Method of manufacturing modeled body, method of modeling solidified object, and modeled body

Patent metadata

Field	Value
Publication number	US-11679550-B2
Application number	US-202117534452-A
Country	US
Kind code	B2
Filing date	Nov 23, 2021
Priority date	Nov 30, 2020
Publication date	Jun 20, 2023
Grant date	Jun 20, 2023

Abstract

A method of manufacturing a modeled body includes: modeling including applying a modeling solution to each layer of powder laid in a layer, to solidify the powder to model a solidified object; sintering the solidified object to obtain a sintered body of the solidified object; and removing a sacrificial body from the sintered body, to obtain a modeled body. At the modeling, the modeling solution is applied to a modeled body area in the solidified object and a border area in the solidified object such that, after the modeling solution is applied, a density of the powder at the border area is smaller than a density of the powder in the modeled body area. The modeled body area corresponds to the modeled body. The border area corresponds to a border between the modeled body and the sacrificial body.

First claim

What is claimed is:

1. A method of manufacturing a modeled body comprising:
modeling including applying a modeling solution to each layer of powder laid in a layer, to solidify the powder to which the modeling solution is applied, to model a solidified object;
sintering the solidified object modeled at the modeling to obtain a sintered body of the solidified object; and
removing a sacrificial body from the sintered body, to obtain a modeled body in which the sacrificial body is removed from the sintered body,
wherein at the modeling, the modeling solution is applied to a modeled body area in the solidified object and a border area in the solidified object such that, after the modeling solution is applied, a density of the powder at the border area is smaller than a density of the powder in the modeled body area, the modeled body area corresponding to the modeled body, the border area corresponding to a border between the modeled body and the sacrificial body,
the powder is a material having fluidity lower than fluidity of aluminum powder, and
at the modeling, the modeling solution is applied such that an application amount of the modeling solution to a unit area of the border area is smaller than an application amount of the modeling solution to a unit area of the modeled body area.

2. The method of manufacturing the modeled body according to claim 1 , wherein at the modeling, an identical modeling solution is applied to the modeled body area and the border area.

3. The method of manufacturing the modeled body according to claim 1 , wherein at the modeling, the modeling solution is applied to a surface of the border area and an inner part of the border area such that, after the modeling solution is applied, a density of the powder in the surface of the border area is smaller than a density of the powder in the inner part.

4. The method of manufacturing the modeled body according to claim 1 , wherein at the modeling, the modeling solution is applied such that, after the modeling solution is applied, areas where a density of the powder is larger and areas where a density of the powder is smaller are alternate in the border area.

5. The method of manufacturing the modeled body according to claim 4 , wherein at the modeling, the modeling solution is applied such that, after the modeling solution is applied, the areas where the density of the powder is larger and the areas where the density of the powder is smaller are latticed.

6. A method of modeling a solidified object that is used for a method of manufacturing a modeled body including:
sintering a solidified object to obtain a sintered body; and
removing a sacrificial body from the sintered body, to obtain a solidified object in which the sacrificial body is removed from the sintered body,
the method of modeling a solidified object comprising:
applying a modeling solution to each layer of powder laid in a layer and solidifying the powder to which the modeling solution is applied, to model the solidified object,
wherein at the modeling the modeling solution is applied to a modeled body area in the solidified object and a border area in the solidified object such that, after the modeling solution is applied, a density of the powder in the border area is smaller than a density of the powder in the modeled body area, the modeled body area corresponding to the modeled body, the border area corresponding to a border between the modeled body and the sacrificial body,
the powder is a material having fluidity lower than fluidity of aluminum powder, and
at the modeling, the modeling solution is applied such that an application amount of the modeling solution to a unit area of the border area is smaller than an application amount of the modeling solution to a unit area of the modeled body area.

Assignees

• Yamaguchi Daichi
• Ricoh Co Ltd

Inventors

• Yamaguchi Daichi

Classifications

• B29C64/165

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

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title