METHOD FOR MANUFACTURING THREE-DIMENSIONAL SHAPED OBJECT AND THREE-DIMENSIONAL SHAPED OBJECT

• US 20150210016A1
• Filed: 01/20/2015
• Published: 07/30/2015
• Est. Priority Date: 01/30/2014
• Status: Active Grant

• Current Assignee: Seiko Epson Corporation (Seiko Group)
• Original Assignee: Seiko Epson Corporation (Seiko Group)
• Inventors: OKAMOTO, Eiji
• Granted Patent: US 9,579,852 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/43 characterised by material
• CPC Class Codes: B22F 10/62 by chemical means
• CPC Class Codes: B22F 10/68 Cleaning or washing
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 33/448 destructible B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457
• 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
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2033/04 Polymers of esters
• CPC Class Codes: B29K 2105/0032 Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10T 428/24893 including particulate material

Abstract

In a method for manufacturing a three-dimensional shaped object in which layers formed by ejecting and curing ink including a curing resin are laminated, the method includes a layer forming process of forming the layers by using a composition for three-dimensional shaped object including powder for three-dimensional shaped object, and an ink ejecting process of ejecting an object formation ink and a sacrificial layer formation ink to the layers. In the ink ejecting process, the object formation ink and the sacrificial layer formation ink penetrate into the layers while forming a boundary between a region where the object formation ink penetrates in the layers and a region where the sacrificial layer formation ink penetrates into the layers.

Claims

1. A method for manufacturing a three-dimensional shaped object in which layers formed by ejecting and curing ink including a curing resin are laminated, the method comprising:

forming the layers by using a composition for three-dimensional shaped object including powder for three-dimensional shaped object constituted by particles; and

ejecting an object formation ink to form a region where the three-dimensional shaped object is provided and a sacrificial layer formation ink to form a sacrificial layer in a region at a side of an outermost layer of the three-dimensional shaped object, which is adjacent to a region to become the outermost layer of the three-dimensional shaped object,

during the ejecting, the object formation ink and the sacrificial layer formation ink penetrate into the layers while forming a boundary between a region where the object formation ink penetrates in the layers and a region where the sacrificial layer formation ink penetrates into the layers.

2. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

the ejecting includes performing the ejecting of the object formation ink and the ejecting of the sacrificial layer formation ink within the same scanning, or within 100 milliseconds.

3. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

an infiltration rate of the object formation ink and the sacrificial layer formation ink to the layers is adjusted.

4. The method for manufacturing the three-dimensional shaped object according to claim 3, wherein

adjustment of the infiltration rate of the object formation ink and the sacrificial layer formation ink is performed by adjusting an ejecting amount of the object formation ink and the sacrificial layer formation ink.

5. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

a curing material of the sacrificial layer formation ink has hydrophilicity.

6. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

the sacrificial layer formation ink includes one or more elements selected from a group consisting of tetrahydrofurfuryl(meth)acrylate, ethoxyethoxyethyl (meth)acrylate, polyethylene glycol di(meth)acrylate, (meth)acryloyl morpholine, and (meth)acrylic acid 2-(2-vinyloxyethoxy)ethyl.

7. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

the object formation ink includes one or more elements selected from a group consisting of (meth)acrylic acid 2-(2-vinyloxyethoxy)ethyl, polyether-based aliphatic urethane(meth)acrylate oligomer, 2-hydroxy-3-phenoxypropyl(meth)acrylate, and 4-hydroxybutyl(meth)acrylate.

8. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

as the object formation ink, in addition to a colored ink including a coloring agent, a colorless ink that does not include the coloring agent is used, and

the colorless ink is used to form the region of the outermost layer, and the colored ink is used to form a region positioned inside than the outermost layer.

10. The method for manufacturing the three-dimensional shaped object according to claim 1, wherein

when a refractive index of the particles is denoted as n1, and when a refractive index of a curing material of the curing resin included in the object formation ink is denoted as n2, a relationship of |n1−

n2|≦

0.2 is satisfied.

11. A three-dimensional shaped object manufactured by the manufacturing method for manufacturing the three-dimensional shaped object according to claim 1.

9. The method for manufacturing the three-dimensional shaped object according to claim, wherein

as the colored ink including the coloring agent, color ink and white ink are used, and

the white ink is used to form a region inside than a region formed by using the colored ink.