金属3Dプリンティングとは、金属材料を使って3次元データに基づいてさまざまな造形をする技術です。チタン・アルミニウム・ステンレスなどの金属材料を粉末化したものに、レーザを照射し焼結と積層を繰り返すことで、さまざまな形状の部品を金属で作ることができます。
現在、金属3Dプリンティングでは従来の成形、切削技術ではできなかったような構造を高強度に製造できるさまざまな製造プロセスが普及し始めており、航空部品や宇宙産業、医療機器など、複雑かつ厳しい品質基準を求められる分野での採用が進んでいます。
さまざまな形状での金属製品の造形が可能な金属3Dプリンタをさらに普及させていくためにはより高品質に、より早く製造できることが求められます。現状、主要な金属3Dプリンタは製造するもののサイズによりますが、1つの作成に数時間から数日を要する対象物もあります。そのため、大量生産によるコストダウンが進んでいません。その課題を解決する1つの手法として複数の高出力なレーザ光源を装置に搭載し、タクトタイムの向上を実現する手法がありますが、装置そのものが大型化し高額になってしまいます。
このような課題を解決する光学機器としてレーザ光を自由に位相制御可能なLCOS-SLMがあります。LCOS-SLMを装置に組み込むことで1本のレーザ光源を様々な形状かつ、多点に分岐させることができます。ただ、金属加工に使用されるレーザ光源は高出力なため、通常のLCOS-SLM以上の高い耐光性能が求められています。
今回、カバーガラスに従来材料よりも熱伝導率が約30倍高いサファイアガラスを採用することで、液晶層の熱をカバーガラスに伝えやすくしました。さらに、LCOS-SLMのパッケージ内部に熱伝導率の高い充填剤を封入するとともに内部構造を最適化することで、カバーガラスの放熱効率を高めています。この結果、LCOS-SLMの液晶層の温度上昇を抑制し、耐光性能を世界最高クラスとなる700 Wまで高めることに成功しました。本製品をレーザ金属加工装置に組み込むことで、金属3Dプリンタにおける大幅なタクトタイム向上、それに伴うコストダウンにより、金属3Dプリンティング市場の拡大に貢献することが期待されています。
LCOS-SLM レーザ金属加工向けタイプ(X15213-03CL)
熱伝導性が高いヘッド部の構造
レーザ金属加工向けタイプに700 W以上のレーザを照射した場合の位相変調特性
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