Forming method and formed article

Abstract

A forming method includes: forming a formed article including a first part and a second part using a first metal for the first part and a second metal for the second part; and removing the second part from the formed article by immersing the formed article in an electrolyte solution and causing a current to flow in the second part.

Claims

1. A method for forming an article, the method comprising: forming a first part of the article to include a substrate portion and an eaves portion by depositing a plurality of layers in a stacked arrangement, the first part comprising a first metal; forming a second part of the article by depositing a plurality of layers in a stacked arrangement such that the second part supports the eaves portion, the second part comprising a second metal, wherein the eaves portion overhangs the second part such that the second part supports the eaves portion after the first part and the second part are formed; sintering the first metal and the second metal; and removing the second part from the article by immersing the article in an electrolyte solution and causing a current to flow in the second part, wherein the removal of the second part causes the eaves portion to overhang a space where the second part was located prior to the removal of the second part, the space being open, wherein when a long side of an upper surface of the first part is set to an X direction in the Cartesian coordinate system, a short side of the first part is set to a Y direction in the Cartesian coordinate system that crosses the X direction, and a thickness direction of the first part that crosses the X and Y directions is set to a Z direction in the Cartesian coordinate system, the eaves portion extends from the substrate portion in the X direction and the space is defined as being in the Z direction beneath the eaves portion such that a step in the Z direction is formed at a transition between the substrate portion and the eaves portion.

2. The method according to claim 1, comprising sintering the first metal after forming each of the plurality of layers of the first metal and sintering the second metal after forming each of the plurality of layers of the second metal.

3. The method according to claim 1, wherein an oxidation potential of the second metal is lower than an oxidation potential of the first metal.

4. The method according to claim 3, wherein in the removing of the second part, a potential which is equal to or higher than the oxidation potential of the second metal and lower than the oxidation potential of the first metal is applied to the article.

5. The method of claim 1, comprising: forming a first plurality of layers, wherein each layer in the first plurality of layers includes a portion of a substrate of the first part of the article and the second part of the article; sintering each of the first plurality of layers after forming each of the first plurality of layers; forming a second plurality of layers over the first plurality of layers in a stacked arrangement to form a second portion of the first part of the article using the first metal, wherein the second portion of the article includes the eaves portion of the article, wherein the second part is arranged to support at least the eaves portion while the second plurality of layers are formed; sintering each of the second plurality of layers after forming each of the second plurality of layers.

6. The method of claim 1, further comprising forming an alloy layer at an interface between the first part and the second part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.

(2) FIG. 1 is a perspective view illustrating a three-dimensional object as a formed article according to an embodiment.

(3) FIGS. 2A to 2F are sectional views illustrating a method of forming the three-dimensional object according to the embodiment.

(4) FIG. 3 is a view illustrating a method of removing a support portion according to the embodiment.

(5) FIGS. 4A and 4B are sectional views illustrating a forming method according to a modification example.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

(6) Hereinafter, an embodiment in which the invention is embodied will be described with reference to drawings.

(7) Formed Article

(8) First, a three-dimensional object as a formed article according to an embodiment will be described with reference to FIG. 1. FIG. 1 is a perspective view illustrating a three-dimensional object as a formed article according to an embodiment. As illustrated in FIG. 1, a three-dimensional object 1 according to the embodiment includes a main body portion 10 as a first part. The main body portion 10 has a substrate 11 and an eaves portion 12. The main body portion 10 (the surface on the upper side illustrated in FIG. 1) has a substantially rectangular upper surface and has a region ranging from the substrate 11 to the eaves portion 12. The main body portion 10 is made of metal (first metal).

(9) A direction along the long side of the upper surface of the main body portion 10 is set to an X direction and a direction crossing the X direction along the short side of the upper surface is set to a Y direction. A direction which is the thickness direction of the main body portion 10 and crosses the X direction and the Y direction is set to a Z direction. The main body portion 10 has a shape in which the eaves portion 12 extends from the upper direction of the substrate 11 (+Z direction) to the +X direction. The main body portion 10 can be formed to have a shape in which the lower portion of the eaves portion 12 (Z direction) is removed from a rectangular parallelepiped body having a bottom surface with the same size as the size of the upper surface.

(10) Forming Method

(11) The three-dimensional object 1 (main body portion 10) according to the embodiment is formed by three-dimensional forming. More specifically, based on three-dimensional data of the final shape of the three-dimensional object 1 which is designed using three-dimensional CAD or the like as illustrated in FIG. 1, data is created in which the three-dimensional object 1 is divided into thin plates having planes defined by the X direction and the Y direction. Then, each layer of the thin plate-like layers is formed using a 3D printer or dispenser and laminated in the +Z direction so as to form the three-dimensional object 1.

(12) On the lower side of three-dimensional object 1 (main body portion 10) (Z direction) illustrated in FIG. 1, only the substrate 11 is present. However, the substrate 11 and the eaves portion 12 are present on the upper side (+Z direction). In other words, the substrate 11 is a part to be grounded and the eaves portion 12 is a part to be floating in the space. Therefore, when the three-dimensional object 1 is formed by laminating the thin plate-like layers having planes defined by the X direction and the Y direction, a member which supports the lower side of the eaves portion 12 is required.

(13) In the embodiment, when the three-dimensional object 1 is formed, as a member which supports the eaves portion 12 of the main body portion 10, a support portion 20 (refer to FIG. 2E) as a second part is formed together with the main body portion 10. The main body portion 10 is formed and then the support portion 20 is removed. Accordingly, the data in which the above-described three-dimensional object 1 is divided into thin plates includes the main body portion 10 and the support portion 20. The support portion 20 is made of metal (second metal).

(14) The metal for the main body portion 10 (first metal) and the metal for the support portion 20 (second metal) are selected so as to have a combination in which the oxidation potential of the metal for the support portion 20 is lower than the oxidation potential of the metal for the main body portion 10. For example, different combinations of cases of using silver (Ag) as the metal for the main body portion 10 and copper (Cu) as the metal for the support portion 20, using copper (Cu) as the metal for the main body portion 10 and tin (Sn) as the metal for the support portion 20, using tin (Sn) as the metal for the main body portion 10 and zinc (Zn) as the metal for the support portion 20, and the like can be used.

(15) Hereinafter, the forming method according to the embodiment will be described with reference to FIGS. 2A to 3. FIGS. 2A to 2F are sectional views illustrating a method of forming the three-dimensional object according to the embodiment. FIGS. 2A to 2F correspond to sectional views taken along a line A-A in FIG. 1. FIG. 3 is a view illustrating a method of removing a support portion according to the embodiment.

(16) As illustrated in FIG. 2A, the material of the metal for the main body portion 10 is disposed in a region in which the substrate 11 is provided on a substrate 30 as a main body portion metal material layer 10a corresponding to the data in which the main body portion 10 is divided into thin plates. In addition, the material of the metal for the support portion 20 is disposed in a region which overlaps with a region in which the eaves portion 12 is provided on the substrate 30 as seen from a plan view, as a support portion metal material layer 20a corresponding to the data in which the support portion 20 is divided into thin plates.

(17) As the material of the metal for the main body portion 10 and the material of the metal for the support portion 20, for example, powdered metal, a metal powder paste using a binder, and the like are used. As the material of the metal for the main body portion 10 and the material of the metal for the support portion 20, a wire-shaped material or a tape-shaped material may be used. The substrate 30 is provided for supporting the main body portion 10 (main body portion metal material layer 10a) and the support portion 20 (support portion metal material layer 20a) in the process of forming the three-dimensional object 1.

(18) Next, as illustrated in FIG. 2B, for example, the main body portion metal material layer 10a and the support portion metal material layer 20a are sintered by irradiation with laser light to form a thin plate-like main body portion metal material layer 10b and a support portion metal layer 20b. Next, although not illustrated in the drawing, the main body portion metal material layer 10a and the support portion metal material layer 20a illustrated in FIG. 2A are disposed on the thin plate-like main body portion metal material layer 10b and the support portion metal layer 20b and sintered to form a thin plate-like main body portion metal material layer 10b and a support portion metal layer 20b.

(19) As illustrated in FIG. 2C, a process of disposing and sintering the above-described main body portion metal material layer 10a and the support portion metal material layer 20a is repeatedly performed and thus the thin plate-like main body portion metal layer 10b and the support portion metal layer 20b are respectively and sequentially laminated and integrated. Further, the main body portion metal material layer 10a and the support portion metal material layer 20a are disposed thereon and sintered. In the layers including only the substrate 11 without the eaves portion 12 in the main body portion 10 to be formed, the main body portion metal layer 10b is laminated in the region in which the substrate 11 is provided and the support portion metal layer 20b is laminated in a region overlapping with the region in which the eaves portion 12 is provided as seen from a plan view.

(20) Since both the main body portion metal material layer 10a and the support portion metal material layer 20a are sintered as described above in a process of forming a rectangular parallelepiped body 1a, the support portion metal layer 20b has the same strength as the main body portion metal layer 10b. Thus, the rectangular parallelepiped body 1a can be more easily and accurately formed.

(21) As illustrated in FIG. 2D, in the layers including the substrate 11 and the eaves portion 12 in the main body portion 10 to be formed, only the main body portion metal material layer 10a is disposed in the region in which the substrate 11 is provided and the region in which the eaves portion 12 is provided and sintered and the main body portion metal layer 10b is laminated.

(22) As illustrated in FIG. 2E, the rectangular parallelepiped body 1a including the main body portion 10 and the support portion 20 is formed by laminating the main body portion metal layer 10b up to the uppermost layer. In the rectangular parallelepiped body 1a, the support portion 20 is positioned between the eaves portion 12 and the substrate 30 so as to support the eaves portion 12.

(23) Next, the rectangular parallelepiped body 1a is detached from the substrate 30 and then the support portion 20 is removed from the rectangular parallelepiped body 1a. In the process of removing the support portion 20 from the rectangular parallelepiped body 1a, for example, a potentiostat 5 illustrated in FIG. 3 is used. As illustrated in FIG. 3, the rectangular parallelepiped body 1a (working electrode), a counter electrode 6 and a reference electrode 7 are connected to the potentiostat 5. The rectangular parallelepiped body 1a, the counter electrode 6 and the reference electrode 7 are immersed in an electrolyte solution 9 stored in a solution layer 8.

(24) By using the potentiostat 5, a predetermined potential with a constant value is applied to the rectangular parallelepiped body 1a using the reference electrode 7 as a reference. As described above, the oxidation potential of the metal for the support portion 20 (second metal) is lower than the oxidation potential of the metal for the main body portion 10 (first metal). As the predetermined potential, a potential which is equal to or higher than the oxidation potential of the metal for the support portion 20 and lower than the oxidation potential of the metal for the main body portion 10 is applied to oxidize only the metal for the support portion 20. Such a predetermined potential is set as follows according to the combinations of the above-described respective metals.

(25) When the predetermined potential is set to Va, in the case in which the metal for the main body portion 10 (first metal) is silver (Ag) and the metal for the support portion 20 (second metal) is copper (Cu), the oxidation potential of silver is +0.800 V and the oxidation potential of copper is +0.342 V. Thus, the predetermined potential Va is +0.342 Va<+0.800. In the case in which the metal for the main body portion 10 is copper (Cu) and the metal for the support portion 20 is tin (Sn), the oxidation potential of tin is 0.138 V and thus the predetermined potential Va is 0.138 Va<+0.342. In the case in which the metal for the main body portion 10 is tin (Sn) and the metal for the support portion 20 is zinc (Zn), the oxidation potential of zinc is 0.762 V and thus the predetermined potential Va is 0.762 Va<0.138.

(26) By applying the predetermined potential to the rectangular parallelepiped body 1a, a current flows between the rectangular parallelepiped body 1a and the counter electrode 6, that is, between the support portion 20 and the counter electrode 6. When a current flows therebetween, the potential which is equal to or higher than the oxidation potential of the second metal is applied to the support portion 20. Thus, the second metal is oxidized and ionized. Accordingly, the support portion 20 made of the second metal is dissolved in the electrolyte solution 9 from the surface which is in contact with the electrolyte solution 9. Since the metal for the main body portion 10 is not oxidized, the entire support portion 20 is dissolved and the support portion 20 is removed from the rectangular parallelepiped body 1a and only the main body portion 10 is present. As a result, as illustrated in FIG. 2F, the three-dimensional object 1 including only the main body portion 10 is obtained.

(27) According to the forming method of the embodiment, the rectangular parallelepiped body 1a including the main body portion 10 and the support portion 20 is formed using the first metal and the second metal and the support portion 20 is removed from the rectangular parallelepiped body 1a in a process of removing the support portion 20. In the process of removing the support portion 20, the metal for the support portion 20 (second metal) is selectively oxidized, dissolved in the electrolyte solution 9, and removed by itself. Thus, it is possible to easily remove the support portion 20. Therefore, the three-dimensional object 1 can be more easily formed compared to the related art which requires a mold and machining.

(28) Further, in a process of forming the rectangular parallelepiped body 1a, the powdered metal for the main body portion 10 (first metal) and the metal for the support portion 20 (second metal) are also sintered. Thus, the support portion 20 has the same strength as the main body portion 10 and the support portion 20 can be handled in the same manner as the main body portion 10. Accordingly, compared to the case in which the main body portion 10 is formed when the metal for the support portion 20 is in a powder state, the rectangular parallelepiped body 1a can be more easily and accurately formed. In the process of removing the support portion 20, since the sintered second metal is oxidized and ionized, and the support portion is removed, some of the metal for the support portion 20 (second metal) can be prevented from remaining on the surface of the three-dimensional object 1 (main body portion 10).

(29) A three-dimensional object which can be formed by the forming method according to the embodiment is not limited to the three-dimensional object 1 illustrated in FIG. 1. According to the forming method of the embodiment, for example, a three-dimensional object having a shape with a hollow space, a three-dimensional object having a complicated inner shape, and three-dimensional objects having other shapes can be formed.

(30) The above-described embodiment is merely an aspect of the invention and may be arbitrarily modified and applied within the range of the invention. As a modification example, for example, the following example can be considered.

Modification Example

(31) In the above-described embodiment, the rectangular parallelepiped body 1a including the main body portion 10 and the support portion 20 is formed by repeatedly performing the process of disposing and sintering the metal for the main body portion 10 (first metal) and the metal for the support portion 20 (second metal). However, the invention is not limited to the embodiment. A configuration in which an alloy layer is formed at the interface between the main body portion 10 and the support portion 20 by repeatedly performing the process may be adopted. In addition, the alloy layer may remain in the finally obtained three-dimensional object.

(32) Also in a modification example, similar to the processes of the embodiment shown in FIGS. 2A to 2D, the process of disposing and sintering the metal for the main body portion 10 (first metal) and the metal for the support portion 20 (second metal) is repeatedly performed. When such a process is repeatedly performed, an alloy of the first metal and the second metal is formed at a portion in which the main body portion 10 is in contact with the support portion 20 by the combination of the first metal and the second metal in some cases.

(33) FIGS. 4A and 4B are sectional views illustrating a forming method according to a modification example. FIG. 4A is a view corresponding to FIG. 2E in the above-described embodiment. As illustrated in FIG. 4A, a rectangular parallelepiped body 1b includes the main body portion 10 and the support portion 20. However, an alloy layer 40 of the first metal and the second metal is formed at the interface between the main body portion 10 and the support portion 20. When the alloy layer 40 is present at the interface between the main body portion 10 and the support portion 20 in the rectangular parallelepiped body 1b, stress generated between the main body portion 10 and the support portion 20 due to the fact that the thermal expansion coefficient of the first metal is different from the thermal expansion coefficient of the second metal can be alleviated because the alloy layer 40 functions as a buffering member. Accordingly, in the process of forming the rectangular parallelepiped body 1b, warpage or deformation generated due to the difference in thermal expansion coefficient between the first metal and the second metal can be suppressed.

(34) FIG. 4B is a view corresponding to FIG. 2F in the above-embodiment. When the alloy layer 40 is formed in the rectangular parallelepiped body 1b as illustrated in FIG. 4A, the alloy layer 40 may remain in a three-dimensional object 2 which is finally obtained as illustrated in FIG. 4B. In addition, even when the alloy layer 40 is formed in the rectangular parallelepiped body 1b, the alloy layer 40 may not remain in the three-dimensional object 1 which is finally obtained as illustrated in FIG. 2F. Whether or not the alloy layer 40 finally remains can be determined by, for example, controlling the setting of the potential to be applied to the rectangular parallelepiped body 1b, the length of potential application time, and the like in the process of removing the support portion 20.