Three-dimensional modeling device and method for manufacturing three-dimensional modeled object

Abstract

A three-dimensional modeling device and a method for manufacturing a three-dimensional object are capable of heating layers of modeling material stacked in a modeling area through simple control, and stacking a new layer of modeling material on the heated layer of modeling material to form a three-dimensional object. The three-dimensional modeling device comprises: a plasticizing unit that plasticizes the material to generate modeling material; a stage for stacking the modeling material; a nozzle having a nozzle opening that ejects the modeling material from the nozzle opening toward the modeling area on the stage; a moving mechanism that can change the relative position of the nozzle and the stage; and a heating unit having a heater and a heating element that heats the modeling material stacked in the modeling area using heat supplied from the heater. The nozzle opening is located between the stage and the heating unit in the stacking direction of the modeling material, and the heating unit is configured to change its relative position with the stage together with the nozzle, and the heating element covers at least the modeling area when viewed along the stacking direction.

Description

Technical Field

[0001] The present disclosure relates to a three-dimensional modeling device and a method for manufacturing a three-dimensional modeled object. Background Art

[0002] Regarding the three-dimensional modeling device, for example, in the device described in Patent Document 1, the already set layer is heated by using an energy source connected to the head via a support arm, and a subsequent layer is stacked on the heated already set layer, thereby improving the adhesion between the already set layer and the subsequent layer.

[0003] Patent Document 1: Japanese Patent Application No. 2017-523063

[0004] In the device described in Patent Document 1, the area in front of the nozzle must be heated in order to laminate subsequent layers onto the heated, already-prepared layer. Therefore, each time the nozzle's movement direction changes, the energy source must be moved to a position that can heat the area in front of the nozzle, potentially complicating control. Summary of the Invention

[0005] According to a first aspect of the present disclosure, a three-dimensional modeling apparatus is provided. The three-dimensional modeling apparatus comprises: a plasticizing unit that plasticizes a material to generate a modeling material; a stage on which the modeling material is stacked; a nozzle having a nozzle opening that ejects the modeling material from the nozzle opening toward a modeling area on the stage; a moving mechanism capable of changing the relative position of the nozzle and the stage; and a heating unit having a heater and a heating element that heats the modeling material stacked in the modeling area using heat supplied from the heater, the nozzle opening being located between the stage and the heating unit in the direction in which the modeling material is stacked, the heating unit being configured to change its relative position with the stage together with the nozzle, and the heating element covering at least the modeling area when viewed along the stacking direction.

[0006] According to a second aspect of the present disclosure, a method for manufacturing a three-dimensional object is provided. The method includes a stacking step, wherein a nozzle having a nozzle opening is moved relative to a stage, and a modeling material is ejected from the nozzle opening to a modeling area on the stage to plasticize the material, thereby stacking layers of the modeling material in the modeling area. In the stacking step, a heating element disposed above the nozzle opening is moved relative to the stage together with the nozzle, and the heating element heats the modeling material stacked in the modeling area. The heating element covers at least the modeling area when viewed along the stacking direction of the modeling material. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 This is a first diagram showing a schematic configuration of a three-dimensional modeling apparatus in a first embodiment.

[0008] Figure 2 This is a second diagram showing a schematic configuration of the three-dimensional modeling apparatus in the first embodiment.

[0009] Figure 3 It is a schematic perspective view showing the structure of the groove forming surface side of the screw.

[0010] Figure 4 It is a plan view showing the structure of the opposing surface side of the cylindrical body.

[0011] Figure 5 It is a diagram showing the structure of the lower surface side of the heating unit.

[0012] Figure 6 It is a diagram showing the structure of the upper surface side of the heating unit.

[0013] Figure 7 This is a first schematic diagram showing the positional relationship between the heating unit and the stage.

[0014] Figure 8 This is a second schematic diagram showing the positional relationship between the heating unit and the stage.

[0015] Figure 9 It is a flowchart of three-dimensional modeling processing.

[0016] Figure 10 This is a diagram showing an example of how a three-dimensional object is formed.

[0017] Figure 11 It is a diagram showing the structure of the lower surface side of the heating unit in the second embodiment.

[0018] Explanation of symbols

[0019] 20…Material supply unit; 20a…First material supply unit; 20b…Second material supply unit; 22…Supply path; 30…Plasticizing unit; 30a…First plasticizing unit; 30b…Second plasticizing unit; 31…Screw housing; 32…Drive motor; 40…Screw; 41…Upper surface; 42…Groove-forming surface; 43…Side; 44…Material inlet; 45…Groove; 46…Ribbon; 47…Center; 50…Cylinder; 52…Opposing surface; 54…Guide groove; 56…Connecting Through hole; 58…Plasticizing heater; 58a…First plasticizing heater; 58b…Second plasticizing heater; 61…Nozzle; 61a…First nozzle; 61b…Second nozzle; 62…Nozzle opening; 62a…First nozzle opening; 62b…Second nozzle opening; 63…Front end face; 63a…First front end face; 63b…Second front end face; 65…Nozzle flow path; 100…Three-dimensional molding device; 200…Molding section; 200a…First molding section; 200b…Second molding section Molded portion; 210…fixing member; 211…fixing plate; 215…tilting plate; 216…upper screw; 217…lower screw; 220…rotating plate; 221…pin; 222…groove; 223…rotation adjustment screw; 225…support arm; 300…stage; 311…stage upper surface; 400…moving mechanism; 410…first electric actuator; 420…second electric actuator; 430…third electric actuator; 431…movable portion; 500…control Part; 600, 600B…heating part; 610…heater; 611, 611B…separate heater; 620…heating component; 621…separate component; 622…central component; 623…first cutout portion; 624…second cutout portion; 625…fixing screw; 630…support portion; 631…support plate; 632…first through hole; 633…second through hole; 636…frame portion; 637…support beam; 638…connecting beam; 641…adjusting screw. DETAILED DESCRIPTION

[0020] A. First embodiment:

[0021] Figure 1 This is a first diagram showing a schematic configuration of a three-dimensional modeling apparatus 100 according to the first embodiment. Figure 2 2 is a second diagram showing a schematic configuration of the three-dimensional modeling apparatus 100 in the first embodiment. Figure 1 as well as Figure 2, arrows along the mutually orthogonal X, Y, and Z directions are shown. The X, Y, and Z directions are directions along the X-axis, Y-axis, and Z-axis, which are three mutually orthogonal spatial axes, and include both directions along one side of the X-axis, Y-axis, and Z-axis and their opposite directions. The X-axis and the Y-axis are axes along the horizontal plane, and the Z-axis is an axis along the plumb line. The -Z direction is the plumb direction, and the +Z direction is the direction opposite to the plumb direction. The -Z direction is also referred to as "down," and the +Z direction is also referred to as "up." Arrows along the X, Y, and Z directions are also shown appropriately in other figures. Figure 1 as well as Figure 2 The X, Y, and Z directions in the figure are the same as the X, Y, and Z directions in other figures. In addition, in this specification, orthogonal includes a range of 90°±10°.

[0022] The three-dimensional modeling apparatus 100 includes a modeling unit 200 , a stage 300 , a moving mechanism 400 , a control unit 500 , and a heating unit 600 .

[0023] The control unit 500 is a device that controls the overall operation of the 3D modeling apparatus 100. The control unit 500 is comprised of a computer equipped with one or more processors, memory, and an input / output interface for external signal input and output. The control unit 500 performs various functions, including the 3D modeling processing described later, by executing programs and commands loaded from a main storage device via the processor. It should be noted that, instead of being comprised of a computer, the control unit 500 can be implemented as a combination of multiple circuits that implement at least a portion of each function. The control unit 500 is sometimes referred to as an information processing device.

[0024] Under the control of the control unit 500, the molding unit 200 discharges a molding material (molded solid material into a paste) onto a molding stage 300, which serves as the base for a three-dimensional object. The molding unit 200 includes a material supply unit 20, which serves as a source of material before it is converted into molding material; a plasticizing unit 30, which plasticizes the material to produce molding material; and a nozzle 61, which discharges the produced molding material. The molding unit 200 is sometimes referred to as a head.

[0025] The three-dimensional modeling apparatus 100 of this embodiment includes a first modeling section 200a and a second modeling section 200b as modeling sections 200. The first modeling section 200a includes a first material supply section 20a as the material supply section 20, a first plasticizing section 30a as the plasticizing section 30, and a first nozzle 61a as the nozzle 61. The second modeling section 200b includes a second material supply section 20b as the material supply section 20, a second plasticizing section 30b as the plasticizing section 30, and a second nozzle 61b as the nozzle 61. In this embodiment, the first modeling section 200a and the second modeling section 200b are arranged side by side in the X direction, such that the positions of the first nozzle 61a and the second nozzle 61b in the Y direction coincide. The second modeling section 200b is located in the +X direction relative to the first modeling section 200a. The structures of the first modeling section 200a and the second modeling section 200b are identical. Hereinafter, when there is no particular distinction between the first and second modeling sections 200a and 200b, both will sometimes be referred to simply as the modeling section 200. In order to distinguish between the components of the two, the components of the first molding portion 200a are denoted by the symbol "a", and the components of the second molding portion 200b are denoted by the symbol "b".

[0026] The material supply unit 20 contains materials in the form of granules or powders. In this embodiment, ABS resin formed into granules is used as the material. The material supply unit 20 in this embodiment is composed of a hopper. Figure 2 As shown, a supply path 22 connecting the material supply part 20 and the plasticizing part 30 is provided below the material supply part 20. The material supply part 20 supplies the material to the plasticizing part 30 via the supply path 22. It should be noted that the details of the material will be described later.

[0027] like Figure 2 As shown, the plasticizing section 30 includes a screw housing 31, a drive motor 32, a screw 40 and a barrel 50. The plasticizing section 30 plasticizes at least a portion of the material supplied from the material supply section 20 to generate a fluid pasty molding material, and supplies it to the nozzle 61. "Plasticizing" refers to heating a thermoplastic material to melt it. "Melting" not only means that a thermoplastic material is heated to a temperature above its melting point and becomes liquid, but also means that a thermoplastic material is heated to a temperature above its glass transition point and softens, exhibiting fluidity. It should be noted that the screw 40 of this embodiment is a so-called flat screw, sometimes also referred to as a "vortex."

[0028] The screw housing 31 is a frame for accommodating the screw 40. A barrel 50 is fixed to the lower surface of the screw housing 31, and the screw 40 is accommodated in the space surrounded by the screw housing 31 and the barrel 50. The screw 40 has a groove forming surface 42 with a groove 45 formed on the surface opposite to the barrel 50. A drive motor 32 is fixed to the upper surface of the screw housing 31. The rotating shaft of the drive motor 32 is connected to the upper surface 41 side of the screw 40. It should be noted that the drive motor 32 may not be directly connected to the screw 40. For example, the screw 40 and the drive motor 32 may also be connected via a reducer. The drive motor 32 is driven under the control of the control unit 500.

[0029] The barrel 50 is disposed below the screw 40. The barrel 50 has an opposing surface 52 that faces the groove-forming surface 42 of the screw 40. A communication hole 56 is provided in the barrel 50 on the central axis RX of the screw 40, communicating with the nozzle flow path 65 of the nozzle 61 (described later). A plasticizing heater 58 is built into the barrel 50 at a position opposing the groove 45 of the screw 40. The temperature of the plasticizing heater 58 is controlled by the control unit 500.

[0030] Figure 3 This is a schematic perspective view showing the structure of the groove forming surface 42 side of the screw 40. The central portion 47 of the groove forming surface 42 of the screw 40 is configured as a concave portion connected to one end of the groove 45. The central portion 47 is connected to the groove 45. Figure 2 The communicating holes 56 of the cylindrical body 50 are shown facing each other. The central portion 47 intersects the central axis RX.

[0031] The groove 45 constitutes a so-called vortex groove. The groove 45 extends in a spiral shape in an arc shape from the central portion 47 toward the outer periphery of the screw 40. The groove 45 can also be configured to extend in an involute curve or a spiral shape. The groove forming surface 42 is provided with a ridge portion 46 that constitutes the side wall portion of the groove 45 and extends along each groove 45. The groove 45 continues to the material inlet 44 formed on the side surface 43 of the screw 40. The material inlet 44 is a portion that receives the material supplied via the supply path 22 of the material supply portion 20. As Figure 2 As shown, in this embodiment, three grooves 45 are formed, separated by ridges 46. It should be noted that the number of grooves 45 is not limited to three and may be one or more. The grooves 45 are not limited to a spiral shape and may also be spiral or involute curves, or may extend in an arc from the center toward the periphery.

[0032] Figure 4: This is a top view showing the structure of the opposing surface 52 side of the cylinder 50. As mentioned above, a connecting hole 56 is formed in the center of the opposing surface 52. A plurality of guide grooves 54 are formed around the connecting hole 56 of the opposing surface 52. One end of each guide groove 54 is connected to the connecting hole 56, and extends in a spiral shape from the connecting hole 56 to the outer periphery of the opposing surface 52. Each guide groove 54 has the function of guiding the molding material to the connecting hole 56. It should be noted that one end of the guide groove 54 does not have to be connected to the connecting hole 56. In addition, the guide groove 54 does not have to be formed on the cylinder 50.

[0033] like Figure 2 As shown, the nozzle 61 includes a nozzle flow path 65 and a front end face 63 having a nozzle opening 62. The nozzle flow path 65 is a flow path for the molding material formed within the nozzle 61 and is connected to the communication hole 56 of the cylindrical body 50. The front end face 63 is the surface that constitutes the front end portion of the nozzle 61 that protrudes in the -Z direction toward the stage 300. The nozzle opening 62 is provided at the end of the nozzle flow path 65 on the side that communicates with the atmosphere and is a portion where the flow path cross section of the nozzle flow path 65 is reduced. The molding material generated in the plasticizing section 30 is supplied to the nozzle 61 via the communication hole 56 and ejected from the nozzle opening 62 via the nozzle flow path 65.

[0034] like Figure 1 as well as Figure 2 As shown, the stage 300 is arranged at a position opposite to the front end face 63 of the nozzle 61. The three-dimensional modeling device 100 ejects modeling material from the nozzle opening 62 of the nozzle 61 to the modeling area on the stage 300, and stacks layers of modeling material in the modeling area, thereby modeling a three-dimensional modeled object. The modeling area refers to the area on the stage upper surface 311, which is the upper surface of the stage 300, and the area above the stage upper surface 311, where the three-dimensional modeled object is modeled. In this embodiment, the stage upper surface 311 is configured to be parallel to the X direction and the Y direction. It should be noted that the direction of stacking modeling materials is sometimes referred to as the stacking direction. The stacking direction includes both the direction along one side of the same axis and the opposite direction thereof. In this embodiment, it is the direction along the Z axis.

[0035] The moving mechanism 400 is capable of changing the relative position of the nozzle 61 and the stage 300. In the present embodiment, the moving mechanism 400 changes the relative position of the nozzle 61 and the stage 300 by moving the molding unit 200 along the Z direction, which is the stacking direction, and moving the stage 300 in a direction intersecting the stacking direction. More specifically, the moving mechanism 400 of the present embodiment changes the relative position of the nozzle 61 and the stage 300 in the Z direction by moving the molding unit 200 along the Z direction, and changes the relative position of the nozzle 61 and the stage 300 in the X and Y directions by moving the stage 300 in the X and Y directions orthogonal to the Z direction. Figure 1 As shown, the moving mechanism 400 is composed of a first electric actuator 410 that moves the stage 300 in the X direction, a second electric actuator 420 that moves the stage 300 and the first electric actuator 410 in the Y direction, and a third electric actuator 430 that moves the molding section 200 in the Z direction. More specifically, the third electric actuator 430 moves the first molding section 200a and the second molding section 200b in the Z direction by moving a movable portion 431 to which the first molding section 200a and the second molding section 200b are fixed in the Z direction.

[0036] It should be noted that the movable portion 431 is also provided with a Figure 5 as well as Figure 6 The heating unit 600 is fixed to the fixing member 210 shown. Therefore, the third electric actuator 430 of this embodiment moves the heating unit 600 along the Z direction together with the shaping unit 200 while maintaining the positional relationship between the two units. In other words, the heating unit 600 is configured to change its relative position to the stage 300 together with the nozzle 61.

[0037] Each of the aforementioned electric actuators 410 to 430 is driven under the control of the control unit 500. In other embodiments, the moving mechanism unit 400 may, for example, move the stage 300 in the Z direction and the molding unit 200 in the X and Y directions. Alternatively, the stage 300 may be moved in the X, Y, and Z directions without moving the molding unit 200. Alternatively, the molding unit 200 may be moved in the X, Y, and Z directions without moving the stage 300. It should be noted that, hereinafter, the change in the relative position of the nozzle 61 with respect to the stage 300 may sometimes be referred to as simply "movement of the nozzle 61." In this embodiment, for example, moving the stage 300 in the +X direction relative to the nozzle 61 may also be referred to as moving the nozzle 61 in the -X direction. Similarly, the change in the relative position of the molding unit 200 or the heating unit 600 (described later) with respect to the stage 300 may sometimes be referred to as simply "movement of the molding unit 200" or "movement of the heating unit 600."

[0038] Figure 5 1 and 2 are diagrams showing the structure of the lower surface side of the heating unit 600 . Figure 6 600 is a diagram showing the structure of the upper surface side of the heating unit 600. The heating unit 600 is a component for heating the molding material in the molding area stacked on the stage 300. Figure 5 as well as Figure 6 As shown, the heating portion 600 includes a heater 610 , a heating member 620 , and a support portion 630 .

[0039] The heating element 620 of this embodiment is composed of a plurality of individual elements 621 arranged in a direction intersecting the stacking direction. More specifically, the heating element 620 is composed of a total of 15 individual elements 621 arranged in a matrix of 3 rows and 5 columns. The individual elements 621 are formed of metal such as SUS. Figure 5 As shown, the individual components 621 have a rectangular plate shape, and when viewed along the Z direction, the 15 individual components 621 are arranged in a manner that forms a rectangular shape as a whole. The row direction of the rows of individual components 621 is along the direction of the Y axis, and the column direction is along the direction of the X axis. Hereinafter, the columns constituting the rows of individual components 621 are sometimes referred to as the first column C1, the second column C2, the third column C3, the fourth column C4, and the fifth column C5, from the column closest to the -X direction. In addition, the three individual components 621 constituting the nth column are sometimes collectively referred to as "the individual components 621 of the nth column." It should be noted that in Figure 6 In the figure, the shapes along the X and Y directions of the individual component 621 closest to the -X direction and closest to the +Y direction among the multiple individual components 621, and the central component 622 which is the individual component 621 located in the center in the X and Y directions are schematically shown by single-dot chain lines.

[0040] like Figure 5 as well as Figure 6As shown, the central component 622 is formed with a first cutout 623 and a second cutout 624. The first cutout 623 and the second cutout 624 are formed at the center of the central component 622 in the Y direction and at the ends of the central component 622 in the -X direction and the +X direction, respectively. The outer edges of the first cutout 623 and the second cutout 624 are formed in an arc shape. As described later, the first cutout 623 is used to insert the first nozzle 61a of the first molding section 200a into the heating section 600 along the Z direction, and the second cutout 624 is used to insert the second nozzle 61b of the second molding section 200b into the heating section 600 along the Z direction. It should be noted that, apart from the first cutout 623 and the second cutout 624, the central component 622 has the same structure as the other individual components 621. When there is no need to distinguish between the central component 622 and the other individual components 621, the central component 622 may be simply referred to as the individual component 621.

[0041] The heater 610 of this embodiment is composed of a plurality of individual heaters 611 that can be controlled individually. Figure 5 as well as Figure 6 In the figure, the shapes of the individual heaters 611 in the X and Y directions are schematically indicated by dotted lines. In this embodiment, the heater 610 is composed of five individual heaters 611. Each individual heater 611 is composed of a rubber heater having a rectangular plate shape, and is arranged along the X direction corresponding to the columns of the individual components 621 described above, with the longitudinal direction facing the Y direction. In more detail, as shown in FIG. Figure 5 As shown, the individual heaters 611 are arranged in the +Z direction of the individual components 621 so as to span the three individual components 621 forming each column of the individual components 621. Each individual heater 611 is electrically connected to the control unit 500 via wiring (not shown), and is individually temperature-controlled by the control unit 500. In this embodiment, the individual heater 611 corresponding to the individual components 621 in the nth column may also be referred to as the "nth column individual heater 611."

[0042] The heating element 620 uses heat supplied from the heater 610 to heat the molding material stacked in the molding area on the stage 300. In this embodiment, each individual heater 611 supplies heat to the individual elements 621. More specifically, in this embodiment, the individual heaters 611 in the nth column heat the three individual elements 621 that make up the nth column, thereby supplying heat to these three individual elements 621. The heat supplied from the individual heaters 611 to the individual elements 621 is then transferred to the molding material stacked in the molding area, thereby heating the molding material stacked in the molding area.

[0043] Figure 5 as well as Figure 6 The support portion 630 shown is a member for supporting the heater 610 and the heating member 620. The support portion 630 of this embodiment includes a rectangular plate-shaped support plate 631 that supports the heater 610 and the heating member 620, and a frame portion 636 that supports the support plate 631.

[0044] like Figure 6 As shown, the support plate 631 has a rectangular plate shape. The support plate 631 is formed of a metal such as SUS. The above-mentioned individual heater 611 is bonded to the -Z direction surface of the support plate 631. The above-mentioned individual component 621 is fixed to the support plate 631 by fixing screws 625 in such a way that the individual heater 611 is clamped in the Z direction by the individual component 621 and the support plate 631. Figure 5 as well as Figure 6 As shown in FIG. 6 , the fixing screws 625 are provided at positions that do not overlap with the individual heater 611 when viewed along the X direction. In this embodiment, four fixing screws 625 are provided for one individual component 621 .

[0045] In this embodiment, the individual component 621 can be removed from the support plate 631 by loosening all four fixing screws 625 provided on the individual component 621. Furthermore, an individual component 621 that is the same as or different from the removed individual component 621 can be fixed to the portion of the support plate 631 from which the individual component 621 was removed using the four fixing screws 625. In other words, the heating unit 600 of this embodiment is configured so that each individual component 621 can be individually attached and detached.

[0046] like Figure 5 as well as Figure 6 As shown, a first through-hole 632 and a second through-hole 633, both having a circular cross-sectional shape, are formed in the center portion of the support plate 631 in the Y direction. When viewed in the Z direction, with the central member 622 fixed to the support plate 631, a portion of the outer edge of the first through-hole 632 overlaps with the outer edge of the first cutout 623 formed in the central member 622. Similarly, a portion of the outer edge of the second through-hole 633 overlaps with the outer edge of the second cutout 624. Like the first cutout 623 described above, the first through-hole 632 is used to insert the first nozzle 61a into the heating unit 600 in the Z direction. Like the second cutout 624, the second through-hole 633 is used to insert the second nozzle 61b into the heating unit 600 in the Z direction.

[0047] like Figure 6As shown, the frame portion 636 is arranged in the +Z direction of the support plate 631. The frame portion 636 includes a pair of support beams 637 extending in the X direction to support both ends of the support plate 631 in the Y direction, and a pair of connecting beams 638 extending in the Y direction to connect the support beams 637. The support plate 631 is fixed to the support beams 637 via fittings (not shown).

[0048] The heating unit 600 of this embodiment has an individual adjustment unit that can adjust the distance between each individual component 621 and the stage 300 for each individual component 621. In this embodiment, the fixing screws 625 and Figure 5 The adjustment screws 641 shown function as individual adjustment units. Each adjustment screw 641 consists of a set screw that penetrates the individual component 621 in the Z direction. Five adjustment screws 641 are provided at both ends of each individual component 621 in the X direction, spaced evenly apart in the Y direction. Each adjustment screw 641 is positioned so that it does not overlap with the fixing screw 625 or the individual heater 611 when viewed in the Z direction. When the individual component 621 is secured to the support plate 631, the adjustment screws 641 are used with their tips in the +Z direction in contact with the lower surface of the support plate 631.

[0049] By rotating the adjustment screw 641 and changing the length of the portion of the adjustment screw 641 protruding in the +Z direction relative to the individual component 621, the position of the individual component 621 relative to the support plate 631 can be changed. More specifically, after loosening the fixing screw 625, the adjustment screw 641 is rotated to change the position of the individual component 621 relative to the support plate 631. By tightening the fixing screw 625 again, the individual component 621 can be fixed to the support plate 631 with the position of the individual component 621 relative to the support plate 631 changed. Thus, in this embodiment, the fixing screw 625 and the adjustment screw 641 allow the distance between each individual component 621 and the stage 300 to be adjusted for each individual component 621. Hereinafter, the length of the portion of the adjustment screw 641 protruding in the +Z direction relative to the individual component 621 will sometimes be referred to as the protrusion amount of the adjustment screw 641. It should be noted that the individual adjustment unit can also be used to adjust the tilt of each individual component 621 relative to the stage 300. For example, while fixing the protrusion of the adjustment screw 641 provided at the end in the -X direction of a separate component 621, the inclination of the separate component 621 relative to the stage 300 can be adjusted in the X direction by changing the protrusion of the adjustment screw 641 provided at the end in the +X direction.

[0050] As described above, the heating unit 600 of this embodiment is fixed to the movable unit 431 via the fixing member 210. Figure 5 as well as Figure 6 As shown, the fixing member 210 comprises a fixing plate 211, an inclined plate 215, a rotating plate 220 and a pair of supporting arms 225. The fixing plate 211 is fixed to Figure 1 The tilting plate 215 is fixed to the fixed plate 211 so that the tilt of the tilting plate 215 relative to the Y-axis and the Z-axis can be adjusted. The rotating plate 220 is fixed to the tilting plate 215 so that the tilt of the rotating plate 220 relative to the X-axis and the Z-axis can be adjusted. The support arms 225 are fixed to the rotating plate 220. The connecting beams 638 of the support portion 630 described above are fixed to each support arm 225.

[0051] like Figure 6 As shown, the tilting plate 215 is fixed to the fixed plate 211 by a pair of upper screws 216 and a pair of lower screws 217, allowing adjustment of the tilt of the tilting plate 215 relative to the Y-axis and the Z-axis. An upper screw 216 is provided at each end of the tilting plate 215 in the X direction. A lower screw 217 is provided at each end of the tilting plate 215 in the X direction, one in the -Z direction. Rotating the pair of upper screws 216 adjusts the distance between the +Z-direction end of the tilting plate 215 and the fixed plate 211, while rotating the pair of lower screws 217 adjusts the distance between the -Z-direction end of the tilting plate 215 and the fixed plate 211. Therefore, for example, by rotating the lower screws 217 while the upper screws 216 are fixed, or by rotating the lower screws 217 while the lower screws 217 are fixed, the tilt of the tilting plate 215 relative to the fixed plate 211 can be changed, allowing adjustment of the tilt of the tilting plate 215 relative to the Y-axis and the Z-axis.

[0052] The rotating plate 220 is secured to the tilting plate 215 via a pin 221, four slots 222, and four rotation adjustment screws 223 corresponding to each slot 222, allowing adjustment of the rotating plate 220's tilt relative to the X- and Z-axes. The pin 221 is provided to penetrate the X- and Y-center portions of the rotating plate 220 and the X- and Y-center portions of the tilting plate 215 in the Y-direction. Two slots 222 are formed at each end of the rotating plate 220 in the X-direction, penetrating the rotating plate 220 in the Z-direction. Rotation adjustment screws 223 are inserted into each slot 222 to secure the rotating plate 220 and the tilting plate 215. The slots 222 are shaped to form a portion of an arc in the X- and Z-directions, centered at the portion where the pin 221 is located. Therefore, when each rotation adjustment screw 223 is loosened, the rotating plate 220 can be rotated about the pin 221, adjusting its tilt relative to the X- and Z-axes. Furthermore, by tightening the rotation adjustment screws 223 again, the rotating plate 220 can be fixed in a state where the inclination of the rotating plate 220 relative to the X-axis and the Z-axis is changed.

[0053] The fixing member 210 of this embodiment functions as an adjustment mechanism capable of adjusting the tilt of the heating member 620 relative to the stage 300. More specifically, by changing the tilt of the tilt plate 215 relative to the Y and Z axes, the tilt of the rotating plate 220, the support arm 225, the frame 636, and the support plate 631 relative to the Y and Z axes changes. This causes the overall tilt of the heating member 620, which is fixed to the support plate 631, relative to the stage 300 to change in the Y and Z directions. Furthermore, by changing the tilt of the rotating plate 220 relative to the X and Z axes, the tilt of the support arm 225, the frame 636, and the support plate 631 relative to the X and Z axes changes. This causes the overall tilt of the heating member 620 relative to the stage 300 to change in the X and Z directions. Thus, the fixing member 210, functioning as an adjustment mechanism, can adjust the tilt of the entire heating member 620 relative to the stage 300.

[0054] like Figure 2As shown, the nozzle opening 62 is located between the stage 300 and the heating section 600 in the Z direction. In other words, the heating section 600 is located above the first nozzle opening 62a and the second nozzle opening 62b. More specifically, the first shaping section 200a is configured such that the first nozzle 61a penetrates the heating section 600 in the Z direction via the first through-hole 632 and the first cutout 623. The portion including the first front end face 63a of the first nozzle 61a is located in the -Z direction of the heating section 600. Similarly, the second shaping section 200b is configured such that the second nozzle 61b penetrates the heating section 600 in the Z direction via the second through-hole 633 and the second cutout 624. The portion including the second front end face 63b of the second nozzle 61b is located in the -Z direction of the heating section 600. Furthermore, in this embodiment, the heating section 600 is located between the plasticizing heater 58 and the nozzle opening 62 in the Z direction. In other words, the heating portion 600 is located below the first plasticizing heater 58 a of the first plasticizing portion 30 a and below the second plasticizing heater 58 b of the second plasticizing portion 30 b .

[0055] It should be noted that in this embodiment, the heating unit 600 is configured such that the individual component 621 closest to the stage 300 in the Z direction among the individual components 621 is located above the nozzle opening 62. For example, the heating unit 600 may be configured such that the mechanical unit is adjusted to tilt the heating component 620 as a whole to position its ends in the X and Y directions closest to the stage 300. The individual adjustment unit is then used to position the individual component 621 at its end closest to the stage 300. In this case, the individual component 621 at its end will also be closer to the +Z direction than the nozzle opening 62.

[0056] The heating member 620 is configured to cover at least the molding area on the stage 300 when viewed along the Z direction. More specifically, the heating member 620 is configured to cover at least the molding area when viewed along the Z direction, regardless of how the moving mechanism 400 changes the relative position of the heating member 600 and the stage 300.

[0057] Figure 7 This is a first schematic diagram showing an example of the positional relationship between the heating unit 600 and the stage 300 . Figure 8 This is a second schematic diagram illustrating an example of the positional relationship between the heating unit 600 and the stage 300 . Figure 7 The figure shows a state where the shaping unit 200 of this embodiment is closest to the stage 300 in the -X direction. Figure 8 FIG. 2 shows a state where the molding unit 200 is closest to the +X direction relative to the stage 300. Figure 7 as well as Figure 8 In FIG, the range Mx of the shaping area in the X direction of this embodiment is indicated by a solid arrow. Figure 7 In the example of , when viewed along the Z direction, the second nozzle opening 62b of the second nozzle 61b is located at a position overlapping with the end of the range Mx in the -X direction. Figure 8 In the example of , when viewed along the Z direction, the first nozzle opening 62a of the first nozzle 61a is located at a position overlapping with the end of the range Mx in the +X direction. Figure 7 as well as Figure 8 , one end Eg1 and the other end Eg2 of the heating member 620 in the X direction are indicated by dotted lines. The one end Eg1 is located in the +X direction of the other end Eg2.

[0058] like Figure 7 as well as Figure 8 As shown, regardless of how the moving mechanism 400 changes the relative position of the heating unit 600 and the stage 300 in the X direction, the X-direction range Mx of the modeling area remains between one end Eg1 and the other end Eg2 in the X direction. In other words, regardless of how the moving mechanism 400 changes the relative position of the heating unit 600 and the stage 300 in the X direction, the modeling area remains positioned between one end Eg1 and the other end Eg2 in the X direction. In other words, the modeling area is positioned inward of the outer periphery of the heating element 620 in the X direction. Similarly, although not shown in the figure, the modeling area is also positioned inward of the outer periphery of the heating element 620 in the Y direction.

[0059] Figure 9 3D modeling processing of the method for manufacturing a three-dimensional object is shown in FIG. 3D modeling processing is executed when the control unit 500 receives a start operation from the user.

[0060] In step S110, the control unit 500 acquires modeling data from an external computer, recording medium, or the like. The modeling data includes modeling path data indicating the movement path of the nozzle 61 for forming each layer of the three-dimensional object. The modeling path data is associated with injection amount data indicating the injection amount of the material ejected from the nozzle 61.

[0061] In step S120, the control unit 500 controls the molding unit 200 and the moving mechanism 400 based on the molding data acquired in step S110 to stack layers of molding material in the molding area on the stage 300, thereby molding a three-dimensional object. More specifically, in step S120, the control unit 500 controls the moving mechanism 400 to move the nozzle 61 relative to the stage 300 while simultaneously ejecting the molding material generated by controlling the plasticizing unit 30 from the nozzle opening 62 into the molding area on the stage 300, thereby stacking layers of molding material in the molding area. Step S120 is sometimes referred to as a stacking process.

[0062] Figure 101 is a diagram showing an example of how a three-dimensional object OB is formed. Figure 10 Indicates Figure 9 In the stacking process of step S120 shown in FIG. 1 , the fifth layer Ly5 is stacked on the fourth layer Ly4 of the three-dimensional object OB. Figure 10 In FIG, the position of the individual heater 611 is schematically indicated by a dotted line and a hatched line tilted upward to the right. Figure 10 In, with Figure 7 as well as Figure 8 Similarly, the range Mx of the molding area in the X direction of this embodiment is indicated by a solid arrow. When stacking the nth layer, the control unit 500 controls the heating unit 600 to heat the molding material constituting the n-1th layer using the heating component 620 while spraying the molding material onto the n-1th layer, which is the layer already stacked in the molding area on the stage 300. As a result, the adhesion between the nth layer and the n-1th layer is improved, thereby improving the strength of the three-dimensional molding object OB. Figure 10 In the example shown in FIG. 1 , since the modeling material for forming the fifth layer Ly5 is ejected onto the heated fourth layer Ly4, the adhesion between the fourth layer Ly4 and the fifth layer Ly5 is improved. It should be noted that in this embodiment, when the first layer is stacked directly above the stage upper surface 311, the control unit 500 uses the heating member 620 to heat the stage upper surface 311. This prevents warping caused by the modeling material ejected onto the stage upper surface 311 from rapidly cooling, thereby improving the modeling accuracy of the three-dimensional object OB.

[0063] In step S120, the control unit 500 of this embodiment controls the individual heaters 611 among the plurality of individual heaters 611 to supply heat to at least the individual component 621 covering the molding area when viewed along the Z direction, thereby heating the molding material stacked in the molding area. More specifically, the control unit 500 of this embodiment controls the minimum individual heaters 611 for heating the molding material using the individual component 621 covering the molding area when viewed along the Z direction. For example, Figure 10In the example shown in FIG. 3 , the molding area is covered by the individual components 621 in the third row C3 and the individual components 621 in the fourth row C4. In this case, the control unit 500 of this embodiment activates only the individual heaters 611 in the third row C3 and the individual heaters 611 in the fourth row C4, heating the molding material stacked in the molding area using only the individual components 621 in the third row C3 and the fourth row C4. For example, the control unit 500 pre-stores the relationship between the control values associated with the movement of the stage 300 in the X and Y directions by the movement mechanism 400 and the positions of each individual component 621 in the X and Y directions. Based on this relationship, the control unit 500 individually controls the individual heaters 611. This allows the individual components 621 to heat the entire molding area while controlling only a minimum number of individual heaters 611. In other embodiments, the control unit 500 may activate all individual heaters 611 in step S120, for example, to supply heat from the individual heaters 611 to all individual components 621, thereby heating the molding area.

[0064] The three-dimensional modeling apparatus 100 of the present embodiment described above includes a heating unit 600 having a heater 610 and a heating element 620. The nozzle opening 62 is located between the stage 300 and the heating unit 600 in the Z direction. The heating unit 600 is configured to change its relative position to the stage 300 along with the nozzle 61, and the heating element 620 covers at least the modeling area. This configuration allows the heating element 620 to heat the modeling material stacked in the modeling area regardless of the relative position of the nozzle 61 and the stage 300 in the X and Y directions. Therefore, the modeling material stacked in the modeling area can be heated through simple control, and the modeling material can be ejected onto the heated modeling material layer to form a three-dimensional object. Furthermore, compared to a configuration in which the heating unit 600 is located between the nozzle opening 62 and the stage 300 in the Z direction, the modeling material stacked in the modeling area is less likely to come into contact with the heating unit 600, thereby increasing the likelihood of achieving high-precision modeling of a three-dimensional object.

[0065] In this embodiment, the heating member 620 is composed of a plurality of individual members 621 arranged in a direction intersecting the stacking direction. Therefore, compared with a case where the heating member 620 is composed of a single member, deformation or damage of the entire heating member 620 can be suppressed.

[0066] Furthermore, in this embodiment, the heater 610 is composed of a plurality of individually controllable individual heaters 611, and each individual heater 611 supplies heat to the individual component 621. Therefore, by individually controlling the individual heaters 611, the likelihood of efficiently heating the molding material stacked in the molding area by the individual components 621 increases.

[0067] Furthermore, in this embodiment, when shaping a three-dimensional object, the control unit 500 controls the individual heaters 611 to supply heat to at least the individual components 621 that cover the shaping area when viewed in the Z direction, thereby heating the shaping material stacked in the shaping area. Therefore, the heat supplied from the individually controlled individual heaters 611 to the individual components 621 heats the shaping material stacked in the shaping area regardless of the relative positions of the nozzle 61 and the stage 300 in the X and Y directions. Furthermore, by controlling the minimum number of individual heaters 611 required to heat the shaping material, for example, using the individual components 621 that cover the shaping area when viewed in the Z direction, the shaping material stacked in the shaping area can be heated more efficiently.

[0068] Furthermore, in this embodiment, the heating unit 600 includes an individual adjustment unit that can adjust the distance between each individual component 621 and the stage 300 for each individual component 621. This allows the individual adjustment unit to adjust the distance between each individual component 621 and the stage 300 for each individual component 621. Therefore, even if the heating unit 600 is locally deformed, for example, the individual adjustment unit can be used to adjust the distance between each individual component 621 and the stage 300, thereby maintaining a uniform distance between each individual component 621 and the stage 300 throughout the heating unit 620. This increases the likelihood that the individual components 621 can uniformly heat the molding material stacked in the molding area, regardless of the relative position of the nozzle 61 and the stage 300 in the X and Y directions. This improves the likelihood that a three-dimensional object can be molded with high precision.

[0069] In this embodiment, the heating unit 600 is configured to be able to individually attach and detach individual components 621. Therefore, for example, only an individual component 621 that has been stained or deformed can be removed from the heating unit 600, and a new individual component 621 or an individual component 621 that has been free of stains or deformations can be attached to the heating unit 600.

[0070] Furthermore, in this embodiment, the heating unit 600 is arranged so that the individual components 621 closest to the stage 300 are positioned above the nozzle opening 62. This reduces the likelihood that the molding material stacked in the molding area will come into contact with the individual components 621, thereby increasing the likelihood of molding a three-dimensional object with high precision.

[0071] Furthermore, this embodiment includes an adjustment mechanism configured to adjust the inclination of the heating element 620 relative to the stage 300. This allows the adjustment mechanism to adjust the inclination of the entire heating element 620 relative to the stage 300. Therefore, for example, if the entire heating element 600 is tilted relative to the stage 300, the adjustment mechanism can be used to adjust the inclination of the entire heating element 620 relative to the stage 300, thereby making the distance between the entire heating element 620 and the stage 300 uniform. This increases the likelihood that the individual element 621 can uniformly heat the molding material stacked in the molding area, regardless of the relative position of the nozzle 61 and the stage 300 in the X and Y directions. This improves the likelihood that a three-dimensional object can be molded with high precision.

[0072] In addition, in this embodiment, the plasticizing section 30 includes a flat screw, a barrel 50, and a plasticizing heater 58. Therefore, the entire three-dimensional modeling apparatus 100 can be miniaturized.

[0073] Furthermore, in this embodiment, the heating unit 600 is located between the plasticizing heater 58 and the nozzle opening 62 in the Z direction. Therefore, for example, compared to a configuration in which the plasticizing heater 58 is located between the nozzle opening 62 and the heating unit 600 in the Z direction, the influence of the heat of the plasticizing heater 58 on the molding material stacked in the molding area can be suppressed.

[0074] Furthermore, in this embodiment, the moving mechanism 400 changes the relative position of the nozzle 61 and the stage 300 by moving the nozzle 61 in the Z direction relative to the stage 300 and the stage 300 in the X and Y directions relative to the nozzle 61. This allows the relative position of the nozzle 61 and the stage 300 to be changed without moving the heating member 620, which is configured to cover the molding area when viewed in the Z direction, in the X and Y directions relative to the stage 300. Consequently, the moving mechanism 400 allows for more stable change in the relative position of the nozzle 61 and the stage 300. In particular, even if the heating member 620 is increased in size in the X and Y directions to cover the molding area, increasing its weight, the relative position of the nozzle 61 and the stage 300 can be changed more stably.

[0075] Here, the materials used to create three-dimensional objects in the three-dimensional modeling apparatus 100 described above will be described. In the three-dimensional modeling apparatus 100, various materials, such as thermoplastic materials, metal materials, and ceramic materials, can be used as the main material to create three-dimensional objects. Here, the term "main material" refers to the material that forms the core of the three-dimensional object's shape and constitutes at least 50% by weight of the three-dimensional object. These modeling materials include materials formed by melting these main materials in their pure form, and materials formed into a paste by melting a portion of the components contained along with the main material.

[0076] When a thermoplastic material is used as the main material, the plasticizing section 30 plasticizes the material to produce a modeling material.

[0077] As the material having thermoplasticity, for example, the following thermoplastic resin material can be used.

[0078] <Examples of thermoplastic resin materials>

[0079] General engineering plastics such as polypropylene resin (PP), polyethylene resin (PE), polyacetal resin (POM), polyvinyl chloride resin (PVC), polyamide resin (PA), acrylonitrile butadiene styrene resin (ABS), polylactic acid resin (PLA), polyphenylene sulfide resin (PPS), polyetheretherketone (PEEK), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, polyethylene terephthalate, and engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone.

[0080] In addition to pigments, metals, and ceramics, the thermoplastic material may also contain additives such as wax, flame retardants, antioxidants, and heat stabilizers. The thermoplastic material is plasticized in the plasticizing section 30 by the rotation of the screw 40 and the heating of the plasticizing heater 58, and is converted into a molten state.

[0081] The thermoplastic material is preferably heated to a temperature not lower than its glass transition point and is completely melted before being ejected from the nozzle 61. For example, when ABS resin is used, the temperature when ejected from the nozzle 61 is preferably about 200°C.

[0082] In the three-dimensional modeling apparatus 100, for example, the following metal material can be used as the main material instead of the aforementioned thermoplastic material. In this case, it is preferable to mix the following metal material into a powder material obtained by pulverizing the material, with a component that melts when the modeling material is generated, and then feed the material MR into the plasticizing unit 30.

[0083] <Examples of Metal Materials>

[0084] A single metal of magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or an alloy containing one or more of these metals.

[0085] <Examples of the alloys>

[0086] Maraging steel, stainless steel, cobalt-chromium-molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt-chromium alloy.

[0087] In the three-dimensional modeling apparatus 100, a ceramic material can be used as the main material instead of the aforementioned metal material. Examples of ceramic materials include oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, and zirconium oxide, and non-oxide ceramics such as aluminum nitride. When using the aforementioned metal or ceramic material as the main material, the modeling material ejected onto the stage 300 can also be solidified by sintering.

[0088] The powdered metal or ceramic material fed into the material supply unit 20 as the material MR may be a mixture of a single metal powder, an alloy powder, or a plurality of ceramic powders. Furthermore, the powdered metal or ceramic material may be coated with, for example, the thermoplastic resins listed above or other thermoplastic resins. In this case, the thermoplastic resin may be melted in the plasticizing unit 30 to exhibit fluidity.

[0089] For example, the following solvents may be added to the powder material of the metal material or ceramic material fed as the material MR into the material supply unit 20. As the solvent, one or more solvents selected from the following can be used.

[0090] <Examples of Solvents>

[0091] Water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetates such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and isobutyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and 2,6-lutidine; tetraalkylammonium acetates (for example, tetrabutylammonium acetate); ionic liquids such as butyl carbitol acetate, and the like.

[0092] Furthermore, for example, the following binder may be added to the powder material of the metal material or ceramic material fed into the material supply unit 20 as the material MR.

[0093] <Examples of Adhesives>

[0094] Acrylic resin, epoxy resin, silicone resin, cellulose resin or other synthetic resin or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyetheretherketone) or other thermoplastic resin.

[0095] B. Second embodiment:

[0096] Figure 11 : is a diagram showing the structure of the lower surface side of the heating unit 600B of the three-dimensional modeling apparatus 100 in the second embodiment. In this embodiment, the individual heaters 611B of the heater 610B constituting the heating unit 600B are provided corresponding to the individual components 621. Figure 11 In the above Figure 5 as well as Figure 6 Likewise, the shapes of the individual heater 611B in the X and Y directions are schematically indicated by dotted lines. The structure of the three-dimensional modeling apparatus 100 is the same as that of the first embodiment except for portions not specifically described.

[0097] In this embodiment, individual heaters 611B are provided in a one-to-one correspondence with individual components 621. That is, in this embodiment, 15 individual heaters 611B are provided corresponding to each of the 15 individual components 621. As in the first embodiment, one individual heater 611B is provided in the +Z direction of each individual component 621.

[0098] The control unit 500 Figure 9 In step S120 of the three-dimensional modeling process shown in FIG. , similarly to the first embodiment, the minimum number of individual heaters 611 for heating the modeling material is controlled by the individual components 621 that cover the modeling area on the stage 300 when viewed in the Z direction. In this embodiment, individual heaters 611B are provided corresponding to the individual components 621. Therefore, in step S120, the control unit 500 can heat the entire modeling area using the individual components 621 while controlling only a smaller number of individual heaters 611B than in the first embodiment.

[0099] The three-dimensional modeling apparatus 100 of this embodiment described above can also heat the modeling material layer stacked in the modeling area through simple control, and spray the modeling material onto the heated modeling material layer to form a three-dimensional object. In particular, in this embodiment, the individual heater 611B is provided corresponding to the individual component 621. Therefore, by independently controlling the individual heater 611B, the possibility of using the individual component 621 to effectively heat the modeling material stacked in the modeling area is further increased.

[0100] C. Other implementation methods:

[0101] (C-1) In the above embodiment, the individual heater 611 is a rectangular rubber heater. Alternatively, the individual heater 611 may be a non-rectangular plate, for example, a circular plate. Furthermore, the individual heater 611 may be a non-rubber heater, for example, a halogen heater, a nichrome wire heater, a carbon heater, or the like.

[0102] (C-2) In the above embodiment, the 15 individual components 621 are arranged in a matrix of 3 rows x 5 columns, and the individual components 621 form a rectangular shape as a whole when viewed along the Z direction. In contrast, the number of individual components 621 may not be 15, but may be 2 or more and 14 or less, or 16 or more. Furthermore, the individual components 621 may not be arranged in a matrix, and may be arranged, for example, along a single direction such as the X direction or the Y direction. Furthermore, the individual components 621 may not be configured to form a rectangular shape as a whole, and may, for example, be configured to form a circular shape, an elliptical shape, a triangle, a polygon with a pentagon or larger shape, or the like.

[0103] (C-3) In the above embodiment, the heating member 620 is composed of a plurality of individual members 621. However, the heating member 620 may be composed of a single member.

[0104] (C-4) In the above embodiment, heater 610 is composed of a plurality of individually controllable individual heaters 611. Alternatively, heater 610 may be composed of a single heater such as a rubber heater, a halogen heater, a nichrome wire heater, or a carbon heater.

[0105] (C-5) In the above embodiment, the heating unit 600 includes an individual adjustment unit. Alternatively, the heating unit 600 may not include an individual adjustment unit. Therefore, the heating unit 600 may not be configured to allow adjustment of the distance between each individual component 621 and the stage 300. In this case, for example, the individual components 621 may be fixed to the support plate 631 solely by fixing screws 625.

[0106] (C-6) In the above embodiment, the heating unit 600 is configured so that the individual member 621 can be individually attached and detached. However, the heating unit 600 may not be configured so that the individual member 621 can be individually attached and detached.

[0107] (C-7) In the above embodiment, an adjustment mechanism is provided. Alternatively, the adjustment mechanism may not be provided. Therefore, the three-dimensional modeling apparatus 100 may not be configured to adjust the inclination of the heating member 620 relative to the stage 300. In this case, for example, the heating member 600 may be fixed to the movable portion 431 of the third electric actuator 430 via a fixing member that does not function as an adjustment mechanism.

[0108] (C-8) In the above embodiment, the plasticizing section 30 includes the screw 40 (flat screw) and the barrel 50. Alternatively, the plasticizing section 30 may not include the flat screw and the barrel 50. For example, the plasticizing section 30 may include a coaxial screw, and the coaxial screw may be rotated to plasticize the material to produce the molding material.

[0109] (C-9) In the above embodiment, the three-dimensional modeling apparatus 100 includes two nozzles 61. However, the number of nozzles 61 may be one or three or more. Furthermore, while the three-dimensional modeling apparatus 100 in the above embodiment includes two modeling units 200, the number of modeling units 200 may be one or three or more. A single modeling unit 200 may also include multiple nozzles 61.

[0110] (C-10) In the above embodiment, the shaping section 200 is configured as a head that ejects a material formed into pellets. However, the shaping section 200 may be configured as a head that plasticizes a filamentous material and ejects the material.

[0111] D.Other methods:

[0112] The present disclosure is not limited to the above-mentioned embodiments and can be implemented in various ways without departing from its main purpose. For example, the present disclosure can be implemented in the following ways. In order to solve part or all of the problems of the present disclosure, or to achieve part or all of the effects of the present disclosure, the technical features in the above-mentioned embodiments corresponding to the technical features in the various methods described below can be appropriately replaced or combined. In addition, if the technical feature is not described as essential content in this specification, it can be appropriately deleted.

[0113] (1) According to the first embodiment of the present disclosure, a three-dimensional modeling device is provided. The three-dimensional modeling device comprises: a plasticizing portion that plasticizes a material to generate a modeling material; a stage for stacking the modeling material; a nozzle having a nozzle opening, from which the modeling material is ejected toward a modeling area on the stage; a moving mechanism portion that can change the relative position of the nozzle and the stage; and a heating portion having a heater and a heating component that heats the modeling material stacked in the modeling area using heat supplied from the heater. The nozzle opening is located between the stage and the heating portion in the stacking direction of the modeling material, the heating portion is configured to change its relative position with the stage together with the nozzle, and the heating component covers at least the modeling area when viewed along the stacking direction.

[0114] According to this method, the modeling material stacked in the modeling area can be heated by the heating element regardless of the relative position of the nozzle and the stage in a direction intersecting the stacking direction. Therefore, through simple control, the layers of modeling material stacked in the modeling area can be heated and the modeling material can be ejected onto the heated layers of modeling material, thereby forming a three-dimensional object.

[0115] (2) In the above embodiment, the heating member may be composed of a plurality of separate members arranged in a direction intersecting the stacking direction. According to this embodiment, deformation or damage of the entire heating member can be suppressed compared to a case where the heating member is composed of a single member.

[0116] (3) In the above embodiment, the heater may be composed of a plurality of individually controllable individual heaters, each of which supplies the heat to the individual component. According to this embodiment, by individually controlling the individual heaters, the likelihood of efficiently heating the molding material stacked in the molding area using the individual components increases.

[0117] (4) In the above embodiment, the individual heaters may be provided corresponding to the individual components. According to this embodiment, by individually controlling the individual heaters, the possibility of efficiently heating the molding material stacked in the molding area by the individual components is further increased.

[0118] (5) Alternatively, in the above-described embodiment, the three-dimensional modeling apparatus may include a control unit that controls the plasticizing unit, the moving mechanism unit, and the heating unit to model the three-dimensional modeled object. The control unit controls the individual heaters to heat the modeling material stacked in the modeling area when modeling the three-dimensional modeled object, wherein the individual heaters supply the heat to the individual components that at least cover the modeling area when viewed along the stacking direction. According to such an embodiment, the heat supplied from the individually controlled individual heaters to the individual components allows the modeling material stacked in the modeling area to be heated regardless of the relative position of the nozzle and the stage in a direction intersecting the stacking direction. In addition, for example, by activating the minimum number of individual heaters used to heat the modeling material using the individual components that cover the modeling area when viewed along the stacking direction, the modeling material stacked in the modeling area can be heated more efficiently.

[0119] (6) In the above embodiment, the heating unit may include an individual adjustment unit capable of adjusting the distance between each individual component and the stage for each individual component. According to this embodiment, the distance between each individual component and the stage can be adjusted for each individual component using the individual adjustment unit.

[0120] (7) In the above embodiment, the heating unit may be configured to allow for individual attachment and detachment of the individual components. In this embodiment, only individual components that have been stained or deformed can be removed from the heating unit, and new individual components or individual components that have been free of stains or deformations can be attached to the heating unit.

[0121] (8) In the above embodiment, the heating unit may be arranged so that the individual components closest to the stage in the stacking direction are positioned above the nozzle opening. According to this embodiment, since the molding material stacked in the molding area is less likely to come into contact with the individual components, the possibility of molding a three-dimensional object with high precision increases.

[0122] (9) In the above embodiment, the three-dimensional modeling apparatus may include an adjustment mechanism configured to adjust the inclination of the heating member relative to the stage. According to this embodiment, the adjustment mechanism can adjust the inclination of the entire heating member relative to the stage.

[0123] (10) In the above embodiment, the plasticizing section may include: a flat screw having a groove-forming surface with grooves formed thereon and capable of rotation; a barrel having an opposing surface facing the groove-forming surface and having a communicating hole formed thereon; and a plasticizing heater for heating the material supplied between the flat screw and the barrel. According to this embodiment, the entire three-dimensional modeling apparatus can be miniaturized.

[0124] (11) In the above embodiment, the heating portion may be located between the plasticizing heater and the nozzle opening in the stacking direction. According to this embodiment, compared with an embodiment in which the plasticizing heater is located between the nozzle opening and the heating portion in the stacking direction, the influence of the heat of the plasticizing heater on the molding material stacked in the molding area can be suppressed.

[0125] (12) Alternatively, in the above-described embodiment, the moving mechanism may change the relative position of the nozzle and the stage by moving the plasticizing section and the nozzle relative to the stage in the stacking direction and moving the stage in a direction intersecting the stacking direction. According to this embodiment, the relative position of the nozzle and the stage can be changed without moving the heating member, which is configured to cover at least the molding area when viewed along the stacking direction, relative to the stage in a direction intersecting the stacking direction. Therefore, the moving mechanism allows for more stable change in the relative position of the nozzle and the stage.

[0126] According to a second aspect of the present disclosure, a method for manufacturing a three-dimensional object is provided. This method includes a stacking step, wherein a nozzle having a nozzle opening is moved relative to a stage, and a modeling material is ejected from the nozzle opening into a modeling area on the stage to plasticize the material, thereby stacking layers of the modeling material in the modeling area. In the stacking step, a heating element positioned above the nozzle opening is moved relative to the stage together with the nozzle, and the heating element heats the modeling material stacked in the modeling area. The heating element covers at least the modeling area when viewed along the direction in which the modeling material is stacked.

[0127] According to this method, the modeling material stacked in the modeling area can be heated by the heating element regardless of the relative position of the nozzle and the stage in a direction intersecting the stacking direction. Therefore, through simple control, the layers of modeling material stacked in the modeling area can be heated and the modeling material can be ejected onto the heated layers of modeling material, thereby forming a three-dimensional object.

Claims

1. A three-dimensional modeling device, characterized in that: have: The plasticizing part plasticizes the material to produce the molding material; a loading platform for stacking the modeling materials; a nozzle having a nozzle opening, and spraying the modeling material from the nozzle opening toward the modeling area on the stage; a moving mechanism capable of changing the relative position of the nozzle and the stage; as well as The heating unit includes a heater and a heating member, wherein the heating member heats the molding material stacked in the molding area using heat supplied from the heater. The nozzle opening is located between the stage and the heating portion in the stacking direction of the modeling material. The heating unit is configured to change its relative position with respect to the stage together with the nozzle. The heating member covers at least the shaping area when viewed along the stacking direction. The heating member is composed of a plurality of individual members arranged in a direction intersecting the stacking direction. The three-dimensional modeling apparatus further includes an adjustment mechanism configured to adjust the inclination of the entire heating member relative to the stage so that the individual member uniformly heats the modeling material stacked in the modeling area.

2. The three-dimensional modeling device according to claim 1, characterized in that: The heater is composed of a plurality of individual heaters configured to be individually controllable. Each of the individual heaters supplies the heat to the individual component.

3. The three-dimensional modeling device according to claim 2, characterized in that: The individual heaters are provided corresponding to the individual components.

4. The three-dimensional modeling device according to claim 2 or 3, characterized in that: The three-dimensional modeling device includes a control unit that controls the plasticizing unit, the moving mechanism unit, and the heating unit to shape the three-dimensional object. When shaping the three-dimensional object, the control unit controls the separate heater to heat the shaping material stacked in the shaping area, wherein the separate heater supplies the heat to the separate component that at least covers the shaping area when viewed along the stacking direction.

5. The three-dimensional modeling device according to any one of claims 1 to 3, characterized in that: The heating unit includes an individual adjustment unit capable of adjusting the distance between each of the individual components and the stage for each of the individual components.

6. The three-dimensional modeling device according to any one of claims 1 to 3, characterized in that: The heating unit is configured so that each of the individual components can be individually attached and detached.

7. The three-dimensional modeling device according to any one of claims 1 to 3, characterized in that: The heating unit is arranged so that the individual component closest to the stage in the stacking direction among the individual components is located above the nozzle opening.

8. The three-dimensional modeling device according to any one of claims 1 to 3, characterized in that: The plasticizing part includes: a flat screw having a groove-forming surface on which grooves are formed and capable of rotating; a cylindrical body having an opposing surface facing the groove-forming surface and having a communicating hole formed on the opposing surface; as well as A plasticizing heater heats the material supplied between the flat screw and the barrel.

9. The three-dimensional modeling device according to claim 8, characterized in that: The heating portion is located between the plasticizing heater and the nozzle opening in the stacking direction.

10. The three-dimensional modeling device according to any one of claims 1 to 3, characterized in that: The moving mechanism changes the relative position of the nozzle and the stage by moving the nozzle in the stacking direction relative to the stage and moving the stage in a direction intersecting the stacking direction relative to the nozzle.

11. A method for manufacturing a three-dimensional object using the three-dimensional modeling device according to any one of claims 1 to 10, characterized in that: The method includes a stacking step of ejecting a plasticized molding material from a nozzle opening toward a molding area on the molding area while moving a nozzle having a nozzle opening relative to a stage, thereby stacking layers of the molding material in the molding area. In the stacking step, a heating member disposed above the nozzle opening is moved relative to the stage together with the nozzle, and the molding material stacked in the molding area is heated by the heating member. The heating member covers at least the molding area when viewed along the stacking direction of the molding material. The heating member is composed of a plurality of individual members arranged in a direction intersecting the stacking direction. The inclination of the entire heating member relative to the stage can be adjusted so that the individual member uniformly heats the modeling material stacked in the modeling area.

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