Three-dimensional modeling device

Abstract

A three-dimensional modeling apparatus capable of reducing the possibility of deformation of the shape of a first modeling layer in the case where a second modeling layer is formed, includes a stage, a heater, a nozzle, a moving mechanism, and a control section that performs: a first modeling layer formation process that controls the nozzle and the moving mechanism to cause the nozzle to eject modeling material and form a first modeling layer; an ejection stop process that controls the nozzle to stop the nozzle from ejecting modeling material; a determination process that determines whether a prescribed time has elapsed after the ejection stop process is performed; and a second modeling layer formation process that, in the case where it is determined in the determination process that the prescribed time has elapsed, controls the nozzle and the moving mechanism to cause the nozzle to eject modeling material and form a second modeling layer on the first modeling layer, the control section setting the prescribed time based on information related to the modeling time of the first modeling layer.

Description

TECHNICAL FIELD

[0001] The present application relates to a three-dimensional modeling device. BACKGROUND

[0002] A three-dimensional modeling device is known, which models a three-dimensional modeled object by discharging a molten material from a nozzle and causing it to accumulate and solidify. The three-dimensional modeled object is modeled as a laminate in which a plurality of modeling layers are stacked.

[0003] For example, in Patent Literature 1, a three-dimensional modeling device is described, which discharges a molten material from a nozzle while cooling the molten material by a cooling portion, thereby promoting solidification of the molten material discharged from the nozzle.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent Application Publication No. 2019-34457 SUMMARY

[0007] However, in the three-dimensional modeling device described in Patent Literature 1, since the cooling portion is provided in the vicinity of the nozzle, only the modeling layer in the vicinity of the nozzle is cooled. Therefore, if a layer currently modeled is set as an n-th layer, and a layer modeled before the n-th layer is set as an (n-1)-th layer, depending on the size of the (n-1)-th layer, it is sometimes difficult to sufficiently reduce the temperature of the (n-1)-th layer as a whole. If a molten material is discharged onto the (n-1)-th layer before the (n-1)-th layer as a whole is solidified, the shape of the (n-1)-th layer is deformed.

[0008] One embodiment of the three-dimensional modeling device according to the present application is,

[0009] The three-dimensional modeling device includes:

[0010] a stage;

[0011] a heater; a modeling region of the stage, which is opposed to the stage;

[0012] a nozzle which discharges a modeling material toward the modeling region;

[0013] a moving mechanism which relatively moves the stage and the nozzle; and

[0014] a control portion which controls the nozzle and the moving mechanism,

[0015] The control portion performs the following processing:

[0016] a first modeling layer forming processing which controls the nozzle and the moving mechanism to discharge a modeling material from the nozzle, and forms a first modeling layer;

[0017] an ejection stop process of controlling the nozzle to stop ejection of the modeling material from the nozzle;

[0018] a determination process of determining whether a predetermined time has elapsed after the ejection stop process is performed; and

[0019] a second modeling layer formation process of, in a case where it is determined in the determination process that the predetermined time has elapsed, controlling the nozzle and the moving mechanism to eject the modeling material from the nozzle to form a second modeling layer on the first modeling layer,

[0020] The control section sets the predetermined time based on information related to a modeling time of the first modeling layer. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a side view schematically showing a three-dimensional modeling apparatus according to the present embodiment.

[0022] Figure 2 is a cross-sectional view schematically showing a three-dimensional modeling apparatus according to the present embodiment.

[0023] Figure 3 is a perspective view schematically showing a union screw of a three-dimensional modeling apparatus according to the present embodiment.

[0024] Figure 4 is a plan view schematically showing a cylinder of a three-dimensional modeling apparatus according to the present embodiment.

[0025] Figure 5 is a flowchart for explaining a process of a control section of a three-dimensional modeling apparatus according to the present embodiment.

[0026] Figure 6 is a cross-sectional view for explaining a three-dimensional modeling object formation process of a three-dimensional modeling apparatus according to the present embodiment.

[0027] Figure 7 is a flowchart for explaining a process of a control section of a three-dimensional modeling apparatus according to the present embodiment.

[0028] Figure 8 is a flowchart for explaining a process of a control section of a three-dimensional modeling apparatus according to the first modified example of the present embodiment.

[0029] Figure 9 is a cross-sectional view schematically showing a three-dimensional modeling apparatus according to the second modified example of the present embodiment.

[0030] Figure 10 is a flowchart for explaining a process of a control section of a three-dimensional modeling apparatus according to the second modified example of the present embodiment.

[0031] Reference Signs List

[0032] 10: nozzle; 20: stage; 22: molding area; 30: moving mechanism; 32: first electric actuator; 34: second electric actuator; 36: third electric actuator; 40: support member; 50: heating mechanism; 52: support plate; 54: heater; 56: through-hole; 60: control section; 70: cleaning mechanism; 100: three-dimensional molding apparatus; 110: material supply section; 112: supply path; 120: plasticizing section; 122: screw housing; 124: drive motor; 126: shaft; 130: flat head screw; 131: upper surface; 132: groove forming surface; 133: side surface; 134: first groove; 135: central portion; 136: connecting portion; 137: material introduction portion; 140: barrel; 142: opposing surface; 144: second groove; 146: communication hole; 148: outer periphery; 150: heater; 160: nozzle; 162: nozzle flow path; 164: nozzle opening; 200: three-dimensional molding apparatus. DETAILED DESCRIPTION

[0033] Hereinafter, a preferred embodiment of the present application will be described in detail with reference to the accompanying drawings. Note that the embodiment described below does not unduly limit the scope of the present application described in the claims. Furthermore, not all the configurations described below are essential to the present application.

[0034] 1. Three-dimensional molding apparatus

[0035] 1.1. Overall structure

[0036] First, with reference to the drawings, a three-dimensional molding apparatus according to the present embodiment will be described. Figure 1 is a perspective view schematically showing a three-dimensional molding apparatus 100 according to the present embodiment. Figure 2 is a perspective view schematically showing a three-dimensional molding apparatus 100 according to the present embodiment. Figure 1 is a cross-sectional view taken along line II-II of Figure 1 and Figure 2 In

[0037] As shown in Figure 1 and Figure 2 , the three-dimensional molding apparatus 100 includes, for example, a nozzle 10, a stage 20, a moving mechanism 30, a support member 40, a heating mechanism 50, and a control section 60.

[0038] The three-dimensional modeling device 100 sprays plasticized modeling material from the nozzle 10 toward the stage 20, while simultaneously driving the moving mechanism 30 to change the relative position of the nozzle 10 and the stage 20. As a result, the three-dimensional modeling device 100 shapes a three-dimensional object of the desired form on the stage 20.

[0039] like Figure 2 As shown, the nozzle 10 has, for example, a material supply section 110, a plasticizing section 120, and a nozzle 160. The nozzle 10 sprays molding material toward the molding area 22 of the stage 20.

[0040] Granular or powdered material is fed into the material supply section 110. The material supply section 110 supplies the material as raw material to the plasticizing section 120. The material supply section 110 is, for example, composed of a hopper. The material supplied by the material supply section 110 is, for example, acrylonitrile butadiene styrene (ABS) resin.

[0041] The material supply unit 110 and the plasticizing unit 120 are connected by a supply path 112 provided below the material supply unit 110. The material fed into the material supply unit 110 is supplied to the plasticizing unit 120 via the supply path 112.

[0042] like Figure 2 As shown, the plasticizing section 120 includes, for example, a screw housing 122, a drive motor 124, a flat-head screw 130, a barrel 140, and a heater 150. The plasticizing section 120 plasticizes the solid material supplied from the material supply section 110 to generate a fluid, paste-like molding material, which is then supplied to the nozzle 160.

[0043] It should be noted that plasticization includes the concept of melting, which refers to the change from a solid to a fluid state. Specifically, in the case of materials undergoing a glass transition, plasticization refers to raising the material temperature above the glass transition temperature. In the case of materials not undergoing a glass transition, plasticization refers to raising the material temperature above the melting point.

[0044] The screw housing 122 is a frame that houses the flat-head screw 130. A cylindrical body 140 is provided on the lower surface of the screw housing 122. The flat-head screw 130 is housed in the space surrounded by the screw housing 122 and the cylindrical body 140.

[0045] A drive motor 124 is mounted on the upper surface of the screw housing 122. The drive motor 124 is, for example, a servo motor. The shaft 126 of the drive motor 124 is connected to the upper surface 131 of the flat-head screw 130. The drive motor 124 is controlled by the control unit 60. It should be noted that, although not shown in the figure, the shaft 126 of the drive motor 124 can also be connected to the upper surface 131 of the flat-head screw 130 via a speed reducer.

[0046] The flat head screw 130 has a substantially cylindrical shape in which the size in the direction of the rotation axis R is smaller than the size in the direction orthogonal to the direction of the rotation axis R. In the illustrated example, the rotation axis R is parallel to the Z axis. The flat head screw 130 is rotated about the rotation axis R by the torque generated by the drive motor 124.

[0047] The flat head screw 130 has an upper surface 131, a groove forming surface 132 on the opposite side of the upper surface 131, and a side surface 133 connecting the upper surface 131 and the groove forming surface 132. The first groove 134 is formed on the groove forming surface 132. The side surface 133 is, for example, perpendicular with respect to the groove forming surface 132. Here, Figure 3 is a perspective view schematically showing the flat head screw 130. Note that, for convenience, in Figure 3 , the positional relationship between the upper and lower sides is shown in a state opposite to that shown in Figure 2

[0048] As shown in Figure 3 , the first groove 134 is formed on the groove forming surface 132 of the flat head screw 130. The first groove 134 has, for example, a central portion 135, a connecting portion 136, and a material introduction portion 137. The central portion 135 is opposed to the communication hole 146 formed in the cylinder 140. The central portion 135 communicates with the communication hole 146. The connecting portion 136 connects the central portion 135 and the material introduction portion 137. In the illustrated example, the connecting portion 136 is provided in a spiral shape from the central portion 135 toward the outer periphery of the groove forming surface 132. The material introduction portion 137 is provided at the outer periphery of the groove forming surface 132. That is, the material introduction portion 137 is provided on the side surface 133 of the flat head screw 130. The material supplied from the material supply portion 110 is introduced into the first groove 134 from the material introduction portion 137, and is transported to the communication hole 146 formed in the cylinder 140 through the connecting portion 136 and the central portion 135. The first groove 134 is provided with two, for example.

[0049] Note that the number of the first grooves 134 is not particularly limited. Although not shown, the first grooves 134 can be provided three or more, or only one. In addition, although not shown, the three-dimensional modeling device 100 can have a coaxial screw instead of the flat head screw 130.

[0050] As shown in Figure 2 , the cylinder 140 is provided below the flat head screw 130. The cylinder 140 has an opposite surface 142 opposed to the groove forming surface 132 of the flat head screw 130. The communication hole 146 communicating with the first groove 134 is formed at the center of the opposite surface 142. Here, Figure 4 is a plan view schematically showing the cylinder 140.

[0051] As shown in Figure 4 ​As shown, a second groove 144 and a communication hole 146 are formed on the opposing surface 142 of the cylinder 140. The second groove 144 is formed in plural. In the illustrated example, six second grooves 144 are formed, but the number of the second grooves 144 is not particularly limited. The plural second grooves 144 are formed around the communication hole 146 as viewed in the Z-axis direction. One end of the second groove 144 is connected to the communication hole 146, and extends spirally from the communication hole 146 toward the outer periphery 148 of the cylinder 140. The second groove 144 has a function of introducing the plasticized material into the communication hole 146.

[0052] Note that the shape of the second groove 144 is not particularly limited, and for example, can be linear. In addition, one end of the second groove 144 can not be connected to the communication hole 146. Furthermore, the second groove 144 can not be formed on the opposing surface 142. In addition, if the plasticized material is efficiently introduced into the communication hole 146, it is preferable that the second groove 144 be formed on the opposing surface 142.

[0053] As shown, Figure 2 A heater 150 is provided on the cylinder 140. The heater 150 heats the material supplied between the flat screw 130 and the cylinder 140. The output of the heater 150 is controlled by the control section 60. The plasticizing section 120 generates the plasticized modeling material by the flat screw 130, the cylinder 140, and the heater 150, while transporting the material toward the communication hole 146 and heating the material, and causes the generated modeling material to flow out from the communication hole 146. Note that although not shown, the shape of the heater 150 can be ring-shaped as viewed in the Z-axis direction.

[0054] A nozzle 160 is provided below the cylinder 140. The nozzle 160 ejects the material supplied from the plasticizing section 120 toward the stage 20. A nozzle flow path 162 is formed on the nozzle 160. The nozzle flow path 162 communicates with the communication hole 146. The nozzle flow path 162 has a nozzle opening 164. The nozzle opening 164 is located at the front end of the nozzle 160. The material supplied from the communication hole 146 is ejected from the nozzle opening 164 through the nozzle flow path 162.

[0055] As shown, Figure 1 and Figure 2As shown, the table 20 is disposed below the nozzle 160. In the illustrated example, the table 20 has a shape of a rectangular parallelepiped. The table 20 has a modeling area 22. The modeling material is ejected from the head 10 toward the modeling area 22. The modeling area 22 is a region of an upper surface of the table 20. The modeling area 22 is defined by the position of the nozzle opening 164 of the head 10. For example, in a case where the table 20 is moved by the moving mechanism 30 in the X-axis direction and the Y-axis direction, an end portion of the modeling area 22 in the -X-axis direction is located below the nozzle opening 164 when the table 20 is moved most in the +X-axis direction. An end portion of the modeling area 22 in the +X-axis direction is located below the nozzle opening 164 when the table 20 is moved most in the -X-axis direction.

[0056] The moving mechanism 30 supports the table 20. The moving mechanism 30 relatively moves the table 20 and the head 10. In addition, the moving mechanism 30 relatively moves the table 20 and the heating mechanism 50. The heating mechanism 50 is moved, for example, in conjunction with the movement of the head 10. In the illustrated example, the moving mechanism 30 changes the relative positions of the table 20, the head 10, and the heating mechanism 50 in the X-axis direction and the Y-axis direction by moving the table 20 in the X-axis direction and the Y-axis direction. In addition, the moving mechanism 30 changes the relative positions of the table 20, the head 10, and the heating mechanism 50 in the Z-axis direction by moving the head 10 and the heating mechanism 50 in the Z-axis direction.

[0057] The moving mechanism 30 has, for example, a first electric actuator 32, a second electric actuator 34, and a third electric actuator 36. The first electric actuator 32 moves the table 20 in the X-axis direction. The second electric actuator 34 moves the table 20 in the Y-axis direction. The third electric actuator 36 moves the head 10 and the heating mechanism 50 in the Z-axis direction.

[0058] The support member 40 is connected to the third electric actuator 36. In the illustrated example, the support member 40 extends from the third electric actuator 36 in the -Y-axis direction. The support member 40 supports the head 10 and the heating mechanism 50. The moving mechanism 30 moves the support member 40 in the Z-axis direction by the third electric actuator 36, and moves the head 10 and the heating mechanism 50 in the Z-axis direction.

[0059] The heating mechanism 50 is, for example, generally plate-shaped. The heating mechanism 50 includes, for example, a support plate 52 and a heater 54. The heater 54 is supported by the support plate 52. The heater 54 covers the molding area 22 of the stage 20. The heater 54 is opposite to the stage 20. Viewed from the Z-axis direction, the stage 20 is, for example, located inside the outer edge of the heater 54. The heater 54 heats the molding layer composed of molding material deposited in the molding area 22. The heater 54 is capable of heating the entire molding area 22. The output of the heater 54 is controlled by the control unit 60.

[0060] like Figure 2 As shown, a through hole 56 is formed in the heating mechanism 50. In the illustrated example, the through hole 56 extends through the heating mechanism 50 in the Z-axis direction. The nozzle 160 is located in the through hole 56. In the illustrated example, the flat-head screw 130 and the cylinder 140 are located in the +Z-axis direction of the heating mechanism 50, and the nozzle opening 164 and the stage 20 are located in the -Z-axis direction of the heating mechanism 50.

[0061] It should be noted that the shape of the heating mechanism 50 is not particularly limited as long as the heater 54 can heat the modeling area 22. For example, the three-dimensional modeling device 100 has a chamber (not shown) that houses the nozzle 10, the stage 20, and the moving mechanism 30, and the heating mechanism 50 can heat the modeling area 22 by heating the entire chamber.

[0062] The control unit 60 is, for example, a computer having a processor, main storage device, and an input / output interface for inputting and outputting signals to and from the outside. The control unit 60 performs various functions, for example, by executing programs loaded into the main storage device through the processor. Specifically, the control unit 60 controls the nozzle 10, the moving mechanism 30, and the heating mechanism 50. It should be noted that the control unit 60 may not be a computer, but rather a combination of multiple circuits.

[0063] 1.2. Control Unit Processing

[0064] Figure 5 This is a flowchart illustrating the processing of the control unit 60. For example, a user operates an operation unit (not shown) to output a processing start signal to the control unit 60 to begin processing. The operation unit may consist of, for example, a mouse, keyboard, or touch panel. The control unit 60 begins processing upon receiving the processing start signal. The following describes each process.

[0065] 1.2.1. Processing of Modeling Data

[0066] First, such as Figure 5 As shown, the control unit 60 performs a modeling data acquisition process (step S10) to acquire modeling data for modeling a three-dimensional object.

[0067] For example, the modeling data is generated by causing a slicing software installed in a computer connected to the three-dimensional modeling device 100 to read in shape data. The shape data is data indicating a target shape of a three-dimensional modeled object generated using a three-dimensional CAD (Computer Aided Design) software or a three-dimensional CG (Computer Graphics) software, or the like. As the shape data, for example, data in an STL (Standard Triangulated Language) format or an AMF (Additive Manufacturing File Format), or the like is used. The slicing software divides the target shape of the three-dimensional modeled object into layers of a prescribed thickness, and generates the modeling data for each layer. The modeling data is indicated by a G code or the like.

[0068] The modeling data includes, for example, information related to a movement path of the nozzle 160 with respect to the stage 20, an amount of modeling material ejected from the nozzle 160, an area of each of a plurality of modeling layers that constitute the three-dimensional modeled object, cleaning of the nozzle 160, and the like. The "area of the modeling layer" refers to an area of the modeling layer when viewed from the Z-axis direction that is an ejection direction of the modeling material. The control section 60 acquires the modeling data from a computer connected to the three-dimensional modeling device 100, a recording medium such as a USB (Universal Serial Bus) memory, or the like.

[0069] 1.2.2 Three-Dimensional Modeled Object Formation Process

[0070] Next, the control section 60 performs a three-dimensional modeled object formation process of forming a three-dimensional modeled object on the stage 20 (step S20).

[0071] Specifically, the control section 60 causes the material supplied between the flat head screw 130 and the barrel 140 to be plasticized to generate the modeling material, and causes the modeling material to be ejected from the nozzle 160. The control section 60, for example, continues to generate the modeling material until the three-dimensional modeled object formation process ends. In addition, the control section 60 drives the heater 54. The control section 60, for example, continues to drive the heater 54 until the three-dimensional modeled object formation process ends. Here, Figure 6 is a cross-sectional view for explaining the three-dimensional modeled object formation process.

[0072] As Figure 6 indicated, based on the acquired modeling data, the control section 60 controls the movement mechanism 30 to change the relative position of the nozzle 160 with respect to the stage 20, and controls the nozzle 160 to eject the modeling material toward the stage 20.

[0073] Specifically, before the three-dimensional shaped object formation process starts, that is, before the formation of the build layer L1 as the first layer starts, the nozzle 160 is disposed closer to the initial position in the -X-axis direction than the end portion of the -X-axis direction of the stage 20. When the three-dimensional shaped object formation process starts, as shown in FIG. 1, the control section 60 relatively moves the nozzle 160 in the +X-axis direction with respect to the stage 20 by controlling the moving mechanism 30. As the nozzle 160 passes over the stage 20, the build material is ejected from the nozzle 160. Thereby, the build layer L1 is formed. Figure 6 The control section 60 controls the nozzle 160 and the moving mechanism 30 based on the build data, and performs the build layer formation process of ejecting the build material from the nozzle 160 and forming the build layer Ln-1 on the stage 20 (step S22). The control section 60 performs the build layer formation process of the build layer Ln-1 based on the build data. Figure 6 In the present embodiment, n is an arbitrary natural number, and Ln indicates the build layer up to the n-th layer.

[0074] Here, Figure 7 is a flowchart for more specifically explaining the three-dimensional shaped object formation process of the control section 60.

[0075] When the above-mentioned build data acquisition process ends, as shown in FIG. 2, the control section 60 performs the standby time setting process of setting a standby time based on information related to the build time of the n-1-th build layer Ln-1 (step S21). Figure 7 In the present embodiment, n is an arbitrary natural number, and Ln indicates the build layer up to the n-th layer.

[0076] Here, the "standby time" refers to a time during which the nozzle 10 is made to stand in a state where the ejection of the build material from the nozzle 10 is stopped in step S25 described later after the formation of the build layer Ln-1. The shorter the build time of the build layer Ln-1, the earlier the n-th build layer Ln is formed after the formation of the build layer Ln-1, and thus there is a case where the n-th build layer Ln is formed before the build layer Ln-1 is cured. Therefore, the shorter the build time of the build layer Ln-1, the longer the standby time set by the control section 60.

[0077] The information related to the build time of the build layer Ln-1 is included in the build data. The control section 60 can calculate and set the standby time from the information related to the area of the build layer Ln-1 included in the build data, or can acquire and set the standby time from the build data in a case where the build data directly includes the standby time.

[0078] Next, the control section 60 controls the nozzle 10 and the moving mechanism 30 based on the build data, and performs the build layer formation process of ejecting the build material from the nozzle 10 and forming the build layer Ln-1 on the stage 20 (step S22).

[0079] Next, the control section 60 controls the nozzle 10, and performs the ejection stop process of stopping the ejection of the build material from the nozzle 10 (step S23). Specifically, the control section 60 stops the ejection of the build material from the nozzle 10 by controlling a butterfly valve not shown which is provided on the nozzle 10.

[0080] Next, the control section 60 performs a determination process to determine whether the formation of all the modeling layers is completed based on the modeling data (step S24).

[0081] In a case where it is determined that the formation of all the modeling layers is not completed (NO in step S24), the control section 60 performs a determination process to determine whether the standby time has elapsed after the ejection stop process is performed (step S25). The "standby time" refers to the standby time set in step S21 described above.

[0082] In a case where it is determined that the standby time has not elapsed after the ejection stop process is performed (NO in step S25), the control section 60 repeats step S25 until it is determined that the standby time has elapsed after the ejection stop process is performed. On the other hand, in a case where it is determined that the standby time has elapsed after the ejection stop process is performed (YES in step S25), the control section 60 returns the process to step S21.

[0083] In a case where it is determined that the formation of all the modeling layers is completed (YES in step S24), the control section 60 ends the process.

[0084] 1.3. Effects

[0085] In the three-dimensional modeling apparatus 100, the control section 60 performs the following processes: a first modeling layer formation process of controlling the nozzle 10 and the moving mechanism 30 to eject the modeling material from the nozzle 10 to form a modeling layer Ln-1 as a first modeling layer; an ejection stop process of controlling the nozzle 10 to stop the ejection of the modeling material from the nozzle 10; a determination process of determining whether the standby time has elapsed after the ejection stop process is performed; and a second modeling layer formation process of controlling the nozzle 10 and the moving mechanism 30 to eject the modeling material from the nozzle 10 to form a modeling layer Ln as a second modeling layer on the modeling layer Ln-1 in a case where it is determined that the standby time has elapsed in the determination process. The control section 60 sets the standby time based on information related to the modeling time of the modeling layer Ln-1.

[0086] Therefore, in the three-dimensional modeling apparatus 100, it is possible to reduce the temperature of the entire modeling layer Ln-1 before the modeling layer Ln is formed. Thus, it is possible to cure the entire modeling layer Ln-1. Therefore, it is possible to reduce the possibility that the shape of the modeling layer Ln-1 is deformed in the formation of the modeling layer Ln.

[0087] Further, in the three-dimensional modeling apparatus 100, the modeling layer Ln-1 can be uniformly cooled compared to a case where the modeling layer Ln-1 is locally cooled by a cooling mechanism such as a blower mechanism. In a case where the modeling layer Ln-1 is locally cooled by the cooling section, stress caused by thermal contraction of the modeling layer Ln-1 becomes uneven. In the three-dimensional modeling apparatus 100, since the modeling layer Ln-1 is not cooled using a cooling mechanism such as a blower mechanism, the modeling layer Ln-1 can be gradually cooled, and the uniformity of stress generated in the modeling layer Ln-1 can be improved.

[0088] 2. Modification

[0089] 2.1. First Modification

[0090] Next, with reference to the drawings, a three-dimensional modeling apparatus relating to a first modification of the present embodiment will be described. Figure 8 is a flowchart for explaining a three-dimensional modeling object formation process of the control section 60 of the three-dimensional modeling apparatus relating to the first modification of the present embodiment.

[0091] Hereinafter, in the three-dimensional modeling apparatus relating to the first modification of the present embodiment, differences from the example of the three-dimensional modeling apparatus 100 relating to the present embodiment described above will be described, and the same points will be omitted. The same applies to the three-dimensional modeling apparatuses relating to the second and third modifications of the present embodiment described later.

[0092] As shown in Figure 8 , the three-dimensional modeling apparatus relating to the first modification of the present embodiment differs from the three-dimensional modeling apparatus 100 described above in that a first moving process (step S35) and a second moving process (step S37) are performed.

[0093] As shown in Figure 8 , after the standby time setting process (step S31), the modeling layer formation process (step S32), the ejection stop process (step S33), and the determination process (step S34) are performed, the control section 60 performs the first moving process (step S35) to control the moving mechanism 30 to relatively move the stage 20 and the heater 54, and increase the distance between the stage 20 and the heater 54. Specifically, the control section 60 controls the moving mechanism 30 to move the nozzle 10 and the heating mechanism 50 in the +Z-axis direction, and move the nozzle 10 and the heating mechanism 50 away from the stage 20. By the first moving process, the distance between the upper surface of the modeling layer formed on the stage 20 and the heater 54 becomes, for example, about 15 cm. Note that the contents of the processes of steps S31 to S34 are the same as those of steps S21 to S24 described above, respectively.

[0094] Next, the control section 60 performs determination processing (step S36) to determine whether the standby time has elapsed after the ejection stop processing is performed. The processing content of step S36 is the same as that of the above-described step S25.

[0095] In a case where it is determined that the standby time has elapsed after the ejection stop processing is performed (YES in step S36), the control section 60 performs second movement processing (step S37) to control the movement mechanism 30 so as to relatively move the stage 20 and the heater 54, and reduce the distance between the stage 20 and the heater 54. Specifically, the control section 60 controls the movement mechanism 30 so as to move the nozzle 10 and the heating mechanism 50 in the -Z-axis direction, and cause the nozzle 10 and the heating mechanism 50 to approach the stage 20. Through the second movement processing, the distance between the upper surface of the modeling layer formed on the stage 20 and the heater 54 becomes, for example, about 1 mm.

[0096] Next, the control section 60 returns the processing to step S31.

[0097] In the three-dimensional modeling apparatus according to the first modification example of the present embodiment, the control section 60 performs the following processing: first movement processing to control the movement mechanism 30 so as to increase the distance between the stage 20 and the heater 54 between the ejection stop processing and the determination processing; and second movement processing to control the movement mechanism 30 so as to reduce the distance between the stage 20 and the heater 54 between the determination processing and the second modeling layer formation processing.

[0098] In the three-dimensional modeling apparatus according to the first modification example of the present embodiment, since the distance between the stage 20 and the heater 54 is increased through the first movement processing, the heat dissipation of the modeling layer Ln-1 during the standby time can be improved. If the distance between the stage and the heater is small, the heat dissipation of the modeling layer Ln-1 during the standby time is sometimes hindered by the heater.

[0099] In particular, if the modeling layers are stacked on the stage 20 and the thickness of the entire modeling layers stacked is 2 mm or more, the temperature of the upper surface of the modeling layers stacked is dominated by the output of the heater 54 of the heating mechanism 50, rather than the output of the heater 150 provided on the barrel 140. Therefore, in particular, in a case where the entire thickness of the modeling layers stacked on the stage 20 is 2 mm or more and 7 mm or less, it is preferable to perform the first movement processing.

[0100] Note that, it is also possible to stop the output of the heater 54, but the heat storage amount of the heater 54 is large, and even if the output of the heater 54 is stopped, the temperature of the heater 54 does not immediately decrease sometimes. Therefore, the above-described first movement processing is effective.

[0101] Further, in the three-dimensional modeling apparatus according to the first modification of the embodiment, since the distance between the stage 20 and the heater 54 is reduced by the second movement process, the upper surface of the modeling layer Ln-1 can be heated by the heater 54 when the modeling layer Ln is formed. Thus, the adhesion strength between the modeling layer Ln-1 and the modeling layer Ln can be improved.

[0102] 2.2. Second Modification

[0103] Next, the three-dimensional modeling apparatus according to the second modification of the embodiment will be described with reference to the drawings. Figure 9 is a cross-sectional view schematically showing the three-dimensional modeling apparatus 200 according to the second modification of the embodiment. Figure 10 is a flowchart for explaining the three-dimensional modeling object formation process of the control section 60 of the three-dimensional modeling apparatus 200 according to the second modification of the embodiment.

[0104] As shown in Figure 9 , the three-dimensional modeling apparatus 200 differs from the three-dimensional modeling apparatus 100 described above in that the three-dimensional modeling apparatus 200 includes a cleaning mechanism 70.

[0105] The cleaning mechanism 70 performs cleaning of the nozzle 160. Thus, in the case where the nozzle opening 164 is clogged, the clogging of the nozzle opening 164 can be eliminated. The cleaning mechanism 70 can clean the nozzle 160, and the form thereof is not particularly limited.

[0106] As shown in Figure 10 , after the standby time setting process (step S41), the modeling layer formation process (step S42), the ejection stop process (step S43), and the determination process (step S44) are performed, the control section 60 performs a determination process of determining whether or not the nozzle 10 is cleaned based on the modeling data (step S45). Note that the contents of the processes of steps S41 to S44 are the same as those of steps S21 to S24 described above, respectively.

[0107] In the case where it is determined that the nozzle 10 is cleaned (YES in step S45), the control section 60 performs a determination process of determining whether or not the standby time set in step S41 is longer than the cleaning time of the nozzle 10 by the cleaning mechanism 70 (step S46).

[0108] In the case where it is determined that the standby time is longer than the cleaning time, the control section 60 controls the cleaning mechanism 70 to perform a process of starting cleaning of the nozzle 10 (step S47). By this process, the control section 60 can cause the cleaning mechanism 70 to clean the nozzle 10 during the period from the start of the ejection stop process to the elapse of the standby time.

[0109] Next, the control section 60 performs determination processing (step S48) to determine whether or not a predetermined time has elapsed after the ejection stop processing is performed. The processing content of step S48 is the same as that of step S25 described above.

[0110] In a case where it is determined that the nozzle 10 is not cleaned (NO in step S45), the control section 60 does not perform the processing of steps S46 and S47, but performs the processing of step S48.

[0111] In a case where it is determined that the standby time is not longer than the cleaning time (NO in step S46), the control section 60 does not perform the processing of step S47, but performs the processing of step S48.

[0112] In the three-dimensional modeling device 200, in a case where the standby time is longer than the cleaning time of the nozzle 10 by the cleaning mechanism 70, the control section 60 controls the cleaning mechanism 70 to clean the nozzle 10 during a period from when the ejection stop processing is performed to when the standby time elapses. Therefore, in the three-dimensional modeling device 200, compared to a case where the cleaning is not performed during the standby time and the cleaning time is separately provided, it is possible to shorten the modeling time of the three-dimensional modeled object.

[0113] 2.3. Third Modification

[0114] Next, a three-dimensional modeling device related to a third modification of the present embodiment will be described.

[0115] In the three-dimensional modeling device 100 described above, the material supplied from the material supply section 110 is ABS resin.

[0116] On the other hand, in the three-dimensional modeling device related to the third modification of the present embodiment, the material supplied from the material supply section 110 is a material other than ABS resin, or a material in which other components are added to ABS resin.

[0117] As the material supplied from the material supply section 110, a material in which various materials such as a material having thermoplasticity, a metal material, a ceramic material, and the like are main materials can be listed. Here, the "main material" means a material that becomes the center of the shape of the modeled object, and means a material having a content rate of 50% or more by mass in the modeled object. The above-described material includes a material in which these main materials are fused as a single body, and a material in which a part of components is fused together with the main material to become a paste-like material.

[0118] As the material having thermoplasticity, for example, a thermoplastic resin can be used. As the thermoplastic resin, for example, general engineering plastics, super engineering plastics can be listed.

[0119] Examples of general-purpose engineering plastics include polypropylene (PP), polyethylene (PE), polyacetal (POM), polyvinyl chloride (PVC), polyamide (PA), polylactic acid (PLA), polyphenylene sulfide (PPS), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate.

[0120] Examples of super engineering plastics include polysulfone (PSU), polyethersulfone (PES), polyphenylene sulfide (PPS), polyarylate (PAR), polyimide (PI), polyamide-imide (PAI), polyetherimide (PEI), and polyether ether ketone (PEEK).

[0121] In thermoplastic materials, in addition to pigments, metals, and ceramics, additives such as waxes, flame retardants, antioxidants, and heat stabilizers can be mixed in. In the plasticizing section 120, the thermoplastic material is plasticized by the rotation of the flat-head screw 130 and the heating of the heater 150, transforming it into a molten state. Furthermore, the resulting molding material solidifies due to a decrease in temperature after being ejected from the nozzle 160. Preferably, the thermoplastic material is ejected from the nozzle 160 in a completely molten state, heated above its glass transition temperature.

[0122] In the plasticizing section 120, for example, a metal material can be used as the main material instead of the aforementioned thermoplastic material. In this case, it is preferable to mix the molten components from the formation of the molding material into a powder material in which the metal material is made into powder, and then add it to the plasticizing section 120.

[0123] As metallic materials, examples include single metals such as magnesium (Mg), iron (Fe), cobalt (Co) or chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), and nickel (Ni), or alloys containing one or more of these metals. Additionally, examples include maraging steel, stainless steel, cobalt-chromium-molybdenum alloys, titanium alloys, nickel alloys, aluminum alloys, cobalt alloys, and cobalt-chromium alloys.

[0124] In the plasticizing section 120, ceramic materials can be used as the main material to replace the aforementioned metal materials. Examples of ceramic materials include oxide ceramics such as silicon dioxide, titanium dioxide, alumina, and zirconium oxide, and non-oxide ceramics such as aluminum nitride.

[0125] The powder material of metal or ceramic material supplied from the material supply section 110 may also be a mixture of powders of a single metal or alloy, and powders of various ceramic materials. Alternatively, the powder material of metal or ceramic material may be coated with, for example, the aforementioned thermoplastic resin or other thermoplastic resins. In this case, the thermoplastic resin may melt in the plasticizing section 120, exhibiting fluidity.

[0126] In the powder material of the metal material or the ceramic material supplied from the material supply unit 110, for example, a solvent can also be added. As the solvent, for example, water; ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether, and the like (poly)alkylene glycol monoalkyl ethers; ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, isobutyl acetate, and the like (acetate esters); benzene, toluene, xylene, and the like (aromatic hydrocarbons); methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, acetylacetone, and the like (ketones); ethanol, propanol, butanol, and the like (alcohols); tetraalkylammonium acetates; dimethyl sulfoxide, diethyl sulfoxide, and the like (sulfoxide-based solvents); pyridine, γ-picoline, 2,6-lutidine, and the like (pyridine-based solvents); tetraalkylammonium acetates (for example, tetrabutylammonium acetate, and the like); a butyl carbitol acetate, and the like (ionic liquids), and the like can be listed.

[0127] Further, in the powder material of the metal material or the ceramic material supplied from the material supply unit 110, for example, a binder can also be added. As the binder, for example, an acrylic resin, an epoxy resin, a silicone resin, a cellulose-based resin, or other synthetic resins or PLA, PA, PPS, PEEK, or other thermoplastic resins can be listed.

[0128] The above-described embodiments and modified examples are one example, and are not limited thereto. For example, each of the embodiments and the modified examples can be appropriately combined.

[0129] The present application includes structures substantially the same as the structures described in the embodiments, for example, structures having the same functions, methods, and results, or structures having the same objects and effects. In addition, the present application includes structures in which non-essential parts of the structures described in the embodiments are replaced. In addition, the present application includes structures that have the same functional effects as the structures described in the embodiments or structures that can achieve the same objects. In addition, the present application includes structures to which publicly known technologies are added to the structures described in the embodiments.

[0130] The following can be derived from the above-described embodiments and modified examples.

[0131] One mode of a three-dimensional modeling apparatus is,

[0132] The three-dimensional modeling apparatus includes:

[0133] a stage;

[0134] a heater; a modeling region covering the stage, and opposing the stage;

[0135] a nozzle that discharges a modeling material toward the modeling region;

[0136] a moving mechanism that relatively moves the stage and the nozzle; and

[0137] a control section that controls the nozzle and the moving mechanism,

[0138] the control section performs the following processing:

[0139] a first modeling layer forming process that controls the nozzle and the moving mechanism to eject a modeling material from the nozzle to form a first modeling layer;

[0140] an ejection stop process that controls the nozzle to stop ejecting the modeling material from the nozzle;

[0141] a determination process that determines whether a predetermined time has elapsed after the ejection stop process is performed; and

[0142] a second modeling layer forming process that, when it is determined in the determination process that the predetermined time has elapsed, controls the nozzle and the moving mechanism to eject a modeling material from the nozzle to form a second modeling layer on the first modeling layer,

[0143] the control section sets the predetermined time based on information related to a modeling time of the first modeling layer.

[0144] With this three-dimensional modeling apparatus, it is possible to reduce the possibility that the shape of the first modeling layer is deformed when the second modeling layer is formed.

[0145] Also, in one embodiment of the three-dimensional modeling apparatus,

[0146] the moving mechanism relatively moves the object table and the heater,

[0147] the control section performs the following processing:

[0148] a first moving process that, between the ejection stop process and the determination process, controls the moving mechanism to increase the distance between the object table and the heater; and

[0149] a second moving process that, between the determination process and the second modeling layer forming process, controls the moving mechanism to decrease the distance between the object table and the heater.

[0150] With this three-dimensional modeling apparatus, it is possible to improve the heat dissipation of the first modeling layer during standby time, while also improving the adhesion strength between the first modeling layer and the second modeling layer.

[0151] Also, in one embodiment of the three-dimensional modeling apparatus,

[0152] the three-dimensional modeling apparatus includes a cleaning mechanism that performs cleaning of the nozzle,

[0153] In a case where the prescribed time is longer than a cleaning time of the cleaning mechanism for the nozzle, the control section controls the cleaning mechanism to clean the nozzle during a period from the start of the discharge stop processing to the elapse of the prescribed time.

[0154] With this three-dimensional modeling apparatus, the modeling time of the three-dimensional modeled object can be shortened.

Claims

1. A three-dimensional modeling apparatus characterized by comprising: including: a stage; a heater; a modeling area covering the stage, opposite to the stage; a head that ejects a modeling material toward the modeling area; a moving mechanism that relatively moves the stage and the head; and a control section that controls the head and the moving mechanism, the control section performs the following processes: a first modeling layer forming process that controls the head and the moving mechanism to eject the modeling material from the head to form a first modeling layer; an ejection stop process that controls the head to stop ejecting the modeling material from the head; a determination process that determines whether a prescribed time has elapsed after the ejection stop process is performed; and a second modeling layer forming process that, when it is determined in the determination process that the prescribed time has elapsed, controls the head and the moving mechanism to eject the modeling material from the head to form a second modeling layer on the first modeling layer, the control section sets the prescribed time based on information related to a modeling time of the first modeling layer and information related to an area of the first modeling layer, the shorter the modeling time of the first modeling layer, the longer the prescribed time set by the control section.

2. The three-dimensional modeling apparatus according to claim 1, wherein the moving mechanism relatively moves the stage and the heater, the control section performs the following processes: a first moving process that, between the ejection stop process and the determination process, controls the moving mechanism to increase a distance between the stage and the heater; and a second moving process that, between the determination process and the second modeling layer forming process, controls the moving mechanism to decrease the distance between the stage and the heater.

3. The three-dimensional modeling apparatus according to claim 1 or 2, wherein the three-dimensional modeling apparatus includes a cleaning mechanism that performs cleaning of the head, when the prescribed time is longer than a cleaning time of the cleaning mechanism for the head, the control section controls the cleaning mechanism to clean the head during a period from when the ejection stop process is performed to when the prescribed time elapses. ​ ​ ​

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