Shaping method and shaped object

Patent metadata

Field	Value
Publication number	US-10493694-B2
Application number	US-201816143495-A
Country	US
Kind code	B2
Filing date	Sep 27, 2018
Priority date	Sep 29, 2017
Publication date	Dec 3, 2019
Grant date	Dec 3, 2019

Abstract

A shaped object shaped by a shaping method includes a structure that is shaped by stacking plural constituent layers and a ceiling wall to support the structure. The structure includes plural spiral form parts. Each spiral form part has a cross section in an elliptic shape and extends in a stacking direction while turning with respect to a center position of the elliptic shape. The plural spiral form parts are disposed in matrix in a state where the center positions are separated from each other by a predetermined distance. The spiral form parts that are adjacently disposed in a row direction and a column direction are shaped so that the turning directions are opposite. In at least one cross section of the structure, the major axes of the spiral form parts that are adjacent in the row direction and the column direction are orthogonal to each other.

First claim

What is claimed is:

1. A shaping method for shaping a shaped object including a structure and a ceiling wall configured to support the structure by using a three-dimensional shaping apparatus, the method comprising:
a structure shaping step of shaping the structure, by shaping a constituent layer constituting a part of the structure by irradiation with a light beam, repeatedly a predetermined number of times, so that the constituent layers are stacked into the structure; and
a ceiling wall shaping step of shaping the ceiling wall by irradiation with the light beam,
wherein:
the constituent layer includes a plurality of spiral constituent parts;
the spiral constituent part has a shape in which, when viewed from a stacking direction, a major axis and a minor axis are orthogonal to each other, the major axis corresponding to an axis including a longest direct distance from a center position of the spiral constituent part to an outer periphery of the spiral constituent part and the minor axis corresponding to an axis including a shortest direct distance from the center position to the outer periphery of the spiral constituent part;
the spiral constituent parts are disposed in matrix in a state where the center positions thereof are separated from each other by a predetermined distance; and
in the structure shaping step, the structure that includes a plurality of spiral form parts each extending in the stacking direction while turning with respect to the center position is shaped by the irradiation with the light beam so that, in every shaping of the constituent layer, the spiral constituent parts that are adjacent in a row direction and a column direction are in a state of being turned with respect to the center position by a predetermined angle in opposite directions.

2. The shaping method according to claim 1 , wherein in at least one constituent layer of the constituent layers that are stacked, the major axes of the spiral constituent parts that are adjacent in the row direction and the column direction are orthogonal to each other.

3. The shaping method according to claim 2 , wherein in the spiral constituent parts that are adjacent in the row direction and the column direction and whose major axes are orthogonal to each other, an end on a major axis side and an end on a minor axis side are in contact with each other.

4. The shaping method according to claim 1 , wherein in at least one constituent layer of the constituent layers that are stacked, the major axes of the spiral constituent parts are parallel to each other.

5. The shaping method according to claim 4 , wherein in the constituent layer where the major axes of the spiral constituent parts are parallel to each other, ends of the spiral constituent parts on a major axis side that are diagonally adjacent to each other with respect to the row direction and the column direction are in contact with each other.

6. The shaping method according to claim 1 , wherein a ratio of a length of the major axis to a length of the minor axis of the spiral constituent part is at least 2.8 to 1.

7. The shaping method according to claim 1 , wherein the spiral constituent part has a shape along the major axis that is symmetric about the minor axis when viewed from the stacking direction.

8. The shaping method according to claim 7 , wherein the spiral constituent part has an elliptic, oval, or rhombic shape when viewed from the stacking direction.

9. A shaped object fabricated by using a three-dimensional shaping apparatus, comprising a structure that is shaped by stacking a plurality of constituent layers and a ceiling wall configured to support the structure, wherein:
the structure includes a plurality of spiral form parts each extending in a stacking direction while turning with respect to a center position;
a cross section of the spiral form part has a shape in which a major axis and a minor axis are orthogonal to each other, the major axis corresponding to an axis including a longest direct distance from the center position to an outer periphery of the spiral form part and the minor axis corresponding to an axis including a shortest direct distance from the center position to the outer periphery of the spiral form part;
the spiral form parts are disposed in matrix in a state where the center positions thereof are separated from each other by a predetermined distance; and
the spiral form parts that are adjacently disposed in a row direction and a column direction are shaped so that turning directions are opposite.

10. The shaped object according to claim 9 , wherein in at least one cross section of the structure, the major axes of the spiral form parts that are adjacent in the row direction and the column direction are orthogonal to each other.

11. The shaped object according to claim 10 , wherein in the cross section of the structure where the major axes of the spiral form parts are orthogonal to each other, an end on a major axis side and an end on a minor axis side in the spiral form parts that are adjacent in the row direction and the column direction are in contact with each other.

12. The shaped object according to claim 9 , wherein in at least one cross section of the structure, the major axes of the spiral form parts are parallel to each other.

13. The shaped object according to claim 12 , wherein in the cross section of the structure where the spiral form parts are parallel to each other, ends of the spiral form parts on a major axis side that are diagonally adjacent to each other with respect to the row direction and the column direction are in contact with each other.

14. The shaped object according to claim 9 , wherein a ratio of a length of the major axis to a length of the minor axis of the spiral form part is at least 2.8 to 1.

15. The shaped object according to claim 9 , wherein the cross section of the spiral form part has a shape along the major axis that is symmetric about the minor axis.

16. The shaped object according to claim 15 , wherein the cross section of the spiral form part has an elliptic, oval, or rhombic shape.

17. The shaped object according to claim 9 , further comprising a side wall and a bottom wall, wherein:
the structure is surrounded by the bottom wall, the side wall, and the ceiling wall; and
the spiral form parts are configured to connect between the bottom wall and the ceiling wall.

18. The shaped object according to claim 9 , wherein the shaped object forms at least a part of a mold.

Assignees

• Honda Motor Co Ltd

Inventors

• Takahashi Keisuke
• Kimori Masahito
• Shimoda Akio
• Hayatsu Yusuke

Classifications

• B22F12/57

  Metering means · CPC title

• B22F12/52

  Hoppers · CPC title

• B22F12/46

  with translatory movement · CPC title

• B22F12/224

  for motion along a direction within the plane of a layer · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title