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: A metal powder for use in a metal laser-sintering wherein a three-dimensional shaped object is produced by irradiating a powder layer of the metal powder with a light beam to form a sintered layer and thereby laminating the sintered layers. The metal powder of the present invention is characterized in that it comprises an iron-based powder and at least one kind of powder selected from the group consisting of a nickel powder, a nickel-based alloy powder, a copper powder, a copper-based alloy powder and a graphite powder; and the iron-based powder has been annealed. In such metal powder, the iron-based powder is in a softened state due to the annealing treatment thereof. Accordingly, the use of the metal powder in a metal laser-sintering process makes it possible to reduce a machining resistance attributable to the residual metal powder adherent to the surface of the shaped object, which leads to an achievement of an extended lifetime of a machining tool.

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: Prior to molding, an initial position of at least one movable reference mark, provided in the vicinity of an object of manufacture, is measured by a first position measuring means, and the initial position of the movable reference mark is measured by a second position measuring means provided in a processing means. During the course of molding, measurement of a position of the movable reference mark is carried out by the first position measuring means and the second position measuring means. Then, based on the initial position of the movable reference mark prior to molding and the position of the movable reference mark measured by the first and second position measuring means during the course of molding, an optical beam irradiating position of an optical beam and a processing position of the processing means are corrected.

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.

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 apparatus for producing a laminated object, includes a powder layer forming unit for forming a powder layer of a powdery material, a material supply unit for feeding the powdery material to the powder layer forming unit; and a solidified layer forming unit for forming a solidified layer by irradiating a light beam on a specified portion of the powder layer and sintering or melting the specified portion of the powder layer. The apparatus is configured to produce an integrally laminated three-dimensional object by repeating formation of the powder layer and formation of the solidified layer. The material supply unit includes a cartridge unit charged with the powdery material, the cartridge unit being configured to allow the powdery material to drop downwards.

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: A method of manufacturing a three-dimensionally shaped object by irradiating a metallic material with light beams, wherein the metallic material is supplied at a high density to increase the density and the strength of the three-dimensionally shaped object. The method of manufacturing a three-dimensionally shaped object comprises: an irradiation step of irradiating a metal mesh (2) formed of metal wires and a powder layer (3) formed of metal powder with light beams (L) to form a solidified layer or molten layer; and a laminating step of repeatedly performing the irradiation step for metal meshes to form a three-dimensionally shaped object. In the method, both of the metal mesh (2) and the metal powder are supplied in combination as the metallic material.

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: The invention relates to a method of making a three-dimensional object, comprising the steps of: (a) forming a powder material layer (10) of inorganic material; (b) irradiating an optical beam (L) on a predetermined portion of the powder material layer (10) to form a first sintered layer (11) and integrate the first sintered layer (11) with a second sintered layer (11) just below the first sintered layer (11); (c) repeating the steps (a) and (b) to form a sintered block (B) united with a plurality of the first and second sintered layers (11), the sides of the sintered block (B) including a concave portion (g); (d) removing an excess portion (17) from a surface of the sintered block (B); and (e) repeating the steps (c) and (d) with respect to the sintered block (B) from which the excess portion (17) is removed, in order to make a target shape of a three-dimensional object united with a plurality of the sintered blocks (B).

Abstract: Prior to molding, an initial position of at least one movable reference mark, provided in the vicinity of an object of manufacture, is measured by a first position measuring means, and the initial position of the movable reference mark is measured by a second position measuring means provided in a processing means. During the course of molding, measurement of a position of the movable reference mark is carried out by the first position measuring means and the second position measuring means. Then, based on the initial position of the movable reference mark prior to molding and the position of the movable reference mark measured by the first and second position measuring means during the course of molding, an optical beam irradiating position of an optical beam and a processing position of the processing means are corrected.

Abstract: A three-dimensional object of a desired shape is made by irradiating an optical beam on a metal powder layer to form a sintered layer and by laminating such sintered layer one above another. A metal powder composition for use in making such a three-dimensional object includes an iron-based powder material, a nickel and/or nickel alloy powder material, a copper and/or copper alloy powder material, and a graphite powder material. The graphite powder material acts to enhance the wettability during melting and to reduce microcracks during solidification.

Abstract: To make a three-dimensional object, an optical beam is first irradiated on a predetermined portion of a powder layer to form a sintered layer, which is then covered with a new powder layer. The optical beam is again irradiated on a predetermined portion of the new powder layer to form another sintered layer that has been united with the underlying sintered layer. These processes are repeatedly carried out to form a plurality of sintered layers united together. When the second lower density layer is formed on the first higher density layer, a powder material layer for the lower density layer is formed at a predetermined thickness so as to have a thickness suitable for sintering condition and then the powder material layer is sintered to form the lower density layer.

Abstract: In order for a surface of a three-dimensional sintered object to be smoothly finished by removing unwanted portions and an excessively sintered growth formed during sintering to form sintered layers, the three-dimensional sintered object is formed by repeating successive processes of dispensing a powdery material and directing an optical sintering beam to the powdery material to form the sintered layer, until a required number of integral laminated bodies are formed. During the formation of the integral laminated bodies, trimming is applied to a first zone different from a second zone in which each laminated body is formed, to remove unwanted portions of the respective laminated body.

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: 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.