Apparatus for Forming Layered Object

• US 20090025638A1
• Filed: 06/21/2006
• Published: 01/29/2009
• Est. Priority Date: 07/27/2005
• Status: Active Grant

• Current Assignee: Shofu Incorporated
• Original Assignee: Shofu Incorporated
• Inventors: Inoue, Tomoyuki
• Granted Patent: US 8,267,683 B2
• Time in Patent Office: Days
• US Class Current: 118/712
• CPC Class Codes: A61C 13/0013 using stereolithographic techniques
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61C 5/77 Methods or devices for making crowns
• CPC Class Codes: A63B 71/085 Mouth or teeth protectors A63B71/081 takes precedence
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

Abstract

A layered-object forming apparatus (1) includes a holding mechanism (10) that holds a base (12), a liquid applying device (20) that applies a liquid to a predetermined position from above the base, a powder applying device (30) that allows a powder to fall from above the base, and a powder removing device that removes an unconsolidated powder on the base. Then, a process of applying the liquid by the liquid applying device, subsequently applying the powder by the powder applying device, subsequently consolidating the liquid and the powder applied onto the liquid and then removing the powder that has not been consolidated with the liquid by the powder removing device is repeated, thereby forming a three-dimensional structure on the base. Thus, it is possible to produce a three-dimensional structure that at least partially has a smooth surface, thus allowing omission or simplification of a surface smoothing treatment.

Claims

1. A layered-object forming apparatus comprising:

a holding mechanism that holds a base;

a liquid applying device that applies a liquid to a predetermined position from above the base;

a powder applying device that allows a powder to fall from above the base; and

a powder removing device that removes an unconsolidated powder on the base;

wherein a process of applying the liquid by the liquid applying device, subsequently applying the powder by the powder applying device, subsequently consolidating the liquid and the powder applied onto the liquid and then removing the powder that has not been consolidated with the liquid by the powder removing device is repeated, thereby forming a three-dimensional structure on the base.

2. The layered-object forming apparatus according to claim 1, wherein the holding mechanism is a table on which the base is placed.

3. The layered-object forming apparatus according to claim 1, wherein the holding mechanism is a rod-like member that is inserted in the base.

4. The layered-object forming apparatus according to claim 1, wherein the powder removing device comprises a rotating mechanism for rotating the base and allows the unconsolidated powder to fall by gravity and be removed.

5. The layered-object forming apparatus according to claim 1, wherein the powder removing device comprises an air nozzle for ejecting a gas and blows off and removes the unconsolidated powder by the gas.

6. The layered-object forming apparatus according to claim 1, wherein the powder removing device comprises a suction nozzle for sucking an atmosphere and allows the unconsolidated powder to be sucked into the suction nozzle and removed.

7. The layered-object forming apparatus according to claim 1, further comprising a vibration generating device that vibrates the holding mechanism.

8. The layered-object forming apparatus according to claim 2, further comprising a container surrounding a horizontal periphery of the table, a leveling member that levels off the powder heaped in the container, and a lifting and lowering mechanism that varies a relative position between the container and the table along a height direction.

9. The layered-object forming apparatus according to claim 1, wherein the holding mechanism is a table on which the base is placed,

the layered-object forming apparatus further comprises a container surrounding a horizontal periphery of the table, a leveling member that levels off the powder heaped in the container, and a lifting and lowering mechanism that varies a relative position between the container and the table along a height direction, and

a process of applying the powder into the container by the powder applying device, subsequently leveling off the powder by the leveling member, subsequently applying the liquid by the liquid applying device and then lowering the table relative to the container by the lifting and lowering mechanism is repeated, thereby forming a further three-dimensional structure on the three-dimensional structure.

10. The layered-object forming apparatus according to claim 1, further comprising a three-dimensional measuring device that measures the base or the three-dimensional structure formed on the base.

11. The layered-object forming apparatus according to claim 1, wherein a lower surface of the powder applying device is provided with a plurality of screens that are stacked so as to block an opening formed on the lower surface, each of the plurality of screens is provided with a plurality of holes through which the powder can pass, and falling of the powder is controlled by controlling a movement of at least one of the plurality of screens relative to the other.

12. The layered-object forming apparatus according to claim 11, wherein one of the plurality of screens is an endless screen obtained by connecting both ends of a belt-like screen in annular form.

13. The layered-object forming apparatus according to claim 1, wherein the powder applying device comprises an inclined substrate and a plurality of dividing plates that are arranged on the substrate, the plurality of dividing plates are divided into a plurality of tiers in a vertical direction, more dividing plates are included in an N+1th tier than in an Nth tier from a top when N is a natural number, and each of the dividing plates divides a powder flow from above into two.

14. The layered-object forming apparatus according to claim 1, further comprising an inclination mechanism that varies an orientation of the base to at least two directions including a first direction and a second direction different from the first direction, wherein the apparatus applies the liquid and allows the powder to fall in each of a state where the base faces the first direction and a state where the base faces the second direction.

15. The layered-object forming apparatus according to claim 14, wherein the liquid is applied to and the powder is allowed to fall on the base facing the first direction repeatedly so as to form on the base a first consolidated portion layer that is formed by consolidation of the liquid and the powder, and then the liquid is applied to and the powder is allowed to fall on the base facing the second direction repeatedly so as to form on the base a second consolidated portion layer that is formed by consolidation of the liquid and the powder.

16. The layered-object forming apparatus according to claim 14, wherein a process of applying the liquid to and allowing the powder to fall on the base facing the first direction so as to form on the base a first consolidated portion layer that is formed by consolidation of the liquid and the powder, and a process of applying the liquid to and allowing the powder to fall on the base facing the second direction so as to form on the base a second consolidated portion layer that is formed by consolidation of the liquid and the powder are repeated alternately.