Three-dimensional forming apparatus and three-dimensional forming method

Patent metadata

Field	Value
Publication number	US-10717231-B2
Application number	US-201615163287-A
Country	US
Kind code	B2
Filing date	May 24, 2016
Priority date	May 26, 2015
Publication date	Jul 21, 2020
Grant date	Jul 21, 2020

Abstract

A three-dimensional forming apparatus includes: a stage; a material supply unit that supplies the stage with a sintered material including metal powder and a binder; a head unit that includes an energy radiation unit supplying energy capable of sintering the sintered material to the sintered material supplied by the material supply unit; a head base that holds a plurality of the head units; and a driving unit that is capable of three-dimensionally moving the head base relative to the stage.

First claim

What is claimed is:

1. A three-dimensional forming apparatus comprising:
a stage;
a material supply unit that supplies the stage with a sheet of material formed by kneading a mixture including at least metal powder and a binder;
a plurality of head units, each of which including an energy radiation unit supplying energy and configured to simultaneously sinter a corresponding area of the sheet of material supplied onto the stage, wherein at least one of the corresponding areas joins at least one of the other corresponding areas when the corresponding areas are simultaneously sintered;
a head base that holds the plurality of the head units; and
a driving unit that is capable of three-dimensionally moving the head base relative to the stage.

2. The three-dimensional forming apparatus according to claim 1 , wherein the energy is a laser.

3. A three-dimensional forming method comprising:
supplying a stage with a sheet of material formed by kneading a mixture of at least metal powder and a binder;
forming a single layer by moving a head base that holds a plurality of head units, each of which including an energy radiation unit that supplies energy capable of sintering the sheet of material relative to the stage, supplying the energy to a corresponding area of the sheet of material, and sintering the corresponding area of the sheet of material, wherein at least one of the corresponding areas joins at least one of the other corresponding areas when the corresponding areas are simultaneously sintered; and
forming a second layer in the forming of the single layer by stacking the second layer on a first single layer formed in the forming of the single layer,
wherein the forming of the second layer is repeated a predetermined number of times.

4. The three-dimensional forming method according to claim 3 ,
wherein the energy is a laser.

5. The three-dimensional forming apparatus of claim 1 , wherein each of the corresponding areas of the sheet of material has a predetermined sintering width, and at least two of the plurality of head units are maintained at a predetermined distance in a width direction, and the predetermined distance is substantially same as the predetermined sintering width in the width direction.

6. The three-dimensional forming method of claim 3 , wherein each of the corresponding areas of the sheet of material has a predetermined sintering width, and at least two of the plurality of head units are maintained at a predetermined distance in a width direction, and the predetermined distance is substantially same as the predetermined sintering width in the width direction.

Assignees

• Seiko Epson Corp

Inventors

• Katakura Takahiro
• Miyashita Takeshi
• Kamakura Tomoyuki
• Takeuchi Tetsuhiko

Classifications

• B22F12/22

  Driving means · CPC title

• B22F10/16

  by embedding the binder within the powder bed · CPC title

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B22F10/00 Primary

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title

• Y02P10/25

  Process efficiency · CPC title