Stereolithographic shaping method and apparatus

• US 20020047229A1
• Filed: 10/17/2001
• Published: 04/25/2002
• Est. Priority Date: 10/19/2000
• Status: Abandoned Application

• Current Assignee: Shinko Electric Industries Company Limited (Fujitsu Limited)
• Original Assignee: Shinko Electric Industries Company Limited (Fujitsu Limited)
• Inventors: Yanagisawa, Kenji, Akagawa, Masatoshi
• Application Number:
  US09/981,055
• Publication Number:
  US 20020047229A1
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B29K 2995/0073 smooth
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor

Abstract

A stereolithographic shaping method used for manufacturing a shaped article on a shaping table, and a stereolithographic shaping apparatus for implementing this stereolithographic shaping method are disclosed. The stereolithographic shaping method includes the steps of coating a liquid optically-curable resin onto the surface of a shaped article under manufacture, irradiating light onto the optically-curable resin to cure a required portion to form an optically-shaped resin layer, and repeating this process to sequentially laminate optically-shaped resin layers. After the shaping table is supported so as to be able to control a posture position of the shaping table in an optional three-dimensional direction, the optically-curable resin is blown onto a shaped article on the shaping table, thereby to coat the surface of the shaped article with the optically-curable resin in a predetermined film thickness. Then, the optically-shaped resin layers are formed by controlling the posture position of the shaping table and by irradiating the light onto the optically-curable resin that has been coated on the surface of the shaped article.

Claims

1. A stereolithographic shaping method used for manufacturing a shaped article on a shaping table, the stereolithographic shaping method comprising the steps of coating a liquid optically-curable resin onto the surface of a shaped article under manufacture, irradiating light onto the optically-curable resin, and curing a required portion of the optically-curable resin to form an optically-shaped resin layer, and repeating this process to sequentially laminate optically-shaped resin layers, wherein

the shaping table is supported so as to be able to control a posture position of the shaping table in an optional three-dimensional direction,

the optically-curable resin is blown onto a shaped article on the shaping table, thereby to coat the surface of the shaped article with the optically-curable resin in a predetermined film thickness, and

the optically-shaped resin layers are formed by controlling the posture position of the shaping table and by irradiating the light onto the optically-curable resin that has been coated on the surface of the shaped article.

2. The stereolithographic shaping method according to claim 1, further comprising the step of building an insert article having a three-dimensional structure into the shaped article.

3. The stereolithographic shaping method according to claim 1 or 2, wherein the optically-curable resin is a resin that can be cured with laser beams, and laser beams are used for curing this resin.

4. A stereolithographic shaping apparatus used for manufacturing a shaped article on a shaping table, the stereolithographic shaping apparatus comprising in combination:

a table supporting unit for supporting a shaping table that supports a shaped article, so as to be able to control a posture position of the shaping table in an optional three-dimensional direction;

a coating unit section that is set with the table supporting unit, for controlling a posture position of the shaping table, and blowing a liquid optically-curable resin onto a shaped article formed on the shaping table, thereby to coat the optically-curable resin onto the surface of the shaped article; and

a curved-surface laminating unit section that is set with a table supporting unit that supports a shaped article coated with the optically-curable resin on the surface, for controlling a posture position of the shaping table, irradiating light onto the optically-curable resin that has been coated on the surface of the shaped article, and curing a required portion of the optically-curable resin, thereby forming optically-shaped resin layers.

5. The stereolithographic shaping apparatus according to claim 4, further comprising a cleaning unit section that is set with the table supporting unit, for controlling a posture position of the shaping table, and cleaning an uncured optically-curable resin that has been coated on the surface of the shaped article.

6. The stereolithographic shaping apparatus according to claim 4 or 5, further comprising a flat-surface laminating unit section that is set with the table supporting unit, for controlling a posture position of the shaping table, coating a liquid optically-curable resin flat on the surface of a shaped article formed on the shaping table, irradiating light onto the optically-curable resin, and curing a required portion of the optically-curable resin, thereby forming optically-shaped resin layers.

7. The stereolithographic shaping apparatus according to claim 4 or 5, further comprising a conveying unit section for conveying the table supporting unit between adjacent unit sections, between unit sections such as the coating unit section and the curved-surface laminating unit section or the like.

8. The stereolithographic shaping apparatus according to claim 4, wherein

the coating unit section includes:

a set frame for supporting the table supporting unit;

a rotation table for supporting the set frame, and rotating the table supporting unit at an optional position within a flat surface;

an elevator table for supporting the rotation table, and moving, up and down, the table supporting unit to an optional position; and

a nozzle for blowing the optically-curable resin onto the shaped article.

9. The stereolithographic shaping apparatus according to claim 4, wherein

the curved-surface laminating unit section includes:

a set frame for supporting the table supporting unit;

a rotation table for supporting the set frame, and rotating the table supporting unit at an optional position within a flat surface;

an elevator table for supporting the rotation table, and bringing up and down the table supporting unit to an optional position; and

a light irradiating section for irradiating light onto the optically-curable resin that has been coated on the surface of the shaped article.

10. The stereolithographic shaping apparatus according to claim 5, wherein

the cleaning unit section includes:

a set frame, provided to be able to move up and down, for supporting the table supporting unit;

a cleaning solution spreading section for spraying a cleaning solution toward a shaped article supported by the table supporting unit; and

a tank for storing the cleaning solution after cleaning.

11. The stereolithographic shaping apparatus according to claim 4, wherein

the table supporting unit includes:

a base supporting frame;

a movable frame that is axially supported by the supporting frame in one pair of opposite frame sections; and

a shaping table that is rotatably supported by the other pair of opposite frame sections of the movable frame.

12. The stereolithographic shaping apparatus according to claim 11, wherein

the shaping table is detachably supported by the movable frame.

13. The stereolithographic shaping apparatus according to claim 4, wherein

the optically-curable resin is a resin that can be cured with laser beams, and a laser light source is provided as a light source for curing the optically-curable resin.

14. The stereolithographic shaping apparatus according to claim 4, wherein

the shaped article has built-in an insert article having a three-dimensional structure.