JP2018012195A - Laminate molding apparatus and laminate molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent an intermediate carrier from deforming in an out-of-plane direction caused by a tensile force and improve a precision of a solid object, in a laminate molding apparatus and method configured to convey, transfer onto a stage, laminate a material layer formed on the belt-like intermediate carrier and mold the solid object.SOLUTION: A laminate molding apparatus forms a material layer 1 on an intermediate carrier 2, applying a first tensile force to the intermediate carrier 2 to cause the intermediate carrier to rotatingly move, stops the movement of the intermediate carrier 2 when the material layer 1 reaches a lamination position 12 facing a stage 3, changes a tensile force to be applied to the intermediate carrier 2 to a second tensile force smaller than the first tensile force, and transfers the material layer 1 onto the stage 3.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an additive manufacturing apparatus and additive manufacturing method for a three-dimensional object using additive manufacturing methods, which are called additive manufacturing (AM), three-dimensional printer, rapid prototyping (RP), and the like.

The additive manufacturing method slices the shape data of a three-dimensional object and divides it into a plurality of cross-section data, forms a material layer made of a modeling material according to each cross-section data, and sequentially stacks and integrates the material layers This is a technique for manufacturing a three-dimensional object. The additive manufacturing method does not require a mold and can manufacture a complicated three-dimensional shape, and is therefore used for forming a prototype or manufacturing a single product or a small lot product.
Patent Documents 1 and 2 disclose an additive manufacturing method and additive manufacturing method using an electrophotographic method. In such a method, the modeling material particles are arranged on the intermediate carrier to form a material layer according to the cross-sectional data, and the material layer is transferred onto the material layer previously transferred onto the stage and laminated at the same time. Then, the process of integrating the upper and lower material layers is repeated to produce a three-dimensional object.

Japanese Patent Laid-Open No. 10-207194 Special table 2014-533210 gazette

In the methods described in Patent Documents 1 and 2, a belt-like intermediate carrier is stretched between two rollers, a driving roller and a driven roller, and rotated in a state where a certain tension is applied. The carrier moves, and the material layer thereon is conveyed to the stage. Therefore, the intermediate carrier is deformed due to the tension. For example, in order to suppress meandering of the intermediate carrier, the roller may have a shape called a crown whose outer diameter gradually decreases or increases from the center in the axial direction toward the end. In the case of such a roller, the intermediate carrier is deformed in the out-of-plane direction due to the crown shape. Further, the intermediate carrier is also deformed in the out-of-plane direction due to the inclination of the roller or the like. FIG. 12 shows an example of out-of-plane deformation of an intermediate carrier stretched around a roller with a crown. FIG. 12A is a plan view of a state in which a belt-like intermediate carrier 22 is stretched between two rollers 21a and 21b, and tension is applied to the intermediate carrier 22, and HH ′ in the drawing. FIG. 12B shows the cross section, and FIG. 12C shows the state of the roller 21a viewed from the II ′ cross section. As shown in FIG. 12, the intermediate carrier 22 stretched around the rollers 21 a and 21 b swelled in the center in the axial direction causes out-of-plane deformation in a shape in which the center in the width direction swells outward.
However, in the layered modeling apparatus, when the material layer on the intermediate carrier is transferred / laminated on the stage, the surface of the material layer on the intermediate carrier and the surface of the stage or the material layer already transferred onto the stage Lamination is performed by surface contact with the outermost surface of the laminate comprising In order to achieve uniform contact, the intermediate carrier needs to be in a nearly flat state at least at a position facing the stage, and the accuracy of the three-dimensional object to be manufactured is low when out-of-plane deformation due to tension occurs. It will be lower.
An object of the present invention is to form a material layer on a belt-like intermediate carrier, convey it, and transfer and laminate it on a stage to form a three-dimensional object. It is to suppress the outward deformation and improve the accuracy of the three-dimensional object to be manufactured.

The first of the present invention is a belt-like intermediate carrier,
A material layer forming means for forming a material layer made of a modeling material on one surface of the intermediate carrier;
A modeling unit that includes a stage that faces the one surface of the intermediate carrier and is movable toward the intermediate carrier, and that transfers and laminates the material layer on the intermediate carrier on the stage;
Tension applying means for applying tension to the intermediate carrier;
Transporting means for moving the intermediate carrier and transporting the material layer from the material layer forming means to the modeling means;
A tension control means for controlling the tension imparting means to control the tension imparted to the intermediate carrier,
The tension control means transfers and laminates at least a first tension when the material layer is transported from the material layer forming means to the modeling means, and the material layer is transferred and laminated on the stage by the modeling means. In some cases, the tension applying means is controlled so as to apply a second tension to the intermediate carrier.
The second of the present invention is a first step of forming a material layer made of a modeling material on one surface of the intermediate carrier,
A second step of moving the intermediate carrier and transporting the material layer on the intermediate carrier onto the stage such that the material layer faces the stage;
In the additive manufacturing method of manufacturing a three-dimensional object by repeating the third step of moving the stage toward the intermediate carrier to contact the material layer and transferring and laminating the material layer on the stage There,
In the second step, a first tension is applied to the intermediate carrier,
In the third step, before the material layer is transferred / laminated on the stage, a second tension smaller than the first tension is applied to the intermediate carrier.

In the present invention, the tension applied to the intermediate carrier is controlled by the tension control means, and when the material layer on the intermediate carrier is transferred / laminated on the stage, the tension is relaxed. Out-of-plane deformation of the body can be suppressed. Therefore, in the present invention, the surface of the material layer formed on the intermediate carrier can be uniformly brought into contact with the surface of the stage or the outermost surface of the laminate laminated on the stage, and the three-dimensional object can be obtained with high accuracy. Can be manufactured.
In the present invention, a three-dimensional object can be manufactured with higher accuracy by measuring the shape of the intermediate carrier and controlling the tension.
Furthermore, in the present invention, the position of the material layer on the stage, the amount of movement of the stage to the intermediate carrier, and the size of the material layer formed on the intermediate carrier are controlled according to the tension. Thus, a three-dimensional object can be manufactured with higher accuracy.

It is a front view which shows typically the apparatus structure of the 1st Embodiment of this invention. It is a front view which shows typically the apparatus structure of the 2nd Embodiment of this invention. It is a figure which shows typically the mode of the measurement of the shape of the intermediate | middle carrier in the 2nd Embodiment of this invention. It is a flowchart of the 2nd Embodiment of this invention. It is a front view which shows typically the apparatus structure of the 3rd Embodiment of this invention. It is a front view which shows typically the adjustment method of the position of the material layer in the 3rd Embodiment of this invention. It is a front view which shows typically the apparatus structure of the 4th Embodiment of this invention. In the 4th Embodiment of this invention, it is a front view which shows typically the control method of the distance to the intermediate | middle carrier of a stage. It is a front view which shows typically the apparatus structure of the 5th Embodiment of this invention. It is a front view which shows typically the apparatus structure of the 6th Embodiment of this invention. In the 6th Embodiment of this invention, it is a front view which shows typically the method of adjusting the magnitude | size of a material layer. It is the front view and sectional drawing which show the state which stretched the belt-shaped intermediate carrier to the roller which attached | subjected the crown.

  The additive manufacturing apparatus of the present invention includes a belt-like intermediate carrier, a material layer forming unit that forms a material layer on the intermediate carrier, a modeling unit that transfers and laminates the material layer on a stage, and an intermediate carrier Tension applying means for applying tension to the body, and transport means for the intermediate carrier. And in this invention, it has the tension control means which controls the tension | tensile_strength provision means and controls the tension | tensile_strength provided to the said intermediate | middle carrier. In the present invention, the tension control means controls the first tension when the intermediate carrier is conveyed and the second tension when the material layer is transferred and laminated on the stage.

  The additive manufacturing method of the present invention is a method of manufacturing a three-dimensional object by stacking a plurality of material layers on a stage using the additive manufacturing apparatus of the present invention. In the present invention, when the material layer is transferred / laminated on the stage in the modeling means, rather than the first tension applied to the intermediate carrier when the material layer formed on the intermediate carrier is transported to the modeling means. In addition, the second tension applied to the intermediate carrier is reduced.

  Hereinafter, the additive manufacturing apparatus and additive manufacturing method of the present invention will be specifically described with reference to embodiments. The present invention is not limited to the embodiments described below. Further, in the present invention, the scope of the present invention also includes those in which the embodiments described below are appropriately modified and improved based on the ordinary knowledge of those skilled in the art without departing from the spirit of the present invention. It shall be included in the range. Moreover, in FIG. 1 thru | or FIG. 15, the same code | symbol was attached | subjected to the same member.

[First Embodiment]
FIG. 1 is a front view schematically showing the configuration of the additive manufacturing apparatus according to the first embodiment of the present invention. In the figure, reference numeral 10 denotes one surface of an intermediate carrier 2 having a material layer 1 having an image pattern corresponding to cross-sectional data (slice data) obtained by slicing shape data of a three-dimensional object created in accordance with a control process (not shown). It is a material layer forming means formed on top.

  In the present invention, the intermediate carrier 2 has a belt shape, and in the present embodiment, the intermediate carrier 2 is stretched around rollers 5a and 5b as an endless belt. In this embodiment, the roller 5a is a driven roller, and the roller 5b is a drive roller. An intermediate carrier driving means 7a and a conveyance command generating means 7b are provided as conveying means for the intermediate carrier 2, and the intermediate carrier driving means 7a rotationally drives the roller 5b based on the command generated by the conveyance command generating means 7b. Thereby, the intermediate carrier 2 rotates. In the drawings referred to below, for the sake of convenience, the width direction of the intermediate carrier 2, which is parallel to the rotation axes of the rollers 5a and 5b, intersects the Y direction and the rotation axes of both the rollers 5a and 5b. The direction orthogonal to each other is defined as the X direction, and the direction orthogonal to the X direction and the Y direction is defined as the Z direction.

  A tension applying means 6 is connected to the roller 5b, and a tension is applied to the intermediate carrier 2 by applying a displacement or a load to the roller 5b. The material layer 1 is formed on the intermediate carrier 2 at the material layer forming position 11 with the intermediate carrier 2 stopped. Next, the conveyance command generating means 7b issues a conveyance command, and the intermediate carrier driving means 7a rotates the roller 7b, whereby the intermediate carrier 2 rotates and the material layer 1 advances in the direction of arrow A in FIG. . When the material layer 1 arrives at the material layer stacking position 12, the conveyance command generation means 7b issues a stop command, the intermediate carrier driving means 7a stops the rotation of the roller 7b, the intermediate carrier 2 stops, and the material layer 1 Faces the stage 3. In the present embodiment, the pressing plate 4 is disposed at a position facing the stage 3 with the intermediate carrier 2 interposed therebetween. The stage 3 is configured to reciprocate toward the intermediate carrier 2 in the direction of arrow E (Z direction) and the pressing plate 4 in the direction of arrow D (Z direction), respectively, and constitutes the modeling means of the present invention. .

  The material layer 1 is sandwiched between the pressing plate 4 that has moved toward the intermediate carrier 2 at the material layer stacking position 12 and the stage 3, transferred onto the stage 3, and peeled off from the intermediate carrier 2. At this time, if it is the first material layer 1, it is transferred to the surface of the stage 3, and if it is the second and subsequent material layers 1, the laminate 9 consisting of the material layer 1 transferred first to the stage 3. Is transferred onto the outermost surface of the substrate and laminated on the laminate 9 to be integrated. At this time, when the material layer 1 is made of a thermoplastic material, the material layer 1 is softened or melted by heating, and the entire material layer 1 is integrated with the laminate 9 at the same time. Therefore, the material layer 1 is heated by the heating means (not shown) incorporated in the roller 5b or the heating means (not shown) incorporated in the pressing plate 4 until reaching the modeling means. A cartridge heater is applicable as the heating means, but is not limited thereto.

When the material layer 1 on the intermediate carrier 2 is transferred and laminated on the stage, the stage 3 and the pressing plate 4 are separated from the intermediate carrier 2, and the conveyance command generating means 7b issues a conveyance command. Starts moving again.
By repeating the above operation, a plurality of material layers 1 are sequentially stacked on the stage 3 to form a three-dimensional object.

  When transporting the material layer 1 from the material layer forming position 11 to the material layer stacking position 12, T1 is the first tension applied to the intermediate carrier 2, and T1 drives the intermediate carrier 2 stably. Desirable tension T0 or more is desirable. The intermediate carrier 2 that moves by being applied with the first tension T1 may be deformed out of plane due to the shape of the rollers 5a and 5b, the shape error, the difference in the mounting angle, and the like. In particular, when the rollers 5a and 5b are crowned to suppress meandering of the intermediate carrier 2, the intermediate carrier 2 is deformed in the width direction and the direction orthogonal to the traveling direction.

  In the present invention, tension control means 8 is provided in order to alleviate such deformation. When the material layer 1 reaches the material layer stacking position 12, the conveyance command generation means 7b issues a stop command to the intermediate carrier driving means 7a. At the same time, the tension control unit 8 issues a signal to the tension applying unit 6 to change the tension applied to the intermediate carrier 2 to a second tension T2 smaller than the first tension 1. The second tension T2 is preferably less than T0.

  Then, after the material layer 1 is laminated on the stage 3 or on the outermost surface of the laminated body 9 and peeled off from the intermediate carrier 2, the tension control means 8 commands to change from the second tension T2 to the first tension T1. Is generated. Thus, the first tension T1 is again applied to the intermediate carrier 2, and in this state, the conveyance command generating means 7b issues a conveyance command, and the intermediate carrier 2 starts to rotate again.

  As described above, when the material layer 1 reaches the material layer stacking position 12, by providing the tension control means that weakens the tension of the intermediate carrier 2, the out-of-plane deformation of the intermediate carrier 2 can be suppressed. Therefore, a highly accurate three-dimensional object can be manufactured by bringing the material layer 1 into uniform contact with the surface of the stage 3 or the outermost surface of the laminate 9 on the stage 3.

  In the present embodiment, as the material layer forming means 10, an electrophotographic system using electrostatic force is used. The material layer forming means 10 includes a developing device (not shown), an image carrier, and an exposure device, and forms a particle image composed of particles of a modeling material (modeling material particles) on the image carrier, and the particle image is intermediate The material layer 1 is formed by transferring onto the carrier 2. More specifically, the surface of the image carrier is uniformly charged by a charging device (not shown). The charging method is not particularly limited. Using an exposure device, the charged image carrier is exposed according to the cross-sectional data of the three-dimensional object to be manufactured, and an electrostatic latent image is formed on the surface of the image carrier. Subsequently, when the modeling material particles are supplied from the developing device to the image carrier, the particles are arranged in a region where an electrostatic latent image is formed on the surface of the image carrier. As a result, the electrostatic latent image is visualized, and a particle image of the modeling material particles is formed on the surface of the image carrier.

  Thereafter, the particle image disposed on the image carrier is transferred onto the intermediate carrier 2 to form the material layer 1. When manufacturing a three-dimensional object having a complicated shape such as an overhang structure or a structure having a movable part, it is necessary to dispose a material layer on the space region. Therefore, a material layer in which a space region is filled with a support material is formed by using two types of modeling materials, a structural material that constitutes a three-dimensional object, and a support material that supports the lamination of the structural material. -Remove only the support material after lamination. As described above, when the support material is necessary, the material layer forming means 10 is provided at two locations along the moving direction of the intermediate carrier 2, and the structure material particles are composed of the structure material particles and the support material. Prepare support material particles. Then, one material layer forming means 10 forms a particle image made of structural material particles, and the other material layer forming means 10 forms a particle image made of support material particles, and transfers them to the intermediate carrier 2 at a predetermined timing. . Thereby, the material layer 1 which consists of the particle image by a structural material particle and the particle image by a support material particle can be formed. That is, the material layer 1 is formed by transferring the second layer made of the other to the intermediate carrier 2 to which the first layer made of either the structural material particles or the support material particles has been transferred. When transferring to the intermediate carrier 2, a known transfer method such as electrostatic transfer using electrostatic energy can be used. The order of transferring the particle image to the intermediate carrier 2 is not particularly limited, and the particle image made of the support material particles may be transferred after transferring the particle image made of the structural material particles, or vice versa.

  The present invention does not limit the transfer / laminating means of the material layer 1 in the modeling means to the heating means, but the material layer 1 is formed of a thermoplastic modeling material and is easily transferred / laminated by heat fusion. This is preferable. As the thermoplastic modeling material, a thermoplastic material such as a thermoplastic resin, a thermoplastic metal material, or an inorganic material can be suitably used. The term “thermoplastic” refers to a property that is difficult to deform at room temperature, but exhibits plasticity when heated at a temperature corresponding to the material, can be freely deformed, and becomes solidified again when cooled.

Examples of the thermoplastic resin include ABS (acrylonitrile butadiene styrene resin), PP (polypropylene), PE (polyethylene), PS (polystyrene), PMMA (polymethyl methacrylate), PET (polyethylene terephthalate), PPE (polyphenylene ether), PA ( Nylon / polyamide), PC (polycarbonate), POM (polyacetal), PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), LCP (liquid crystal polymer), fluororesin, urethane resin, elastomer, etc. However, it is not limited to these.
The modeling material may further contain a functional substance such as a pigment or a dispersant in accordance with the function of the target three-dimensional object.

  As described above, when a structural material that constitutes a three-dimensional object and a support material that supports the structural material are used in combination as a modeling material, it is necessary to remove the support material after the laminate 9 is laminated to the uppermost layer. There is. Therefore, the support material must be a material that can be removed from the laminate 9. Specifically, by configuring the structural material with a material having a melting point higher than that of the support material, the completed laminate 9 is heated to a temperature higher than the melting point of the support material and lower than the melting point of the structural material, A method of melting and removing only the support material can be mentioned. Further, by making the structural material a water-insoluble material and making the support material water-soluble, or by allowing the support material to contain a water-soluble material, the completed laminate 9 is dipped in water to provide the support material. It is possible to remove only by dissolving or dispersing.

  As such a water-soluble material, a water-soluble organic material that is a water-soluble organic material, preferably a thermoplastic water-soluble organic material can be used. Specifically, water-soluble monosaccharides, oligosaccharides, polysaccharides, water-soluble saccharides such as dietary fiber, polyalkylene oxide, and polyvinyl alcohol (PVA) are preferably used as the water-soluble organic material.

  In the above embodiment, an example using the electrophotographic method as the material layer forming means 10 has been described. However, the present invention is not limited to such a method. In the present invention, other methods can be used as long as the material layer 1 is formed on the intermediate carrier 2 according to the cross-sectional data and the material layer 1 can be transferred and laminated on the stage 3. .

[Second Embodiment]
The structure of the additive manufacturing apparatus of 2nd Embodiment is shown in FIG. In the present embodiment, shape measuring means 14 for measuring the shape of the intermediate carrier 2 is added to the first embodiment, and the second tension T2 is determined based on the measurement value obtained by the shape measuring means 14. Is. Specifically, the shape measuring unit 14 is preferably a non-contact measuring unit such as a laser displacement meter that measures the distance by reflection of laser light or a capacitance sensor, but is not limited thereto.

  In FIG. 3, the mode of the shape measurement of the intermediate | middle carrier 2 in this embodiment is shown typically. FIG. 3 schematically shows the F-F ′ cross section of FIG. 2, and shows the deformed shape of the intermediate carrier 2 in an exaggerated manner. Reference numeral 2 denotes an intermediate carrier to which a first tension T1 is applied, and 2 'denotes an intermediate carrier to which a second tension T2 is applied. In the present embodiment, three laser displacement meters 14a, 14b, and 14c are used as the shape measuring unit 14, and the distance between both end portions in the width direction (Y direction) and the center portion of the intermediate carrier 2 is measured. And the value of the concave shape displacement h is calculated | required from the difference of the measured value. As shown in FIG. 3, the deformation displacement of the second tension T2 smaller than the first tension T1 is smaller than the deformation displacement h of the second tension T1. If the tension is reduced by the tension control means 8, the concave shape displacement h required by the shape measuring means 14 is also reduced accordingly. The tension when the concave displacement h falls below a certain threshold is determined as the second tension T2.

FIG. 4 shows a flowchart regarding tension reduction and lamination in the present embodiment. The flowchart will be described below.
First, a conveyance command is issued from the conveyance command generating means 7b to the intermediate carrier driving means 7a, the material layer 1 on the intermediate carrier 2 is conveyed to the material layer stacking position 12, and then the conveyance command generating means 7b is instructed to stop. The material layer 1 stops (S1). Next, the tension control means 8 gives a tension reduction command to the tension applying means 6 (S2). Next, the concave displacement h, which is an out-of-plane deformation amount of the intermediate carrier 2 is measured by the shape measuring means 14 (S3). Next, it is determined whether or not the concave displacement h is below a preset threshold value (P1). If not, the process returns to S2. If it is lower, the tension applied at that time is determined as the tension T2, and the transfer and lamination of the material layer 1 onto the stage 3 are executed (S4).

  As a modification of the present embodiment, a tension correction table (not shown) is prepared in advance for the second tension at the time of calibration before the manufacture of the three-dimensional object or at the time of manufacturing the apparatus, and the tension control means 8 is prepared. You may remember it. When transferring and laminating, the second tension stored in the tension correction table can be used as appropriate. Specifically, the second tension T2 is measured in advance based on the flowchart of FIG. 4 for each of a plurality of placement positions of the material layer 1 set on the intermediate carrier 2, and stored in the tension correction table. Keep it. The specific indication position of the placement position set on the intermediate carrier 2 can be determined from the command value of the transport command generating means 7b. That is, a method of creating a tension correction table by associating the command value of the conveyance command generating means 7b with the tension T2 and arranging the tension correction table in the tension control means 8 to be used for stacking can be used. it can.

  The intermediate carrier 2 is not always uniform in mechanical properties due to uneven thickness or uneven residual stress due to the processing process. Even when the same tension is applied, the intermediate carrier 2 is loaded with the material layer 1. The amount of deformation differs for each position. Therefore, it is desirable to change the second tension T2 depending on the location. Therefore, as exemplified in the present embodiment, by using the shape measuring unit 14, the second tension T <b> 2 that differs depending on the location of the intermediate carrier 2 can be optimally determined.

[Third Embodiment]
The structure of the additive manufacturing apparatus of 3rd Embodiment is shown in FIG. In this embodiment, in addition to the configuration of the first embodiment, adjustment is performed to adjust the position on the stage 3 where the material layer 1 on the intermediate carrier 2 is to be laminated in a direction parallel to the traveling direction of the intermediate carrier 2. It has a configuration in which means 15 and adjustment amount calculation means 16 for determining the adjustment amount of the position are added. The adjustment amount calculation means 16 determines the adjustment amount of the position of the stage 3 adjusted by the adjustment means 15 based on the tension command value issued by the tension control means 8.

  FIG. 6 shows a schematic diagram of a method for adjusting the position of the stage 3 by the adjusting means 15 in the present embodiment. FIG. 6A shows a state in which the first tension T1 is applied to the intermediate carrier 2, and FIG. 6B shows a state in which the second tension T2 is applied to the intermediate carrier 2. When the tension to be applied is changed from T1 to T2, the roller 5b moves by dx1 as shown in FIG. 6B, and the distance between the roller 5a and the roller 5b changes by dx1 as the movement proceeds. With the change, the position of the material layer 1 also changes by dx2 parallel to the X direction. That is, as the tension applied to the intermediate carrier 2 is changed, the position (X position) of the material layer 1 is also changed by dx2 in the same direction. Since the second tension T2 is different for each placement position of the material layer 1 on the intermediate carrier 2, it is considered that the amount of change dx2 of the X position of the material layer 1 is also different for each placement position. In order to adjust the position change, the adjustment unit 15 is driven by the same amount as the X position change amount dx2 of the material layer 1 to adjust the position of the material layer 1.

The moving amount dx1 of the roller 5b is a value determined by the second tension T2 determined by the tension control means 8. The X position change amount dx2 of the material layer 1 is a value determined by the moving amount dx1 of the roller 5b. That is, the X position change amount dx2 of the material layer 1 can be determined by the second tension T2. Therefore, in the present embodiment, the adjustment amount of the adjustment means 15 is determined by the adjustment amount calculation means 16 based on the tension command value T2 issued by the tension control means 8. As a method for determining dx2, for example, when the stacking position 12 is located at the center of the roller 5a and the roller 5b, the following holds from the geometric relationship.
dx2 = dx1 / 2
From this, if dx1 is determined from the second tension T2, dx2 can be automatically determined.

  As an application example of the present embodiment, an adjustment amount correction table (not shown) is created and stored in advance at the time of calibration in the stage before manufacturing a three-dimensional object or at the time of manufacturing the apparatus, and the three-dimensional object is manufactured. There is a case where data is read from the table and used. The adjustment amount correction table can be created by calculating or measuring the X position change amount dx2 of the material layer 1 accompanying the change in tension. For example, the second tension T2 is determined at a certain mounting position, and the X position change dx2 of the material layer 1 is measured and stored. Further, at another placement position, the second tension T2 'is determined, and the X position change amount dx2' of the material layer 1 is measured and stored. As described above, the X position change amount dx2 of the material layer 1 is calculated or measured in advance based on the second tension T2 at a plurality of placement positions, an adjustment amount correction table is created, and the adjustment amount calculation means 16 Remember it.

  In this example, the placement position of the material layer 1 on the intermediate carrier 2 and the adjustment amount of the X position of the material layer 1 when the placement position is transferred to the material layer stacking position 12 are the second. Correspondence is made through the tension T2. As a result, the command value for transporting the intermediate carrier 2 to the material layer stacking position 12 (command value issued by the transport command generating means 7b) and the adjustment amount correction table 19 are collated to determine and adjust dx2. The method can also be applied. As a method of measuring the X position change amount of the material layer 1, for example, an image acquisition unit such as a camera is provided, the material layer 1 is photographed before and after the tension change, the images are compared, and the X position change amount is calculated on a pixel basis. It can be measured and calculated, but the method is not limited to this.

  In the present embodiment, the adjusting means 15 is used to correct the amount of change in the X position of the material layer 1 accompanying the change in the tension applied to the intermediate carrier 2, but the adjusting means 15 is not used. In addition, a method of performing correction by adjusting the conveyance amount of the intermediate carrier 2 can be used. For example, by transporting the intermediate carrier 2 by an amount corresponding to the adjustment amount, the material layer 1 can be displaced to the correct lamination position 12 when changing to the second tension T2.

  As described above, by applying the present embodiment, even when the tension applied to the intermediate carrier 2 is changed, an error in the stacking position accompanying the change in the X position of the material layer 1 can be suppressed. It is possible to realize additive manufacturing of a three-dimensional object having a high height.

[Fourth Embodiment]
The configuration of the additive manufacturing apparatus of the fourth embodiment is shown in FIG. The present embodiment is provided with a movement adjusting means (not shown) that adjusts the moving amount of the stage 3 based on a change in tension applied to the intermediate carrier 2 with respect to the first embodiment. FIG. 8 shows a schematic diagram of a method for adjusting the amount of movement of the stage 3 in the present embodiment. FIG. 8A shows a state in which the first tension T1 is applied to the intermediate carrier 2, and FIG. 8B shows a state in which the second tension T2 is applied to the intermediate carrier 2.

  When the tension applied to the intermediate carrier 2 is changed from T1 to T2, as shown in FIG. 8B, the roller 5b moves by dx1, but the distance between the roller 5a and the roller 5b changes by dx1 along with the movement. To do. Along with the change, the intermediate carrier 2 bends due to its own weight, so the position of the material layer 1 in the Z direction (Z position) also changes by dz. That is, the Z position of the material layer 1 changes as the tension applied to the intermediate carrier 2 is changed. Since the second tension T2 differs depending on the placement position of the material layer 1 on the intermediate carrier 2, it is conceivable that the amount of change dz of the Z position of the material layer 1 also differs depending on the placement position. In order to adjust the position change, the amount of movement of the stage 3 in the Z direction is adjusted according to the Z position change amount dz of the material layer 1.

  The moving amount dx1 of the roller 5b is a value determined by the second tension T2 determined by the tension control means 8. Further, the Z position change amount dz of the material layer 1 is a value determined by the moving amount dx1 of the roller 5b. That is, the Z position change amount dz of the material layer 1 can be determined by the second tension T2. Therefore, in this embodiment, the amount of movement of the stage 3 in the Z direction is determined based on the tension command value T2 issued by the tension control means 8. As a method for determining dz, for example, the dz may be calculated from a catenary line equation with tension and gravity, but is not limited thereto.

  As an application example of the present embodiment, a movement amount correction table (not shown) is created and stored in advance at the time of calibration before the manufacture of a three-dimensional object or at the time of manufacturing an apparatus. A form in which data is read from the table and used at the time of manufacture is conceivable. The movement amount correction table can be created by calculating or measuring the Z position change dz of the material layer 1 accompanying the tension change in advance for each of the placement positions of the plurality of material layers 1 on the intermediate carrier 2. . For example, the second tension T2 is determined at a certain mounting position, and the Z position change amount dz of the material layer 1 is measured and stored. Further, the second tension T2 'is determined at another placement position, and the Z position change amount dz' of the material layer 1 is measured and stored. As described above, for a plurality of placement positions, based on the second tension T2, the Z position change amount dz of the material layer 1 is measured in advance to create a movement amount correction table, which is stored in an accessible memory. It is good to leave.

  In this example, the placement position of the material layer 1 on the intermediate carrier 2 and the amount of movement of the stage 3 in the X direction when the placement position is conveyed to the material layer stacking position 12 are the second tension. Correspondence is made through T2. Thus, a method of determining and adjusting dz by comparing the command value for transporting the intermediate carrier 2 to the material layer stacking position 12 (command value issued by the transport command generating means 7b) and the movement amount correction table. Can also be applied. As a method for measuring the Z position change amount dz of the material layer 1, for example, a non-contact measuring means such as a laser displacement meter that measures the distance by reflection of laser light or a capacitance sensor can be cited. By these means, the displacement amount can be measured before and after the tension change of the intermediate carrier 2 and the Z position change amount dz can be calculated. However, the present invention is not limited to this.

  In addition, since the X direction length of the intermediate carrier 2 is very long relative to the X direction length of the material layer 1, the influence of the deflection of the intermediate carrier 2 due to its own weight on the flatness is very small. The accuracy is not expected to be affected.

  As described above, by applying this embodiment, even when the tension of the intermediate carrier 2 is changed, an error in the stacking position due to the Z position change of the material layer 1 can be suppressed, and the accuracy is high. Layered modeling of a three-dimensional object can be realized.

[Fifth Embodiment]
The structure of the additive manufacturing apparatus of 5th Embodiment is shown in FIG. In the present embodiment, a contact detection unit 17 and a contact position measurement unit 18 are provided for the pressing plate 4 of the first embodiment. The contact detection means 17 determines whether or not the pressing plate 4 has contacted the intermediate carrier 2. As a specific example of the contact detection means 17, a force sensor for monitoring the force at the time of contact, a sensor for energizing by contact, and the like can be used, but this is not restrictive. Further, the contact position measuring means 18 measures the amount of movement of the pressing plate 4 before contact is determined by the contact detecting means 17. As described above, as the tension of the intermediate carrier 2 is changed, the Z position of the material layer 1 also changes. Therefore, it is necessary to change the amount of movement of the stage 3 in the Z direction in accordance with the amount of change in the Z position of the material layer 1. In order to determine the amount of change, the pressing plate 4 measured by the contact position measuring means 18. The amount of movement is used. At this time, since the amount of movement of the pressing plate is the amount of change in the Z position of the material layer 1, the difference in the amount of movement of the pressing plate with respect to the amount of movement of the stage 3 in the Z direction before the tension change is obtained. The amount of movement of the stage 3 in the Z direction can be calculated. Thus, by using the contact detection means 17 and the contact position measurement means 18, the amount of movement of the stage 3 in the Z direction after changing the tension can be determined.

  In addition, since the X direction length of the intermediate carrier 2 is very long relative to the X direction length of the material layer 1, the influence of the deflection of the intermediate carrier 2 due to its own weight on the flatness is very small. The accuracy is not expected to be affected.

  As described above, by applying this embodiment, even when the tension of the intermediate carrier 2 is changed, an error in the stacking position due to the Z position change of the material layer 1 can be suppressed, and the accuracy is high. Layered modeling of a three-dimensional object can be realized.

[Sixth Embodiment]
The structure of the additive manufacturing apparatus of 6th Embodiment is shown in FIG. The present embodiment is provided with means corresponding to the expansion and contraction change of the material layer 1 accompanying the change of the tension applied to the intermediate carrier 2 with respect to the first embodiment. In FIG. 11, the mode of the expansion-contraction change of the material layer 1 in this embodiment is shown. FIG. 11A shows a state where the first tension T1 is applied to the intermediate carrier 2, and FIG. 11B shows a state where the second tension T2 is applied to the intermediate carrier 2.

When the tension applied to the intermediate carrier 2 is changed from T1 to T2, the roller 5b moves by dx1 as shown in FIG. 11B, but the distance between the roller 5a and the roller 5b changes by dx1 along with the movement. To do. With the change, the length of the intermediate carrier 2 changes, so that the length of the material layer 1 also changes from L to dL. That is, the length of the material layer 1 changes as the tension applied to the intermediate carrier 2 is changed. In order to adjust the length change, the material layer forming means 10 is formed by expanding and contracting the X direction of the material layer 1 according to the length change amount dL of the material layer 1. The expansion / contraction rate of the material layer 1 can be considered to be equal to the expansion / contraction rate of the intermediate carrier 2 because it is on the intermediate carrier 2. At this time, as shown in FIG. 11, when the length of the intermediate carrier 2 before the tension change is X, the expansion / contraction rate E is expressed by the following equation.
E = (L−dL) / L = (x−dx1) / x

  The moving amount dx1 of the roller 5b is a value determined by the second tension T2 determined by the tension control means 8. That is, the expansion / contraction rate E of the material layer 1 can be determined by the second tension T2. Therefore, in this embodiment, the expansion / contraction rate E of the material layer 1 is determined based on the command value T2 of the tension generated by the tension control means 8. Then, the material layer 1 is formed by the material layer forming means 10 by multiplying the reciprocal of the expansion / contraction ratio E by the length in the X direction.

  As an application example of the present embodiment, a tension expansion / contraction rate correction table (not shown) is created and stored in advance at the time of calibration before entering the manufacture of a three-dimensional object or at the time of manufacturing the device, and at the time of modeling It is also preferable to read and use the data. The tension expansion / contraction rate correction table can be created by calculating or measuring the expansion / contraction rate E of the material layer 1 associated with the tension change in advance for each of the placement positions of the plurality of material layers 1 on the intermediate carrier 2. . Then, when the corresponding placement position is conveyed to the material layer forming position 11, the material layer 1 obtained by multiplying the length in the X direction by the reciprocal of the stretch rate E of the placement position stored in the stretch rate correction table. It is formed by the material layer forming means 10. For example, the second tension T2 is determined at a certain mounting position, and the expansion / contraction rate E of the material layer 1 is measured and stored. Also, at another placement position, the second tension T2 'is determined, and the expansion / contraction rate E' of the material layer 1 is measured and stored. Thus, at a plurality of placement positions, the expansion / contraction rate E of the material layer 1 is measured in advance based on the second tension T2 and stored in an accessible memory as an expansion / contraction rate correction table. As a result, the formation position 11 and the expansion / contraction rate are associated with each other via the tension T2. Thereby, the expansion / contraction rate E is determined by comparing the command value for transporting the intermediate carrier 2 to the formation position 11 (command value issued by the transport command generating means 7b) and the expansion / contraction rate correction table. Then, when the corresponding placement position is conveyed to the formation position 11, the material layer 1 having a size corresponding to the expansion / contraction rate E is formed. As a method of measuring the expansion / contraction rate E, for example, an image acquisition unit such as a camera is provided, the material layer 1 is photographed before and after the tension change, the images are compared, and the length change amount dL is measured on a pixel basis. You can, but this is not the only way.

  As described above, by applying this embodiment, even when the tension of the intermediate carrier 2 is changed, it is possible to suppress a modeling error associated with the expansion / contraction change of the material layer 1, and a highly accurate three-dimensional object. Laminated modeling can be realized.

As described above, by using the characteristic configuration of the first to sixth embodiments, the material in a state in which the deformation in the out-of-plane direction of the intermediate carrier 2 due to the applied tension is minimized. Layer 1 can be laminated. As a result, the material layer 1 on the intermediate carrier 2 can be uniformly brought into contact with the stage 3 or the outermost surface layer of the laminate 9 on the stage 3, and the accuracy of the three-dimensional object can be improved. Become.
The first to sixth embodiments may be implemented by combining two or more embodiments.

  1: material layer, 2: intermediate carrier, 3: stage, 4: pressing plate, 6: tension applying means, 8: tension control means, 10: material layer forming means, 14: shape measuring means, 15: adjusting means, 16: adjustment amount calculation means, 17: contact detection means, 18: contact position measurement means

Claims (23)

A belt-like intermediate carrier;
A material layer forming means for forming a material layer made of a modeling material on one surface of the intermediate carrier;
A modeling unit that includes a stage that faces the one surface of the intermediate carrier and is movable toward the intermediate carrier, and that transfers and laminates the material layer on the intermediate carrier on the stage;
Tension applying means for applying tension to the intermediate carrier;
Transporting means for moving the intermediate carrier and transporting the material layer from the material layer forming means to the modeling means;
A tension control means for controlling the tension imparting means to control the tension imparted to the intermediate carrier,
The tension control means transfers and laminates at least a first tension when the material layer is transported from the material layer forming means to the modeling means, and the material layer is transferred and laminated on the stage by the modeling means. The additive manufacturing apparatus is characterized by controlling the tension applying means so as to apply a second tension to the intermediate carrier. Comprising a measuring means for measuring the shape of the intermediate carrier,
The additive manufacturing apparatus according to claim 1, wherein the tension control unit determines the second tension based on a measurement value obtained by the measurement unit.   The tension control unit is configured to determine the second tension for each mounting position determined based on a measurement value measured by the measuring unit at each of a plurality of mounting positions of the material layer in the intermediate carrier. The additive manufacturing apparatus according to claim 2, further comprising a tension correction table stored in advance. An adjusting means for adjusting the position on the stage where the material layer on the intermediate carrier is to be laminated in a direction parallel to the traveling direction of the intermediate carrier;
4. The adjustment means according to claim 1, further comprising an adjustment amount calculation means for determining an adjustment amount of a position on the stage where the material layer is to be laminated based on the second tension. The additive manufacturing apparatus according to any one of the preceding claims.   The adjustment amount calculation unit is configured to determine the material for each placement position determined by the adjustment amount calculation unit based on the second tension at each of the plurality of placement positions of the material layer on the intermediate carrier. The additive manufacturing apparatus according to claim 4, further comprising an adjustment amount correction table in which the adjustment amount of the position of the layer is stored in advance.   The additive manufacturing apparatus according to any one of claims 1 to 5, wherein an amount of movement of the stage to the intermediate carrier is determined based on the second tension.   A movement amount correction table that stores in advance the movement amount of the stage at each of the mounting positions determined based on the second tension at each of the plurality of mounting positions of the material layer on the intermediate carrier; The additive manufacturing apparatus according to claim 6, wherein the additive manufacturing apparatus is provided.   8. The pressing plate according to claim 1, further comprising a pressing plate that is disposed at a position facing the stage with the intermediate carrier interposed therebetween and is movable with respect to the other surface of the intermediate carrier. The additive manufacturing apparatus described in 1. A pressing plate sandwiched between the intermediate carriers and disposed at a position facing the stage, and movable relative to the other surface of the intermediate carrier;
Contact detection means for determining that the pressing plate is in contact with the intermediate carrier;
Contact position measuring means for measuring the amount of movement of the pressing plate before contact is determined by the contact detecting means,
6. The additive manufacturing apparatus according to claim 1, wherein the movement amount of the stage is determined based on the movement amount of the pressing plate measured by the contact position measuring unit. .   The material layer forming unit forms the material layer with a size corrected based on the expansion / contraction ratio of the material layer calculated based on the second tension. The additive manufacturing apparatus according to claim 1.   An expansion / contraction rate correction table that stores in advance the expansion / contraction rate of the material layer for each placement position calculated based on the second tension at each of the plurality of placement positions of the material layer on the intermediate carrier. The additive manufacturing apparatus according to claim 10, wherein the additive manufacturing apparatus is provided. A first step of forming a material layer made of a modeling material on one surface of the intermediate carrier;
A second step of moving the intermediate carrier and transporting the material layer on the intermediate carrier onto the stage such that the material layer faces the stage;
In the additive manufacturing method of manufacturing a three-dimensional object by repeating the third step of moving the stage toward the intermediate carrier to contact the material layer and transferring and laminating the material layer on the stage There,
In the second step, a first tension is applied to the intermediate carrier,
In the third step, an additive manufacturing method characterized by applying a second tension smaller than the first tension to the intermediate carrier before transferring and laminating the material layer on the stage. .   13. The additive manufacturing method according to claim 12, wherein, in the third step, the first tension is applied to the intermediate carrier after the material layer is transferred and laminated on the stage.   The additive manufacturing method according to claim 12 or 13, wherein the second tension is determined based on a measurement value obtained by measuring the shape of the intermediate carrier.   The shape of the intermediate carrier is measured at each of the plurality of placement positions of the material layer on the intermediate carrier, and the second tension is determined in advance for each placement position based on the obtained measurement value. The additive manufacturing method according to claim 14, wherein the additive manufacturing method is performed.   The position of the material layer on the stage is adjusted in a direction parallel to the traveling direction of the intermediate carrier based on the second tension. The additive manufacturing method described.   In each of the plurality of placement positions of the material layer on the intermediate carrier, an adjustment amount of the position of the material layer for each placement position is determined in advance based on the second tension. The additive manufacturing method according to claim 16.   18. The movement amount of moving the stage toward the intermediate carrier in the third step is determined based on the second tension. 18. The additive manufacturing method.   The movement amount of the stage for each mounting position is determined in advance based on the second tension at each of a plurality of mounting positions of the material layer on the intermediate carrier. The additive manufacturing method according to 18.   In the third step, the material layer is moved by moving a pressing plate facing the stage across the intermediate carrier until it comes into contact with the intermediate carrier, and moving the stage toward the intermediate carrier. 20. The additive manufacturing method according to claim 12, wherein the material layer is transferred and laminated on the stage by sandwiching the substrate between the stage and the pressing plate.   In the third step, the pressing plate facing the stage is moved across the intermediate carrier until it comes into contact with the intermediate carrier, and the stage is moved to the intermediate carrier based on the amount of movement of the pressing plate. The material layer is transferred and laminated on the stage by moving the material layer and sandwiching the material layer between the stage and the pressing plate. The additive manufacturing method.   13. The expansion ratio of the material layer is calculated based on the second tension in the first step, and the material layer is formed with a size corrected based on the expansion ratio. The additive manufacturing method according to any one of items 21 to 21.   23. The expansion / contraction rate for each mounting position is calculated in advance based on the second tension at each of a plurality of mounting positions of the material layer on the intermediate carrier. Additive manufacturing method.

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