JP2000309057A - Optical three-dimensional molding method and apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To smoothly mold a complicated shape by a simple process and a device by using a photo-curing resin composition of which the melting temperature is in a specified range, keeping an optically uncured photo-curing resin composition which constitutes the same surface as an already formed photo-curing layer under a solidified state at lower than the melting temperature, and repeating a laminate forming. SOLUTION: On a mounting base 11, a photo-curing resin composition R1 having a melting temperature in a range of 5-90 deg. under an optically uncured state, is applied. Light is emitted under a control from the top of the photo-curing resin composition R1, and a photo-curing layer Rc1 having a specified pattern and a thickness is formed. Then, an optically uncured photo-curing resin composition R1 constituting the same surface as the photo-curing layer Rc1 is placed under a solidified state Rs1 by setting a temperature at less than the melting temperature, and on the surface, a photo-curing resin composition R2 is applied. Then, light is irradiated to the photo-curing resin composition R2 under a control, and a photo-curing layer Rc2 is integrally laminate- formed. In addition, an optically uncured photo-curing resin composition R2 constituting the same surface as the photo-curing layer Rc2 is placed under a solidified state Rs2 by setting a temperature at lower than the melting temperature, and the same process is repeated hereafter.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for optically producing a three-dimensional object using a photocurable resin composition. More specifically, the present invention uses a specific photocurable resin liquid composition, an overhang portion, a spaced portion,
A complex three-dimensional structure with multiple legs with different lengths can be placed in a molding bath with a separate support from the three-dimensional structure, or the trouble of providing support to the three-dimensional structure itself. The present invention relates to a method and apparatus for easily and smoothly producing optically without special operations.

[0002]

2. Description of the Related Art In general, liquid photocurable resin compositions are widely used as coating materials (particularly hard coating agents), photoresists, dental materials and the like. Recently, three-dimensional CAG
The method of three-dimensionally optically molding the photocurable resin composition based on the data input to can accurately produce a three-dimensionally shaped object having a desired shape and dimensions, and has a complicated structure Even so, it has attracted particular attention because it can be shaped. Regarding the optical three-dimensional molding technology, a required amount of controlled light energy is supplied to a liquid photo-curable resin to cure it in a thin layer, and then a liquid photo-curable resin is further supplied thereon, and then the light is controlled under control. An optical three-dimensional molding method for producing a three-dimensional object by repeating the process of irradiating and laminating and curing in a thin layer is disclosed in Japanese Patent Application Laid-Open No. Sho 56-14.
No. 4478, and its basic practical method is further proposed in Japanese Patent Application Laid-Open No. 60-247515, after which a number of proposals concerning optical three-dimensional modeling technology have been made.

[0003] As a method of optically producing a three-dimensional molded article, an ultraviolet laser controlled by a computer so as to obtain a desired pattern on a liquid surface of a liquid photocurable resin composition placed in a molding bath is selected. To a predetermined thickness, and then supply one layer of a liquid photo-curable resin composition on the photo-cured layer, and similarly irradiate with an ultraviolet laser, as described above. A method of curing and repeating the above-mentioned laminating / photocuring operation until a desired three-dimensional structure is obtained is generally widely adopted. By such a general-purpose optical three-dimensional modeling method, a three-dimensional molded article having a complicated shape including an overhang portion, a separation portion, a plurality of legs having different lengths, an uneven portion, and the like is widely performed. In this case, the individual photo-cured layers formed one after another by light irradiation are in the form of an extremely thin thin film, and the laminate formed by laminating the thin films is also thin, and is itself inferior in shape retention. In addition, the photocurable resin composition in the shaping bath is liquid and hardly has the ability to support the photocurable layer. Therefore, when manufacturing a three-dimensional molded article of a complicated shape having an overhang portion, a spacing portion, a plurality of legs having different lengths, irregularities, and the like, the molding portion formed by photo-curing during molding is formed. Problems such as sagging, deformation, dimensional deviation, and position movement are likely to occur. Therefore, in order to prevent such a problem from occurring, a method of performing stereolithography while arranging a separately manufactured support in a molding bath and supporting the molded object by the support, or a target three-dimensional molded object. A method of performing modeling while simultaneously forming an extra support portion (a method using a so-called support) is generally adopted.

The above points will be specifically described with reference to the drawings. For example, as shown in FIG. 1A, in a three-dimensional model having a disk portion 2 between upper and lower cylindrical portions 1a and 1b,
When the optical molding is performed in layers one after another from the lower end of the cylindrical portion 1a, the diameter of the disk portion 2 is larger than the diameter of the cylindrical portion 1 so that the disk portion 2 forms an overhang portion. If the shaping of the overhang portion is performed as it is without using a support, the disk portion 2 may hang down during shaping, or a trouble such as an inclination may occur, and it is difficult to form a horizontal disk structure. Therefore, it becomes difficult to produce a three-dimensional structure having a desired shape and dimensions. Therefore, conventionally, at the time of molding the disk portion 2 forming the overhang portion, (a) for example,
A method of performing stereolithography while disposing a separate support 3 as shown in (b1) and (b2) of FIG. 1 in a modeling bath and supporting the overhang portion with the support 3 [(b1 of FIG. 1)] ) Is a longitudinal sectional view during stereolithography, and FIG.
2) is a plan view as viewed from below during stereolithography.];
For example, a method of performing stereolithography while forming a support portion 4 as shown in (c1) and (c2) of FIG. 1 integrally with a three-dimensional molded object while preventing the overhang portion from sagging or deforming [FIG. (C1) is a longitudinal sectional view of the optically formed object, FIG.
(C2) is a plan view of the optically formed object viewed from below.];
And so on.

[0005] For example, as shown in FIG. 2A, there are left and right leg portions 6 and 7 having different lengths on the left and right below the central connecting plate portion 5, and further on the upper portion of the connecting plate portion 5. In the three-dimensional object having left and right arms 8 and 9 extending upward, a three-dimensional object in a molding bath 12 containing a liquid photocurable resin composition is shown in FIG.
As shown in FIG. 2, stereolithography is performed from the lower end of the long leg 6, and when the modeling height of the leg 6 reaches the lower end position of the short leg 7 as shown in FIG. Left and right legs 6,7
Is performed at the same time. In this case, the thin-layered shaped portion 7a for forming the short leg portion 7 is not connected to the shaped portion 6a for forming the long leg portion 6 and is not placed on the mounting table. Since it floats on the photocurable resin composition, it is easy to move, and the distance between the modeling part 6a and the modeling part 7a is hard to be maintained at the designed value. for that reason,
Conventionally, as shown in (c), for example, as shown in (d) (longitudinal cross-sectional view) and (e) (top plan view) of FIG. A method of manufacturing a three-dimensional structure having the support portion 10 as shown in FIG. 1 (f) by providing support for forming a support portion 10 for connecting the formation portion 7a to the formation object 6a; Generally adopted.

[0006] However, in the case of the method shown in the above (a) in which a support separate from the three-dimensionally formed object is arranged in a molding bath to perform stereolithography, the support is prepared in advance and the support is formed. Complicated labor of arranging in a modeling bath is required. Moreover, it is necessary to design in advance the shape and dimensions of the support suitable for preventing drooping and deformation in the overhang part, and to arrange the support at an appropriate position. Requires a high degree of skill. Furthermore, the contact trace of the support is likely to remain on the surface of the obtained three-dimensional structure at the place supported by the support, so that the appearance of the three-dimensional structure becomes poor,
In some cases, it is necessary to perform a repair process such as polishing and smoothing the portion.

In the case of the method shown in (b) or (c) above, in which the support portion is formed integrally with the three-dimensional object at the time of stereolithography, the support portion formed integrally with the three-dimensional object is formed after the end of the molding. Complicated labor of cutting and removing is required. In addition, in order that the support portion can be easily cut and removed, and that the appearance of the three-dimensional structure is not impaired by cutting the support portion, the shape and size of the support portion and the support portion need to be reduced. It is necessary to sufficiently consider the position at which the support is provided, and considerable skill is required for providing the support. Further, in removing the support part, the support part is removed while sufficiently distinguishing which part is the support part and which part is the part constituting the final target three-dimensional structure in the obtained three-dimensional structure. Therefore, it is difficult to remove the support unit unless the operator is capable of reading the CAD data and the component drawings.

For the purpose of solving the above-mentioned problems in general-purpose optical three-dimensional molding in which a liquid photocurable resin composition placed in a molding bath is irradiated with light to produce a three-dimensional molded product, Japanese Patent Application Laid-Open No. 63-72526 has been proposed. In the publication, a solidifying material such as wax is used as a second material together with a first material comprising a liquid photocurable resin composition, and the solidifying material prevents sagging and deformation of an overhang portion and the like. Meanwhile, a method of optically producing a three-dimensional structure has been proposed. More specifically,
In this publication, (1) a liquid photocurable resin composition is applied to a molding table, and (2) a mask formed in a predetermined pattern is superimposed on a coating layer of the photocurable resin composition, and light is irradiated. (3) sucks and removes the uncured photocurable resin composition, and (4) solidifies the solidified voids formed by sucking the uncured photocurable resin composition. The two materials are applied, (5) the second material applied is cooled and solidified, and (6) the upper surface of the solidified material is ground to obtain dimensional accuracy in the Z direction. A liquid photocurable resin composition was applied on top, and the above-mentioned (2)-
There is disclosed an optical three-dimensional molding method that is repeated a number of times until the three-dimensional molded object for the purpose of the step (7) is formed. According to this method, the solidifying second material functions as a supporting material for preventing the overhang portion and the like from sagging and deforming.

However, the above-mentioned Japanese Patent Application Laid-Open No.
In the case of using the optical three-dimensional molding method described in Japanese Patent No. 526, it is necessary to separately use a second material for supporting the shape of the molded object together with the photocurable resin composition for producing the three-dimensional molded object. And (3) for absorbing the uncured photocurable resin composition after light irradiation with the use of the second material.
The step of applying the solidifying second material to the voids generated by sucking the uncured photocurable resin composition; and the step of (4), wherein the solidified second material is solidified in order to obtain dimensional accuracy in the Z direction. A number of extra steps such as the step (6) for surface grinding the upper surface of the two materials must be added. As a result, the optical three-dimensional modeling operation becomes extremely complicated, and the production of the optical three-dimensional modeling takes time and effort, and accordingly, the apparatus becomes complicated, large, and expensive. further,
When the second material such as wax applied on the photocurable layer in the step (2) is not sufficiently removed in the surface grinding step (6) and remains on the photocurable layer, the photocurable layer is removed. Next, since a second material such as wax is interposed between the photocurable layer formed thereon and the photocurable layer, adhesion between the photocurable layers is inhibited, and delamination of the photocurable layer is likely to occur. The strength of the three-dimensional object to be obtained is reduced. In addition, since the photocurable resin composition used in the optical three-dimensional molding method is generally expensive, after the production of the three-dimensional molded article, the uncured photocurable resin composition that did not participate in the photocuring is recovered. Although it is usually performed to recycle, in the case of the optical three-dimensional molding method described in the above-mentioned publication, a large amount of the second material such as wax in the uncured photocurable resin composition Due to the mixing, it is necessary to completely separate the second material and then reuse the photocurable resin composition for optical three-dimensional modeling, which is a great deal in purification, recovery and reuse of the photocurable resin composition. Labor and expense.

[0010]

SUMMARY OF THE INVENTION An object of the present invention is to produce a three-dimensionally shaped object having a complicated shape having an overhang portion, a spacing portion, a plurality of legs having different lengths, and an uneven portion. No need to place the support separately in the modeling bath,
Further, an optical three-dimensional molding method and apparatus capable of easily and smoothly manufacturing a target three-dimensional molded object without forming (supporting) a support portion serving as a support on the three-dimensional molded object itself at the time of molding. It is to provide. Furthermore, an object of the present invention is to use only a photocurable resin composition without using a second material such as wax for supporting the shape of a three-dimensional molded object, and to use an overhang portion, a separation portion, and a long portion. By providing a method and apparatus capable of smoothly and optically modeling a three-dimensional molded article having a complicated shape having a plurality of legs, irregularities, and the like having different lengths with a simple process and apparatus. is there.

[0011]

The present inventor has made various studies in order to achieve the above object. As a result, the photocurable resin composition has a melting temperature in the range of 5 to 90 ° C. before being cured by light, and from the solid to the liquid or from the liquid to the solid at the melting temperature. When using a photocurable resin composition that changes phase reversibly to, and when forming a photocurable layer by irradiating the photocurable resin composition with light,
Located just below the photo-cured layer to be formed,
The photocurable resin composition constituting the same surface as the already formed photocurable layer is kept in a solidified state at a temperature lower than its melting temperature, and the solidified photocurable resin composition layer and the already cured When the photocurable layer is formed by irradiating light while supporting the photocurable resin composition applied in one layer on the solid surface of the photocured layer, a separate support is placed in the modeling bath. Even if it does not perform or attach the support to the three-dimensional object itself, or even without using a second material such as wax as a support material, an overhang portion, a spacing portion, a plurality of legs having different lengths, It has been found that a three-dimensional structure having a complicated shape and structure having irregularities and the like can be easily and smoothly manufactured with high dimensional accuracy without sagging, deformation, or movement of the above-mentioned portions.

Further, in performing the above-mentioned optical three-dimensional modeling, the present inventor has proposed that the photocurable resin composition applied in one layer to the surface of the solidified photocurable resin composition is a liquid. It was found that the photocuring of the applied photocurable resin composition may be carried out in a liquid state or in a solid state. Further, the present inventor, when performing the optical three-dimensional modeling by the above method using a photocurable resin composition having a melting temperature at the time of uncured light within the range of 5 to 90 ° C., After the end of the operation, or in some cases, in the middle, when the temperature is equal to or higher than the melting temperature of the photocurable resin composition, the photocurable resin composition that did not participate in photocuring became liquid and was formed by photocuring. It can be easily and smoothly separated from the three-dimensional object, and further, since the photocurable resin composition thus separated does not contain the second material such as wax, the subsequent optical three-dimensional object forming operation as it is Was found to be reusable. Furthermore, the separation of the light-uncured photocurable resin composition from the three-dimensional molded article formed by photocuring is not performed by heating and melting, but in some cases using a solvent to solidify the photocurable resin composition. May be carried out by a method of dissolving, and the present invention has been completed based on those various findings.

That is, the present invention provides: (1) (A) (i) forming a photocurable layer having a predetermined pattern and thickness by irradiating light to the surface of a layered photocurable resin composition under control; (Ii) applying one layer of the photocurable resin composition on the photocurable layer formed in (i) and irradiating the light under control to form the photocurable layer formed in (i). A photo-curable layer having a predetermined pattern and a thickness is integrally laminated on the photo-curable layer; (iii) one layer of the photo-curable resin composition is applied on the photo-curable layer formed in the above (ii) under control. And irradiating light on the photocured layer formed in (ii) to integrally form a photocured layer having a predetermined pattern and thickness; (iv) until a desired three-dimensional structure is formed. (Ii)
(i) a method of producing a three-dimensional structure by repeating the photocurable layer lamination forming step of (i); (B) as a photocurable resin composition, in the range of 5 to 90 ° C when not photocured. (C) In all or a part of the steps (ii) to (iv) of the above (A), a photocurable resin composition having a melting temperature is used. While keeping the uncured photocurable resin composition constituting the solidified state at a temperature lower than its melting temperature, one layer of the photocurable resin composition is applied on the surface and controlled. A method of irradiating light to form a light-cured layer integrally and laminated; and a method of manufacturing a three-dimensional structure.

Further, the present invention provides: (2) The three-dimensionally shaped object according to the above (1), wherein the photocurable resin composition having a melting temperature in the range of 15 to 80 ° C. is used as the photocurable resin composition. (3) In all or a part of the steps (ii) to (iv) of the above (A), the photocurable resin composition constituting the same surface as the already formed photocurable layer is used. While maintaining the solidified state as a temperature below its melting temperature, on the surface,
One-layer photocurable resin composition is applied and light is controlled under control to perform a photolithography operation to sequentially form a photocurable layer integrally to form a three-dimensional molded article having a desired structure and dimensions. After the completion of the optical shaping operation, the photocurable resin composition is heated to a temperature equal to or higher than the melting temperature of the photocurable resin composition to liquefy the light-uncured photocurable resin composition and separate from the three-dimensional molded article formed by photocuring. (4) a method for producing a three-dimensional structure according to (1) or (2) above; (4) photocuring that has already been formed in all or a part of the steps (ii) to (iv) in (A). Applying one layer of the photocurable resin composition on the surface while keeping the uncured photocurable resin composition constituting the same surface as the layer in a solid state at a temperature lower than its melting temperature. Lithography that irradiates light under control to form a layer of photocurable layers 3D modeling having the desired structure and dimensions by performing the operation, after the stereolithography operation is completed, the solidified photocurable resin composition is dissolved in a solvent, and the 3D modeling formed by photocuring (5) a method for producing a three-dimensional molded object according to the above (1) or (2), which comprises separating the object from the object; In applying one layer of the photo-curable resin composition to the surface in the state and irradiating the photo-curable resin composition with the light, (a) applying the photo-curable resin composition in a liquid state and controlling the surface in a liquid state under control (B) applying the photocurable resin composition in a liquid state and then solidifying by cooling to a temperature lower than its melting temperature after solidifying the photocurable resin composition in a liquid state; Light on the surface under control Irradiation to form a photocured layer having a predetermined pattern and thickness;
(C) After applying the photocurable resin composition in a solid state, the composition is heated to a temperature equal to or higher than the melting temperature to be liquefied, and the surface is irradiated with light under control in a liquid state to form a photocured layer having a predetermined pattern and thickness. And (d) applying the photocurable resin composition in a solid state, and then irradiating the surface of the solid state with light under control to form a photocurable layer having a predetermined pattern and thickness. The above (1), which employs any of the above methods
Any one of (3) to (4).

Further, the present invention provides: (6) a photocuring method for sequentially supplying one layer of the photocurable resin composition onto a mounting table or a photocurable layer formed by curing the photocurable resin composition. A light irradiation device for repeatedly forming and laminating a photocured layer having a predetermined pattern and thickness under control until a final three-dimensional structure is formed; An optical three-dimensional molding apparatus including an optical shaping unit and a temperature adjusting unit that sets the photocurable resin composition to a temperature lower than its melting temperature. In the present invention, (7) the temperature adjusting means melts the photocurable resin composition constituting the same surface as the already formed photocurable layer in all or a part of the photolithography step. (3) the optical three-dimensional modeling apparatus according to the above (6), which is a cooling means having a control means for maintaining the temperature at a temperature lower than the temperature; and (8) the light existing in the optical three-dimensional modeling system during or after the stereolithography. The optical three-dimensional modeling apparatus according to (6) or (7), further including a heating means for heating the cured photocurable resin composition to a temperature equal to or higher than its melting temperature.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail. In the present invention, as described above, (i) applying the photocurable resin composition on the mounting table, and irradiating the surface of the photocurable resin composition with light under control to obtain a predetermined pattern and a predetermined thickness. (Ii) applying one layer of the photocurable resin composition on the photocurable layer formed in (i) above, and irradiating light under control to form the photocurable layer; (Iii) forming one layer of the photocurable resin composition on the photocurable layer formed in (ii) above, on the photocurable layer formed in (ii); Applying the object and irradiating the light under control so as to integrally form a photo-cured layer having a predetermined pattern and thickness on the photo-cured layer formed in (ii);
(Iv) The above (ii) until the desired three-dimensional object is formed
The three-dimensional structure is manufactured by repeating the step of i) forming the layer of the photocurable layer.

In the present invention, the series of steps (i) to (i)
In producing the three-dimensional molded object according to v), when the photocurable resin composition is not cured with light, that is, when it is not cured with light, it has a melting temperature in the range of 5 to 90 ° C. It is necessary to use a photocurable resin composition that undergoes a reversible phase change from solid to liquid or from liquid to solid at a temperature. The melting temperature of the photocurable resin composition is preferably in the range of 15 to 80C, more preferably in the range of 20 to 60C. Here, the “melting temperature” in the present specification refers to a temperature at which the photocurable resin composition changes from a substantially non-fluid state to a fluid state due to an increase in temperature.

If the melting temperature of the photocurable resin composition is lower than 5 ° C., the photocurable resin composition constituting the same surface as the already formed photocurable layer is solidified and applied thereon. When functioning as a support layer for one layer of the photocurable resin composition, it is difficult for the photocurable resin composition to be cooled and solidified, and strong cooling is required for cooling and solidifying the photocurable resin composition. Necessary and thermally disadvantageous. On the other hand, when the melting temperature of the photo-curable resin composition is higher than 90 ° C., one layer of the photo-curable resin composition is applied in liquid form on the mounting table or the already formed photo-curable layer, and then one after another. A high heating temperature is required when photo-curing, laminating, and shaping are performed, and when the temperature is lowered even a little, the photo-curable resin composition is solidified and the coating operation becomes difficult. Furthermore, after the end of the stereolithography operation, heating at a high temperature is also required when the photocurable resin composition is heated to a temperature equal to or higher than its melting temperature and separated from the three-dimensional molded product obtained by liquefaction. Thermal efficiency etc. decrease.

The photocurable resin composition used in the present invention has a sharp melting point (for example, a melting point of 30 ° C.) as long as its melting temperature is in the range of 5 to 90 ° C. Alternatively, a certain range of melting temperature (eg, 30
(Melting temperature of ~ 35 ° C).
In the present invention, the type of the photo-curable resin composition is particularly limited as long as the photo-curable resin composition is capable of optical three-dimensional modeling and has a melting temperature in the range of 5 to 90 ° C. described above. There is no limitation, and any may be used.

In the present invention, the photocurable resin composition having a melting temperature in the range of 5 to 90 ° C. is used for the above (i).
In producing a three-dimensional object by a series of steps (i) to (iv), (I) in all of the steps (ii) to (iv), the same surface as the already formed photocured layer is formed. While maintaining the photocurable resin composition in a solid state at a temperature lower than its melting temperature, a layer of the photocurable resin composition is applied to the surface and irradiated with light under control to form a photocurable layer. To form a three-dimensional object by laminating them together; or (II) forming part of the steps (ii) to (iv) to form the same surface as the already formed photocured layer. While keeping the photocurable resin composition in a solidified state at a temperature lower than its melting temperature, one layer of the photocurable resin composition is applied on the surface, and light is controlled to irradiate light to cure. It is necessary to produce the three-dimensional object by laminating the layers together. Here, the “solidified state” referred to in the present specification is:
Refers to a state without fluidity, in addition to the so-called solid state,
Wax, jelly, gel and the like are included.

In particular, when the above method (II) is adopted, if the support is not performed at the time of molding, such as an overhang portion, a separated portion, a leg portion having a different length on the left and right, and an uneven portion, drooping occurs. At the time of molding of a portion where deformation, movement, and the like are likely to occur, the photocurable resin composition constituting the same surface as the already formed photocurable layer is kept at a temperature lower than its melting temperature and is kept in a solidified state. It is at least necessary to perform the molding operation while functioning as. Then, at the time of shaping of a portion where sagging, deformation, position movement, etc. do not occur even if support is no longer performed, the photocurable resin composition constituting the same surface as the already formed photocurable layer is cooled and solidified. Instead, the molding may be performed while maintaining the liquid state, or may be performed in a solid state.

In the case of employing the method (I), at the end of the stereolithography operation, the three-dimensional molded article formed by photocuring is surrounded by the photocurable resin composition in a cooled and solidified state ( The photo-curable resin composition is incorporated into the photo-curable resin composition in a cooled and solidified state), so that it is heated to a temperature equal to or higher than the melting temperature of the photo-curable resin composition, and the photo-curable resin composition is heated. By liquefying, a three-dimensional molded object can be separated from the photocurable resin composition. In addition, the liquefied photocurable resin composition can be recovered and reused as it is for subsequent stereolithography. When the method (II) is employed, the photocurable resin composition which did not participate in the photocuring (the photocurable resin composition which did not participate in the formation of the three-dimensional molded article) at the end of the photolithography operation ) Is in a state separated from the solidified three-dimensional object that has already been liquefied and has been photocured, so that the three-dimensional object is recovered as it is and the photocurable resin composition in the liquefied state is recovered as it is. Then, it can be reused for subsequent stereolithography. In some cases, a method of dissolving the photo-curable resin composition in a solidified state, which is not photo-cured, with a solvent and separating the photo-curable resin composition from the three-dimensional structure formed by photo-curing may be employed. As the solvent in that case, any solvent can be used as long as it is a solvent that does not dissolve the photo-curable photocurable resin composition, but does not dissolve the three-dimensional structure formed by photocuring. It is preferable to use a solvent that does not cause a deterioration in the physical properties of the composition.

In the present invention, one layer of the photocurable resin composition is applied to the surface of the mounting table and / or the solidified surface constituting the same surface as the already formed photocurable layer, and irradiated with light. (A) applying the photocurable resin composition in a liquid state, and irradiating the surface of the photocurable resin composition in a liquid state under control to form a photocurable layer having a predetermined pattern and thickness. (B) applying the photocurable resin composition in a liquid state, cooling the resin composition to a temperature lower than its melting temperature, solidifying the composition, and irradiating light to the surface of the solidified resin under control to obtain a predetermined pattern. And (c) applying the photocurable resin composition in a solid state and then heating it above the melting temperature to liquefy it, and irradiating the surface in a liquid state with light under control. To form a photo-cured layer having a predetermined pattern and thickness. And (d) applying the photocurable resin composition in a solid state, and then irradiating the surface of the solid with the light under control to form a photocurable layer having a predetermined pattern and thickness. Any of the following methods may be employed.

As a specific optical three-dimensional molding method in the case of employing the method (a), the surface of the liquid photocurable resin composition on a mounting table is irradiated with light under control. A step of forming a photocurable layer having a predetermined pattern and thickness; a step of solidifying the photocurable resin composition constituting the same surface as the photocurable layer formed in the above step at a temperature lower than its melting temperature; Applying one layer of the photocurable resin composition in a liquid state on the solidified layer formed in the step, and irradiating the surface of the liquid photocurable resin composition with light in a controlled manner; A step of laminating and forming a photo-cured layer having a predetermined pattern and a thickness on the cured layer; setting the photo-curable resin composition constituting the same surface as the photo-cured layer formed in the above step to a temperature lower than its melting temperature. The step of solidifying; and One layer of the photo-curable resin composition is applied in a liquid state on the solidified layer thus formed, and the surface of the liquid photo-curable resin composition is irradiated with light under control to form a layer on the photo-cured layer formed in the above step. Forming a photo-cured layer having a predetermined pattern and thickness on the substrate, and performing the three-dimensional molding by repeating the above steps until the desired three-dimensional molded object is formed. A method for producing a molded article can be given.

As a specific optical three-dimensional molding method when the method (b) is adopted, a photocurable resin composition is applied in a liquid state on a mounting table, and then the temperature is lowered to a temperature lower than its melting temperature. Cooling and solidifying; irradiating the surface of the photocurable resin composition solidified in the above step with light under control to form a photocured layer having a predetermined pattern and thickness; Applying one layer of the photo-curable resin composition in a liquid state on the solidified layer after the step; and cooling the photo-curable resin composition applied in the above-mentioned step to a temperature lower than its melting temperature and photo-curing. Solidifying the curable resin composition; and irradiating the surface of the photocurable resin composition solidified in the above step with light under control to form a photocured layer having a predetermined pattern and thickness. And the target three-dimensional object is shaped It said until it is ~
The method for producing a three-dimensional object can be exemplified by performing the three-dimensional object by repeatedly returning the step.

Further, as a specific optical three-dimensional molding method when the above method (c) is adopted, a photocurable resin composition is applied in a solid state on a mounting table and then heated to a temperature higher than its melting temperature. And irradiating the surface with light under control to form a photocurable layer having a predetermined pattern and thickness; a photocurable resin composition constituting the same surface as the photocurable layer formed above To a temperature lower than its melting temperature; and solidifying one layer of a solid photocurable resin composition on the solidified layer formed in the above step; and Subjecting the curable resin composition to liquefaction at a temperature equal to or higher than its melting temperature, and irradiating the surface with light under control to form a photocurable layer having a predetermined pattern and thickness. The above until a three-dimensional object is formed Method for producing a three-dimensional object which comprises performing stereolithography by returning repeatedly preliminary steps and the like.

As a specific optical three-dimensional molding method when the method (d) is adopted, a photocurable resin composition is applied in a solid state on a mounting table, and the solid state is applied to the surface as it is. Irradiating light under control to form a photo-cured layer having a predetermined pattern and thickness; the photo-curable resin composition constituting the same surface as the photo-cured layer formed in the above step is directly cooled to a temperature lower than the melting temperature. Applying a layer of a solid photocurable resin composition thereon while maintaining the solidified state at a temperature; and controlling the surface of the solid photocurable resin composition applied in the above step under control. Irradiating light to form a photocured layer having a predetermined pattern and thickness; and repeating the above steps until the desired three-dimensional structure is formed. Three-dimensional modeling consisting of doing A method for producing a product can be mentioned.

The photocurable resin composition is solidified on the mounting table and / or on the surface of the already formed photocurable layer and the cooled and solidified photocurable resin composition constituting the same surface as the photocurable layer. When applied in a form, the photocurable resin composition may be applied in the form of a sheet, film, or thin film in advance, or may be applied in the form of a powder. The photocurable resin composition is applied on a mounting table in the form of a solidified sheet, film, or thin film, or a photocured layer that has been formed and a photocured layer that has been cooled and solidified to form the same surface as the photocured layer. When applied on the surface of the curable resin composition and cured by irradiating it in the form of a solid sheet, film or thin film without liquefaction, the surface tension generated in the liquid photocurable resin composition Since the surface of the photocurable resin composition liquid does not protrude and is light-cured in a flat state, the three-dimensional structure obtained has a flat surface and excellent dimensional accuracy without corners and the like of the obtained three-dimensional structure. You can get things. Further, the photocurable resin composition is applied in the form of solid powder on a mounting table or the surface of a photocurable layer already formed and a solidified photocurable resin composition constituting the same surface as the photocurable layer. In the case where it is hardened by irradiating it with light in the form of solid powder without liquefaction, a porous three-dimensional structure can be obtained.

In the present invention, the method for cooling the photocurable resin composition constituting the same surface as the already formed photocurable layer to a temperature lower than the melting temperature thereof is not particularly limited, and the light constituting the same surface may be cooled. Any method may be used as long as it can smoothly cool and solidify the curable resin composition.For example, a method in which optical three-dimensional modeling is performed in a cooling chamber maintained at a temperature lower than the melting temperature of the photocurable resin composition, or a method already formed. It can be carried out by, for example, spraying a cooling fluid (gas or liquid) having a temperature lower than its melting temperature onto the surface of the photocurable resin composition constituting the same surface as the photocured layer.

In the method for producing a three-dimensional object according to the present invention, one layer of the photocurable resin composition is sequentially supplied onto the mounting table or onto the photocurable layer formed by curing the photocurable resin composition. A light irradiation device for repeatedly performing formation and lamination of a photocurable layer having a predetermined pattern and thickness under control until a final three-dimensional molded object is formed. It can be performed by using the optical three-dimensional modeling apparatus of the present invention including the optical shaping means provided and the temperature adjusting means for cooling the photocurable resin composition to a temperature lower than its melting temperature. In the above-described optical three-dimensional modeling apparatus of the present invention, as the temperature adjusting means, in all or a part of the stereolithography process, a photocurable resin composition constituting the same surface as the already formed photocurable layer Cooling means having control means for keeping the material below its melting temperature is preferably employed. Further, the optical three-dimensional modeling apparatus of the present invention further includes heating means for heating the uncured photocurable resin composition present in the optical three-dimensional modeling system to a temperature equal to or higher than its melting temperature during or after the stereolithography. You may have.

In the method and apparatus of the present invention, the method of irradiating the photocurable resin composition with light is not particularly limited. For example, a photocurable layer is formed by a drawing method by irradiating a spot-like light beam. Alternatively, the light-cured layer may be formed by irradiating a linear light beam, or the light-cured layer may be formed by irradiating a light beam in a plane using a mask or the like. The type of light to be applied is not particularly limited, and any light used in optical three-dimensional printing can be used.
Any of active energy rays generated from an e-Cd laser, a xenon lamp, a metal halide lamp, a mercury lamp, a fluorescent lamp and the like can be used. Among them, a laser beam is preferably employed in terms of the molding speed, high molding accuracy due to high light-collecting property, and the like. In addition, the intensity of light to be irradiated, the distance between the surface of the photocurable resin composition and the light source, and the like can be appropriately set according to each situation.

The present invention will be described with reference to the drawings for a better understanding of the present invention without any limitation. First, for example, a case of manufacturing the three-dimensional structure shown in FIG. 1A will be described with reference to FIG. A photocurable resin composition R1 having a melting temperature in the range of 5 to 90 ° C. when light is not cured is applied on a mounting table 11 for mounting a three-dimensional structure such as a table [FIG. (A)], light is irradiated under control from above (not shown) to form a photocurable layer Rc1 having a predetermined pattern (a circular shape having a diameter corresponding to the lower end surface of the columnar portion 1a) and a thickness. [FIG. 3 (b)]. Next, the non-photocured photocurable resin composition R1 constituting the same surface as the photocurable layer Rc1 is set at a temperature lower than its melting temperature to a solidified state Rs1 (FIG. 3C), and the solidified state is changed. While keeping the surface, one layer of the photocurable resin composition R2 is applied on the surface [FIG. 3 (d)], and light is radiated under control to form a photocurable layer Rc2 integrally and integrally [ (E) of FIG. 3, and then the photo-curable photocurable resin composition R2 constituting the same surface as the photocurable layer Rc2 is set to a solidified state Rs2 at a temperature lower than its melting temperature [(f) of FIG. Thereafter, the same process is repeated to form the shaping portion Rc corresponding to the columnar portion 1a on the mounting table 11 [(g) of FIG. 3]. The modeling part Rc is surrounded on its side by a photo-uncured photocurable resin composition Rs that has been solidified at a temperature lower than the melting temperature.

Next, the photocurable resin composition R which has not been cured
A layer of a photocurable resin composition for forming a disk portion 2 corresponding to an overhang portion on the surface thereof while maintaining a solidified state at a temperature lower than its melting temperature and functioning as a support member. S1 is performed [(h) in FIG. 3], and light is radiated under control to form a photo-cured layer Sc1 having a predetermined pattern (a circular shape having a diameter corresponding to the lower end surface of the disk portion 2) and a thickness. Then, the photocurable resin composition constituting the same surface as the photocurable layer Sc1 is formed at a temperature lower than the melting temperature of the photocurable resin composition while keeping the solidified state on the surface, One layer of the photo-curable resin composition S2 is applied, and light is radiated under control to form a photo-cured layer integrally (FIG. 3 (j)). Thereafter, the same operation is repeated to form a circle. A modeling part Sc corresponding to the plate part 2 is formed [(k) in FIG. 3]. Thereafter, the same molding operation is repeated to form a molding portion corresponding to the columnar portion 1b, whereby the three-dimensional molded object A shown in FIG. It is formed on the mounting table 11 in a state of being built in the object Rs [(l) in FIG. Next, the three-dimensional structure A is obtained by heating the obtained molded object A to the melting temperature of the photocurable resin composition while the molded object A is placed on the mounting table 11 or taken out of the mounting table 11.
And the liquid photocurable resin composition R are separated and collected [(m) in FIG. 3].

In the above-described series of molding operations, when molding the disk portion 2 having the overhang shape, in order to prevent the overhang portion from sagging or deforming downward, the photo-curing applied to one layer is performed. The uncured photocurable resin composition constituting the same surface as the already formed photocurable layer immediately below the resin composition needs to be kept in a solid state at a temperature lower than the melting temperature. However, the columnar portion 1b located on the upper portion of the disk portion 2 is not overhanged on the disk portion 2 having a larger diameter, and the columnar portion 1b
Since there is little danger of sagging and deformation during molding,
In the molding of b, the light-uncured photocurable resin constituting the same surface as the already formed photocurable layer immediately below the photocurable resin composition applied in one layer for forming the cylindrical portion 1b The composition may be left in a liquid state, unlike the case described above. In that case, upon completion of the stereolithography operation,
Since the photocurable resin composition is in a liquid state and has already been separated from the obtained three-dimensional structure, a melting operation for separating the photocurable resin composition from the three-dimensional structure is unnecessary.

Further, for example, the case of manufacturing the three-dimensional structure shown in FIG. 2A will be described below with reference to FIG. The photocurable resin composition R1 having a melting temperature in the range of 5 to 90 ° C. is applied to the mounting table 11 when the light is not cured [FIG. 4 (a)], and light is controlled from the upper surface side under control. Irradiates the photocurable layer R having a predetermined pattern (square shape corresponding to the lower end surface of the leg 6) and thickness.
c1 is formed [(b) of FIG. 4]. Next, the photocurable layer Rc1
The photocurable resin composition constituting the same surface as above is set to a solidified state Rs1 at a temperature lower than its melting temperature, and one layer of the photocurable resin composition is applied on the surface while maintaining the solidified state. The light curable layer Rc2 is integrally formed by laminating light under control [FIG. 4 (c)], and thereafter, the same operation is repeated until the shaped part up to the middle of the leg 6 is placed on the mounting table 11. [(D) of FIG. 4]. Then, while keeping the photocurable resin composition at a temperature lower than its melting temperature and in a solidified state so as to function as a support member, one layer of the photocurable resin composition is applied to the surface of the photocurable resin composition and the light is controlled under control. To form a photocurable layer for forming the legs 6 and 7 [FIG. 4 (e)]. Then, the photocurable resin composition constituting the same surface as the photocurable layer is removed. While maintaining the solidified state at a temperature lower than the melting temperature, the operation of applying one layer of the photo-curable resin composition on the surface and irradiating light under control to form a photo-cured layer is repeated. Forming portions 6a and 7a corresponding to 6 and the leg portion 7 are respectively formed [(f) of FIG. 4].

Further, the photocurable resin composition constituting the same surface as the surface of the leg 6 and the leg 7 is placed on the shaping portion corresponding to the leg 6 and the leg 7 at a temperature lower than the melting temperature. While maintaining the solidified state, a layer of the photocurable resin composition is applied to the surface, and light is radiated from the upper surface under control to form a light having a square shape corresponding to the lower end surface of the connecting plate portion 5. A hardened layer is formed, and the operation is repeated to form a shaped portion corresponding to the connecting plate portion 5 ((g) in FIG. 4). Thereafter, in the same manner,
Forming portions corresponding to the arms 8 and 9 are formed on the connecting plate portion 5, and the three-dimensional structure A shown in FIG. 2A is cooled and solidified to form a photo-curable photo-curable resin composition. It is formed on the mounting table 11 while being built in Rs [(h) of FIG. Next, the three-dimensional object A and the liquid photocurable resin composition R are separated and recovered by heating the obtained object A to the melting temperature [(i) in FIG. 4].

In the above-described series of molding operations for producing the three-dimensional object shown in FIG.
Since the lengths of the legs 6 and 7 are different in the three-dimensional structure shown in FIG. 1, if the uncured photocurable resin composition is made liquid before the end of the stereolithography operation, the Since the modeled object is not placed smoothly on the mounting table 11 and stands upside down, the entire photocurable resin composition used for modeling is set to a temperature lower than its melting temperature until the optical modeling operation is completed. It is desirable to carry out molding while maintaining the solid state.

In the above, FIG. 1 (a) and FIG. 2 (a)
Although the method of the present invention has been described by taking as an example the case of manufacturing a three-dimensional structure shown in FIG. 1, the three-dimensional structure that can be manufactured by the present invention is, of course, shown in FIGS. 1 (a) and 2 (b). The three-dimensional structure having various shapes and structures is not limited to the one and can be manufactured. For example, according to the method of the present invention, precision parts, electric and electronic parts, furniture, building structures, automotive parts, various containers, castings, molds, models for machining, and models for machining, complex models, Parts for designing heat medium circuits, analyzing heat medium behavior of complex structures, and other three-dimensional objects with complex shapes and structures, especially overhanging parts, separated parts (connected during molding) This is effective for manufacturing a three-dimensional structure having a complicated structure such as a part having different lengths, portions having different lengths, irregularities, curves and curved surfaces, and the like.

[0039]

EXAMPLES The present invention will be described in detail with reference to the following examples, but the present invention is not limited to the following examples.

<< Synthesis Example 1 >> [Production of urethane-containing acrylic compound] 2-hydroxyethyl acrylate ε-caprolactone was placed in a 4-liter four-necked flask equipped with a stirrer, a temperature controller, a thermometer and a condenser. 1600 g of a 6-mol adduct ("Braccel FA-6" manufactured by Daicel Chemical Industries, Ltd.),
0.36 g of hydroxy monomethyl ether, 0.55 g of di-n-butyltin dilaurate and 222 g of isophorone diisocyanate were added and reacted at 40 to 50 ° C. for 30 minutes, and further reacted at a temperature of 80 to 90 ° C. to obtain colorless. At room temperature (25 ° C.), a product (urethane-modified acrylic compound) was obtained which exhibited a viscous liquid of 50,000 centipoise.

<< Preparation Example 1 >> [Preparation of Photocurable Resin Composition] The urethane obtained in Synthesis Example 1 was placed in a 5-liter three-necked flask equipped with a stirrer, a cooling tube, and a dropping funnel with side tubes. 1200 g of a fluorinated acrylic compound, 600 g of morpholine acrylamide, and 200 g of 2,2-bis [4- (acryloxy-diethoxy) phenyl] propane were charged, and the atmosphere was replaced with nitrogen under reduced pressure. Next, 60 g of 2,2-dimethoxy-2-phenylacetophenone (photoradical polymerization initiator) was added in an environment where ultraviolet rays were blocked, and mixed and stirred at a temperature of 30 ° C. until completely dissolved (mixing and stirring time was about 1 hour) to obtain a colorless and transparent photocurable resin composition.
When this photocurable resin composition was allowed to stand at 20 ° C., it was solidified into a wax, and
When heated to 5 ° C., a liquid composition having fluidity was obtained.

<< Example 1 >> [Optical three-dimensional molding] (1) Using the photocurable resin composition obtained in Preparation Example 1 above, an ultra-high-speed optical molding system (“SOLIFORM500” manufactured by Teijin Seiki Co., Ltd.) )) Using water-cooled Ar laser light (output 500 mW; wavelengths 333, 351, 36).
4 nm) perpendicularly to the surface, and under irradiation energy conditions of 20 to 30 mJ / cm ² , with a slice pitch (lamination thickness) of 0.127 mm and an average modeling time of 2 minutes per layer, see FIG. Then, according to the method described above, a three-dimensional structure having the shape and dimensions shown in FIG. In this case, the cooling and solidification of the photo-uncured photo-curable resin composition constituting the same surface as the already formed photo-cured layer is performed by 10 ° C. from the surface of the photo-curable resin composition. And the temperature of the entire object placed on the mounting table was kept at 10 ° C. during the optical shaping operation. In addition, when performing photolithography of one layer of the photocurable resin composition on the photocurable layer that has already been formed, the temperature of the photocurable resin composition is set to 40 ° C., and the liquid is set to a uniform thickness by a knife coater. Was applied so as to form a layer. (2) After the stereolithography operation of the above (1) is completed, the molded object is taken out of the mounting table and transferred to the enameled bat,
When placed in a warm air heater at 0 ° C. and allowed to stand for 30 minutes, the photo-curable resin composition surrounding the three-dimensional structure was melted and liquefied and separated from the three-dimensional structure. And the photocurable resin composition were individually collected.

(3) After washing the three-dimensional structure obtained in the above (2) with isopropyl alcohol to completely remove the uncured photocurable resin composition adhering to the three-dimensional structure, 3 KW For 10 minutes to post cure. (4) As a result, a three-dimensional structure as designed having the structure shown in FIG. 1A without any sagging or deformation at the overhang portion (disk portion 2) and other portions was obtained. From these results, according to the method of the present invention, even for a three-dimensional model having a complicated shape having an overhang portion or the like, a support member is provided separately or support is provided on the three-dimensional model itself. Therefore, it was confirmed that the intended three-dimensional object was smoothly obtained. (5) For reference, a dumbbell test piece according to JIS 7113 is prepared by performing the same operation as in the above (1) to (3), and the mechanical characteristics thereof are measured according to JIS K711.
3, the tensile strength was 2 MPa, the tensile elongation was 29%, and the tensile modulus was 6 MPa.

[0044]

According to the optical three-dimensional molding method and apparatus of the present invention, a three-dimensional molded article having a complicated shape having an overhang portion, a separation portion, a plurality of legs having different lengths, an uneven portion, and the like, Without placing the support separately in the modeling bath, and without forming the support part that becomes the support on the three-dimensional molded object itself at the time of modeling (without performing the support), sagging, deformation, movement, etc. of the above-mentioned portion , And can be manufactured easily, with high dimensional accuracy, and smoothly.
Further, in the case of the present invention, the overhang portion, the separation portion, and the length are formed using only the photocurable resin composition without using the second material such as wax for supporting the shape of the three-dimensional molded object. A three-dimensional structure having a complicated shape having a plurality of legs, irregularities, and the like having different sizes can be optically formed in a short time and with a simple process and apparatus. Further, in the case of the method and apparatus of the present invention, by heating and liquefying the photocurable resin composition not involved in photocuring at or above its melting temperature, from a three-dimensional molded article formed by photocuring. It can be easily and smoothly separated, and the photocurable resin composition thus separated does not contain a second material such as wax, so that it can be reused as it is for subsequent optical three-dimensional molding work. can do.
Further, in the present invention, the photocurable resin composition is solidified in the form of a sheet, a film or a thin film, and is applied on a mounting table, or forms the same surface as the already formed photocurable layer and the photocurable layer. When applied on the surface of the photocurable resin composition which has been cooled and solidified, and is cured by irradiating it in the form of a solid sheet, film or thin film without liquefaction, a liquid photocurable resin composition is used. No rise of the photocurable resin composition liquid surface due to the surface tension generated in the
Since the photocuring is performed in the flat state, the corners of the obtained three-dimensional structure are not rounded, and a three-dimensional structure having a flat surface and excellent dimensional accuracy can be obtained. Further, the photocurable resin composition is applied in the form of solid powder on a mounting table or the surface of a photocurable layer already formed and a solidified photocurable resin composition constituting the same surface as the photocurable layer. In the case where it is hardened by irradiating it with light in the form of solid powder without liquefaction, a porous three-dimensional structure can be obtained.

[Brief description of the drawings]

FIG. 1 shows an example of a three-dimensional structure having an overhang portion.
It is a figure which shows the example at the time of manufacturing the three-dimensional molded item by the conventional optical three-dimensional molding method.

FIG. 2 shows an example of a three-dimensional object having different lengths of left and right legs.
It is a figure which shows the example at the time of manufacturing the three-dimensional molded item by the conventional optical three-dimensional molding method.

FIG. 3 is a diagram showing an example of a case where the three-dimensional structure shown in FIG. 1A is manufactured by the optical three-dimensional structure method of the present invention.

FIG. 4 is a diagram showing an example of a case where the three-dimensional structure shown in FIG. 2A is manufactured by the optical three-dimensional structure method of the present invention.

[Explanation of symbols]

 Reference Signs List 1a cylindrical portion 1b cylindrical portion 2 disk portion 3 separate support 4 support portion integrated with three-dimensional object 5 connecting plate portion 6 leg portion 7 leg portion 8 arm portion 9 arm portion 10 support portion 11 mounting table

Claims (14)

[Claims] (A) (i) a surface of the layered photocurable resin composition is irradiated with light under control to form a photocurable layer having a predetermined pattern and thickness; One layer of the photocurable resin composition is applied on the photocurable layer formed in i), and light is radiated under control to form a predetermined pattern and thickness on the photocurable layer formed in (i). (Iii) applying one layer of the photocurable resin composition on the photocurable layer formed in (ii) above, and irradiating light under control; A photo-cured layer having a predetermined pattern and a thickness is integrally formed on the photo-cured layer formed in (ii); (iv) the above-mentioned (ii) until a desired three-dimensional structure is formed.
(i) a method of producing a three-dimensional structure by repeating the photocurable layer lamination forming step of (i); (B) as a photocurable resin composition, in the range of 5 to 90 ° C when not photocured. (C) In all or a part of the steps (ii) to (iv) of the above (A), a photocurable resin composition having a melting temperature is used. While keeping the uncured photocurable resin composition constituting the solidified state at a temperature lower than its melting temperature, one layer of the photocurable resin composition is applied on the surface and controlled. A method of irradiating light to form a layer of the photocurable layer integrally; and a method of manufacturing a three-dimensional structure. 2. A photo-curable resin composition comprising 15 to 80
The method for producing a three-dimensional structure according to claim 1, wherein a photocurable resin composition having a melting temperature in the range of ° C is used. 3. A photo-uncured photo-curable resin constituting the same surface as a photo-cured layer already formed in all or a part of the steps (ii) to (iv) of (A). While maintaining the composition in a solidified state at a temperature lower than its melting temperature, one layer of the photocurable resin composition is applied to the surface, and light is radiated under control to laminate the photocurable layers one by one. Perform a stereolithography operation to form a three-dimensional molded article having the desired structure and dimensions, and after the stereolithography operation is completed, heat to a temperature equal to or higher than the melting temperature of the photocurable resin composition to cure the photo-uncured resin. The method for producing a three-dimensional structure according to claim 1, wherein the method comprises liquefying the photocurable resin composition and separating it from a three-dimensional structure formed by photocuring. 4. An uncured photocurable resin constituting the same surface as an already formed photocurable layer in all or a part of the steps (ii) to (iv) of (A). While maintaining the composition in a solidified state at a temperature lower than its melting temperature, one layer of the photocurable resin composition is applied to the surface, and light is radiated under control to laminate the photocurable layers one by one. Perform a stereolithography operation to form a three-dimensional molded article having a target structure and dimensions, and after the stereolithography operation is completed, dissolve the photocurable resin composition in a solidified state in a solvent, and perform photocuring. The method for producing a three-dimensional structure according to claim 1, wherein the three-dimensional structure is separated from the formed three-dimensional structure. 5. A solidified surface constituting the same surface as the mounting table and / or the already formed photocurable layer is coated with one layer of the photocurable resin composition and irradiated with light to be cured. (A) a method in which the photocurable resin composition is applied in a liquid state, and the surface of the liquid is irradiated with light in a controlled manner to form a photocurable layer having a predetermined pattern and thickness; After applying the photocurable resin composition in a liquid state, the composition is cooled to a temperature lower than its melting temperature and solidified, and in the solidified state, the surface is irradiated with light under control to have a predetermined pattern and thickness. A method for forming a layer; (c) applying the photocurable resin composition in a solid state, heating the composition to a temperature equal to or higher than the melting temperature, and liquefying the composition; A method for forming a photocurable layer having: And (d) a method of applying the photocurable resin composition in a solid state, and then irradiating the surface of the solid with the light under control to form a photocurable layer having a predetermined pattern and thickness; The method for producing a three-dimensional structure according to any one of claims 1 to 4, which employs any one of the following. 6. A step of irradiating the surface of the liquid photocurable resin composition in a liquid state on a mounting table under control to form a photocurable layer having a predetermined pattern and thickness; Solidifying the photocurable resin composition forming the same surface as the photocured layer at a temperature lower than its melting temperature; one layer of the photocurable resin composition on the solidified layer formed in the above step. Applying a liquid to the surface of the liquid photocurable resin composition under control to form a photocurable layer having a predetermined pattern and thickness on the photocurable layer formed in the above step; A step of solidifying the photocurable resin composition constituting the same surface as the photocurable layer formed in the above step at a temperature lower than its melting temperature; and one layer on the solidified layer formed in the above step. Apply the photocurable resin composition in liquid form A step of irradiating the surface of the curable resin composition with light under control and laminating and forming a photocurable layer having a predetermined pattern and a thickness on the photocurable layer formed in the above step. The method of manufacturing a three-dimensional object according to any one of claims 1 to 5, wherein the three-dimensional object is formed by repeating the above steps until a three-dimensional object to be formed is formed. 7. A step of applying the photo-curable resin composition in a liquid state on a mounting table and then cooling it to a temperature lower than its melting temperature to solidify; Irradiating light under control to form a photo-cured layer having a predetermined pattern and thickness; one layer of the photo-curable resin composition in a liquid state on the solidified layer after the above-mentioned step under cooling A step of applying; a step of cooling the photocurable resin composition applied in the above step to a temperature lower than its melting temperature to solidify the photocurable resin composition; and a photocurable resin composition solidified in the above step. Irradiating the surface of the object with light under control to form a photo-cured layer having a predetermined pattern and thickness; and
The method of manufacturing a three-dimensional structure according to any one of claims 1 to 5, wherein the three-dimensional structure is performed by repeatedly returning the step. 8. After applying the photocurable resin composition in a solid state on a mounting table, the composition is heated to a temperature higher than its melting temperature to be liquefied, and the surface is irradiated with light under control to obtain a predetermined pattern and thickness. Forming a photocurable layer having the same surface as the photocurable layer formed above; solidifying the photocurable resin composition at a temperature lower than its melting temperature; Applying a one-layer solid photocurable resin composition thereon; and liquefying the photocurable resin composition applied in the above step at a temperature equal to or higher than its melting temperature, and controlling the surface of the photocurable resin composition under light. Forming a photo-cured layer having a predetermined pattern and thickness by irradiating the solid-state molding by repeating the above steps until the desired three-dimensional structure is formed. Claim 1 which consists of Method for producing a three-dimensional object according to any one of. 9. A step of applying a photocurable resin composition in a solid state on a mounting table, and irradiating the surface of the photocurable resin composition in a controlled manner with the solid state to form a photocurable layer having a predetermined pattern and thickness. A photocurable resin composition constituting the same surface as the photocurable layer formed in the above step is kept in a solidified state at a temperature lower than the melting temperature, and one layer of a solid photocurable resin is further formed thereon. Applying the composition; and irradiating the surface of the solid photocurable resin composition in the above step with light under control to form a photocurable layer having a predetermined pattern and thickness; The three-dimensional structure according to any one of claims 1 to 5, wherein the three-dimensional structure is performed by repeating the above steps until the target three-dimensional structure is formed. Method. 10. A three-dimensional structure formed by photocuring by heating the photocurable resin composition to a temperature equal to or higher than the melting temperature of the photocurable resin composition after the completion of the photolithography operation to liquefy the photocurable resin composition. The method for producing a three-dimensional structure according to any one of claims 6 to 9, comprising separating the three-dimensional structure from the three-dimensional structure. 11. The method according to claim 6, further comprising dissolving the uncured photocurable resin composition using a solvent after the stereolithography operation is completed to separate the photocurable resin composition from the three-dimensional molded article formed by photocuring. The method for producing a three-dimensional structure according to any one of the above. 12. A photocurable resin composition supply means for sequentially supplying one layer of photocurable resin composition onto a mounting table or onto a photocurable layer formed by curing the photocurable resin composition. An optical shaping means including a light irradiation device for repeatedly forming and laminating a photocurable layer having a predetermined pattern and thickness under control until a final three-dimensional molded object is formed, and a photocurable resin composition An optical three-dimensional object forming apparatus having a temperature adjusting means for bringing an object to a temperature lower than its melting temperature. 13. The method according to claim 1, wherein the temperature adjusting means sets the temperature of the photocurable resin composition constituting the same surface as the already formed photocurable layer to a temperature lower than its melting temperature in all or a part of the optical shaping process. The optical three-dimensional modeling apparatus according to claim 12, which is a cooling unit having a control unit for maintaining the three-dimensional shape. 14. The method according to claim 12, further comprising heating means for heating the uncured photocurable resin composition present in the optical three-dimensional molding system to a temperature equal to or higher than its melting temperature during or after the stereolithography. An optical three-dimensional modeling apparatus according to the above.