band also annealed. The measurement device16then measures the annealed material123on the base110a. The controller17compares the shape of the material123on the base110ameasured by the measurement device16with the threshold stored in the storage unit17a.

If the material123on the base110ais formed into the layer110bhaving the predetermined shape, the controller17again controls the first supply device31and the second supply device32to newly form a layer110bon the formed layer110b.

When the material123on the base110ais attached to a position different from the predetermined shape, the controller17controls the removing device46to apply the laser light200to the attached material123aand evaporate the unnecessary material123a. Thus, the controller17applies the laser light200to the part where the shape of the material123measured by the measurement device16is different from the predetermined shape to remove the unnecessary material123, thereby trimming the material123so that the layer110bwill be formed into a predetermined shape.

After the end of the trimming, the controller17again controls the first supply device31and the second supply device32to newly form a layer110bon the formed layer110b. The layers110bare repeatedly formed and stacked in this way so that the stack formation100is formed.

The stack forming apparatus1having the above-mentioned configuration can supply the predetermined amounts of the first material121and/or the second material122to the nozzles33by the controller17, and mix the first material121and the second material122by the nozzles33and spray the materials by the laser light200. Thus, the materials121and122can be supplied by a predetermined ratio, and different materials can be used for the stack formation100. The stack formation100will then be a slanted material.

The stack forming apparatus1uses the melting device45to remelt the material123(layer110b) supplied onto the base110ainto layer form, and can remove residual stress by annealing. Moreover, the mixing of the materials121and122can be ensured, and strength can therefore be improved.

Furthermore, the stack forming apparatus1compares the shape of the material123measured by the measurement device16with the threshold in the storage unit17a, and removes the unnecessarily supplied material123, and can therefore trim in accordance with the shape of the supplied material123. Thus, even if the material123is configured to be injected from the nozzles33, the scattered and attached unnecessary material123can be removed, and the stack formation100having the predetermined shape can be formed.

As described above, the stack forming apparatus1according to the first embodiment can form, anneal, and trim the slanted material, and manufacture the stack formation100by using the materials121and122in powder form.

Second Embodiment

Now, a stack forming apparatus1A according to the second embodiment is described with reference toFIG. 5,FIG. 5is an explanatory diagram schematically showing the configuration of the stack forming apparatus1A according to the second embodiment. Components of the stack forming apparatus1A according to the second embodiment that are similar to the components of the stack forming apparatus1according to the first embodiment described above are provided with the same reference signs and not described in detail.

As shown inFIG. 5, the stack forming apparatus1A comprises a treatment tank11, a stage12, a moving device13, a nozzle device14, an optical device15A, a measurement device16, and a controller17. The stack forming apparatus1A is configured to stack layers of a material supplied by the nozzle device14on a target110provided on the stage12, and thereby enables a stack formation100having a predetermined shape to be formed.

The optical device15A comprises a pair of light sources41, a first optical system42A connected to one of the light sources41via the cable210, and a second optical system43connected to the other light source41via a cable210.

The first optical system42A is configured to be able to supply laser light200emitted from the light source41to nozzles33and to apply the laser light200to a first material121and a second material122injected to the target110. The second optical system43is configured to be able to apply the laser light200emitted from the light source41to a layer110bon a base110aand to the materials121and122.

More specifically, the first optical system42A comprises a first lens51, a second lens52, a third lens53, and a galvano-scanner55A. The first optical system42A comprises an adjustment device which can move the first lens51, the second lens52, and the third lens53in two axial directions; more specifically, in directions that intersect at right angles with or intersect with an optical path.

The galvano-scanner55A is configured to be able to split the parallel light converted by the first lens51into the second lens52and the third lens53. The galvano-scanner55A comprises a first galvano-mirror58and a second galvano-mirror59. Each of the galvano-mirrors58and59is configured to be able to vary the inclination angle and split the laser light200.

The first optical system42A is configured to dispense with the fourth lens54and the first galvano-mirror57of the optical system42described above. This first optical system42A constitutes a melting device45which uses the first galvano-mirror58and the third lens53to apply the laser light200to the first material121(123) and the second material122(123) supplied to the target110, and thereby remelts the materials121and122into layer form and anneal the materials.

The second optical system43comprises, for example, the first lens51and the fourth lens54. The second optical system43constitutes a removing device46A which uses the laser light200supplied from the light source41to remove unnecessary parts formed on the base110aand the layer110hby the first material121and the second material122. For example, the light source41connected to the second optical system43is configured to be able to emit picosecond laser as the laser light200. The second optical system43may be configured to dispense with the galvano-scanner or configured to have the galvano-scanner.

This stack forming apparatus1A is similar in configuration to the stack forming apparatus1, and is configured so that the first optical system42A including the melting device45of the optical device15A is provided separately from the removing device46A (43).

In the same manner as the stack forming apparatus1described above, this stack forming apparatus LA is configured to be able to mix and inject the first material121and the second material122by the nozzles33, and supply predetermined amounts of the first material121and/or the second material122by the controller17. Thus, the materials121and122can be supplied at a predetermined ratio, and different materials can be used for the stack formation100. The stack formation100will then be a slanted material.

The stack forming apparatus1A uses the melting device45to remelt the material123(layer110b) supplied onto the base110ainto layer form, and can remove residual stress by annealing. Moreover, the mixing of the materials121and122can be ensured, and strength can therefore be improved.

Furthermore, the stack forming apparatus1A compares the shape of the material123measured by the measurement device16with a threshold in a storage unit17a, and removes the unnecessarily supplied material123, and can therefore trim in accordance with the shape of the supplied material123. Thus, even if the material123is configured to be injected from the nozzles33, the scattered unnecessary material123can be removed, and the stack formation100having the predetermined shape can be formed.

As described above, the stack forming apparatus1A according to the second embodiment can form, anneal, and trim the slanted material, and manufacture the stack formation100by using the materials121and122in powder form.

Third Embodiment

Now, a stack forming apparatus1B according to the third embodiment is described with reference toFIG. 6.FIG. 6is an explanatory diagram schematically showing the configuration of the stack forming apparatus1B according to the third embodiment. Components of the stack forming apparatus1B according to the third embodiment that are similar to the components of the stack forming apparatus1according to the first embodiment and the components of the stack forming apparatus1A according to the second embodiment described above are provided with the same reference signs and not described in detail.

As shown inFIG. 6, the stack forming apparatus1B comprises a treatment tank11, a stage12, a moving device13, a nozzle device14, an optical device15E, a measurement device16, and a controller17. The stack forming apparatus1B also comprises a removing device46B. The stack forming apparatus1B is configured to stack layers of a material supplied by the nozzle device14on a target110provided on the stage12, and thereby enables a stack formation100having a predetermined shape to be formed.

The optical device15B comprises a light source41, and an optical system42B connected to the light source41via a cable210.

The optical system42B is configured to be able to supply laser light200emitted from the light source41to nozzles33and to apply the laser light200to a predetermined range of a first material121and a second material122injected toward the target110.

More specifically, the optical system42B comprises a first lens51, a second lens52, a third lens53, a galvano-scanner55A, and an application range adjustment mechanism56which adjusts the application range of the laser light200. The optical system42B comprises an adjustment device which can move the first lens51, the second lens52, and the third lens53in two axial directions, more specifically, in directions that intersect at right angles with or intersect with an optical path. This optical system42B is configured to be able to use the application range adjustment mechanism56to adjust the application range of the laser light200supplied to the target110by a first galvano-mirror58and the third lens53. The optical system42B constitutes a melting device45B which can remelt and anneal the first material121(123) and the second material122(123) by the laser light200having its application range adjusted by the first lens51, the third lens53, the first galvano-mirror58, and the application range adjustment mechanism56.

The application range adjustment mechanism56comprises a zoom mechanism56awhich can enlarge the application range of the laser light200, and a mask mechanism56bwhich forms the application range enlarged by the zoom mechanism56ainto a predetermined shape. The zoom mechanism56ais connected to the controller17via a signal line220, and is configured to be able to enlarge the range of the laser light200to remelt the materials121and122. When the range of the laser light20f) is enlarged, the controller17increases the output of the light source41to a power range such that the materials121and122can be melted by the laser light200.

The mask mechanism56bis connected to the controller17via, the signal line220, and is configured to be able to change the shape of the application range of the laser light200depending on the part of a layer110bto which the laser light200is to be applied. For example, under the control of the controller17, the mask mechanism56bis configured to be able to change masks depending on the application position and apply the laser light200to an appropriate application range of the layer110b.

The removing device46B is, for example, a cutting device configured to be able to cut the material123by a cutting tool. The removing device46B is connected to the controller17via the signal line220, and is configured to be able to be movable by the controller17.

This stack forming apparatus1B is similar in configuration to the stack forming apparatuses1and1A, and is configured to use the application range adjustment mechanism56to vary the application range of the laser light200by the melting device45B which melts the materials121and122. The stack forming apparatus1B is also configured to cut and remove unnecessary materials by the removing device46B.

In the same manner as the stack forming apparatuses1and1A described above, this stack forming apparatus1B is configured to be able to supply predetermined amounts of the first material121and/or the second material122by the controller17, and mix and inject the first material121and the second material122by the nozzles33. Thus, the materials121and122can be supplied at a predetermined ratio, and different materials can be used for the stack formation100. The stack formation100will then be a slanted material.

The stack forming apparatus1B compares the shape of the material123measured by the measurement device16with a threshold in a storage unit17a, and can perform trimming to remove the unnecessarily supplied material123by the removing device46B. Thus, even if the material123is configured to be injected from the nozzles33, the scattered unnecessary material123can be removed, and the stack formation100having the predetermined shape can be formed.

The stack forming apparatus1B uses the melting device45B to remelt the material123(layer110b) supplied onto the base110ainto layer form, and can remove residual stress by annealing. Moreover, the mixing of the materials121and122can be ensured, and strength can therefore be improved.

The stack forming apparatus1B can adjust the application range of the laser light200by the application range adjustment mechanism56when remelting and annealing the layer blob on the base110a. As a result, the treatment time for the annealing can be reduced.

As described above, the stack forming apparatus1B according to the third embodiment can form, anneal, and trim the slanted material, and manufacture the stack formation100by using the materials121and122in powder form.

Fourth Embodiment

Now, a stack forming apparatus1C according to the fourth embodiment is described with reference toFIG. 7andFIG. 8.FIG. 7is an explanatory diagram schematically showing the configuration of the stack forming apparatus1C according to the fourth embodiment,FIG. 8is an explanatory diagram showing an example of the manufacture of a stack formation100using the stack forming apparatus1C. Components of the stack forming apparatus1C according to the fourth embodiment that are similar to the components of the stack forming apparatus1according to the first embodiment described above are provided with the same reference signs and not described in detail.

As shown inFIG. 7, the stack forming apparatus1C comprises a treatment tank11, a stage12, a moving device13, a nozzle device14C, an optical device15, a measurement device16, and a controller17.

The nozzle device14C is configured to be able to supply predetermined amounts of materials to the target110on the stage12, and to be able to emit laser light200. More specifically, the nozzle device14comprises a first supply device31which can supply a first material121, a second supply device32which can supply a second material.122, a first nozzle33aconnected to the first supply device31and the optical device15, a second nozzle33bconnected to the second supply device32and the optical device15, and supply pipes34which connect the first supply device31and the first nozzle33aas well as the second supply device32and the second nozzle33b.

The first nozzle33aand the second nozzle33bare respectively connected to the first supply device31and the second supply device32via the supply pipes34. These nozzles33aand33bare connected to the optical device15via a cable210which can transmit the laser light200. The nozzles33aand33bare configured to be movable relative to the stage12.

Each of the nozzles33aand33bcomprises a cylindrical outer envelope36, an injection hole37which is provided in the outer envelope36and which injects the first material121and the second material122from its distal end, a light passage38which transmits the laser light200, and optical lenses39provided in the light passage38.

Now, a manufacturing method of the stack formation100using the stack forming apparatus1C is described with reference toFIG. 8.

First, as shown inFIG. 8, the controller17controls the first supply device31to spray a predetermined amount of the first material121from the nozzle33awithin a predetermined range. More specifically, the first supply device31is controlled by the controller17, and the first material121in powder form is injected from the injection holes37toward the target110to produce a predetermined material for the layer110bto be formed. The laser light200is applied to melt the injected first material121.

The second supply device32is then controlled, and a predetermined amount of the second material122is injected from the nozzle33btoward the target110and thus melted by the laser light200, whereby the second material122is sprayed within a predetermined range.

Thus, as shown inFIG. 8, the first material121and the second material122are provided on a base110a. More specifically, the first material121is attached to the base110a, and the second material122is then attached to the first material121. In other words, the first material121and the second material122are stacked on the base110a. The laser light200is then applied to an aggregate of the materials121and122by a melting device45to remelt the aggregate of the materials121and122and thus form the layer110b. As a result, the materials121and122are mixed to form the layer110b, and the layer110bis annealed. A material123on the base110aannealed by remelting is then measured by the measurement device16. The controller17compares the shape of the material123on the base110ameasured by the measurement device16with the threshold stored in the storage unit17a.

If the material123on the base110ais formed into the layer110bhaving the predetermined shape, the controller17again controls the first supply device31to supply the first material121, and then controls the second supply device32to supply the second material122. The melting device45is then controlled to remelt and then anneal the materials121and122, and a layer110bis newly formed on the layer110b.

When the material123on the base110ais attached to a position different from the predetermined shape, the controller17controls a removing device46to apply the laser light200to the attached material123and evaporate the attached material123. Thus, the controller17applies the laser light200to and thereby trims the part where the shape of the material123measured by the measurement device16is different from the predetermined shape.

After the end of the trimming, the controller17again controls the first supply device31and the second supply device32to newly form a layer110bon the formed layer110b. The layers110bare repeatedly formed and stacked in this way so that the stack formation100is formed.

The stack forming apparatus10having the above-mentioned configuration can form, anneal, and trim the slanted material, and manufacture the stack formation100by using the materials121and122in powder form, as in the first embodiment described above.

The stack forming apparatuses1,1A,1B, and1C according to the embodiments are not limited to the configurations described above. For example, each of the stack forming apparatuses1,1A,1B, and1C is configured to comprise the treatment tank11having the main chamber21and the auxiliary chamber22in the examples described above, but is not limited to this configuration. For example, the treatment tank11may be configured to have the main chamber21alone, or may be configured to have an auxiliary chamber which does not have the conveying device24. However, when the treatment tank11is configured to use the auxiliary chamber22, the atmosphere in the main chamber21can be maintained, and it is easier to continue operation in the main chamber21and the auxiliary chamber22. When the stack formation100is configured to be conveyed to the auxiliary chamber22, the material injected from the nozzles33in the main chamber21and thus airborne in the main chamber21do not easily escape from the chamber. This, it is preferable that the treatment tank11is configured to have the auxiliary chamber22adjacent to the main chamber21.

In the examples described above, the optical device15comprises the melting device45which remelts the materials121and122supplied from the nozzles33to form the layer110band anneals the materials. However, this is not a limitation. For example, the stack forming apparatus may be configured to form the layer110bnot by melting but by sintering and annealing the layer110b.

In the examples described above, the measurement device16is configured to comprise the camera61, and the image processor62which performs image processing in accordance with the information measured by the camera61. However, this is not a limitation. The measurement device16may have any other configuration that can measure the shape of the material supplied onto the base110a.

In the examples described above, the stack forming apparatus1is configured so that the nozzles33and the stage12are movable. However, this is not a limitation. The stack forming apparatus may be configured so that the nozzles33alone or the stage12alone is movable.

In the examples described above, two nozzles33having the injection holes37different in diameter are provided. However, this is not a limitation. More than two nozzles33may be provided. When more than one nozzle33is provided, the most efficient nozzle33can be used depending on the area and shape to which the material is to be injected, and the stack formation100can be efficiently formed.