JPH0518704B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method and an apparatus for obtaining a desired three-dimensional shape using a photocurable resin that is cured by irradiation with light.

[Conventional technology]

The method of forming three-dimensional shapes using photocurable resin is a method that can easily and accurately form complex three-dimensional shapes without using molds or special processing tools. It is considered to be used in the production of Specifically, for example, there are methods disclosed in JP-A-61-114817 and JP-A-63-141724.

The method described in JP-A-61-114817 is carried out as follows. A photocurable resin liquid is supplied into a container to form a resin liquid layer of a certain thickness, and this resin liquid layer is irradiated with laser light from above the liquid surface to partially photocure this resin liquid layer. . At that time, by sequentially moving the focal position of the laser beam,
A photocurable layer having a predetermined pattern can be formed. Next, a new resin liquid is supplied onto this photocured layer to form a new resin liquid layer, and this resin liquid layer is again irradiated with laser light. By repeating such steps and sequentially stacking the photocured layers, a resin product having a desired three-dimensional shape can be obtained.

However, this method has a problem in that it is difficult to accurately and quickly set the thickness of the thin resin liquid layer, which determines the thickness of the photocured layer. That is, in this prior art, since the thickness of the thin layer of resin liquid is determined by the amount of resin liquid supplied to the storage container, the amount of resin liquid supplied must be controlled extremely accurately. However, it is very difficult to control the amount of resin liquid supplied with high precision, and variations in the thickness of the resin liquid thin layer inevitably occur. If there is variation in the thickness of the resin liquid thin layer, naturally there will be variation in the thickness of the photocured layer that is formed, and the accuracy of the three-dimensional shape will decrease.

On the other hand, the method described in JP-A-63-141724 is carried out as follows, and therefore does not require control of the amount of resin liquid supplied as in the above method. That is, in this method, as shown in FIG. 11, a photocurable resin liquid 20 is stored in a tank 10 and a molding table 50 that can be raised and lowered is provided. Once the molding table 50 is submerged slightly below the liquid level and then raised to a position slightly below the resin liquid level, the molding table 50
A photocurable resin liquid thin layer 21 having a thickness corresponding to the required thickness is naturally formed thereon. Therefore, this photocurable resin liquid thin layer 21 is irradiated with laser light 30. As a result, the first photocured layer 40 is formed on the molding table 50. Next, when the molding table 50 is submerged below the liquid level again and lifted to a position slightly below the tip below the liquid level, the second layer is formed on top of the photo-cured layer 40 formed earlier. A new photocurable resin liquid thin layer 21 having the same thickness is formed. Then, the next photocured layer 40 is formed on the previous photocured layer 40 by irradiating the laser beam 30 again.
Then, after submerging the molding table 50 again, lift it to a position slightly below the second time below the liquid level,
A new photocurable resin liquid thin layer 21 with a thickness corresponding to the third layer formed on the second photocurable layer 40
is irradiated with laser light 30 to form the next photocured layer 40.
is laminated on the second photocured layer 40.
Thereafter, by repeating this process as many times as necessary, the molding table 5
A desired three-dimensional shape 45 can be obtained on 0.

According to this method, in the process of lifting the molding table 50, most of the resin liquid 20 located on the three-dimensional shape 45 that is being formed is naturally removed to the outside of the three-dimensional shape 45, and photocured layer 4
Between 0 and the resin liquid level, there is a resin liquid thin layer 21 with a thickness t determined by the surface tension, viscosity, specific gravity of the resin liquid, and the interfacial tension between the photocuring layer (or molding table) and the resin liquid. Since it is formed naturally, there is no need to control the amount of resin liquid supplied as in the prior art described above.

[Problem to be solved by the invention]

However, it has been found that this method also has various problems as described below.

That is, when the three-dimensional shape 45 that is in the process of being formed is lifted up to just below the liquid level by the forming table 50,
The resin liquid 20 above the three-dimensional shape 45 is the three-dimensional shape 4
5 and is removed from the three-dimensional shape 45, but since the resin liquid 20 is a highly viscous liquid, it is only slowly removed from the three-dimensional shape 45 at this time. Therefore, the new resin liquid thin layer 21 formed on the three-dimensional shape 45 immediately after lifting is caused by surface tension, etc., as shown in FIG. 12a - an enlarged view of part A in FIG. 11. As such, it bulges out a little from the periphery, and both shoulders 21a, 21a are rounded and do not have the same thickness as the inner part 21b. This condition will not go away until a considerable amount of time has passed. Therefore, the influence of this state still remains at the stage of laser beam irradiation, and the laminated structure of the three-dimensional shape 45 is not a stack of planar photocured layers 40 as shown in FIG. Shoulder 4 as shown in Figure 12a
The first problem is that 0a becomes a stack of curved photocuring layers 40.

When a three-dimensional shape that is in the process of being formed is moved up and down in a resin liquid pool, a phenomenon occurs in which the resin liquid flows upward or downward relative to the three-dimensional shape when viewed from the side of the three-dimensional shape. There was also the problem that the three-dimensional shape was distorted by the flow. This sagging deformation is most likely to occur when the thickness of the three-dimensional shape is thin or when the three-dimensional shape has a protruding part such as an eaves. When there is a protruding part in a three-dimensional shape, in order to avoid the occurrence of such sagging deformation, conventionally, a support has been purposely provided on the protruding part. There was a problem in that complex control was required to form a laminated photo-cured layer containing the following.

Three-dimensional shapes include three-dimensional shapes 4 shown in Figure 13.
There are some, such as No. 5, which have portions 451 and 452 of different sizes on their respective upper surface areas. When such a three-dimensional shape 45 is placed on the molding table 50 and raised inside the resin pool, the parts 451, 452
There is a difference in the thicknesses t ₁ and t ₂ of the resin liquid thin layer 21 remaining on the resin liquid layer 21 such that the thickness t ₁ on the large area portion 451 is larger than the thickness t ₂ on the small area portion 452. . This is due to the following reasons. When the upper end of the three-dimensional shape 45 rises to a predetermined position below the liquid level, the amount of resin liquid on both parts is:
The amount on the large area portion 451 is larger than the amount on the small area portion 452. In both parts, the resin liquid 20 that cannot be held due to surface tension or the like flows out from above each part, but the flow rate at this time is extremely small because the resin liquid 20 has a high viscosity. Therefore, at the time of laser beam irradiation, there is still a large difference in the amount of remaining resin liquid on both parts 451 and 452, and this appears as a difference in the thickness of the resin liquid thin layer 21 in both parts. When forming a three-dimensional shape having portions with large and small horizontal cross-sectional areas, in this way, at the formation stage of each photo-cured layer, the difference in the thickness of the photo-cured layer between the portions with large and small horizontal cross-sectional areas is Therefore, as the photocured layers are laminated, this difference in thickness is accumulated, resulting in a problem that the height of each part of the three-dimensional shape does not match the design.

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a method and apparatus for forming a three-dimensional shape that does not cause the above-mentioned stacking of curved surfaces, sagging deformation, and deviation in height.

[Means to solve the problem]

Therefore, a method for forming a three-dimensional shape according to the present invention that solves the above problem involves irradiating a photocurable resin liquid with light to form a photocured layer of a predetermined shape, and stacking a plurality of photocured layers. In the method of forming a desired three-dimensional shape, the height of the photo-cured layer at each stage is set at a position surrounding the formation position of the three-dimensional shape according to the formation of the photo-cured layer at each stage constituting the three-dimensional shape. It is characterized by providing a peripheral wall that rises in stages to be at the same height as the surface.

In this case, a photocurable resin liquid reservoir is provided, and at each stage of forming the first photocured layer constituting the three-dimensional shape, the three-dimensional shape that is being formed and the surrounding wall are once exposed to light. By sinking it into a curable resin liquid pool and then raising it, it is also possible to form a photocurable resin liquid layer that will become the first photocurable layer on the three-dimensional shape that is being formed.
In addition, at each stage of forming the first photocured layer constituting the three-dimensional shape, by supplying a photocurable resin liquid into the peripheral wall surrounding the three-dimensional shape in the middle of formation, the three-dimensional shape in the middle of formation can be It is also possible to form a photocurable resin liquid layer thereon, which becomes the first photocurable layer.

The three-dimensional shape forming device according to the present invention includes a first
A tank storing a photocurable resin liquid, a first photocuring layer forming a three-dimensional shape in the tank, and a second photocuring layer forming a peripheral wall surrounding the first photocuring layer are placed on top and bottom. an elevating means for immersing the three-dimensional shape in the middle of formation and the peripheral wall surrounding it in a photocurable resin liquid by moving the three-dimensional shape in the middle of formation and the peripheral wall surrounding it; and a laser generating means for irradiating light onto the liquid resin layer, and secondly, a first photocured layer constituting a three-dimensional shape and a second photocured layer forming a peripheral wall surrounding the first photocured layer are placed. a means for supplying a photocurable resin liquid from above into a peripheral wall surrounding a three-dimensional shape that is in the process of being formed; and a laser generating means for irradiating light onto the photocurable resin liquid layer. Thirdly, a peripheral wall provided at a position surrounding the three-dimensional shape formation position, and a laser disposed within the peripheral wall so as to be vertically movable. a means for lifting and lowering the
A photocurable resin liquid pool consisting of a space surrounded by the lifting means and a peripheral wall, a means for supplying the photocurable resin liquid to the photocurable resin liquid pool from above, and an inside of the photocurable resin liquid pool. and a laser generating means for irradiating light.

The peripheral wall may be made of any material and structure as long as the photocurable resin liquid can be stored inside the peripheral wall. The peripheral wall is provided so as to surround the three-dimensional shape in a frame shape at a position outside the outer shape of the three-dimensional shape to be formed. In general, it is preferable that the size of the inner area of the surrounding wall is approximately the same at any height of the surrounding wall, but the horizontal cross section should be adjusted to fit the three-dimensional shape formed inside the wall. It can also be shaped.

The peripheral wall can be formed from a resin liquid at the same time as the three-dimensional shape is formed, as described below. According to this, the height of the peripheral wall can be increased in accordance with the height of the three-dimensional shape. However, in cases where such a method is not used, in order to raise the height of the peripheral wall in stages, it is necessary to surround a fixed molding table that forms a three-dimensional shape with a peripheral wall, and then raise this peripheral wall in stages. Alternatively, the circumferential wall may be fixed, and the forming table may be lowered in stages to relatively increase the height of the circumferential wall. The peripheral wall or the molding table may be raised and lowered by ordinary mechanical or electrical drive means. In order to accurately set the height of the peripheral wall or the molding table, sensor means for detecting the surface position of the photocuring layer may be provided.

In this invention, the peripheral wall can be formed using the same molding method at the same time as the three-dimensional shape is formed. That is, it is also possible to form a peripheral wall made of a photocurable layer by irradiating the photocurable resin liquid with light. To describe this in detail, first, a photocurable resin liquid is supplied onto a flat surface such as a molding table. In this way, a thin layer of resin liquid is formed on the flat surface with a thickness that is naturally determined by the action of surface tension and the like.
Once the first stage of the resin liquid thin layer is formed in this manner, this resin liquid thin layer is then irradiated with light to form a photocured layer constituting the desired three-dimensional shape. At this time, a frame-shaped second photocured layer is also formed at a position surrounding the outer periphery of the photocured layer for three-dimensional shape formation, that is, the first photocured layer. Both photo-cured layers formed from the same resin liquid thin layer are naturally formed at the same surface height, and uncured resin liquid remains at the same surface height between both photo-cured layers. If the second photocurable layer can store the remaining photocurable resin liquid inside it, then
The width and shape can be set arbitrarily. If new resin liquid is supplied to both photocured layers and the surface of the resin liquid,
A thin layer of resin liquid is naturally formed with a thickness determined by the effects of surface tension, etc. Therefore, light is irradiated onto the first photocurable layer and the second photocurable layer to form the next first and second photocurable layers thereon. Thereafter, this process is repeated as many times as necessary. In this method, the height of the peripheral wall is increased in stages by simultaneously forming the first photocured layer that forms the three-dimensional shape and the second photocured layer that forms the peripheral wall. It is also possible.

As a means for supplying the photocurable resin liquid, in addition to a method of dipping the molding table, a coating method such as spray coating can also be used. Spray coating is a preferred method because it can supply the resin liquid quickly and with a uniform thickness, but flow coating and various other liquid supply means can also be employed. The resin liquid that has flowed down to the outside of the peripheral wall can be recovered by an appropriate recovery means.

The thickness of the resin liquid thin layer 21 formed is determined to be a constant thickness depending on the properties of the resin liquid, such as the magnitude of surface tension. However, if this thickness is too thick, the resin liquid can be scraped off with a doctor knife or the like to make it thinner.

In the method of the present invention, configurations other than those described above, such as the material of the resin liquid and the light irradiation means, are carried out in the same configuration as in a normal three-dimensional shape forming method.

[Effect]

As shown in FIG. 1, a portion of the photocurable resin liquid supplied onto the three-dimensional shape, the peripheral wall, and the surface of the resin liquid remaining inside the peripheral wall by dipping or spraying methods, etc. A photocurable resin liquid thin layer 21 having a thickness t determined by the action of surface tension, etc.
Thus, the resin liquid 20 remains on the three-dimensional shape 45, the peripheral wall 46, and the surface of the resin liquid 20 remaining inside the peripheral wall 46, and the rest flows out to the outside of the peripheral wall. At this time,
As shown in FIG. 1, on the peripheral wall 46 located at the outer peripheral edge of the photocurable resin liquid thin layer 21, the shoulder portion 21a of the resin liquid thin layer 21 is rounded, but on the three-dimensional shape 45, , since the peripheral wall 46 is provided on the outside of the three-dimensional shape 45 and the outer peripheral edge of the photocurable resin liquid thin layer 21 extends to the peripheral wall 46,
Such roundness does not occur at all in the photocurable resin liquid thin layer 21 in this portion.

In this case, the thickness t determined by the surface tension or the like of the photocurable resin liquid thin layer 21 differs depending on the size of the area on which the resin liquid 20 is applied, as described above.
Therefore, when supplying resin liquid onto a three-dimensional shape without providing a peripheral wall around the three-dimensional shape, depending on the size of each area inside the three-dimensional shape,
The thickness of the thin layer of resin liquid varies slightly. As the number of laminations of photocurable layers increases, these subtle thickness errors accumulate and become impossible to ignore. On the contrary,
As shown in FIG. 2a, the three-dimensional shape 45 is
6, and the inner bottom of the peripheral wall is made into a stand 50 without an opening.As shown in FIG. It is stored. This thickness t is determined depending on the size of the inner region of the peripheral wall 46 and is not related to the horizontal cross-sectional area of each inner portion of the three-dimensional shape 45. That is, within the three-dimensional shape 45, there are a portion 451 with a large top surface area and a portion 45 with a small top surface area.
2, even if there is a resin liquid thin layer 21 on each
The thicknesses t ₁ and t ₂ match the thickness t, and there is no difference between them. Furthermore, even when the three-dimensional shape 45 is moved up and down within the resin liquid reservoir, the peripheral wall 46 is filled with the resin liquid 20 in a stationary state.
5, the resin liquid does not flow.

When a peripheral wall 46 is provided around the three-dimensional shape 45, as shown in FIGS. 1 and 2, the size of the inner area of the peripheral wall 46 is approximately the same regardless of the height of the peripheral wall. If they are made to be the same, the thickness of the photocurable resin liquid thin layer 21 will always be a constant value determined by the inner cross-sectional area S of the peripheral wall 46, and the accumulation of the above-mentioned thickness errors can be avoided.
As a result, a thin resin liquid layer 21 having a uniform thickness can be formed on the three-dimensional shape 45 at least in the area S ₀ .

By forming the peripheral wall with the photocurable resin liquid simultaneously with the progress of forming the three-dimensional shape, it is possible to reliably and easily provide the peripheral wall with exactly the same height as the three-dimensional shape that is being formed.

When forming a three-dimensional shape having a protruding portion in the direction of the circumferential wall, at the same time as forming a photocured layer that constitutes the protruding portion and each part of the circumferential wall, a thin connecting layer connecting the protruding portion and the circumferential wall is formed. If a photocured layer is also formed, a three-dimensional shape having a portion protruding in the direction of the peripheral wall can be easily produced.

When simultaneously forming the peripheral wall from a photocurable resin liquid,
At each stage of forming the first photocured layer constituting the three-dimensional shape, the first photocured layer and the second photocured layer constituting the peripheral wall are formed.
By making the distance between the photocured layer and the photocuring layer constant, the control data for forming the three-dimensional shape plus a certain value can be used as the control data for forming the peripheral wall. I can do it.

[Example] Next, an example of the present invention will be described in detail below with reference to the drawings.

3 and 4 show the overall structure of the apparatus used for carrying out the present invention, and in the tank 14, for example, modified polyurethane methacrylate, oligoester acrylate, urethane acrylate, epoxy acrylate, photosensitive polyimide,
A photocurable resin liquid 20 such as amino alkyd is stored. The molding table 50 on which the three-dimensional shape (molded product) 45 is placed and formed is made of a plate without an opening, and is connected to an elevating mechanism (not shown) via an elevating arm 51, so that it can be moved up and down. It's summery.
A peripheral wall 46 is provided on the molding table 50 so as to surround the three-dimensional shape 45 . Molding table 5
A laser irradiation mechanism (not shown) is provided above the molding table 50 so that the laser beam 30 can be irradiated onto the molding table 50. The structure of the laser irradiation mechanism can be the same as that of a normal three-dimensional shape forming apparatus. For example, as shown in FIG. 4, one example includes a laser generator 31, a shutter 32, a condensing lens 33, and a reflecting mirror 34.

A method for forming a three-dimensional shape using such an apparatus will be described.

The molding table 50 is slightly immersed in the photocurable resin liquid 20 in the tank 14 and lifted to form a thin layer of the resin liquid with a uniform thickness on its flat surface. Excess resin liquid 20 flows down from the outer edge of molding table 50 and is collected in tank 14. Next, the laser beam 30
The resin liquid thin layer is photocured by scanning exposure to form a first photocured layer 40 constituting a three-dimensional shape 45. At this time, the laser beam 30 is also scanned and exposed in a frame shape of a constant width at a position slightly outside of a position substantially corresponding to the outer shape of the three-dimensional shape on the outside of the first photocuring layer 40, so that the peripheral wall 46 The second frame-shaped
A photocurable layer 43 is formed. The resin liquid 20 that has not been exposed remains accumulated inside the photocured layer 43. Next, the molding table 50 is immersed in the resin liquid 20 again, and both photocured layers 40, 43 are
And on the surface of the resin liquid 20 between them, as above,
A thin resin liquid layer 21 having a uniform thickness t is formed. At this time, the excess resin liquid 20 flows down to the outside of the three-dimensional shape 45. Then, in the same manner as above, scanning exposure with the laser beam 30 is performed to form the photocured layer 4.
A new photocuring layer 40 is formed on top of the photocuring layer 40. Also at this time, the second photocured layer 43 is formed outside the first photocured layer 40 in a frame shape.

Note that after submerging the molding table 50 in the photocurable resin liquid 20 in the tank 14, it is lifted and the photocurable layer 40 is removed.
When forming a new resin liquid thin layer 21 on top, as shown in FIG.
By bringing the upper end to a position slightly below the liquid level and stopping, a new thin resin liquid layer 21 can be formed thereon. The same applies when forming the resin liquid thin layer 21 on the molding table 50.

As shown in FIG. 5, the peripheral wall 46 is formed so that its shape resembles the outer shape of the three-dimensional shape, that is, the distance between the two photocured layers 40 and 43 varies depending on the formation stage of each photocured layer. It can also be formed so that it is always constant.

By repeating these steps, the third
As shown in the drawings and FIG. 5, the first photocured layer 40 is stacked on a molding table 50 to form a desired three-dimensional shape 45. As shown in FIG. A peripheral wall 46 made of the second photocuring layer 43 is formed on the outside of the three-dimensional shape 45 . Once the three-dimensional shape 45 is completed, the peripheral wall 46 may be discarded.

In the above process, since the inside of the peripheral wall 46 is always filled with the resin liquid 20 and completely covers the entire three-dimensional shape 45, the thickness of the resin liquid thin layer 21 on the surface of each part inside the three-dimensional shape 45 is is becoming uniform.

This invention can also be implemented as shown in FIG. That is, first, when the resin liquid 20 is sprayed onto the surface of the molding table 50 from the spray nozzle 60, the resin liquid 20 spreads on the molding table 50 with a uniform thickness to form a thin layer of resin liquid. Excess resin liquid 20 flows down from the outer edge of the molding table 50 and is collected in the resin reservoir 14. Next, the resin liquid thin layer is photocured by scanning exposure with laser light 30,
A first photocured layer 40 that forms a three-dimensional shape is formed. At this time, on the outside of the first photocuring layer 40,
A frame-shaped second photocuring layer 4 that will become a peripheral wall is formed by scanning and exposing a laser beam 30 in a frame shape of a constant width at a position that approximately corresponds to the outer shape of the three-dimensional shape or at a position that is slightly outside.
form 3. Also at this time, the second photocuring layer 43
The resin liquid 20 that has not been exposed remains accumulated inside. Next, when the resin liquid 20 is sprayed again from the spray nozzle 60, a thin layer of the resin liquid with a uniform thickness t is formed on the surfaces of both the photocured layers 40, 43 and the resin liquid 20 between them, and the excess The resin liquid 20 is the second photocurable layer 43
flowing down outside. At this time, the spraying by the spray nozzle 60 may be started not from the peripheral wall of the tank 14 but from the position of the second photocurable layer 43. After spraying, scanning exposure with laser light 30 is performed in the same manner as described above. Also at this time, a frame-shaped second photocuring layer 43 is formed outside the photocuring layer 40 .

Note that before irradiating the laser beam 30, the molding table 50 is lowered by a height corresponding to the thickness t of the thin resin liquid layer 21. This is because if the molding table 50 remains fixed, each time the resin liquid thin layers are stacked and formed, the position of the uppermost resin liquid layer becomes higher, and the focal point of the laser beam 30 is raised accordingly. In contrast, the molding table 5
If 0 is lowered stepwise, the position of the thin resin liquid layer will always be at a constant height, and the laser beam 30 will be lowered stepwise.
This is because there is no need to change the focal point position.

In this case as well, by repeating these steps, the first photocured layer 40 is stacked on the molding table 50 and a desired three-dimensional shape 45 is formed, as shown in FIG. . A peripheral wall 46 made of a second photocurable layer 43 is formed on the outside of the three-dimensional shape 45 . Once the three-dimensional shape 45 is completed, the peripheral wall 46 may be discarded. In the above step, the second
Since the inner side of the peripheral wall 46 consisting of the photocuring layer 43 has a flat surface having a substantially constant area, the resin liquid sprayed on the surfaces of both the photocuring layers 40 and 43 and the resin liquid 20 The thickness t of the resin liquid thin layer formed by 20 is always constant.

In the above embodiment, the resin liquid 20 is supplied by spray coating with the spray nozzle 60, so even if a high viscosity resin liquid 20 is used, the resin liquid spreads quickly and forms a uniform and thin resin. A thin liquid layer can be formed in a short time. When the resin liquid 20 is roughly supplied to the surfaces of the photocuring layers 40 and 43 in a semi-cured state, the resin liquid 20
The photo-curing layer 40,
There is a concern that the photocured layers 40 and 43 may be deformed, but if spray coating is used, there is less impact or pressure during supply, and there is no concern that the semi-cured photocured layers 40 and 43 will be deformed. Note that instead of the spray nozzle 60,
The resin liquid 20 can also be supplied by arranging a plurality of shower nozzles or by using a flow coater.

Next, FIG. 7 shows an apparatus partially different from the embodiment described above.

Molding table 53 for forming three-dimensional shape 45
An elevating shaft 54 is connected to the lower surface so that the elevating shaft 54 can be moved up and down. A cylindrical peripheral wall 57 is fixedly installed on the outer periphery of the molding table 53 via a sliding packing 59 . The molding table 53 moves up and down inside this peripheral wall 57. A photocurable resin liquid 20 is stored in the upper part of the molding table 53 surrounded by a peripheral wall 57 . That is, the space above the molding table 53 constitutes a photocurable resin liquid reservoir. A skirt portion 58 is provided in the middle of the outer peripheral surface of the peripheral wall 57 and is curved outward so as to guide the resin liquid 20 flowing down along this surface. Resin liquid 2 that fell along the skirt portion 58
0 is recovered by a recovery means such as the resin reservoir tank 14 of the above embodiment. A spray nozzle 60 similar to that described above is provided above the molding table 53.

A method for forming a three-dimensional shape using the above-mentioned apparatus will be explained.

First, in the first stage, the forming table 53 is placed on the peripheral wall 57.
Raise it to the same level as the top of the. When the resin liquid 20 is supplied from the spray nozzle 60 onto the molding table 53, the resin liquid 20 spreads over the surface of the molding table 53 to form a thin layer of resin liquid. After that, the laser beam 30 is scanned and exposed to form a photocured layer 40 that forms a three-dimensional shape.
form. In addition, in this example, the second photo-cured layer (photo-cured layer for peripheral wall) 43 as in the previous example is used.
need not be formed simultaneously. Next, the molding table 53
is lowered so that the surface of the photocuring layer 40 and the upper end of the peripheral wall 57 are at the same height. The uncured resin liquid 20 remains in the area inside the peripheral wall 57 where the photocured layer 40 is not present, and together with the highly cured layer 40 and the peripheral wall 57 forms a flat surface. Operate the spray nozzle 60 again to spray the resin liquid 2.
If 0 is supplied, a new thin resin liquid layer is formed on the surface of the peripheral wall 57 and the like. By repeating these steps, a three-dimensional shape 45 in which the photocured layers 40 are stacked is formed.

In the above methods, as shown in Figure 8,
If it is desired to quickly reduce the thickness of the photocurable resin liquid thin layer 21 to a thickness _t0 that is thinner than the thickness t determined by surface tension, the surface layer of the resin liquid may be scraped off using a doctor knife 80.

Among the three-dimensional shapes, there is also a three-dimensional shape 45 having a portion 45a projecting in the direction of the peripheral wall 46, as shown in FIG. 9a and FIG. 9b showing the main part thereof. In such a device, when the resin liquid 20 is supplied, the portion 45a may be agitated and deformed by the movement of the resin liquid 20, and it is necessary to prevent this.

Therefore, in the present invention, when forming the three-dimensional shape 45, at the same time as forming a photocuring layer that constitutes each part of the protruding portion 45a and the peripheral wall 46, the protruding portion 45a and the peripheral wall 46 are connected. A photocured layer that becomes the thin connection layer 48 is also formed.
Specifically, as shown in FIG. 10a, after the three-dimensional shape 45 and the peripheral wall 46 have been formed up to the formation position of the protruding portion, as shown in FIG. The hardened layer is shaped into a three-dimensional shape 4
The first cured layer 5 and the second photocured layer 46 are simultaneously formed so as to be continuous with each other. The photocured layer serving as the connection layer 48 may have a thickness necessary to function as a support, so when this thickness is reached, the formation of the connection layer 48 is completed. After that, as shown in FIG. 10c, a photocurable layer corresponding to the entire thickness of the protruding portion 45a is laminated thereon, and a photocurable resin liquid is supplied to the desired height.
A three-dimensional shape 45 is obtained as shown in FIG. 10d. After that, the connection layer 48 is formed into a three-dimensional shape 45.
The desired three-dimensional shape 45 as shown in FIG. 10e is obtained by separating the material from the material.

〔Effect of the invention〕

According to the method for forming a three-dimensional shape according to the present invention, rounded shoulders do not occur in the thin resin liquid layer on the three-dimensional shape. In addition, the surfaces of the photo-cured layer, the peripheral wall, and the resin liquid accumulated between them are all always at the same height at each stage of forming each photo-cured layer, and new resin liquid is supplied above them. Therefore, this resin liquid can form an accurate, uniform, and extremely thin layer of resin liquid due to the effect of surface tension and the like. As a result, the thickness of the photocured layer at each stage is accurate, uniform, and thin, and the shape accuracy of the three-dimensional shape is excellent, and the step difference between each photocured layer in the three-dimensional shape is not noticeable. becomes.

According to this invention, since the three-dimensional shape that is being formed is buried in the resin liquid that is in a stationary state inside the peripheral wall, even when the three-dimensional shape moves up and down within the resin liquid pool, the resin liquid relative to the three-dimensional shape No flow occurs. Therefore, no sagging deformation occurs in the three-dimensional shape.

In this invention, if the circumferential wall is made such that the size of the inner area is approximately the same regardless of the height of the circumferential wall, the three-dimensional shape will always have a uniform thickness. Since a thin film of resin liquid can be formed, the dimensional accuracy of the three-dimensional shape is improved.

In this invention, if the thin resin liquid layer is irradiated with light to obtain the second photocured layer that becomes the peripheral wall,
In addition to the above effects, it is possible to reliably form a peripheral wall having exactly the same height as the first photocured layer, and no parts for the peripheral wall or a mechanism for changing its height are required. In addition,
Even if a second photocured layer is formed in addition to the first photocured layer, the irradiation range of light is only slightly expanded and the irradiation time does not increase significantly.
This method is much more efficient than operating a peripheral wall.

In this invention, when forming a three-dimensional shape having a protruding part in the direction of the peripheral wall, at the same time as the photocuring layer constituting the protruding part is formed, a thin connecting layer connecting the protruding part and the peripheral wall is formed. A photo-cured layer can also be formed, thereby making it possible to easily produce a three-dimensional shape having a protruding portion without deformation.

In this invention, if the peripheral wall is made to match the outer shape of the three-dimensional shape, the control data for forming the three-dimensional shape can be used as the control data for forming the peripheral wall, thereby simplifying the control operation.

[Brief explanation of drawings]

Fig. 1 is an explanatory drawing for explaining the operation of this invention, and Fig. 2 a and b are also explanatory drawings for explaining the operation of this invention, and Fig. a shows the three-dimensional shape and the state where the peripheral wall is placed on the molding table A perspective view, Figure b is a sectional view showing the state where the molding table is raised from within the resin liquid pool, Figures 3a and b
3C is a sectional view showing a modification of FIG. 3A, FIG. 4 is a perspective view of this embodiment, and FIG. 6, 7 and 8 are sectional views showing another example of the resin liquid thin layer forming method in this invention, and FIGS. 9a and 9b are in the peripheral wall direction. Figure 10 shows a three-dimensional shape with a protruding part; Figure a is a sectional view showing the three-dimensional shape in a resin liquid pool; Figure b is a plan view of only the three-dimensional shape and the peripheral wall; Figure 10. a to e are explanatory diagrams sequentially showing the steps of producing the three-dimensional shape of FIG. 9, FIG. 11 is a cross-sectional view showing a conventional example, and FIGS. 12 a and b are explanatory diagrams explaining the problems of the conventional method. Figures 13a and 13b are explanatory diagrams for explaining another problem with the conventional example, in which figure a is a perspective view showing a state where a three-dimensional shape is placed on a molding table, and figure b is a perspective view of the molding table from within the resin liquid pool. FIG. 3 is a cross-sectional view showing a raised state. 14... Tank, 20... Photocurable resin liquid, 30...
... Laser light, 40 ... First photocuring layer, 43 ...
Second photocured layer, 45...Three-dimensional shape, 46...
Peripheral wall, 50, 53... Molding table, 57... Peripheral wall, 6
0...Spray nozzle.

Claims (1)

[Scope of Claims] 1. A method in which a photocurable resin liquid is irradiated with light to form a photocured layer in a predetermined shape, and a plurality of photocured layers are stacked to form a desired three-dimensional shape. As the photo-cured layer of each stage forming the three-dimensional shape is formed at the position surrounding the shape formation position, its height increases step by step so that it becomes the same height as the surface of the photo-cured layer of each stage. A method for forming a three-dimensional shape, characterized by providing a peripheral wall. 2. A photocurable resin liquid reservoir is provided, and at each stage of forming the first photocurable layer constituting the three-dimensional shape, the three-dimensional shape that is being formed and the peripheral wall surrounding it are temporarily coated with the photocurable resin. The three-dimensional shape according to claim 1, wherein the three-dimensional shape is lowered into the liquid pool and then raised to form a photocurable resin liquid layer that becomes the first photocurable layer on the three-dimensional shape that is being formed. How to form. 3. At each stage of forming the first photocured layer constituting the three-dimensional shape, by supplying a photocurable resin liquid into the peripheral wall surrounding the three-dimensional shape that is in the process of being formed, 2. The method for forming a three-dimensional shape according to claim 1, wherein a photocurable resin layer serving as the first photocurable layer is formed on the substrate. 4. Simultaneously with the formation of the photocured layer at each stage constituting the three-dimensional shape, light is also irradiated to the photocurable resin liquid at positions surrounding the formation position of the three-dimensional shape to form a second photocured layer that will become the peripheral wall. The method for forming a three-dimensional shape according to any one of claims 1 to 3, further comprising forming a three-dimensional shape. 5. When forming a three-dimensional shape having a protruding part in the direction of the peripheral wall, at the same time as forming a photocured layer that constitutes the protruding part and each part of the peripheral wall, a thin connection is created to connect the protruding part and the peripheral wall. 5. The method for forming a three-dimensional shape according to claim 4, wherein a photocured layer serving as a layer is also formed. 6. The method for forming a three-dimensional shape according to any one of claims 1 to 5, wherein the size of the inner region of the peripheral wall is approximately the same at any height position of the peripheral wall. 7. A claim in which the distance between the first photocured layer and the second photocured layer constituting the peripheral wall is made constant at each stage of forming the first photocured layer constituting the three-dimensional shape. Item 4. The method for forming a three-dimensional shape. 8 A tank storing a photocurable resin liquid, a first photocurable layer constituting a three-dimensional shape, and a second photocurable layer serving as a peripheral wall surrounding the first photocurable layer are placed and moved up and down in the tank. a lifting means for immersing a three-dimensional shape in the process of being formed and a peripheral wall surrounding it in a photocurable resin liquid; A three-dimensional shape forming apparatus comprising a laser generating means for irradiating light onto a resin liquid layer. 9 Lifting means for moving up and down on which a first photocured layer constituting a three-dimensional shape and a second photocured layer serving as a peripheral wall surrounding the first photocured layer are mounted, and a lifting means that moves up and down within the peripheral wall surrounding the three-dimensional shape that is being formed. A tertiary device comprising a means for supplying a photocurable resin liquid from above, and a laser generating means for irradiating light onto a three-dimensional shape in the process of being formed and a photocurable resin liquid layer formed by the supply on a peripheral wall surrounding the three-dimensional shape. Original shape forming device. 10 A peripheral wall provided at a position surrounding a three-dimensional shape formation position, an elevating means disposed within the surrounding wall so as to be movable up and down, and a photocurable resin liquid reservoir consisting of a space surrounded by the elevating means and the surrounding wall. A three-dimensional shape forming apparatus comprising means for supplying a photocurable resin liquid from above to the photocurable resin liquid pool, and a laser generating means for irradiating light into the photocurable resin liquid pool. 11. Claim 8, wherein the circumferential wall has an inner area whose size is approximately the same at any height of the circumferential wall.
10. The three-dimensional shape forming device according to any one of items 1 to 10.