US 12,103,083 B2
Three-dimensional shaped article production method
Eiji Okamoto, Matsumoto (JP); Masaya Ishida, Hara-mura (JP); Hiroshi Wada, Azumino (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. 17/165,069.
Application 17/165,069 is a continuation of application No. 15/414,214, filed on Jan. 24, 2017, abandoned.
Claims priority of application No. 2016-015321 (JP), filed on Jan. 29, 2016.
Prior Publication US 2021/0154891 A1, May 27, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B33Y 40/00 (2020.01); B22F 7/00 (2006.01); B22F 10/16 (2021.01); B22F 10/43 (2021.01); B22F 10/47 (2021.01); B22F 10/60 (2021.01); B28B 1/00 (2006.01); B29C 35/08 (2006.01); B29C 64/40 (2017.01); B32B 18/00 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); B22F 12/30 (2021.01); B22F 12/55 (2021.01); B29K 105/16 (2006.01)
CPC B22F 7/006 (2013.01) [B22F 10/43 (2021.01); B22F 10/47 (2021.01); B28B 1/001 (2013.01); B29C 35/0805 (2013.01); B29C 64/40 (2017.08); B32B 18/00 (2013.01); B33Y 10/00 (2014.12); B33Y 40/00 (2014.12); B33Y 80/00 (2014.12); B22F 10/16 (2021.01); B22F 10/60 (2021.01); B22F 12/30 (2021.01); B22F 12/55 (2021.01); B22F 2999/00 (2013.01); B29C 2035/0838 (2013.01); B29K 2105/16 (2013.01); C04B 2235/6026 (2013.01); C04B 2235/77 (2013.01); C04B 2235/9615 (2013.01); C04B 2237/341 (2013.01); C04B 2237/343 (2013.01); C04B 2237/346 (2013.01); C04B 2237/348 (2013.01); C04B 2237/68 (2013.01); Y02P 10/25 (2015.11)] 10 Claims
OG exemplary drawing
 
1. A method for producing a three-dimensional shaped article by stacking layers to form a stacked body, the method comprising:
a constituent layer formation step of forming a constituent layer which correspond to a constituent region of the three-dimensional shaped article using a constituent material containing metal particles and a binder;
a support layer formation step of forming a support layer that are in contact with the constituent layer and that support the constituent layer using a support layer forming material containing a binder;
a stacking step of forming the stacked body by repeatedly performing the constituent layer formation step and the support layer formation step; and
a sintering step of sintering the stacked body including the constituent layers and the support layers at the same time in a high-temperature chamber,
wherein, a volume decrement of the support layers in the sintering step is higher than a volume decrement of the constituent layers in the sintering step,
wherein, the support layer in a space, which is surrounded by the constituent layer in at least two directions, includes a first region and a second region, each of the first region and the second region having a volume change in the sintering step and a volume decrement of the first region is larger than a volume decrement of the second region in the sintering step with
the first region of the support layer in the space being decomposed and removed, and is turned into a form of powder accompanying the sintering step, and the second region of the support layer having a honeycomb structure, a truss structure, or a lattice structure that is collapsed during the sintering step and remains within the space following decomposition and removal of the first region with the space is isotropically shrunk.