Layered manufacturing method and layered manufacturing device

Abstract

After preparing a plurality of flat plate material members by compressing material powder, a region of an initial flat plate material member corresponding to a designed cross sectional shape is irradiated with irradiated light (laser light) L, to form an initial cross sectional element that is hardened after being melted. The surface of the initial cross sectional element is then leveled. Next, the next flat plate material member is arranged on the surface of an already manufactured section having a leveled one side surface. Irradiated light is then irradiated to a region of the new flat plate material member corresponding to the designed cross sectional shape at the layer position of the new flat plate material member, and a layer cross sectional member is formed by hardening after melting, and integrated with an already formed section. The surface of the layered cross sectional element is then leveled. After that the layering of the flat plate material members, layered cross sectional element formation and layered surface leveling are sequentially repeated. As a result, it is possible to manufacture a solid body of high strength simply and quickly.

1 . A layered manufacturing method, with powder as a raw material, for forming a desired solid body, comprising first executing steps of: 
 preparing a plurality of flat plate-shaped material members formed by compressing material powder;    irradiating laser light from one direction side to a region of an initial one of the flat plate material members corresponding to a designed cross sectional shape, to form an initial cross sectional element that is hardened after locally heating and melting; and    leveling the one direction side surface of the initial cross sectional element, followed by the repeated execution of steps of    arranging the flat plate material member on the one direction side of part of an already formed section;    irradiating laser light from one side to a region of the flat plate material member corresponding to a designed cross sectional shape of a layered position of the flat plate-shaped material member of a desired solid object, to form a layered cross sectional element that is hardened after locally heating and melting, together with integration of the one direction side with part already formed on an opposite side; and    leveling the one side surface of the layered cross sectional element.    
   
   
       2 . The layered manufacturing method of  claim 1 , wherein porosity of the flat plate member is 50%.  
   
   
       3 . The layered manufacturing method of  claim 1 , wherein the material powder is a powder of metal or alloy.  
   
   
       4 . The layered manufacturing method of  claim 1 , wherein respective materials of the flat plate material members are determined in accordance with respective layer positions of the flat plate material members.  
   
   
       5 . The layered manufacturing method of  claim 1 , further comprising steps of: 
 removing part of the initial one of the flat plate material members other than the initial cross sectional element, carried out between forming the initial cross sectional element and leveling the initial surface; and    removing part of the layered flat plate material members other than the layered cross sectional element, carried out between formation of the layered cross sectional element and leveling of the layered surface.    
   
   
       6 . The layered manufacturing method of  claim 1 , further comprising a step of: 
 shaping a side surface of a cross sectional element section formed in the newest, immediately before or immediately after leveling of the initial surface, and immediately before or immediately after leveling of the layered surface.    
   
   
       7 . A layered manufacturing device, for manufacturing a desired solid object, with a plurality of flat plate material members formed by compressing powder raw material as starting material, comprising: 
 a stage device, having a stage for mounting the flat plate material members, capable of driving the stage three dimensionally;    conveying means for conveying the plate material members towards the stage;    laser light irradiation means for irradiating laser light from one side in order to locally heat and melt a specified region of the flat plate material members; and    surface leveling means for leveling one side surface of a cross sectional element formed by solidifying after being melted by the laser light.    
   
   
       8 . The layered manufacturing device of  claim 7 , further provided with surplus material removal means for removing surplus material section other than the cross sectional element.  
   
   
       9 . The layered manufacturing device of  claim 7 , further provided with side surface shaping means for shaping a side surface of a cross-sectional element having the one side surface leveled.