Abstract: An apparatus for making a three-dimensional object includes a table, a powdery layer-former that forms a powdery layer on the table, and an optical beam-irradiator that irradiates an optical beam on a predetermined region of the powdery layer to sinter the predetermined region of the powdery layer. A chamber for accommodating the table and the powdery layer-former and a lid for opening and closing an opening defined in the chamber at a location immediately above an optical beam-irradiating range are provided. The three-dimensional object is taken out from the chamber through the opening upon completion of the sintering, and the optical beam-irradiator is disposed at a position deviated from immediately above the optical beam-irradiating range to obliquely irradiate the optical beam on the powdery layer.

Abstract: There is provided a stacked-layers forming device including a powder layer-forming part for forming a powder layer, an optical device for forming a solidified layer by irradiating a predetermined portion of the powder layer with a light beam and a powder replenishing means for supplying the powder material to above a base on which the powder layer and the solidified layer are stacked or onto an upper surface of a base frame which surrounds the base. The powder replenishing means includes an approximately cylindrical member in which the powder material is charged and a screw member which is installed within the approximately cylindrical member wherein a rotation of the screw member conveys the powder material in the approximately cylindrical member.

Abstract: In a method for producing a three-dimensionally shaped object, a powder layer is formed by feeding a powdery material to a substrate and a solidified layer is formed by irradiating a light beam on a specified portion of the powder layer to sinter or melt the specified portion of the powder layer. A three-dimensionally shaped object having a plurality of solidified layers laminated one above another is obtained by repeating the powder layer formation and the solidified layer formation. In the method, a stress is preliminarily applied to the substrate to reduce the amount of deformation of the substrate after production of the shaped object prior to the powder layer forming step.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (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 thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a heater element is disposed on the solidified layer during the repeated steps (i) and (ii), and thereby the heater element is situated within the three-dimensional shaped object.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (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 thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a part of a surface portion of the three-dimensional shaped object is formed as a low-density solidified portion whose solidified density ranges from 50% to 90% so that an application of pressure can be performed by a gas flowing through the low-density solidified portion.

Abstract: A method for manufacturing a three-dimensional shaped object wherein the warping of the base plate is suitably addressed. The method of the present invention comprises: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer on a base plate with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed; wherein, prior to or upon the manufacturing of the three-dimensional shaped object, the base plate is subjected to a heat treatment, thereby causing the base plate to be warped, and at least a lower surface of the warped base plate is subjected to a flattening process.

Abstract: In a method for producing a three-dimensionally shaped object, (i) a solidified layer is formed by irradiating a light beam on a specified portion of a powder layer to sinter or melt the specified portion. Further, (ii) another solidified layer is formed by placing a new powder layer on the solidified layer obtained in step (i), and irradiating the light beam on a specified portion of the new powder layer to sinter or melt the specified portion of the new powder layer. The steps (i) and (ii) are repeated to produce a three-dimensionally shaped object. In the method, a gas is supplied to a mirror used in scanning the light beam.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed in a chamber; wherein a localized gas flow is provided in the chamber, and at least a part of a fume generated by the irradiation of the light beam is entrained by the localized gas flow.

Abstract: Disclosed is a mold for resin injection molding that can realize rapid heating or cooling. A resin injection molding mold includes a cavity mold and a core mold and is produced on a base plate by metal photofabrication. The cavity mold is provided with a cavity warm water circuit for allowing warm water for heating to flow and a cavity cold water circuit for allowing cold water for cooling to flow. The core mold is also provided with a core warm water circuit and a core cold water circuit. The core mold includes an air blowing passage for feeding warm air or cold air into a resin molding part and a suction passage (36) for sucking a gas within the resin molding part. The resin molding part side of the air blowing passage and the suction passage is formed of a low-density shaping part that has a low metallic powder sintered density and is permeable to gas.

Abstract: An apparatus for making a three-dimensional object includes a table, a powdery layer-former that forms a powdery layer on the table, and an optical beam-irradiator that irradiates an optical beam on a predetermined region of the powdery layer to sinter the predetermined region of the powdery layer. A chamber for accommodating the table and the powdery layer-former and a lid for opening and closing an opening defined in the chamber at a location immediately above an optical beam-irradiating range are provided. The three-dimensional object is taken out from the chamber through the opening upon completion of the sintering, and the optical beam-irradiator is disposed at a position deviated from immediately above the optical beam-irradiating range to obliquely irradiate the optical beam on the powdery layer.

Abstract: A method for producing a three-dimensionally shaped object, includes the steps of: (i) forming a solidified layer by irradiating a light beam on a specified portion of a powder layer placed on a shaping table to sinter or melt the specified portion; (ii) forming another solidified layer by placing a new powder layer on the solidified layer thus obtained, and irradiating the light beam on a specified portion of the new powder layer to sinter or melt the specified portion of the new powder layer; and (iii) repeating the step (ii) to produce a three-dimensionally shaped object. When performing the steps (i) to (iii) within a chamber, at least a part of an ambient gas in the chamber is exhausted from the chamber through a gas passage of a shaping tank.

Abstract: An object of the present invention is to easily eliminate fumes inside a chamber, so as to improve a positional accuracy of irradiation with a light beam and a machining accuracy in a method for manufacturing a three-dimensional shaped object. A stacked-layers forming device 1 includes a powder layer forming unit 3, a light beam irradiating unit 4, a base 22 which is fixed and on which a powder layer 32 is formed, a lifting/lowering frame 34 which surrounds the circumference of the base 22 and is freely capable of being lifted and lowered, a cover frame 36 which has a window 36a allowing transmission of light beam in its top surface, and whose bottom surface is opened, and which is disposed on the lifting/lowering frame 34 to form a chamber C, and a gas tank 71 for supplying an ambient gas. The lifting/lowering frame 34 is lowered to reduce the volume of the chamber C, so as to discharge fumes generated inside the cover frame 36, which performs replacement with the ambient gas.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer on a base plate with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam; wherein the solidified layers are formed such that they have a high-density portion whose solidified density is 95 to 100% and a low-density portion whose solidified density is 0 to 95% (excluding 95%); and wherein the high-density portion is a portion of the three-dimensional shaped object, to which the force is applied when the three-dimensional shaped object is used.

Abstract: A lamination shaping apparatus has a powder layer preparing means and an optical unit which irradiates a light beam to an intended portion of a powder layer so as to sinter or melt for solidifying the portion into a cured layer. Preparation of the powder layer and curing of the cured layer are repeated to fabricate a three-dimensional object in which a plurality of the cured layers are laminated and integrated. The apparatus includes a fixed base carrying thereon the powder layer and the cured layer, an elevator frame surrounding a periphery of the fixed base, and driving means for driving the elevator frame to move vertically. The powder layer is formed within a space above the base and surrounded by an interior surface of the elevator fame such that the powder layer (cured layer) can be stacked on the base with the base being kept at a fixed position, thereby facilitating to fabricate a precisely shaped object.

Abstract: An apparatus for making a three-dimensional object includes a powdery layer-forming unit for forming a powdery layer on a table and an optical beam-irradiating unit for irradiating an optical beam on a predetermined region of the powdery layer to sinter the predetermined region. The optical beam-irradiating unit is disposed at a position spaced from immediately above an optical beam-irradiating range to obliquely irradiate the optical beam on the powdery layer. Because fumes generated by irradiating and heating the powdery layer with the optical beam rise towards a position immediately above them, the optical beam is irradiated from the position spaced from immediately above the optical beam-irradiating range, thereby reducing a cloud of the optical beam-irradiating unit that may be caused by the fumes.

Abstract: There is provided a stacked-layers forming device including a powder layer-forming part for forming a powder layer, an optical device for forming a solidified layer by irradiating a predetermined portion of the powder layer with a light beam and a powder replenishing means for supplying the powder material to above a base on which the powder layer and the solidified layer are stacked or onto an upper surface of a base frame which surrounds the base. The powder replenishing means includes an approximately cylindrical member in which the powder material is charged and a screw member which is installed within the approximately cylindrical member wherein a rotation of the screw member conveys the powder material in the approximately cylindrical member.

Abstract: Disclosed is a mold for resin injection molding that can realize rapid heating or cooling. A resin injection molding mold includes a cavity mold and a core mold and is produced on a base plate by metal photofabrication. The cavity mold is provided with a cavity warm water circuit for allowing warm water for heating to flow and a cavity cold water circuit for allowing cold water for cooling to flow. The core mold is also provided with a core warm water circuit and a core cold water circuit. The core mold includes an air blowing passage for feeding warm air or cold air into a resin molding part and a suction passage (36) for sucking a gas within the resin molding part. The resin molding part side of the air blowing passage and the suction passage is formed of a low-density shaping part that has a low metallic powder sintered density and is permeable to gas.

Abstract: Manufacturing equipment for a metal powder sintered component includes: a powder layer forming portion that supplies metal powder to form a powder layer; a light beam irradiator that irradiates a give point on the powder layer with light beams to sinter the powder layer and thus form a sintered layer; and a cutter that cuts a shaped object in which sintered layers are integrally stacked. The light beam irradiator has a scan head X shaft that moves a scan head in X direction parallel to a surface irradiated with light beams and a scan head Y shaft that moves the scan head in Y direction, so that the scan head moves in a direction parallel to the irradiated surface to perform irradiation with light beams. Since the scan head moves parallel to the irradiated surface, the irradiated area can be increased. Since the irradiation height can be small, the accuracy of light beam scanning can be enhanced.

Abstract: A three-dimensional object is made by repeating a process. An optical beam is irradiated on a predetermined portion of a powdery layer to form a sintered layer. A new powdery layer is formed on a surface of the sintered layer. An optical beam is irradiated on a predetermined portion of the new powdery layer to form a new sintered layer united with the underlying sintered layer. Because a portion of the sintered layer that is higher than a predetermined level is removed as occasion demands, the abnormally sintered portion on the sintered layer can be removed, making it possible to prevent stoppage of the shaping process, which may be caused by the abnormally sintered portion.

Abstract: A method for producing a three-dimensionally shaped object, includes a powder layer forming step of supplying a powdery material to form a powder layer; a solidified layer forming step of irradiating a light beam on a specified portion of the powder layer to sinter or melt the powder layer into a solidified layer; and a step of repeating the powder layer forming step and the solidified layer forming step to integrally laminate the solidified layer to produce the three-dimensionally shaped object. The solidified layer is integrally formed on an upper surface of a substrate and the thickness of the substrate is decided by a maximum horizontal cross-sectional area of the shaped object. The substrate is made of a material having the Young's modulus greater than that of the shaped object.