Method for manufacturing three-dimensional shaped object, additive manufacturing apparatus, and article

Abstract

A method for manufacturing a three-dimensional shaped object includes an nth layer forming step, an n+1th layer forming step, and a curing step. In the nth layer forming step, a cured portion of an nth layer, a first and second portions each of which is an uncured portion of the material are formed. In the n+1th layer forming step, a cured portion of an n+1th layer, and a third portion formed at a region adjacent to the cured portion of the n+1th layer and communicated with the first portion are formed. In the curing step, the second portion is cured prior to the n+1th layer forming step and the first and third portions are cured after the n+1th layer forming step, or the first, second and third portions are cured after the n+1th layer forming step.

What is claimed is: 
     
         1 . A method for manufacturing a three-dimensional shaped object by solidifying a material, the method comprising:
 an n th  layer forming step of forming a cured portion of an n th  layer, where n is a natural number of 2 or greater, by curing the material, a first portion which is an uncured portion of the material at a region adjacent to the cured portion of the n th  layer, and a second portion which is an uncured portion of the material at a region adjacent to the cured portion of the n th  layer and connected with an uncured portion of an n-1 layer;   an n+1 layer forming step of forming a cured portion of an n+1 layer at a region adjacent to the second portion by curing the material, and forming a third portion at a region adjacent to the cured portion of the n+1 layer and connected with the first portion which is the uncured portion of the material; and   a curing step of curing the second portion prior to the n+1 layer forming step and curing the first and third portions after the n+1 th  layer forming step, or curing the first, second and third portions after the n+1 layer forming step.   
     
     
         2 . The method according to  claim 1 , wherein the first portion is formed at a portion surrounded by the cured portion of the n th  layer. 
     
     
         3 . The method according to  claim 1 , wherein the second portion of the n th  layer is connected with the uncured portion of the n-1 layer within a range of 25% to 100% in an area ratio when viewed in a lamination direction. 
     
     
         4 . The method according to  claim 1 , wherein the material is a photocuring resin in a liquid state. 
     
     
         5 . The method according to  claim 4 , wherein in the curing step, the material of at least the second portion and one of the first and third portions is cured using light having a stronger intensity than an intensity of light used in the n th  layer forming step and the n+1 layer forming step. 
     
     
         6 . The method according to  claim 4 , wherein in the n th  layer forming step, light having a weaker intensity than an intensity of light used to form the n th  layer is irradiated on at least one of the first and second portions. 
     
     
         7 . The method according to  claim 6 , wherein in the n th  layer forming step, the light having the weaker intensity than the intensity of the light used to form the n th  layer is irradiated on the first and second portions, and
 wherein in the n th  layer forming step, the intensity of light irradiated on the first and second portions is increased stepwise or successively toward the cured portion of the n th  layer. 
 
     
     
         8 . The method according to  claim 6 , wherein in the n th  layer forming step, intensity of light irradiated on the second portion is increased stepwise or successively as it moves from the uncured portion of the n-1 th  layer. 
     
     
         9 . The method according to  claim 5 , wherein in the curing step, direction of light irradiated on the material is adjusted.