Three-dimensional shaped article production method

Patent metadata

Field	Value
Publication number	US-11660669-B2
Application number	US-202016792995-A
Country	US
Kind code	B2
Filing date	Feb 18, 2020
Priority date	Feb 20, 2019
Publication date	May 30, 2023
Grant date	May 30, 2023

Abstract

A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a second metal powder having a second average particle diameter and a binder to a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid containing at least either the second meal powder at a lower concentration than the first liquid or a third metal powder having a larger average particle diameter than the second average particle diameter and containing a binder to at least a portion of a surface layer region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.

First claim

What is claimed is:

1. A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers, comprising:
a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table;
a layer formation step of forming a first layer by compressing the first metal powder supplied to the shaping table;
a first liquid supply step of supplying a first liquid containing a binder and a second metal powder having a second average particle diameter that is an average particle diameter 1/10 or more and ½ or less the first average particle diameter to a portion of a constituent region of the first layer where the three-dimensional shaped article is formed, the constituent region containing a surface layer region that defines an outline of the three-dimensional shaped article and an internal region other than the surface layer region;
a second liquid supply step of supplying at least either a second liquid or a third liquid to at least a portion of the surface layer region of the first layer so that a metal density in at least the portion of the surface layer region of the first layer is higher than a metal density in the internal region of the first layer, the second liquid containing the binder and the second metal powder, in which a concentration of the second metal powder in the second liquid is lower than a concentration of the second metal powder in the first liquid, the third liquid containing the binder and a third metal powder having a larger average particle diameter than the second average particle diameter; and
a sintering step of sintering a metal in the constituent region by heating a stacked body of the layers including the first layer.

2. The three-dimensional shaped article production method according to claim 1 , wherein in the second liquid supply step, the second liquid is supplied to the entire surface layer region.

3. The three-dimensional shaped article production method according to claim 1 , wherein the first liquid and the second liquid are supplied to the internal region.

4. The three-dimensional shaped article production method according to claim 3 , wherein the first liquid and the second liquid are alternately supplied to the internal region at every layer.

5. The three-dimensional shaped article production method according to claim 1 , wherein the first liquid is supplied to the internal region other than the surface layer region in the constituent region without supplying the second liquid.

Assignees

• Seiko Epson Corp

Inventors

• Tsunoya Akihiko

Classifications

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F10/34

  of powder characteristics, e.g. density, oxidation or flowability · CPC title

• B22F12/63

  Rollers · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title