Method for manufacturing three-dimensional shaped object and three-dimensional shaped object

Patent metadata

Field	Value
Publication number	US-2017203366-A1
Application number	US-201515329441-A
Country	US
Kind code	A1
Filing date	Jul 28, 2015
Priority date	Jul 30, 2014
Publication date	Jul 20, 2017
Grant date	—

Abstract

There is provided a method for manufacturing a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming by an irradiation with a light beam in order to provide a selective laser sintering method capable of reducing a warp of the three-dimensional shaped object, the warp being due to a stress around an upper surface of the three-dimensional shaped object. Especially, in the present invention, a part of a region for the formation of the solidified layer is not irradiated with the light beam to form a non-irradiated portion, thereby providing at least one slit-groove at an upper surface of the three-dimensional shaped object, the slit-groove being for reducing a stress of the three-dimensional shaped object.

First claim

1 . A method for manufacturing a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming, the repetition comprising:
(i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification of the powder; and (ii) forming another solidified layer by newly forming a powder layer on the formed solidified layer, followed by an irradiation of a predetermined portion of the newly formed powder layer with the light beam, wherein a part of a region for the formation of the solidified layer is not irradiated with the light beam to form a non-irradiated portion, thereby providing at least one slit-groove at an upper surface of the three-dimensional shaped object, the slit-groove being for reducing a stress of the three-dimensional shaped object.

2 . The method according to claim 1 , wherein a plurality of the slit-grooves are provided such that they have a regular arrangement at the upper surface of the three-dimensional shaped object.

3 . The method according to claim 1 , wherein a slit-opening of the slit-groove has a shorter dimension of 0.05 mm to 1 mm.

4 . The method according to claim 1 , wherein a depth dimension of the slit-groove is in the range of 10% to 50% with respect to a thickness dimension of the three-dimensional shaped object.

5 . The method according to claim 1 , wherein a slit-opening of the slit-groove is provided such that a shorter dimension of the slit-opening gradually increases from a bottom of the slit-groove to the upper surface of the three-dimensional shaped object.

6 . The method according to claim 1 , wherein a slit-opening of the slit-groove has a longer direction which is in at least two orientations.

7 . The method according to claim 6 , wherein the slit-opening has a shape of a cross.

8 . The method according to claim 1 , wherein the three-dimensional shaped object used as a mold for a resin product is manufactured, a parting-surface of the mold being provided with the slit-groove.

9 . The method according to claim 1 , wherein the slit-groove is filled with a filling material.

10 . A three-dimensional shaped object made of laminated solidified layers, each of the laminated solidified layers being formed by irradiating a powder layer with a light beam,
wherein the three-dimensional shaped object has at least one slit-groove at an upper surface of the three-dimensional shaped object, the slit-groove being for reducing a stress of the three-dimensional shaped object.

11 . The three-dimensional shaped object according to claim 10 , wherein a plurality of the slit-grooves at the upper surface of the three-dimensional shaped object are in a regular arrangement.

12 . The three-dimensional shaped object according to claim 10 , wherein the three-dimensional shaped object is one used as a mold for a resin product, a parting-surface of the mold being provided with the slit-groove.

13 . The three-dimensional shaped object according to claim 12 , wherein the slit-groove serves as a gas-vent in a resin molding process.

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Takenami Masataka
• Abe Satoshi
• Mori Mikio

Classifications

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F12/67

  Blades · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B29C33/10

  with incorporated venting means · CPC title