Method and apparatus for molding three-dimensional object and molding data generation method for three-dimensional object

Patent metadata

Field	Value
Publication number	US-9694542-B2
Application number	US-201514840669-A
Country	US
Kind code	B2
Filing date	Aug 31, 2015
Priority date	Sep 12, 2014
Publication date	Jul 4, 2017
Grant date	Jul 4, 2017

Abstract

A method for molding a three-dimensional object, includes building up layers formed of bonded powder to form a three-dimensional object; and forming a support below the three-dimensional object. The method is performed by a three-dimensional object molding apparatus that includes a powder lamination molding apparatus to form a three-dimensional object by building up layers formed of bonded powder; and a molding data generator to generate data for each layer of the three-dimensional object that the powder lamination molding apparatus laminates, in which a support is formed below the three-dimensional object.

First claim

What is claimed is:

1. A method for molding a three-dimensional object, comprising:
building up layers formed of bonded powder to form a three-dimensional object;
forming a support below the three-dimensional object; providing unsolidified powder between the three-dimensional object and the support;
removing a part above the support as a removed molding object including the three-dimensional object supported by the support via the unsolidified powder; and
drying the removed molding object including the three-dimensional object supported by the support via the unsolidified powder by a drying furnace.

2. The method as claimed in claim 1 , wherein the support has the same external shape as that of the three-dimensional object as projected onto the support.

3. The method as claimed in claim 1 , wherein the support has a size larger than that of the three-dimensional object as projected onto the support.

4. The method as claimed in claim 1 , wherein the support is molded and dried before forming the layer of the three-dimensional object.

5. The method as claimed in claim 1 , wherein the support is a plate.

6. The method as claimed in claim 1 , wherein the support is a tray.

7. The method as claimed in claim 1 , wherein the support is formed between a molding stage and a bottommost part of the three-dimensional object formed on the molding stage.

8. A method for molding a three-dimensional object, comprising:
building up layers formed of bonded powder to form a three-dimensional object;
forming a support below the three-dimensional object; and
setting a molding condition for molding the support different from a molding condition for molding the three-dimensional object.

9. The method as claimed in claim 8 , further comprising:
discharging liquid droplets of a molding liquid to the powder; and
forming a layer in which the powder is bonded, while using the liquid droplet for molding the support, other than the liquid droplet for molding the three-dimensional object.

10. The method as claimed in claim 8 , wherein the support is a plate.

11. The method as claimed in claim 8 , wherein the support is a tray.

12. A method for molding a three-dimensional object, comprising:
building up layers formed of bonded powder to form a three-dimensional object;
forming a support below the three-dimensional object;
providing unsolidified powder between the three-dimensional object and the support; and
removing a part above the support as a removed molding object including the three-dimensional object supported by the support via the unsolidified powder,
wherein the support has an external shape equal to or larger than an external shape of the three-dimensional object as projected onto the support, and
wherein the removed molding object including the three-dimensional object has the unsolidified powder attached around the three-dimensional object within dimensions of the support.

13. The method as claimed in claim 12 , wherein the support is a plate.

14. The method as claimed in claim 12 , wherein the support is a tray.

Assignees

• Sakura Shozo
• Ricoh Co Ltd

Inventors

• Sakura Shozo

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C67/0092

  Operations & Transport · mapped topic

• B29C67/0081 Primary

  Operations & Transport · mapped topic

• B29C64/40

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · 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