Method for manufacturing three-dimensional object, three-dimensional object, titanium-containing intermediate three-dimensional object, and titanium-containing three-dimensional object
A method for manufacturing a three-dimensional object includes: a modeling step of modeling an intermediate object by applying a binding fluid to a metal powder containing titanium; and a sintering step of sintering the intermediate object to produce a three-dimensional object. The modeling step is performed in a vacuum or inert gas atmosphere. When the modeling step is performed in a modeling area and the method includes a curing step of curing the binding fluid included in the intermediate object in a curing area different from the modeling area after the modeling step and before the sintering step, the curing step is performed in a vacuum or inert gas atmosphere. A moving path for moving the intermediate object having gone through the modeling step from the modeling area to the curing area is in a vacuum or inert gas atmosphere.
1 . A three-dimensional object manufactured by a method, the method including:
a modeling step of modeling an intermediate object by applying a binding fluid to a titanium-containing metal powder, the modeling step further including:
a metal powder layer forming step of forming a metal powder layer by supplying the titanium-containing metal powder to an area of flat shape; and
a binding fluid application step of applying the binding fluid to a partial area of the metal powder layer based on a planar shape of a three-dimensional modeling side layer among a plurality of three-dimensional modeling side layers into which the three-dimensional object is divided along a predetermined direction, whereby the titanium-containing metal powder in the partial area is bound to form an intermediate modeling side layer of the intermediate object; and
a sintering step of sintering the intermediate object to produce the three-dimensional object, wherein
the modeling step is performed in a vacuum or inert gas atmosphere,
the metal powder layer forming step and the binding fluid application step are repeated in order, whereby the intermediate modeling side layers are stacked in succession to form the intermediate object,
the three-dimensional object comprising:
a surface layer neighboring area including a topmost three-dimensional modeling side layer of the three-dimensional object stacked in the modeling step has a porosity higher than that of a core area in an inside of the three-dimensional object; and
multiple pits and projections at a surface of the three-dimensional object.
2 . The three-dimensional object according to claim 1 , wherein
the three-dimensional object has a slope inclined with respect to a stacking direction of the plurality of three-dimensional modeling side layers at the surface of the three-dimensional object,
the slope includes steps between adjoining ones of the three-dimensional modeling side layers, and the steps are formed in a continuous staircase pattern along an inclined direction, and
the steps are stacking traces indicating borders between the adjoining ones of the three-dimensional modeling side layers.
3 . A titanium-containing three-dimensional object that is three-dimensionally modeled by application of a binding fluid to a metal powder containing titanium, cured, and sintered,
the titanium-containing three-dimensional object comprising:
a density of 3.5 g/cm 3 or higher; and
multiple pits and projections at a surface of the titanium-containing three-dimensional object.
4 . A titanium-containing three-dimensional object that is three-dimensionally modeled by application of a binding fluid to a metal powder containing titanium, cured, and sintered,
the titanium-containing three-dimensional object comprising:
0.06% or less by weight of carbon that is contained in the titanium-containing three-dimensional object with reference to a weight of the titanium-containing three-dimensional object; and
multiple pits and projections at a surface of the titanium-containing three-dimensional object.
5 . A titanium-containing three-dimensional object that is three-dimensionally modeled by application of a binding fluid to a metal powder containing titanium, cured, and sintered,
the titanium-containing three-dimensional object comprising:
a surface layer neighboring area of the titanium-containing three-dimensional object having a porosity higher than that of a core area in an inside of the titanium-containing three-dimensional object; and
multiple pits and projections at a surface of the titanium-containing three-dimensional object.