METHOD AND APPARATUS FOR MANUFACTURING STRUCTURE

• US 20140374958A1
• Filed: 06/17/2014
• Published: 12/25/2014
• Est. Priority Date: 06/20/2013
• Status: Active Grant

• Current Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Original Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Inventors: Taniuchi, Hiroshi, Nakajima, Kazuhiro
• Granted Patent: US 9,770,870 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 64/10 Processes of additive manufacturing
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/214 Doctor blades
• CPC Class Codes: B29C 64/223 Foils or films, e.g. for transferring layers of building material from one working station to another
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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 manufacturing method of a structure includes, in this order: providing a layer constituted by a support member and a modeling layer by bringing a regulating surface of a regulating member into contact with the modeling layer provided on a surface of an intermediate transfer member, pouring a material for the support member which becomes the support member to fill the periphery of the modeling layer while the regulating surface abutting the modeling layer, and solidifying the material for the support member; removing the regulating member from the layer constituted by the support member and the modeling layer.

Claims

1. A manufacturing method of a structure in which the structure is manufactured by laminating a modeling layer which becomes the structure while supporting the structure under formation with a support member, the method comprising, in this order:

preparing the modeling layer provided on a surface of an intermediate transfer member;

providing a layer constituted by the support member and the modeling layer by making a regulating surface of a regulating member for regulating an upper surface of the modeling layer on the opposite side of a surface which is in contact with the intermediate transfer member abut the upper surface of the modeling layer, pouring a material for the support member which becomes the support member to fill a gap between the intermediate transfer member and the regulating member in the periphery of the modeling layer while the regulating member abutting the upper surface of the modeling layer, and solidifying the material for the support member;

removing the regulating member from the layer constituted by the support member and the modeling layer;

overlapping the layer constituted by the support member and the modeling layer exposed when the regulating member is removed and the structure under formation or a support member which supports the structure with each other while supporting the layer constituted by the support member and the modeling layer by the intermediate transfer member; and

removing the intermediate transfer member from the layer constituted by the support member and the modeling layer overlapped in the overlapping step.

2. The manufacturing method of a structure according to claim 1, wherein, in preparing the modeling layer, the modeling layer is formed by providing a modeling material which becomes the modeling layer on a surface of the intermediate transfer member and bringing the material which becomes the modeling layer and the regulating surface into contact.

3. The manufacturing method of a structure according to claim 1, wherein, in preparing the modeling layer, the modeling material is provided on the surface of the intermediate transfer member by ejecting the modeling material which becomes the modeling layer from a liquid ejection head which ejects the liquid through an ejection port to the surface of the intermediate transfer member.

4. The manufacturing method of a structure according to claim 2, wherein the modeling material solidifies when illuminated by UV light, and the modeling layer is formed by illuminating UV light on the modeling material in a state in which the regulating surface and the surface of the modeling layer on the opposite side abut each other.

5. The manufacturing method of a structure according to claim 4, wherein UV light is made to illuminate the modeling material through the regulating surface of the regulating member.

6. The manufacturing method of a structure according to claim 1, wherein the material for the support member is paraffin wax.

7. A manufacturing apparatus of a structure in which the structure is manufactured by laminating a modeling layer which becomes the structure while supporting the structure under formation with a support member, the apparatus comprising:

a preparing unit configured to prepare the modeling layer provided on a surface of an intermediate transfer member;

a providing unit configured to provide a layer constituted by the support member and the modeling layer by making a regulating surface of a regulating member for regulating an upper surface of the modeling layer on the opposite side of a surface which is in contact with the intermediate transfer member abut the upper surface of the modeling layer, pouring a material for the support member which becomes the support member to fill a gap between the intermediate transfer member and the regulating member in the periphery of the modeling layer while the regulating member abutting the upper surface of the modeling layer, and solidifying the material for the support member;

a first removing unit configured to remove the regulating member from the layer constituted by the support member and the modeling layer provided by the providing unit;

an overlap unit configured to overlap the surface of the layer constituted by the support member and the modeling layer exposed when the first removing unit configured to remove the regulating member removed the regulating member and the structure under formation or a support member which supports the structure with each other while supporting the layer constituted by the support member and the modeling layer by the intermediate transfer member; and

a second removing unit to remove the intermediate transfer member from the layer constituted by the support member and the modeling layer overlapped by the overlap unit.

8. The manufacturing apparatus of a structure according to claim 7, wherein the preparing unit prepares the modeling layer by forming the modeling layer by providing a modeling material which becomes the modeling layer on a surface of the intermediate transfer member and bringing the material which becomes the modeling layer and the regulating surface into contact.

9. The manufacturing apparatus of a structure according to claim 7, wherein the preparing unit provides the modeling material on the surface of the intermediate transfer member by ejecting the modeling material which becomes the modeling layer from a liquid ejection head which ejects the liquid through an ejection port to the surface of the intermediate transfer member.

10. The manufacturing apparatus of a structure according to claim 8, wherein the modeling material solidifies when illuminated by UV light, and the modeling layer is formed by illuminating UV light on the modeling material in a state in which the regulating surface and the surface of the modeling layer on the opposite side abut each other.

11. The manufacturing apparatus of a structure according to claim 10, wherein the regulating member includes an illuminating unit configured to illuminate UV light and illuminates UV light on the modeling material through the regulating surface of the regulating member.

12. The manufacturing method of a structure according to claim 7, wherein the material for the support member is paraffin wax.