Sodick Co., Ltd.

Yasuyuki Miyashita

Ichiro Araie

Shuji Okazaki

Toshio Kaji

Katsuhiko Kobayashi

Masahiro Takano

Yuta Yoshida

Yoshitaka Kato

Kei Mochizuki

Yoshifumi Ichikawa

Seishi Kobayashi

Kensuke Kashimura

Atsushi Kawamura

Hiroyasu Miyakawa

A method for preparing an additive manufacturing program includes a loading step, a dividing step, an overhang calculating step, a subdividing step, a maintaining step, and an outputting step. In the loading step, a three-dimensional model is loaded. In the dividing step, the three-dimensional model is divided into divided layers. In the overhang calculating step, an overhang angle or overhang length of the divided layer is calculated. In the subdividing step, at least a part of the divided layer including an overhang portion is subdivided into two or more in a lamination direction. In the maintaining step, neither subdivision of the divided layer nor addition of a support structure supporting the divided layer is performed. The subdividing step and the maintaining step are selectively performed based on the overhang angle or overhang length. In the outputting step, an additive manufacturing program defining a command pertaining to additive manufacturing is output.

Method for preparing additive manufacturing program, method for additive manufacturing, and additive manufacturing apparatus

The present invention provides a system capable of estimating a molding state in a manufacturing process of the lamination molded object. According to the present invention, provided is a system for estimating a molding state in a manufacturing process of the lamination molded object including an image acquisition unit and an analysis unit. The lamination molded object is manufactured by repeating a material layer forming step of forming a material layer by supplying material powder onto a molding region and a solidified layer forming step of forming a solidified layer by irradiating the material layer with a laser beam. The image acquisition unit is configured to acquire image data of a spatter generated around a molten pool formed by irradiation with the laser beam. The analysis unit is configured to analyze the image data to estimate a parameter representing the molding state.

Lamination molding apparatus, molding state estimation system, molding state estimation method, molding state estimation program, and learning method of learning model for molding state estimation

An irradiation device of a lamination molding apparatus includes: at least one laser source, generating a laser beam; a first galvano scanner, scanning the laser beam; a second galvano scanner, scanning the laser beam; and an irradiation controller, controlling the laser source, the first galvano scanner, and the second galvano scanner. Irradiable ranges of the laser beams by using the first galvano scanner and the second galvano scanner respectively include an entire of a molding region. A first X-axis galvano mirror and a first Y-axis galvano mirror of the first galvano scanner and a second X-axis galvano mirror and a second Y-axis galvano mirror of the second galvano scanner are disposed to be plane-symmetric to each other.

Lamination molding apparatus

A method for producing a three-dimensional molded object includes forming a solidified layer by irradiating an irradiation region of a material layer with a laser beam or an electron beam, obtaining data about projections having a height higher than a predetermined value formed on a surface of the solidified layer, calculating heights of the projections, areas of the projections, or the number of the projections based on the data, and determining a molded state of the solidified layer by making a comparison between the calculated heights of the projections and a first threshold relating to heights of the projections, between the calculated areas of the projections and a second threshold relating to an areas of the projections, or between the calculated number of the projections and a third threshold relating to the number of the projections.

Method for producing three-dimensional molded object and lamination molding apparatus

A lamination molding method, which repeats a material layer forming step of forming a material layer and a solidifying step of irradiating an irradiation region of the material layer with laser beams scanned by n scanners to form a solidified layer, includes: a first dividing step and an irradiation order deciding step. In the first dividing step, the irradiation region is divided to 2n-1 or more divided regions by a plurality of first dividing lines in a manner that irradiation time of each of the divided regions to which the laser beams are simultaneously irradiated becomes equal. In the irradiation order deciding step, an irradiation order of the divided regions in the solidifying step is decided in a manner that the laser beams are simultaneously irradiated to the divided regions that are not adjacent, and the laser beams are not simultaneously irradiated to the divided regions that are adjacent.

Lamination molding method and lamination molding system

A lamination molding apparatus includes a molding room, a chamber, a chamber window, a molding table, a molding table driving device, surrounding walls, an irradiation device, a measuring unit, and a controller. The measuring unit includes a first measuring device acquiring a measured value of a light intensity, and a second measuring device acquiring a value of a beam diameter, and measures laser beams outputted based on set values of light intensity during molding. The controller determines an abnormality has occurred when a slope of a linear function obtained from a relationship between the measured value of the light intensity and the value of the beam diameter at a predetermined height is out of a predetermined range, or when a slope of a linear function obtained from a relationship between the measured value of the light intensity and a value of a focal position is out of a predetermined range.

Lamination molding apparatus and method for producing three-dimensional molded object

A method for producing a three-dimensional molded object includes forming a solidified layer, calculating a laser power, calculating a scanning speed, calculating a beam diameter, and determining that the solidified layer is poor when the laser power is outside a first reference range related to the laser power, the scanning speed is outside a second reference range related to the scanning speed, or the beam diameter is outside a third reference range related to the beam diameter.

Method for producing three-dimensional object using movable lens with control of laser power, scan speed and beam diameter

A calibration method of an additive manufacturing apparatus includes an irradiation trace forming step, an imaging step, a specifying step, and a correction step. The irradiation trace forming step scans laser beams with each of a plurality of scanners with respect to a plurality of target positions on a calibration plate installed on a molding region, and forms a plurality of irradiation traces having different shapes for each of the plurality of scanners. The imaging step simultaneously images the plurality of irradiation traces formed with respect to the same target position. The specifying step specifies a plurality of irradiated positions of the laser beam scanned by each of the plurality of scanners. The correction step generates correction data that specifies a deviation amount at any point of a laser coordinate system related to each of the plurality of scanners.

Additive manufacturing apparatus and calibration method thereof

A laminating and shaping apparatus includes a laser radiation unit configured to radiate a laser to a powder layer and form sintered sections, an imaging unit configured to image the sintered sections, a calculation device configured to calculate actual laser radiation positions from positions of the sintered sections and calculate a positional deviation of the laser radiation position at each of the sintered sections, and a correction device configured to correct the actual laser radiation position of each of the sintered sections to a target laser radiation position. The laser radiation unit forms sintered sections to surround the irradiation region by performing laser radiation on places including outermost positions in the irradiation region, and as the recoater head is moved in the horizontal uniaxial direction after imaging of the plurality of sintered sections by the imaging unit, at least a plurality of sintered sections are removed from the irradiation region.

Method of correcting a laser radiation position

A lamination molding apparatus, including: a chamber covering a desired molding region and being filled with an inert gas of predetermined concentration; a molding table configured to be vertically controllable in the chamber; a laser beam emitter to irradiate a predetermined irradiation region with a laser beam to form a sintered layer and irradiate a predetermined target irradiation position with the laser beam to form a sintered trace, the irradiation region being disposed on a material powder layer formed on the molding table for each of a plurality of divided layers obtained by dividing a desired three-dimensional object at a predetermined thickness.

Three dimensional printer

A powder sintering lamination molding method which can improve the quality of the molded product without extending the time required for the lamination molding. A powder sintering lamination molding method, including the steps of, irradiating an irradiation region of the sliced layer of a molded product surrounded by an outline profile with a laser to selectively sinter the material powder of the material powder layer within the irradiation region; wherein a cooling period is provided after the laser is irradiated along the first line and before the laser is irradiated along the second line.

Growing community of inventors

Kanagawa, Japan

Yasuyuki Miyashita