Patent Description:
In the related art, production methods for producing a three-dimensional shaped article by stacking layers have been performed. Among these, a three-dimensional shaped article production method in which a three-dimensional shaped article is formed on a support has been disclosed.

For example, <CIT> (Patent Document <NUM>) discloses a three-dimensional shaped article production method in which a three-dimensional shaped article is formed on an up-and-down table as a support while sintering a metal powder layer.

However, in a three-dimensional shaped article production method in which a three-dimensional shaped article is formed on a support as disclosed in Patent Document <NUM>, a sintered body of the three-dimensional shaped article is integrated with the support, or the like, and therefore, it is difficult to separate the sintered body of the three-dimensional shaped article from the support.

<CIT> discloses a method of manufacturing a three-dimensional structure, in which the three-dimensional structure is manufactured by laminating a layer, the method including: forming the layer using a three-dimension formation composition containing particles, a binding resin, and a water-based solvent; removing the water-based solvent from the layer by heating the layer; and applying a binding solution containing a binder to the layer, in which the binding resin has an ammonium salt of a carboxyl group as a functional group.

<CIT> discloses a <NUM>-D shaping device having nozzles for discharging model material, a first support material and a second auxiliary support material having release performance. As such discharge of liquids having different characteristics by an ink jet head is facilitated. Also, releasability is facilitated between a conventional support material and a conventional model material.

<CIT> discloses a method and apparatus for three-dimensional part fabrication from a slurry which comprises at least a polymer, an organic binder and a solvent. The slurry is formed as a sacrificial layer and solidified by drying. The sacrificial layer can be disintegretaed by being soaked in a developer, or irradiated with an energy beam to form a part layer which does not dissolve in the developer.

<CIT> discloses a manufacturing method of a three-dimensional structure which manufactures a three-dimensional structure by laminating layers, the method including: forming the layers using a composition "A" containing three-dimensional formation powders and a solvent; discharging a binding solution for binding the three-dimensional formation powders to the layers; binding the three-dimensional formation powders by curing the discharged binding solution; removing the non-bound three-dimensional formation powders using the solvent; and additionally adding the three-dimensional formation powders to a mixed solution generated by the removing and containing the non-bound three-dimensional formation powders and the solvent, and preparing a composition "B" containing the three-dimensional formation powders and the solvent.

An advantage of some aspects of the invention is to reduce the load when a three-dimensional shaped article is separated from a support.

According to a first aspect of the invention, there is provided a three-dimensional shaped article production method according to claim <NUM>.

According to this aspect of the invention, after the separation step of separating the second layer from the support, the sintering step of sintering the second layer is performed. Therefore, the integration or the like of the sintered body of the three-dimensional shaped article with the support can be suppressed, and the load when the three-dimensional shaped article is separated from the support can be reduced.

Also according to this aspect, before the separation step, a separation promotion step of promoting the separation of the second layer from the support is performed. Therefore, the separation step can be facilitated.

Also according to this aspect, the separation promotion step is a heating step of performing heating at a temperature higher than the decomposition temperature of the binder contained in the first composition and lower than the decomposition temperature of the binder contained in the second composition. Therefore, the separation promotion step can be performed easily.

Also according to this aspect, a binding force between the first particles by the binder contained in the first composition is smaller than a binding force between the second particles by the binder contained in the second composition. Therefore, when the second layer (a stacked body of the three-dimensional shaped article) is separated from the support in the separation step, the second layer is easily separated from the support without damaging the three-dimensional shaped article.

According to the preferable feature of claim <NUM>, the amount of the binder contained in the first composition is smaller than the amount of the binder contained in the second composition. Therefore, a binding force between the first particles by the binder contained in the first composition can be made smaller than a binding force between the second particles by the binder contained in the second composition. As a result, when the second layer (a stacked body of the three-dimensional shaped article) is separated from the support in the separation step, the second layer is easily separated from the support without damaging the three-dimensional shaped article.

According to the preferable feature of claim <NUM>, the separation promotion step is an electromagnetic wave irradiation step of irradiating the first composition with an electromagnetic wave through the support. Therefore, the separation promotion step can be performed easily.

According to the preferable feature of claim <NUM>, a titania layer is formed on the support. The binder which is in contact with the titania layer is easily decomposed by irradiation with an electromagnetic wave, and therefore, in the separation step, the separation of the second layer from the support can be particularly easily performed through the titania layer.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, wherein like numbers reference like elements.

Hereinafter, embodiments according to the invention will be described with reference to the accompanying drawings.

<FIG> are schematic configuration views showing a configuration of a three-dimensional shaped article production apparatus according to an embodiment of the invention.

Here, the three-dimensional shaped article production apparatus according to this embodiment includes two material supply sections (head bases) and one heating section. Among these, <FIG> are views showing only one material supply section (a material supply section which supplies a constituent material (a material containing particles constituting a three-dimensional shaped article, a solvent, and a binder)). <FIG> are views showing one material supply section (a material supply section which supplies a support layer forming material for forming a support layer that supports a three-dimensional shaped article when the three-dimensional shaped article is formed) and one heating section (a heating section using a laser for sintering the support layer forming material).

The "three-dimensional shaping" as used herein refers to the formation of a so-called "three-dimensional shaped article", and also includes, for example, the formation of a shape with a thickness even if the shape is a plate shape or a so-called two-dimensional shape. Further, the "supporting" as used herein includes supporting from the lower side, and in addition thereto, also includes supporting from the lateral side, and in some cases, supporting from the upper side.

A three-dimensional shaped article production apparatus <NUM> (hereinafter referred to as "forming apparatus <NUM>") shown in <FIG> includes a base <NUM> and a stage <NUM> which is provided movably in the X, Y, and Z directions shown in the drawing or drivably in the direction of rotation about the Z axis by a drive device <NUM> as a drive unit provided for the base <NUM>.

Then, as shown in <FIG>, the three-dimensional shaped article production apparatus <NUM> includes a head base support section <NUM>, one end of which is fixed to the base <NUM>, and to the other end of which, a head base <NUM> that holds a plurality of head units <NUM> each including a constituent material ejection section <NUM> that ejects a constituent material is held and fixed.

Further, as shown in <FIG>, the three-dimensional shaped article production apparatus <NUM> includes a head base support section <NUM>, one end of which is fixed to the base <NUM>, and to the other end of which, a head base <NUM> that holds a plurality of head units <NUM> each including a support layer forming material ejection section <NUM> that ejects a material for forming a support layer that supports a three-dimensional shaped article is held and fixed.

Here, the head base <NUM> and the head base <NUM> are provided in parallel in the XY plane.

The constituent material ejection section <NUM> and the support layer forming material ejection section <NUM> have the same configuration. However, the configuration is not limited thereto.

On the stage <NUM>, layers <NUM>, <NUM>, and <NUM> are formed in the process for forming a three-dimensional shaped article <NUM>. In the formation of the three-dimensional shaped article <NUM>, thermal energy is applied by a laser or the like, and therefore, in order to protect the stage <NUM> from heat, by using a sample plate <NUM> having heat resistance, the three-dimensional shaped article <NUM> may be formed on the sample plate <NUM>. The sample plate <NUM> of this embodiment is made of a metal so that it is sturdy and can make the surface smooth (capable of producing the three-dimensional shaped article <NUM> with higher accuracy) and also is easily produced. However, as the sample plate <NUM>, for example, by using a ceramic plate, high heat resistance can be obtained, and also the reactivity with the constituent material of the three-dimensional shaped article to be melted (or which may be sintered) is low, and thus, alteration of the three-dimensional shaped article <NUM> can be prevented. Incidentally, in <FIG> and <FIG>, for the sake of convenience of explanation, three layers: the layers <NUM>, <NUM>, and <NUM> are shown as examples, however, the layers (up to the layer 50n in <FIG> and <FIG>) are stacked until the desired shape of the three-dimensional shaped article <NUM> is obtained. In this manner, in the forming apparatus <NUM> of this embodiment, the three-dimensional shaped article <NUM> can be formed by using the sample plate <NUM>, and also the three-dimensional shaped article <NUM> can be formed without using the sample plate <NUM>. Therefore, either of the stage <NUM> and the sample plate <NUM> can serve as the support when forming the three-dimensional shaped article <NUM>. However, in the following description, a case where the three-dimensional shaped article <NUM> is formed using the sample plate <NUM> is assumed and described.

Here, the layer <NUM> is a so-called release layer, and is constituted by a support layer <NUM> formed from a support layer forming material ejected from the support layer forming material ejection section <NUM>. The layer <NUM> is a first layer S1 formed by supplying the support layer forming material as a first composition containing first particles and a binder onto the support (see <FIG>).

Further, the layers <NUM>, <NUM>,. , and 50n are each constituted by a support layer <NUM> formed from the support layer forming material ejected from the support layer forming material ejection section <NUM> and a constituent layer <NUM> formed from the constituent material ejected from the constituent material ejection section <NUM>. In other words, the layers <NUM>, <NUM>,. , and 50n are a second layer S2 composed of one layer or a plurality of layers formed by supplying the constituent material as a second composition containing second particles and a binder onto the layer <NUM> as the first layer S1 (see <FIG>).

<FIG> is an enlarged conceptual view of a portion C showing the head base <NUM> shown in <FIG>. As shown in <FIG>, the head base <NUM> holds a plurality of head units <NUM>. Although a detailed description will be given later, each head unit <NUM> is configured such that the constituent material ejection section <NUM> included in a constituent material supply device <NUM> is held by a holding jig 1400a. The constituent material ejection section <NUM> includes an ejection nozzle 1230a and an ejection drive section 1230b that allows the constituent material to be ejected from the ejection nozzle 1230a by a material supply controller <NUM>.

<FIG> is an enlarged conceptual view of a portion C' showing the head base <NUM> shown in <FIG>. As shown in <FIG>, the head base <NUM> holds a plurality of head units <NUM>. Each head unit <NUM> is configured such that the support layer forming material ejection section <NUM> included in a support layer forming material supply device <NUM> is held by a holding jig 1900a. The support layer forming material ejection section <NUM> includes an ejection nozzle 1730a and an ejection drive section 1730b that allows the support layer forming material to be ejected from the ejection nozzle 1730a by the material supply controller <NUM>. Further, in the case where a material which can be sintered is used as the support layer forming material, a laser irradiation section <NUM> for sintering the support layer forming material and a galvanometer mirror <NUM> which determines the position of the laser light from the laser irradiation section <NUM> are provided on the upper side of the stage <NUM>.

As shown in <FIG>, the constituent material ejection section <NUM> is connected to a constituent material supply unit <NUM> which houses a constituent material made to correspond to each head unit <NUM> held by the head base <NUM> through a supply tube <NUM>. Then, a given constituent material is supplied to the constituent material ejection section <NUM> from the constituent material supply unit <NUM>. In the constituent material supply unit <NUM>, the constituent material of the three-dimensional shaped article <NUM> to be shaped by the forming apparatus <NUM> according to this embodiment is housed in a constituent material housing section 1210a, and each individual constituent material housing section 1210a is connected to each individual constituent material ejection section <NUM> through the supply tube <NUM>. In this manner, by including the individual constituent material housing sections 1210a, a plurality of different types of materials can be supplied from the head base <NUM>.

As shown in <FIG>, the support layer forming material ejection section <NUM> is connected to a support layer forming material supply unit <NUM> which houses a support layer forming material made to correspond to each head unit <NUM> held by the head base <NUM> through a supply tube <NUM>. Then, a given support layer forming material is supplied to the support layer forming material ejection section <NUM> from the support layer forming material supply unit <NUM>. In the support layer forming material supply unit <NUM>, the support layer forming material constituting a support layer when shaping the three-dimensional shaped article <NUM> is housed in a support layer forming material housing section 1710a, and each individual support layer forming material housing section 1710a is connected to each individual support layer forming material ejection section <NUM> through the supply tube <NUM>. In this manner, by including the individual support layer forming material housing sections 1710a, a plurality of different types of materials can be supplied from the head base <NUM>.

Examples of the support layer forming material and the constituent material (the materials of the first particles and the second particles) include simple substance powders of magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper, (Cu), and nickel (Ni), alloys containing at least one metal among these (a maraging steel, stainless steel, cobalt-chrome-molybdenum, a titanium alloy, a nickel alloy, an aluminum alloy, a cobalt alloy, and a cobalt-chrome alloy), various metal oxides such as silica, alumina, titanium oxide, zinc oxide, zircon oxide, tin oxide, magnesium oxide, and potassium titanate, various metal hydroxides such as magnesium hydroxide, aluminum hydroxide, and calcium hydroxide, various metal nitrides such as silicon nitride, titanium nitride, and aluminum nitride, various metal carbides such as silicon carbide and titanium carbide, various metal sulfides such as zinc sulfide, various metal carbonates such as calcium carbonate and magnesium carbonate, various metal sulfates such as calcium sulfate and magnesium sulfate, various metal silicates such as calcium silicate and magnesium silicate, various metal phosphates such as calcium phosphate, various metal borates such as aluminum borate and magnesium borate, composite compounds and the like thereof, and gypsum (various hydrates of calcium sulfate and anhydrous calcium sulfate).

A mixed powder of these materials can be used by being mixed with a solvent and a binder to form a mixed material or the like in the form of a slurry (or a paste).

It is also possible to use general purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate. In addition thereto, it is also possible to use engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyether ether ketone.

In this manner, the constituent material and the support layer forming material are not particularly limited, and a metal other than the above-mentioned metals, a ceramic, a resin, or the like can also be used.

Examples of the solvent include water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetate esters such as ethyl acetate, n-propyl acetate, iso-propyl acetate, n-butyl acetate, and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, and acetyl acetone; alcohols such as ethanol, propanol, and butanol; tetra-alkyl ammonium acetates; sulfoxide-based solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and <NUM>,<NUM>-lutidine; and ionic liquids such as tetra-alkyl ammonium acetate (for example, tetra-butyl ammonium acetate, etc.), and one type or two or more types in combination selected from these can be used.

As the binder, for example, an acrylic resin, an epoxy resin, a silicone resin, a cellulosic resin, or another synthetic resin, or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PVDF (polyvinylidene fluoride), CMC (carboxymethyl cellulose), or another thermoplastic resin can be used.

The forming apparatus <NUM> includes a control unit <NUM> as a control device which controls the stage <NUM>, the constituent material ejection section <NUM> included in the constituent material supply device <NUM>, and the support layer forming material ejection section <NUM> included in the support layer forming material supply device <NUM> based on the data for shaping a three-dimensional shaped article to be output from a data output device such as, for example, a personal computer (not shown) or the like. The control unit <NUM> includes a control section (not shown) which controls the stage <NUM> and the constituent material ejection section <NUM> so that these members are driven and operated in cooperation with each other, and also controls the stage <NUM> and the support layer forming material ejection section <NUM> so that these members are driven and operated in cooperation with each other.

The stage <NUM> is provided movably on the base <NUM>, and a signal for controlling the start and stop of movement, the direction of movement, the amount of movement, the speed of movement, or the like of the stage <NUM> is generated in a stage controller <NUM> based on a control signal from the control unit <NUM> and sent to the drive device <NUM> included in the base <NUM>, and the stage <NUM> moves in the X, Y, or Z direction shown in the drawing. In the constituent material ejection section <NUM> included in the head unit <NUM>, a signal for controlling the amount of the material ejected from the ejection nozzle 1230a in the ejection drive section 1230b included in the constituent material ejection section <NUM> or the like is generated in the material supply controller <NUM> based on a control signal from the control unit <NUM>, and a predetermined amount of the constituent material is ejected from the ejection nozzle 1230a based on the generated signal.

In the same manner, in the support layer forming material ejection section <NUM> included in the head unit <NUM>, a signal for controlling the amount of the material ejected from the ejection nozzle 1730a in the ejection drive section 1730b included in the support layer forming material ejection section <NUM> or the like is generated in the material supply controller <NUM> based on a control signal from the control unit <NUM>, and a predetermined amount of the support layer forming material is ejected from the ejection nozzle 1730a based on the generated signal.

Next, the head unit <NUM> will be described in further detail. The head unit <NUM> has the same configuration as that of the head unit <NUM>, and therefore, a description of the detailed configuration of the head unit <NUM> will be omitted.

<FIG> show one example of the holding form of a plurality of head units <NUM> and the constituent material ejection sections <NUM> held by the head base <NUM>, and among these, <FIG> are external views of the head base <NUM> viewed from the direction of the arrow D shown in <FIG>.

As shown in <FIG>, a plurality of head units <NUM> are held by the head base <NUM> through a fixing unit (not shown). Further, as shown in <FIG>, in the head base <NUM> of the forming apparatus <NUM> according to this embodiment, the head units <NUM> are included such that the following <NUM> units: a head unit <NUM> in the first row from the lower side in the drawing, a head unit <NUM> in the second row, a head unit <NUM> in the third row, and a head unit <NUM> in the fourth row are arranged in a staggered manner (alternately). Then, as shown in <FIG>, while moving the stage <NUM> in the X direction with respect to the head base <NUM>, the constituent material is ejected from each head unit <NUM>, whereby constituent layer constituting parts <NUM> (constituent layer constituting parts 50a, 50b, 50c, and 50d) are formed. The procedure for forming the constituent layer constituting parts <NUM> will be described later.

Incidentally, although not shown in the drawing, the constituent material ejection sections <NUM> included in the respective head units <NUM> to <NUM> are configured to be connected to the constituent material supply unit <NUM> through the ejection drive section 1230b with the supply tube <NUM>.

As shown in <FIG>, the constituent material ejection section <NUM> ejects a material M which is the constituent material of the three-dimensional shaped article from the ejection nozzle 1230a to the layer <NUM> (the support layer <NUM> as the release layer) as the first layer S1 formed on the sample plate <NUM> placed on the stage <NUM>. In the head unit <NUM>, an ejection form in which the material M is ejected in the form of a liquid droplet is illustrated, and in the head unit <NUM>, an ejection form in which the material M is ejected in the form of a continuous body is illustrated. The ejection form of the material M may be in the form of either a liquid droplet or a continuous body, however, in this embodiment, a case where a form in which the material M is ejected in the form of a liquid droplet is adopted will be described. Incidentally, a supply form of the material M is not limited to such a configuration, and for example, a configuration in which a material in the form of a solid at normal temperature is converted into a liquid by heating and ejected, or the like may be adopted.

The material M ejected in the form of a liquid droplet from the ejection nozzle 1230a flies substantially in the direction of gravity and lands on the sample plate <NUM>. The stage <NUM> moves, and by the material M landing on the sample plate <NUM>, the constituent layer constituting parts <NUM> are formed. An assembly of the constituent layer constituting parts <NUM> is formed as the layer <NUM> constituting the second layer S2 or the constituent layer <NUM> of the three-dimensional shaped article <NUM>.

Next, the procedure for forming the constituent layer constituting parts <NUM> will be described with reference to <FIG>.

<FIG> are plan views conceptually illustrating the relationship between the arrangement of head units <NUM> of this embodiment and the form of formation of the constituent layer constituting parts <NUM>. <FIG> are side views conceptually illustrating the form of formation of the constituent layer constituting parts <NUM>.

First, when the stage <NUM> moves in the +X direction, the material M is ejected in the form of a liquid droplet from the plurality of ejection nozzles 1230a, and the material M is placed at a predetermined position on the sample plate <NUM>, and therefore, the constituent layer constituting parts <NUM> are formed.

More specifically, first, as shown in <FIG>, while moving the stage <NUM> in the +X direction, the material M is placed at predetermined positions at regular intervals on the sample plate <NUM> from the plurality of ejection nozzles 1230a.

Subsequently, as shown in <FIG>, while moving the stage <NUM> in the -X direction shown in <FIG>, the material M is newly placed so as to fill the gap between the materials M placed at regular intervals.

However, a configuration in which while moving the stage <NUM> in the +X direction, the materials M are ejected from the plurality of ejection nozzles 1230a so that the materials M overlap with each other (so as not to form a gap) at predetermined positions on the sample plate <NUM> (not a configuration in which the constituent layer constituting parts <NUM> are formed by the reciprocation of the stage <NUM> in the X direction, but a configuration in which the constituent layer constituting parts <NUM> are formed by only one way movement of the stage <NUM> in the X direction) may be adopted.

By forming the constituent layer constituting parts <NUM> as described above, the constituent layer constituting parts <NUM> (the constituent layer constituting parts 50a, 50b, 50c, and 50d) for one line (of the first line in the Y direction) in the X direction of the respective head units <NUM>, <NUM>, <NUM>, and <NUM> as shown in <FIG> are formed.

Subsequently, in order to form constituent layer constituting parts <NUM>' (constituent layer constituting parts 50a', 50b', 50c', and 50d') of the second line in the Y direction of the respective head units <NUM>, <NUM>, <NUM>, and <NUM>, the head base <NUM> is moved in the -Y direction. As for the amount of movement, when the pitch between the nozzles is represented by P, the head base <NUM> is moved in the -Y direction by a distance of P/n (n represents a natural number). In this embodiment, a description will be given by assuming that n is <NUM>.

By performing the same operation as described above as shown in <FIG>, the constituent layer constituting parts <NUM>' (constituent layer constituting parts 50a', 50b', 50c', and 50d') of the second line in the Y direction as shown in <FIG> are formed.

Subsequently, in order to form constituent layer constituting parts <NUM>" (constituent layer constituting parts 50a", 50b", 50c", and 50d") of the third line in the Y direction of the respective head units <NUM>, <NUM>, <NUM>, and <NUM>, the head base <NUM> is moved in the - Y direction. As for the amount of movement, the head base <NUM> is moved in the -Y direction by a distance of P/<NUM>.

Then, by performing the same operation as described above as shown in <FIG>, the constituent layer constituting parts <NUM>" (constituent layer constituting parts 50a", 50b", 50c", and 50d") of the third line in the Y direction as shown in <FIG> are formed, and thus, the constituent layer <NUM> can be obtained.

Further, as for the material M ejected from the constituent material ejection section <NUM>, from any one unit or two or more units of the head units <NUM>, <NUM>, <NUM>, and <NUM>, a constituent material different from the other head units can also be ejected and supplied. Therefore, by using the forming apparatus <NUM> according to this embodiment, a three-dimensional shaped article formed from different materials can also be obtained.

Further, by ejecting the support layer forming material from the support layer forming material ejection section <NUM>, the support layer <NUM> can be formed as the layer <NUM> which is the first layer S1 in the same manner as described above. Then, on the layer <NUM> which is the first layer S1, the constituent layer <NUM> and the support layer <NUM> can be formed in the same manner as described above when the layers <NUM>, <NUM>,. , and 50n which are the second layer S2 are formed. The support layer <NUM> can be sintered or the like using the laser irradiation section <NUM> and the galvanometer mirror <NUM> according to the type of the support layer forming material.

The number and arrangement of the head units <NUM> and <NUM> included in the forming apparatus <NUM> according to this embodiment described above are not limited to the above-mentioned number and arrangement. <FIG> schematically show examples of other arrangements of the head units <NUM> placed in the head base <NUM>.

<FIG> shows a form in which a plurality of head units <NUM> are arranged in parallel in the X-axis direction in the head base <NUM>. <FIG> shows a form in which the head units <NUM> are arranged in a lattice in the head base <NUM>. The number of the head units to be arranged is not limited to the examples shown in <FIG>.

Next, one embodiment of a three-dimensional shaped article production method to be performed using the above-mentioned forming apparatus <NUM> according to this embodiment will be described.

<FIG> are schematic views showing one example of a three-dimensional shaped article production process to be performed using the above-mentioned forming apparatus <NUM>. <FIG> show the three-dimensional shaped article production process viewed from the side.

First, <FIG> shows a state where the support layer <NUM> as a release layer is formed as the first layer S1 on the sample plate <NUM> using the support layer forming material ejection section <NUM>. In this embodiment, as the support layer forming material, a material containing ceramic particles as the first particles and a resin as the binder is used. In this embodiment, as the ceramic particles, particles in a spherical shape are used, however, the shape thereof may be a needle shape, a fibrous shape, a leaf shape, or the like.

Here, <FIG> shows a state where the support layer forming material is ejected from the support layer forming material ejection section <NUM> and also a laser from the laser irradiation section <NUM> is irradiated onto the support layer forming material. The ceramic particles as the first particles are not sintered by the irradiation with the laser, and are in a state where since the binder is left in the support layer <NUM>, the particles on the sample plate <NUM> are bound to one another. Incidentally, the laser irradiation conditions may be appropriately changed according to the type or amount of the resin as the binder, or in the case where a solvent is contained in the support layer forming material, the solvent may be evaporated by irradiation with a laser.

Subsequently, <FIG> shows a state where the support layer <NUM> is formed in a region (three-dimensional shaped article non-formation region) other than the three-dimensional shaped article formation region on the support layer <NUM> as the first layer S1 using the support layer forming material ejection section <NUM>.

Subsequently, <FIG> shows a state where the constituent layer <NUM> is formed as the second layer S2 in the three-dimensional shaped article formation region on the support layer <NUM> as the first layer S1 using the constituent material ejection section <NUM>. In this embodiment, as the constituent material, a material containing metal particles as the second particles and a resin as the binder is used. Here, the type and amount of the respective resins is adjusted so that the binding force between the metal particles by the resin contained in the constituent material is larger than the binding force between the ceramic particles by the resin contained in the support layer forming material. In the case where a solvent is contained in the constituent material, the solvent may be evaporated by irradiation with a laser under the conditions that the metal particles are not sintered.

Then, by repeating the formation of the support layer <NUM> shown in <FIG> and the formation of the constituent layer <NUM> shown in <FIG>, a stacked body of the three-dimensional shaped article is formed as shown in <FIG>.

Here, <FIG> shows a state where the stacked body of the three-dimensional shaped article (the second layer S2) formed as shown in <FIG> is released from the sample plate <NUM>. In <FIG>, a state where the support layer <NUM> as the first layer S1 and the stacked body of the three-dimensional shaped article (the second layer S2) are released from each other is shown, however, the sample plate <NUM> and the support layer <NUM> as the first layer S1 may be released from each other. Further, in a part, the support layer <NUM> as the first layer S1 and the stacked body of the three-dimensional shaped article (the second layer S2) may be released from each other, and in another part, the sample plate <NUM> and the support layer <NUM> as the first layer S1 may be released from each other.

<FIG> shows a state where the constituent layers <NUM> in the stacked body of the three-dimensional shaped article released from the sample plate <NUM> as shown in <FIG> are sintered in a high-temperature chamber (heating chamber) <NUM> provided separately from the forming apparatus <NUM> according to this embodiment. As the metal particles, particles having a lower melting point lower than that of the ceramic particles are selected. Further, the sintering step is performed at a temperature, which is lower than the melting points of the metal particles and the ceramic particles, and at which the metal particles are sintered, but the ceramic particles are not sintered.

Incidentally, in <FIG>, as the sintering of the constituent layers <NUM> in the stacked body of the three-dimensional shaped article proceeds, the binder component contained in the support layers <NUM> is decomposed (thermally decomposed), and by applying a small external force thereto, the ceramic particles are separated from each other and fall apart. In this embodiment, a state where the sintering is performed on a ceramic plate <NUM> which has high heat resistance is shown.

Next, one example of the three-dimensional shaped article production method to be performed using the above-mentioned forming apparatus <NUM> (an example corresponding to <FIG>) will be described with reference to a flowchart.

Here, <FIG> is a flowchart of the three-dimensional shaped article production method according to this embodiment.

As shown in <FIG>, in the three-dimensional shaped article production method according to this embodiment, first, in Step S110, the data of the three-dimensional shaped article is acquired. More specifically, the data representing the shape of the three-dimensional shaped article is acquired from, for example, an application program or the like executed by a personal computer.

Subsequently, in Step S120, data for each layer are created. More specifically, in the data representing the shape of the three-dimensional shaped article, the three-dimensional shaped article is sliced according to the shaping resolution in the Z direction, and bitmap data (cross-sectional data) are created for each cross section.

At this time, the bitmap data to be created are data discriminated between the three-dimensional shaped article formation region (constituent layer <NUM>) and the three-dimensional shaped article non-formation region (support layer <NUM>).

Subsequently, in Step S130, it is determined whether the data of the layer to be formed is the data for forming the three-dimensional shaped article non-formation region (support layer <NUM>) or the data for forming the three-dimensional shaped article formation region (constituent layer <NUM>). This determination is performed by the control section included in the control unit <NUM>.

In this step, in the case where the data is determined to be the data for forming the support layer <NUM>, the process proceeds to Step S140, and in the case where the data is determined to be the data for forming the constituent layer <NUM>, the process proceeds to Step S150.

In Step S140, by ejecting the support layer forming material from the support layer forming material ejection section <NUM> based on the data for forming the support layer <NUM>, the support layer forming material is supplied.

Here, the step of forming the layer <NUM> which is the first layer S1 (a first layer formation step) corresponds to this step. However, also the step of forming the support layer <NUM> in the second layer S2 (a second layer formation step) corresponds to this step. Alternatively, the step of forming the support layer <NUM> in the second layer S2 may correspond to step S150, which is discussed below.

Then, when the support layer forming material is ejected in Step S140, a laser is irradiated (energy is applied) from the laser irradiation section <NUM> through the galvanometer mirror <NUM> in Step S160, whereby the ejected liquid droplet (the support layer <NUM>) is solidified.

On the other hand, in Step S150, by ejecting the constituent material from the constituent material ejection section <NUM>, the constituent material is supplied. The step of forming the layers <NUM>, <NUM>,. , and 50n which are the second layer S2 (a second layer formation step) corresponds to this step.

Then, the process is repeated from Step S130 to Step S170 until it is determined in Step S170 that the formation of the stacked body of the three-dimensional shaped article based on the bitmap data corresponding to the respective layers formed in Step S120 is completed.

Then, the stacked body of the three-dimensional shaped article is released from the sample plate <NUM> in Step S180, and the stacked body of the three-dimensional shaped article formed in the above steps is heated in the high-temperature chamber <NUM> in Step S190. More specifically, the three-dimensional shaped article formation region (constituent layer <NUM>) is sintered.

Then, accompanying the completion of Step S190, the three-dimensional shaped article production method of this embodiment is completed.

As described above, the three-dimensional shaped article production method of this embodiment is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body.

Then, the method includes the first layer formation step (corresponding to Step S140) of forming the first layer S1 on the sample plate <NUM> by supplying the support layer forming material which is the first composition containing the ceramic particles and the resin, the second layer formation step (corresponding to Step S150 and also Step S140 in the case where the support layer <NUM> is formed in the second layer S2) of forming the second layer S2 composed of one layer or a plurality of layers (the stacked body of the three-dimensional shaped article) on the first layer S1 by supplying the constituent material which is the second composition containing the metal particles and the resin, and the separation step (corresponding to Step S180) of separating the second layer S2 from the sample plate <NUM> through the first layer S1. The support layer <NUM> in the second layer S2 may or may not be heated depending on whether it is deposited in step S140 or S150.

Then, after the separation step, the sintering step (corresponding to Step S190) of sintering the second layer S2 is performed.

In this manner, by performing the sintering step of sintering the second layer S2 after the separation step of separating the second layer S2 from the sample plate <NUM>, the integration or the like of the sintered body of the three-dimensional shaped article with the sample plate <NUM> can be suppressed, and the load when the three-dimensional shaped article is separated from the sample plate <NUM> can be reduced.

It goes without saying that when the second layer S2 is formed, not only the layer is formed using the support layer forming material for forming the support layer <NUM> in addition to the constituent material as described above, but also the layer may be formed only from the constituent material.

Further, in the three-dimensional shaped article production method of this embodiment, as described above, the binding force between the ceramic particles by the resin contained in the support layer forming material is adjusted to be smaller than the binding force between the metal particles by the resin contained in the constituent material. Therefore, when the second layer S2 is separated from the sample plate <NUM> in the separation step, the second layer S2 is easily separated from the sample plate <NUM> without damaging the three-dimensional shaped article.

Here, as a method for adjusting the binding force between the ceramic particles by the resin contained in the support layer forming material to be smaller than the binding force between the metal particles by the resin contained in the constituent material, for example, a method in which as the binder contained in the support layer forming material and the binder contained in the constituent material, the same binder is used, and the amount of the binder contained in the support layer forming material is made smaller than the amount of the binder contained in the constituent material can be used. By using such a method, the binding force between the ceramic particles by the resin contained in the support layer forming material can be made smaller than the binding force between the metal particles by the resin contained in the constituent material. As a result, when the second layer S2 is separated from the support in the separation step, the second layer S2 is easily separated from the plate <NUM> without damaging the three-dimensional shaped article.

Specifically, for example, the amount of the binder contained in the support layer forming material is set to <NUM>% or more and <NUM>% or less, and the amount of the binder contained in the constituent material can be set larger than this.

Here, it is preferred that the surface of the plate <NUM> is made smooth by setting the arithmetic average surface roughness Ra of the plate <NUM> to <NUM> or less. It is because by making the surface of the plate <NUM> smooth, the occurrence of an anchor effect or the like on the plate <NUM> can be suppressed, and in the separation step, the separation of the second layer S2 from the plate <NUM> can be particularly easily performed.

Further, although not performed in the three-dimensional shaped article production method of this embodiment, a separation promotion step of promoting the separation of the second layer S2 from the plate <NUM> may be performed before the separation step. This is because the separation step can be facilitated.

For example, as the binders contained in the support layer forming material and in the constituent material, a binder whose decomposition temperature is lower than the decomposition temperature of a binder contained in the constituent material can be used, and in the separation promotion step, the heating step of performing heating at a temperature higher than the decomposition temperature of the binder contained in the support layer forming material and lower than the decomposition temperature of the binder contained in the constituent material can be performed. Such a separation promotion step can be easily performed, and by performing the separation promotion step, the binding force between the ceramic particles by the resin contained in the support layer forming material can be easily made smaller than the binding force between the metal particles by the resin contained in the constituent material.

Further, for example, as the stage <NUM> and the plate <NUM>, a material which can transmit an electromagnetic wave can be used, and as the separation promotion step, an electromagnetic wave irradiation step of irradiating the support layer forming material with an electromagnetic wave through the stage <NUM> and the plate <NUM> (for example, from the lower side) can be performed. Such a separation promotion step can be easily performed, and by performing the separation promotion step, the binding force between the ceramic particles by the resin contained in the support layer forming material can be easily made smaller than the binding force between the metal particles by the resin contained in the constituent material.

Incidentally, the separation step may be performed either during the irradiation with an electromagnetic wave or after completion of the irradiation with an electromagnetic wave as long as it is after the irradiation with an electromagnetic wave as the separation promotion step is started. Examples of the constituent material capable of transmitting an electromagnetic wave include zirconia and silicon dioxide.

According to this embodiment, a titania layer is formed on the plate <NUM> as the support. The binder which is in contact with the titania layer is easily decomposed by irradiation with an electromagnetic wave, and therefore, in the separation step, the separation of the second layer S2 from the support (plate <NUM>) can be particularly easily performed through the titania layer.

Claim 1:
A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body, comprising:
a first layer formation step (S140) of forming a first layer (S1) on a support (<NUM>) by supplying a first composition containing ceramic particles as first particles and a resin as a binder;
a solidifying step (S160) of solidifying the first layer (S1) by applying energy to the first layer;
a second layer formation step (S150) of forming a second layer (S2) composed of a plurality of layers on the first layer by supplying a second composition containing metal particles as second particles and a resin as a binder, wherein the type and amount of the respective resins is adjusted so that the binding force between the metal particles by the resin contained in the second composition is larger than the binding force between the ceramic particles by the resin contained in the first composition; and
a separation step (S180) of separating the second layer from the support through the first layer, wherein
after the separation step, a sintering step (S190) of sintering the plurality of layers of the second layer is performed,
wherein before the separation step, a separation promotion step of promoting the separation of the second layer from the support is performed, and
wherein
the decomposition temperature of the binder contained in the first composition is lower than the decomposition temperature of the binder contained in the second composition, and
the separation promotion step is a heating step of performing heating at a temperature higher than the decomposition temperature of the binder contained in the first composition and lower than the decomposition temperature of the binder contained in the second composition.