OPTICAL SHAPING APPARATUS AND OPTICAL SHAPING METHOD

• US 20150202805A1
• Filed: 12/09/2014
• Published: 07/23/2015
• Est. Priority Date: 01/22/2014
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: SARUHASHI, Ken, FURUKAWA, Isamu, IWAMOTO, Kunihiro, ARATA, Konosuke, ASANO, Mitsutoshi, TSUBOI, Kentaro, UEDA, Tetsuji, IKEDA, Junichi
• Granted Patent: US 10,040,224 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 41/22 Making multilayered or multicoloured articles
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/268 using laser beams; using electron beams [EB]
• CPC Class Codes: B29C 64/277 using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
• 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

An optical shaping method according to the present invention is an optical shaping method for shaping a three-dimensional structure by repeating a process for forming a cured resin layer 53 by irradiating an optically curing resin liquid 51 with light so that cured resin layers 53 are laminated. The process for forming the cured resin layer 53 includes, while applying a sheet light Ls to the optically curing resin liquid 51, applying a first light beam L1 intersecting the sheet light Ls to this optically curing resin liquid, and thereby forming the cured resin layer 53 in an area where the sheet light Ls intersects the first light beam L1. The irradiation place of the sheet light Ls is moved and the process for forming the cured resin layer 53 is repeated.

Claims

1. An optical shaping method for shaping a three-dimensional structure by repeating a process for forming a cured resin layer by irradiating an optically curing resin liquid with light so that cured resin layers are laminated, wherein

the process for forming the cured resin layer comprises, while applying a sheet light to the optically curing resin liquid, applying a first light beam intersecting the sheet light to the optically curing resin liquid, and thereby forming the cured resin layer in an area where the sheet light intersects the first light beam, and

an irradiation place of the sheet light is moved and the process for forming the cured resin layer is repeated.

2. The optical shaping method according to claim 1, wherein

each of irradiation energy densities of the sheet light and the first light beam is lowered below a critical irradiation energy density at a gel point of the optically curing resin liquid, and

a sum total of the irradiation energy densities of the sheet light and the first light beam is raised above the critical irradiation energy density.

3. The optical shaping method according to claim 1, wherein the first light reflected by a digital mirror device is applied to the optically curing resin liquid.

4. The optical shaping method according to claims 1, wherein the optically curing resin liquid comprises a multiphoton absorption material.

5. The optical shaping method according to claim 1, wherein a second light beam intersecting the sheet light is applied to the optically curing resin liquid.

6. An optical shaping apparatus that shapes a three-dimensional structure by repeating a process for forming a cured resin layer by irradiating an optically curing resin liquid with light so that cured resin layers are laminated, comprising:

a sheet light source that generates sheet light to be applied to the optically curing resin liquid;

a first light source that generates a first light beam intersecting the sheet light; and

driving unit that moves the sheet light source, wherein

an irradiation place of the sheet light is moved by the driving unit, and a process for forming the cured resin layer in an area where the sheet light intersects the first light beam is repeated.

7. The optical shaping apparatus according to claim 6, further comprising a digital mirror device that reflects the first light beam generated by the first light source, wherein

the first light reflected by the digital mirror device is applied to the optically curing resin liquid.

8. The optical shaping apparatus according to claim 6, further comprising a second light source that generates a second light beam intersecting the sheet light.