Method of manufacturing three-dimensionally formed object and three-dimensionally formed object manufacturing apparatus

Patent metadata

Field	Value
Publication number	US-11745418-B2
Application number	US-202117165604-A
Country	US
Kind code	B2
Filing date	Feb 2, 2021
Priority date	Oct 15, 2015
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

A method of manufacturing a three-dimensionally formed object includes: forming a layer using a flowable composition including constituent material particles of a three-dimensionally formed object and a flowable composition including support portion-forming particles for forming a support portion which supports the three-dimensionally formed object during the formation of the three-dimensionally formed object; and imparting energy to the constituent material particles and the support portion-forming particles, in which in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a melting point of the constituent material particles and are lower than a melting point of the support portion-forming particles.

First claim

What is claimed is:

1. A method of manufacturing a three-dimensionally formed object, the method comprising:
forming a plurality of layers, each of the layers of the plurality of layers being formed using at least one of a first flowable composition including constituent material particles for forming the three-dimensionally formed object ejected from a first ejection nozzle or a second flowable composition including support portion-forming particles for forming a support portion which supports the three-dimensionally formed object during the formation of the three-dimensionally formed object ejected from a second ejection nozzle, the first ejection nozzle ejecting the first flowable composition in the form of a continuous body to form an object area having a first predetermined thickness on a per layer basis, and the second ejection nozzle ejecting the second flowable composition in the form of a continuous body to form a support area having a second predetermined thickness on a per layer basis; and
imparting energy to the plurality of layers including the constituent material particles and the support portion-forming particles,
wherein during the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles in the plurality of layers and a temperature of the support portion-forming particles in the plurality of layers are equal to or higher than a melting point of the constituent material particles and are lower than a melting point of the support portion-forming particles,
wherein before the imparting of the energy, in the same layer of the plurality of layers, the first predetermined thickness of the object area is different from a second predetermined thickness of the support area, and after the imparting the energy, in the same layer of the plurality of layers, an after-imparting-of-the-energy thickness of the object area and an after-imparting-of-the-energy thickness of the support area are substantially same,
wherein a porosity of the object area is lower than a porosity of the support area in the same layer of the plurality of layers.

2. The method of manufacturing a three-dimensionally formed object according to claim 1 , wherein the first predetermined thickness and the second predetermined thickness are determined based on a first reduction degree of the first flowable composition that is a change in volume by the imparting the energy and a second reduction degree of the second flowable composition that is a change in volume by the imparting the energy, the second reduction degree being different from the first reduction degree.

3. The method of manufacturing a three-dimensionally formed object according to claim 1 , wherein the imparting the energy includes placing the plurality of layers in a thermostatic chamber.

4. The method of manufacturing a three-dimensionally formed object according to claim 1 ,
wherein in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a sintering temperature of the support portion-forming particles.

5. The method of manufacturing a three-dimensionally formed object according to claim 1 , further comprising:
wherein the imparting of the energy is performed after forming all layers is complete.

6. The method of manufacturing a three-dimensionally formed object according to claim 1 ,
wherein the constituent material particles include at least one component of aluminum, titanium, iron, copper, magnesium, stainless steel, or maraging steel, and
the support portion-forming particles include at least one component of silica, alumina, titanium oxide, or zirconium oxide.

7. The method of manufacturing a three-dimensionally formed object according to claim 1 , wherein in the forming a plurality of layers, the first ejection nozzle ejects the first flowable composition towards a ceramic plate, the second ejection nozzle ejects the second flowable composition towards the ceramic plate.

Assignees

• Seiko Epson Corp

Inventors

• Okamoto Eiji
• Ishida Masaya
• Hirai Toshimitsu

Classifications

• Y02P10/25

  Process efficiency · 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

• B22F1/107

  containing organic material comprising solvents, e.g. for slip casting · CPC title

• B22F10/14

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

• B22F10/43

  characterised by material · CPC title