Shaping method and shaping device

Patent metadata

Field	Value
Publication number	US-11738504-B2
Application number	US-201916692050-A
Country	US
Kind code	B2
Filing date	Nov 22, 2019
Priority date	May 31, 2017
Publication date	Aug 29, 2023
Grant date	Aug 29, 2023

Abstract

An object shaping method includes a step of forming a powder layer using first powder, a step of placing second powder having an average particle diameter smaller than an average particle diameter of the first powder at a part of a region of the powder layer, and a first heating step of heating the powder layer in which the second powder is placed. The average particle diameter is equal to or larger than 1 nm and equal to or smaller than 500 nm, and the first heating step performs heating the powder layer at a temperature at which particles contained in the second powder are sintered or melted.

First claim

What is claimed is:

1. An object shaping method, comprising:
a step of forming a powder layer including first particles;
a step of placing second particles having a particle diameter smaller than a particle diameter of the first particles at a first region of the powder layer; and
a first heating step of heating at least a part including the first particles and the second particles,
wherein in the first heating step, the second particles are sintered or melted, and a heating temperature of the part is kept lower than a melting point of the first particles.

2. The object shaping method according to claim 1 , further comprising:
a step of removing a powder of the powder layer located at a second region of the powder layer, which is outside the first region.

3. The object shaping method according to claim 2 , further comprising:
a second heating step of heating the part after the step of removing the powder.

4. The object shaping method according to claim 3 , wherein the second heating step comprises heating the part at a temperature higher than the heating temperature in the first heating step.

5. The object shaping method according to claim 1 , wherein the first heating step is performed after repeating the step of forming the powder layer and the step of placing the second particles alternately a plurality of times.

6. The object shaping method according to claim 1 , wherein an average particle diameter of the first particles is 1 μm to 500 μm.

7. The object shaping method according to claim 1 , wherein the first particles and the second particles include at least one same component.

8. The object shaping method according to claim 1 , wherein the second particles are composed mainly of a component contained in the first particles.

9. The object shaping method according to claim 1 , wherein the first particles and the second particles are metal particles or ceramic particles.

10. The object shaping method according to claim 1 , wherein the step of placing the second particles is a step of applying a liquid including the second particles to the first region.

11. The object shaping method according to claim 10 , wherein the liquid includes a binder.

12. The object shaping method according to claim 11 , wherein volume concentration of the binder in the liquid is equal to or smaller than 50 vol %, and/or wherein viscosity of the liquid is equal to or smaller than 50 cP.

13. The object shaping method according to claim 10 , further comprising:
a step of drying the liquid performed between the step of applying the liquid and the first heating step.

14. The object shaping method according to claim 11 , wherein an average particle diameter of the second particles is 1 nm to 500 nm.

15. The object shaping method according to claim 1 , further comprising:
a step of pressurizing the powder layer performed between the step of forming the powder layer and the step of placing the second particles.

16. The object shaping method according to claim 1 , further comprising:
a step of applying a binder to the powder layer performed between the step of forming the powder layer and the first heating step.

17. The object shaping method according to claim 16 , wherein a region to which the binder is applied is a region outside the first region.

18. The method according to claim 1 , wherein the first particles are configured to start sintering together at a first temperature as a temperature of the first particles increases, and the second particles are configured to start sintering together at a second temperature as a temperature of the second particles increases,
wherein the first temperature is not higher than the melting point of the first particles, and the second temperature is not higher than a melting point of the second particles,
wherein the second temperature is lower than the first temperature, and
wherein in the first heating step, the heating temperature of the part is at least the second temperature and is kept below the first temperature.

19. The object shaping method according to claim 18 , wherein the second temperature is at least 100° C. lower than the first temperature.

20. The object shaping method according to claim 18 , wherein in the first heating step, the heating temperature is kept lower than 800° C.

21. The method according to claim 18 , wherein the melting point of the first particles is lower than the melting point of the second particles.

22. The object shaping method according to claim 18 , wherein in the first heating step, a powder of the powder layer located at a second region of the powder layer is heated to at least the second temperature, and the second region is outside the first region.

23. The object shaping method according to claim 2 , wherein the step of removing is performed after the first heating step.

24. An object shaping method, comprising:
a step of forming a powder layer including first particles;
a step of placing second particles having a particle diameter smaller than a particle diameter of the first particles at a first region of the powder layer; and
a first heating step of heating the powder layer at least at the first region and a second region of the powder layer; and
a step of removing a powder of the powder layer located at the second region after the first heating step,
wherein in the first heating step, the second particles are sintered or melted.

25. The method according to claim 24 , wherein the first particles are configured to start sintering together at a first temperature as a temperature of the first particles increases, and the second particles are configured to start sintering together at a second temperature as a temperature of the second particles increases,
wherein the first temperature is not higher than a melting point of the first particles, and the second temperature is not higher than a melting point of the second particles
wherein the second temperature is lower than the first temperature, and
wherein in the first heating step, a heating temperature of the powder of the powder layer located at the second region is kept lower than the first temperature.

26. The method according to claim 25 , wherein in the first heating step, the powder of the powder layer located at the second region is heated at least at the second temperature.

27. The object shaping method according to claim 25 , wherein the second temperature is at least 300° C. lower than the first temperature.

28. The object shaping method according to claim 24 , further comprising:
a second heating step of heating the part after the step of removing the powder.

29. The object shaping method according to claim 24 , wherein the first particles and the second particles contain different materials.

30. The object shaping method according to claim 24 , wherein an average particle diameter of the second particles is 1 nm to 200 nm.

Assignees

• Canon Kk

Inventors

• Sugiyama Akira
• Usami Hirokazu
• Masada Yohei
• Aotani Takaharu

Classifications

• B29C64/153 Primary

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

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B22F10/34

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

• B22F10/385

  Overhang structures · CPC title