US 12,280,534 B2
Method of manufacturing three-dimensionally formed object and three-dimensionally formed object manufacturing apparatus
Eiji Okamoto, Matsumoto (JP); Masaya Ishida, Hara-mura (JP); and Toshimitsu Hirai, Hokuto (JP)
Assigned to Seiko Epson Corporation, Tokyo (JP)
Filed by SEIKO EPSON CORPORATION, Tokyo (JP)
Filed on Feb. 2, 2021, as Appl. No. 17/165,004.
Application 17/165,004 is a continuation of application No. 15/291,483, filed on Oct. 12, 2016, abandoned.
Claims priority of application No. 2015-203486 (JP), filed on Oct. 15, 2015.
Prior Publication US 2021/0154743 A1, May 27, 2021
Int. Cl. B22F 12/00 (2021.01); B22F 3/10 (2006.01); B22F 3/11 (2006.01); B22F 10/22 (2021.01); B22F 10/34 (2021.01); B22F 10/43 (2021.01); B23K 26/144 (2014.01); B23K 26/342 (2014.01); B29C 64/106 (2017.01); B22F 10/10 (2021.01); B22F 10/68 (2021.01); B22F 12/40 (2021.01); B28B 1/00 (2006.01); B29C 64/209 (2017.01); B29C 64/295 (2017.01); B29C 64/321 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01)
CPC B29C 64/106 (2017.08) [B22F 3/1021 (2013.01); B22F 3/11 (2013.01); B22F 10/22 (2021.01); B22F 10/34 (2021.01); B22F 10/43 (2021.01); B23K 26/144 (2015.10); B23K 26/342 (2015.10); B22F 10/10 (2021.01); B22F 10/68 (2021.01); B22F 12/40 (2021.01); B22F 2998/10 (2013.01); B22F 2999/00 (2013.01); B28B 1/001 (2013.01); B29C 64/209 (2017.08); B29C 64/295 (2017.08); B29C 64/321 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); Y02P 10/25 (2015.11)] 6 Claims
OG exemplary drawing
 
1. A method of manufacturing a three-dimensionally formed object, the method comprising:
forming a constituent layer using a first flowable paste including constituent material particles and at least one of a solvent and a binder, wherein a first ejection nozzle ejects the first flowable paste in the form of a continuous body toward a stage;
forming a support layer using a second flowable composition including support portion-forming particles and at least one of a solvent and a binder, wherein a second ejection nozzle ejects the second flowable composition in the form of a continuous body toward the stage, the support portion-forming particles having a sintering temperature higher than a sintering temperature of the constituent material particles;
forming a shape of the three-dimensionally formed object, at least partially surrounded by a support structure, by repeating the steps of forming a constituent layer and forming a support layer;
prior to sintering the shape of the three-dimensionally formed object, pre-sintering the shape of the three-dimensionally formed object by collectively imparting a first energy to the constituent layers of the shape and the support layers of the support structure from a heating portion, the heating portion being controlled by a control unit that controls forming the constituent layer and the support layer, the first energy having a first intensity, the first energy and first intensity raising the constituent layer and the support layer to a temperature lower than the sintering temperature of the constituent material particles and lower than a sintering temperature of the second flowable composition;
removing the support structure; and
moving the three-dimensionally formed object to a thermostatic chamber separate from the stage for sintering; and
after removing the support structure, sintering the shape of the three-dimensionally formed object by collectively imparting second energy having a second intensity to the constituent layers of the shape in the thermostatic chamber separate from the stage, the first intensity of the first energy being weaker than the second intensity of the second energy, wherein the second energy is imparted such that a temperature of the constituent material particles of the constituent layers are equal to or higher than the sintering temperature of the constituent material particles,
wherein the pre-sintering and the removing the support structure are performed before imparting the second energy.