Manufacturing method, manufacturing assistance method, and system

Abstract

By being able to use waste materials to manufacture materials for additive manufacturing with stable quality, it can help to realize material recycling. The first material property value of the first material as a waste material or a material manufactured from a waste material is obtained, based on the first material property value, a first manufacturing parameter used when manufacturing the material for additive manufacturing from the first material is generated, and based on the first manufacturing parameter, the material for additive manufacturing is manufactured from the first material.

Description

Technical Field

[0001] This invention relates to manufacturing methods, manufacturing aids, and systems. This invention claims priority to Japanese Patent Application No. 2021-172407, filed on October 21, 2021. For designated countries where inclusion by reference is permitted, the contents of that application are incorporated herein by reference. Background Technology

[0002] Patent Document 1 discloses a technology related to the reuse of recycled powder ejected from a 3D printer. Specifically, Patent Document 1 describes "the amount of new powder in a primary supply source of new powder local to the 3D printer, the amount of recycled powder in a primary supply source of recycled powder local to the 3D printer, the amount of new powder in a secondary supply source of new powder remotely to the 3D printer, and a memory and processor storing information related to powder resources, including the amount of recycled powder in a secondary supply source of recycled powder remotely to the 3D printer. The processor predicts the use of new powder and recycled powder and the generation of recycled powder by the 3D printer based on the group of printing tasks. Then, based on the powder prediction and the stored information related to powder resources, it manages the new powder resources and recycled powder resources between the primary and secondary supply sources of new powder and / or recycled powder, and a computing system."

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent No. 6808754 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In promoting a circular economy, the recycling of materials from waste materials is an important concept included in the 4Rs (Reuse, Reduce, Repair, and Remanufacture).

[0008] On the other hand, the technology disclosed in Patent Document 1 merely involves reusing residual powder from materials commonly used in 3D printers for additive manufacturing. That is, the technology disclosed in this document does not consider using waste materials containing various components as materials for 3D printers to perform additive manufacturing-based layered modeling. Therefore, the technology in this document makes it difficult to perform additive manufacturing-based layered modeling using waste materials, and it is difficult to facilitate reuse in material recycling.

[0009] The present invention was made in view of the above-mentioned problems, and its object is to enable the manufacture of additive manufacturing materials with stable quality using waste materials, thereby facilitating the recycling of materials.

[0010] Methods for solving problems

[0011] This application contains several means for solving at least some of the above-mentioned problems, as exemplified below. In one aspect of the manufacturing method of the present invention that solves the above-mentioned problems, a first material property value (i.e., a first property value) is obtained as a waste material or a material manufactured from waste material; based on the first property value, a first manufacturing parameter is generated for use when manufacturing an auxiliary manufacturing material from the first material; and based on the first manufacturing parameter, the auxiliary manufacturing material is manufactured from the first material.

[0012] Invention Effects

[0013] According to the present invention, waste materials can be used to manufacture additive manufacturing materials with stable quality, thereby facilitating the recycling of materials. Attached Figure Description

[0014] Figure 1 This is a diagram illustrating an example of the general structure of an ecosystem associated with the circular economy.

[0015] Figure 2 This is a diagram illustrating an example of the general structure of a system.

[0016] Figure 3 This is a flowchart illustrating an example of manufacturing aid processing (AM generated using material manufacturing parameters).

[0017] Figure 4 This is a flowchart illustrating an example of manufacturing aids (generating manufacturing parameters using AM materials for additional manufacturing). Detailed Implementation

[0018] Hereinafter, embodiments of the present invention will be described using the accompanying drawings.

[0019] <Organizations that make up an ecosystem>

[0020] Figure 1 This is a diagram illustrating an example of the general structure of an ecosystem associated with the circular economy. As shown, the ecosystem includes waste material providers, recycling stations, the system itself which manufactures materials for Additive Manufacturing (AM) (hereinafter sometimes referred to as AM materials) and products manufactured using AM materials by Additive Manufacturing devices (hereinafter sometimes referred to as AM devices, 3D printers), and users of the Additive Manufacturing devices (hereinafter sometimes referred to as AM device users).

[0021] A waste material provider is an organization (e.g., including corporations, associations, groups, and individuals) that recycles waste materials containing various components and delivers them to recycling centers. Furthermore, the origin of waste materials refers to materials containing various components, such as automobiles and household appliances.

[0022] A recycling station is an organization that shreds waste materials received from waste material providers, sorts them based on predetermined collection conditions (e.g., the types of waste materials), or produces recycled materials (e.g., material pellets) from waste materials. Additionally, the recycling station provides waste materials (hereinafter, including recycled materials such as material pellets) to this system. Furthermore, the recycling station may also outsource the shredding, collection, and sorting of waste materials to other organizations.

[0023] This system generates first manufacturing parameters (hereinafter, sometimes referred to as the manufacturing process of AM materials) for properly manufacturing AM materials used in AM devices and second manufacturing parameters (hereinafter, sometimes referred to as AM device setting information) for properly manufacturing products using AM materials in AM devices.

[0024] In addition, this system measures the physical properties of waste materials and uses the measurement results to generate first manufacturing parameters. Furthermore, this system measures the physical properties of AM materials manufactured from waste materials using the first manufacturing parameters and uses the measurement results to generate second manufacturing parameters.

[0025] An AM (Advanced Modeling) device is a device capable of augmentation manufacturing. The AM device uses AM materials manufactured from waste materials through this system, for example, to augment products via SLS (Selective Laser Sintering). The following description will explain the conception of this powder sintering lamination process.

[0026] Furthermore, products manufactured by 3D printers (AM devices) can be applied to automobiles, railways, construction equipment, medical devices, or home appliances.

[0027] Furthermore, as shown in the figure, AM materials whose physical properties have changed (deteriorated) due to preheating during the additional manufacturing process of the AM unit are also regenerated and reused. Specifically, the physical properties of the used AM materials used in the AM unit are measured again in this system, and the materials are regenerated into AM materials using a first manufacturing parameter based on these physical properties, and then used again in the AM unit.

[0028] <Batch Relationship>

[0029] Furthermore, in this embodiment, terms such as waste material batch (waste material batch), AM material manufacturing batch, and AM material shipment batch are used. These terms generally refer to batches, but for the sake of caution, they are described below.

[0030] *Waste material batch: This refers to the management unit of waste materials (including recycled materials such as material pellets) transported from the recycling station. It can also be consistent with this batch if the recycling station manages each shipment unit of waste materials in batches.

[0031] *AM material manufacturing batch: This refers to the management unit of AM materials manufactured using more than one batch of waste materials. If AM materials have the same manufacturing batch ID, it means they were manufactured using the same manufacturing process and parameters.

[0032] *AM material shipment batch: is a handling unit (e.g., AM material loaded into a handling container) that ships AM material to an external user (e.g., AM device user).

[0033] Additionally, as can be seen from the context, the manufacturing batch of AM materials is sometimes omitted and referred to simply as the manufacturing batch.

[0034] <Reasons why it is difficult to manufacture AM materials from waste materials>

[0035] Waste materials (e.g., materials from products pulverized into powder) contain a mixture of materials with various physical properties. Therefore, the physical properties of waste materials vary not only according to their collection conditions (e.g., classification methods corresponding to the types of products before they became waste materials), but also according to the years of use and the environment in which the products were used before becoming waste materials. Consequently, the physical properties of each batch of waste materials (the unit managing the waste materials) are different (not converging within a predetermined error range) and are generally different from each other. Furthermore, the raw materials for products that become waste materials sometimes contain additives (in one example, fillers, crystallization accelerators, etc., described later) mixed in during their manufacturing process (e.g., injection molding).

[0036] Therefore, compared to raw materials with consistent and stable properties, the differences in physical property values ​​between batches of waste materials are greater. Consequently, the differences in physical property values ​​between manufacturing batches of AM materials made from waste materials also increase (in other words, it is difficult to make the physical property values ​​of a manufacturing batch conform to the target physical property values ​​(more precisely, the range of target physical property values)). As a result, when AM materials made from waste materials are used in the additive manufacturing of products with complex shapes, issues such as warping may occur, making it difficult to maintain the shape of the product.

[0037] Furthermore, waste materials with a history of manufacturing using metal molds (e.g., extrusion molding, blow molding, injection molding) may contain crystallization accelerators to increase molding speed, sometimes resulting in a faster crystallization rate compared to materials commonly used in SLS. Therefore, if waste materials with such a history are used in SLS, excessive crystallization occurs during the lamination process, leading to warping due to shrinkage and shape errors, making it difficult to maintain consistent product quality.

[0038] The system of this embodiment focuses on the characteristics of such waste materials and generates first manufacturing parameters (AM material manufacturing process) for producing AM materials that can be appropriately used in AM devices, based on the physical property values ​​of the waste materials. Furthermore, this system generates second manufacturing parameters (AM device setting information) for appropriately processing the AM materials manufactured from the waste materials based on the first manufacturing parameters in the AM device.

[0039] Based on such a system, at least one of the following effects can be achieved.

[0040] (Effect 1: AM Material Manufacturer's Perspective) Able to manufacture AM materials with consistent quality.

[0041] (Effect 2: AM device user perspective) It can meet the procurement restrictions that include the proportion of recycled materials in the necessary conditions, and continuously manufacture products with stable quality through AM devices.

[0042] (Effect 3: Social Perspective) By continuously manufacturing products through AM devices, the amount of recycled waste materials can be increased. Furthermore, the manufacture of AM devices capable of producing products with complex shapes can add aesthetic value to the products. As a result, users of recycled basic products (products made from waste or recycled materials) can develop an emotional connection to the products, extending their lifespan until they become waste materials.

[0043] <<Details of the system for manufacturing AM materials and AM devices that use AM materials>>

[0044] Figure 2 This is a diagram illustrating an example of the general structure of the system. As shown, the system includes a property adjustment device 10, a property measuring device 20, and a processor system 100.

[0045] The property measuring device 20 is a device for measuring the first property value as a waste material and the second property value as an AM material manufactured from the waste material. Specifically, the property measuring device 20 measures the crystallization rate and solidification shrinkage of the waste material as the first property value. Furthermore, the property measuring device 20 may also be an assembly of more than one device.

[0046] More specifically, the property measuring device 20 is, for example, a DSC (Differential Scanning Calorimetry) device. The property measuring device 20 performs isothermal DSC to measure the change in heat during the crystallization of waste material at a fixed temperature, and obtains the measurement result representing the crystallization rate of the waste as a property value.

[0047] In addition, the physical property measuring device 20 is, for example, a PVT (Pressure Volume Temperature) measuring device. Specifically, the physical property measuring device 20 performs a PVT measurement by changing the volume of the waste material while changing the temperature and pressure, measuring the volume change before and after solidification, and thereby obtaining a measurement result representing the solidification shrinkage of the waste as a physical property value.

[0048] In addition, the first physical property value may also be a value representing the particle size and density (weight) of the waste material.

[0049] In addition, the property measuring device 20 measures the property value of AM material made from waste material, i.e., the second property value, by the same method as the first property value, and obtains the crystallization rate and solidification shrinkage of AM material.

[0050] Furthermore, the property testing device 20 measures a first property value for each batch of waste material. Additionally, the property testing device 20 measures a second property value for each manufacturing batch of AM material. Moreover, the second property value can be measured for each shipment batch that serves as the shipping unit for AM material, or it can be measured for each batch of waste material.

[0051] The property adjustment device 10 is an apparatus for manufacturing AM (Advanced AM) materials. Specifically, the property adjustment device 10 uses first manufacturing parameters generated by the processor system 100 to manufacture AM materials from waste materials. Therefore, the property adjustment device 10 can also be described as a manufacturing apparatus for AM materials. Furthermore, as described later, the first manufacturing parameter is a value representing the amount of crystallization retardant or filler added to the waste material in such a way that the AM material manufactured from the waste material is within a predetermined range of property values ​​suitable for use in an AM apparatus. Additionally, the first manufacturing parameter may also include the amounts of both crystallization retardant and filler added in groups. Furthermore, the crystallization retardant is an additive that has the property of delaying the crystallization rate.

[0052] Furthermore, as an example, the AM material manufactured by the property adjustment device 10 using the first manufacturing parameters is PBT (Polybutylene terephthalate), PA (Polyamide), PP (Polypropylene), PET (Polyethylene terephthalate), and PPS (Polyphenylene sulfide), as well as materials containing powdered resin, etc.

[0053] <Details of Processor System 100>

[0054] The processor system 100 is a system that reads various programs stored in the memory resource 40 through the processor 30, generates first manufacturing parameters and second manufacturing parameters, communicates with the property measuring device 20, the property adjusting device 10 and the AM device (information transmission and reception) and performs various other processing.

[0055] Furthermore, the processor system 100 may be, for example, a personal computer, a tablet computer, a smartphone, a server computer, a blade server, a cloud server, or other computer, and is a system that includes at least one of these computers. That is, the processor system 100 may also include, for example, a cloud system that includes a cloud server and a tablet computer or smartphone for display.

[0056] Specifically, such as Figure 2 As shown, the processor system 100 includes a processor 30, memory resources 40, a NI (Network Interface Device) 50, and a UI (User Interface Device) 60.

[0057] The processor 30 is a computing device that reads various programs stored in the memory resource 40 and executes the processing corresponding to each program. Alternatively, the processor 30 may be a microprocessor, a CPU (Central Processing Unit), a GPU (Graphics Processing Unit), an FPGA (Field Programmable Gate Array), or other semiconductor devices capable of computation.

[0058] Memory resource 40 is a storage device for storing various types of information. Furthermore, memory resource 40 can be, for example, a non-volatile or volatile storage medium such as RAM (Random Access Memory) or ROM (Read Only Memory). Alternatively, memory resource 40 can also be, for example, a rewritable storage medium such as flash memory, hard disk, or SSD (Solid State Drive), USB (Universal Serial Bus) memory, memory card, and hard disk.

[0059] NI50 is a communication device for communicating with external devices. NI50 can be connected to external devices (in this embodiment, the property measuring device 20, the property adjusting device 10, and the AM device, etc.) via a predetermined communication network such as the Internet or a LAN (Local Area Network). Furthermore, unless otherwise specified below, the processor system 100 performs communication with each device via NI50.

[0060] UI60 is an input device that outputs user (operator) instructions to the processor system 100, and an output device that outputs information generated by the processor system 100. Input devices include, for example, pointer devices such as keyboards, touch panels, and mice, and voice input devices such as microphones.

[0061] Additionally, output devices may include, for example, a display, a printer, and a voice synthesis device. Furthermore, unless otherwise specified below, user operations on the processor system 100 (e.g., information input, output, and processing execution instructions) are performed via the UI 60.

[0062] Furthermore, the various structures, functions, and processing units of this system can be partially or entirely implemented in hardware, for example, through integrated circuit design. Additionally, this system can implement some or all of its functions in software, or through a combination of software and hardware. Moreover, this system can use hardware with fixed circuitry, or it can use hardware capable of modifying at least a portion of the circuitry.

[0063] In addition, this system can also be implemented by users (operators) by performing some or all of the functions or processes implemented by the various programs.

[0064] Furthermore, each DB (database) within the storage resource 40 described below can be a data structure other than a database, such as a file, as long as it is an area capable of storing data.

[0065] <<Structure Information DB110>>

[0066] DB110 is a database that stores information related to the structure of AM devices. The structure of AM devices includes, for example, information related to the type of AM device and various mechanisms (e.g., the position and maximum output value of the laser used to heat AM materials, the size and position of the AM material supply mechanism, the size, position, and drive direction of the roller that flattens the powdered AM material, the settable temperature of the AM material preheater, etc.).

[0067] <<Correspondence record DB120>>

[0068] The correspondence record DB120 is a database that stores information representing the correspondence between waste material batches, first physical property values, manufacturing batches of AM materials, first manufacturing parameters, second physical property values, second manufacturing parameters, and shipment batches of AM materials.

[0069] Specifically, the correspondence record DB120 stores information representing the following correspondences.

[0070] (A) A list of identification information pairs for the batch of waste materials (sometimes recorded as ID) and the first physical property value (which may also be multiple).

[0071] (B) Identification information of the manufacturing batch of AM materials manufactured using the waste materials indicated in (A).

[0072] (C) Identification information of the first manufacturing parameter used to manufacture the manufacturing batch of the AM material indicated in (B).

[0073] (D)(B) indicates the identification information of the second physical property value (or multiple values) of the manufacturing batch of the AM material.

[0074] List of identification information for the shipment batches corresponding to the manufacturing batches of the AM materials indicated in (E) and (B).

[0075] Furthermore, the above is a specific example assuming a many:1:many relationship between the waste material batch, the AM material manufacturing batch, and the AM material shipping batch. This is because, when multiple waste material batches are combined to manufacture AM materials, the quantity of one manufacturing batch becomes excessive as a shipping unit; therefore, it is envisioned to ship in multiple shipping batches.

[0076] Furthermore, the relationship between the waste material batches, AM material manufacturing batches, and AM material shipment batches envisioned in the DB120 correspondence record is not limited to the above, and can also be 1:1:1 (or more), more:1:1, or 1:more:more. A 1:1:1 (or more) relationship can be expected to achieve uniformity of characteristics in AM materials manufactured by generating a first manufacturing parameter that takes into account the characteristics of each waste material and using that parameter.

[0077] <<Product Shape Information DB130>>

[0078] It is a database that stores information representing the shape of products manufactured by AM devices using AM materials.

[0079] <<Physical Property Information DB140>>

[0080] The physical property information DB140 is a database that stores the physical property values ​​of waste materials, i.e., the first physical property values, measured by the physical property measuring device 20, and the physical property values ​​of AM materials manufactured using the waste materials, i.e., the second physical property values.

[0081] Specifically, the property information DB140 stores at least one of the following as the first property value: crystallization rate, solidification shrinkage, powder particle size, and density (weight) of the waste material, or at least one set containing two or more of them. However, the first property value is not limited to these. For example, the correlation between the property value of the waste material and the amount of warpage can also be used as the first property value. Furthermore, the correlation between the property value of the waste material and the amount of warpage can be calculated, for example, based on the previously measured property value of the waste material and the amount of warpage of a sample product obtained by manufacturing an AM material from the waste material and attempting powder sintering and lamination molding using the AM material in an AM apparatus.

[0082] Additionally, in the physical property information DB140, as a second physical property value, for example, at least one of the following: crystallization rate, solidification shrinkage, and density (weight) of the material used for AM, or at least one of a group containing two or more of them. Furthermore, the second physical property value is not limited to these.

[0083] In addition, the first physical property value and the second physical property value are respectively stored in the physical property value information DB140, corresponding to the identification information of the first physical property value and the identification information of the second physical property value.

[0084] <<Manufacturing Parameter Information DB150>>

[0085] The manufacturing parameter information DB150 is a database storing first manufacturing parameters corresponding to the manufacturing process used in manufacturing AM materials and second manufacturing parameters corresponding to the setting information of the AM device used in the AM device for using AM materials. Furthermore, the first and second manufacturing parameters are generated by the processor 30, which reads the manufacturing assistance program 160 described later, using first and second property values, respectively. Additionally, the generated first and second manufacturing parameters are stored in the manufacturing parameter information DB150, each associated with an identification information for the first and second manufacturing parameters, respectively.

[0086] <<<First Manufacturing Parameters>>>

[0087] Specifically, the manufacturing parameter information DB150 stores, for example, at least one of the values ​​related to the amount of crystallization delay agent added, the values ​​related to the amount of filler added, or both, as a group, as the first manufacturing parameter. Furthermore, these added amounts can be absolute values ​​or proportions relative to the amount of waste material.

[0088] <<<Second Manufacturing Parameters (Items that can be set for the AM device)>>>

[0089] Additionally, the manufacturing parameter information DB150 stores items that can be set by the controller of the AM device, such as the laser power and preheating temperature of the AM device as second manufacturing parameters. Furthermore, the laser power is the output intensity of the laser irradiated by the laser mechanism (a laser light source that emits a heating laser for the AM material) onto a base plate (hereinafter, sometimes referred to as a modeling base plate) on which a thin layer of powdered AM material is laid, in a 3D printer (the AM device of this application) that performs powder sintering and lamination modeling using AM material. This 3D printer selectively melts and solidifies the AM material on the modeling base plate by irradiating it with a laser, thus achieving freeform modeling. The preheating temperature is the temperature of the device (heater) that heats the object being modeled and the AM material using a preheating heater provided by the AM device to control the crystallization temperature of the powdered AM material laid on the modeling base plate. More preferably, the preheating temperature includes... Figure 1The temperature of the AM02 room (room) in the central annular region of the AM device is controlled. In this room, the object being shaped is stored together with the AM material that has not yet been melted by the laser. Furthermore, the heater can directly heat the object being shaped, or heat the product being shaped via the AM material in this room, provided the temperature of the object being shaped can be controlled. While the term "object" is used in this specification, it refers to something created by the AM device, specifically a product or a component constituting a product. The AM01 controller of the AM device is set with the preheating temperature and laser power, and the AM01 controller controls the laser source and heater of the AM device.

[0090] By controlling the process described above, the rate of crystallization during the molding process (more specifically, the amount of shrinkage caused by crystallization) can be controlled, thereby reducing warping.

[0091] <<<Second Manufacturing Parameters (Items that can be set in the slicing software)>>>

[0092] In addition, AM device users Figure 1 If the slicing software (or the processor system executing the slicing software) shown in the illustration is omitted, the settings of the slicing software can also be stored as a second manufacturing parameter. Furthermore, the slicing software is software that generates slicing information (e.g., G-code) for the 3D printer based on the object's 3D shape data. The AM01 controller of the AM device receives the generated slicing information via communication or user operation, and controls the movement of the AM device's laser light source, rollers, and molding base plate according to this information.

[0093] The slicing software retains the following settings as used to generate slice information. However, it is not necessary to retain all of them.

[0094] * Spacing of slices (the thickness of the slices). Additionally, typically, the object is cut parallel to the modeling base to create slices.

[0095] * The object's shape angle (more precisely, the angle between any of the XYZ axes of the object's 3D shape data and the shape base (i.e., the sliced ​​surface)).

[0096] * The object's position (configuration) on the modeling base.

[0097] * The maximum length of an object that can be shaped.

[0098] Additionally, the settings of these slicing software programs can be stored as second manufacturing parameters in the manufacturing parameter information DB150. Shrinkage caused by crystallization becomes more pronounced at the longest portions of each slice when the object is decomposed into slices; therefore, by controlling the aforementioned settings, changes in product shape caused by warping can be mitigated.

[0099] <<Manufacturing Auxiliary Program 160>>

[0100] Manufacturing assistance program 160 is a program used to assist AM devices in manufacturing products using waste materials. Specifically, manufacturing assistance program 160 generates first manufacturing parameters and second manufacturing parameters. Furthermore, manufacturing assistance program 160 may be a combination of programs for generating the first manufacturing parameters and programs for generating the second manufacturing parameters. Moreover, manufacturing assistance program 160 may only be one of these programs. Furthermore, manufacturing assistance program 160 stores the first manufacturing parameters, the second manufacturing parameters, and their identification information in manufacturing parameter information DB150. Additionally, manufacturing assistance program 160 stores the identification information of the first manufacturing parameters and the second manufacturing parameters in a correspondence record DB120.

[0101] More specifically, the manufacturing assistance process 160 uses the first physical property value obtained from the physical property measuring device 20 to calculate the amount of crystallization retarder and filler to be added in a manner that allows the AM material (manufacturing batch) manufactured from the waste material batch to be appropriately used in the AM device. Furthermore, the amount of crystallization retarder or filler to be added is a first manufacturing parameter, constituting the manufacturing process of the AM material.

[0102] Additionally, the manufacturing assistance program 160 outputs (sends) manufacturing instructions for the AM material using the first manufacturing parameters to the property adjustment device 10. Furthermore, the output in this specification refers to anything other than transmission to other devices. For example, the output may also allow the parameter to be displayed on a computer used by the operator of the property adjustment device 10. Alternatively, the parameter may be printed on paper for the operator. The output can be in any specific manner as long as the first manufacturing parameters can be input directly or indirectly to the property adjustment device 10. Furthermore, the output may also include identification information for the batch of waste materials used in manufacturing, and identification information for the manufacturing batch assigned to the AM material.

[0103] Furthermore, the manufacturing assistance process 160 uses the second physical property values ​​obtained from the physical property measuring device 20 to calculate the laser power and preheating temperature for appropriately manufacturing products using the AM device for the manufacturing batch (or shipping batch) using the AM material. This laser power and preheating temperature are also considered second manufacturing parameters. Additionally, the manufacturing assistance process 160 generates the second manufacturing parameters such that the relationship between melting point (solidification point) and crystallization temperature is maintained, following a temperature range from high to low. This is because the crystallization temperature is the temperature at which crystallization occurs most rapidly; therefore, crystallization will occur even if the crystallization temperature is exceeded. However, if the crystallization temperature is deviated from, the crystallization rate slows down.

[0104] Additionally, the manufacturing assistance program 160 outputs a second manufacturing parameter. Furthermore, this output can be in any specific manner, as long as the parameter can be input to the AM device and slicing software owned by the AM device user. Here is one example.

[0105] *( Figure 1 (Example) The processor system 100 receives a request from the AM device user containing structural information of the AM device and a manufacturing batch or shipment batch of the AM material. Then, the processor system 100 sends second manufacturing parameters to the AM device user's display computer.

[0106] *The shipment batch of AM materials and the media (paper or non-volatile memory, for example) with the output of the second manufacturing parameters are collectively referred to as shipment.

[0107] Furthermore, the manufacturing assistance program 160 generates the units of the first manufacturing parameter and the second manufacturing parameter as described in the correspondence record DB120.

[0108] Furthermore, the manufacturing assistance procedure 160 can also select a batch of waste materials to be used in the manufacturing of a predetermined batch of AM material from a pool of candidate waste material batches based on a first physical property value. When the range of the target second physical property value varies for each manufacturing batch of AM material, the addition of excessive additives can be avoided by selecting a more suitable waste material. For example, the range of the target second physical property value can be varied based on the structural information of the AM device owned by the AM device user.

[0109] Furthermore, the manufacturing assistance program 160 calculates the coefficients of a function, for example, by performing physical simulations such as basic experiments on a function represented by a predetermined formula (e.g., a quadratic function), and calculates a first manufacturing parameter and a second manufacturing parameter by inputting a first property value and a second property value into the formula containing the calculated coefficients. Moreover, there are no particular limitations on the calculation methods for the first and second manufacturing parameters.

[0110] Furthermore, if the manufacturing assistance program 160 obtains the first and second physical property values ​​from the physical property measuring device 20, it stores them in the physical property value information DB140. Additionally, as described above, the manufacturing assistance program 160 stores the generated first and second manufacturing parameters in the manufacturing parameter information DB150. Furthermore, as partially explained, the manufacturing assistance program 160 may also output manufacturing instructions for AM materials to the physical property adjusting device 10 based on the first manufacturing parameters. Additionally, the manufacturing assistance program 160 may also use the AM materials manufactured by the physical property adjusting device 10 to output manufacturing instructions for the product based on the second manufacturing parameters to the AM device. Furthermore, the actual manufacturing instructions may also be determined and issued by an operator or program other than the manufacturing assistance program 160.

[0111] The above provides a detailed description of the processor system 100.

[0112] <Manufacturing Auxiliary Processing Flow>

[0113] Figure 3 and Figure 4 This is a flowchart illustrating an example of manufacturing support processes. Specifically, Figure 3 This diagram illustrates an example of manufacturing auxiliary processes related to the generation of manufacturing parameters for AM materials. Additionally, Figure 4 This is a diagram illustrating an example of manufacturing aids related to the generation of manufacturing parameters for additional manufacturing using AM materials.

[0114] << Figure 3 Generation and output of the first manufacturing parameters >>

[0115] Figure 3 Manufacturing auxiliary processes, for example, are executed by the processor 30, which reads the manufacturing auxiliary program 160, when the processor 30 receives the execution instruction for processing from the user (operator) of the processor system 100 via the NI50. Additionally, the execution instruction from the user may include, for example, information specifying the batch of waste materials used in the manufacturing of AM materials.

[0116] When manufacturing auxiliary processing begins, the processor 30 refers to the correspondence record DB120 and obtains the first physical property value corresponding to the specified waste material batch from the physical property value information DB140 (step S10). Furthermore, the processor 30 uses the obtained first physical property value to generate first manufacturing parameters related to a predetermined manufacturing batch of AM material (step S20). Specifically, the processor 30 calculates the amount of crystallization delay agent and filler to be added as the first manufacturing parameters, ensuring that the AM material manufactured from the specified waste material is within a predetermined range of physical property values ​​suitable for use in the AM apparatus.

[0117] Next, the processor 30 outputs the generated first manufacturing parameters (step S30). Furthermore, in this step, an instruction to manufacture AM material from a specified batch of waste material may also be output simultaneously. After performing this step, the processor 30 terminates the process.

[0118] Furthermore, the processing performed in each step can also follow the procedures described earlier in this flowchart. The same applies to the initiation trigger and specified information for this process.

[0119] << Figure 4 Generation and output of the second manufacturing parameters >>

[0120] As mentioned above, Figure 4 When a request is received from the AM device user (or the AM device user's display computer) via NI50, the manufacturing aid process is executed by the processor 30, which has read the manufacturing aid program 160.

[0121] While referring to the correspondence record DB120, the processor 30 obtains a second physical property value related to the manufacturing batch (or shipment batch) of the AM material manufactured by the physical property adjustment device 10 from the physical property value information DB140 (step S40). Furthermore, the processor 30 uses the obtained second physical property value to generate second manufacturing parameters (step S50). Specifically, the processor 30 calculates the laser power and preheating temperature for appropriately manufacturing a product using the AM material through the AM device as the second manufacturing parameters. Additionally, the processor 30 may also generate the setting values ​​of the slicing software used in the AM device as the second manufacturing parameters.

[0122] Next, the processor 30 outputs the second manufacturing parameters (step S60), ending the process.

[0123] The above describes the process. Additionally, the processing performed in each step can also follow the procedures described earlier in this flowchart. The same applies to the initiation trigger and specified information for this process.

[0124] According to this embodiment of the system, waste materials can be used to manufacture additive manufacturing materials with stable quality, thereby facilitating material recycling. In particular, according to this system, based on the varying crystallization rates and solidification shrinkage amounts that differ from batch to batch of waste materials, an appropriate amount of crystallization rate retardant or filler can be added to reduce (suppress) warpage, enabling the manufacture of AM materials with stable quality. Furthermore, according to this system, manufacturing parameters (second manufacturing parameters) in the AM apparatus can be obtained that are suitable for individual batch variations that cannot be fully absorbed during adjustments to the manufacturing of AM materials, thus reducing the number of trial runs required for parameter adjustments. Moreover, the inability to fully absorb these variations is due to environmental limitations, cost considerations, the existence of upper limits on the amount of additives that can be added, or the possibility of errors in the manufacturing process of the AM materials.

[0125] Furthermore, this system can meet procurement restrictions that include the proportion of recycled materials in the necessary conditions, and can continuously manufacture products with stable quality through the AM (Advanced Materials) device. Additionally, according to this system, by having users of the AM device continuously manufacture products, the amount of recycled waste materials can be increased. Furthermore, according to this system, in manufacturing based on the AM device capable of producing products with complex shapes, added value from a design perspective can be added to the products, and by fostering an emotional connection between the users of recycled basic products (products made using waste materials and recycled materials) and the products, the period before they become waste materials can be extended.

[0126] Furthermore, waste materials with a product history manufactured through the aforementioned extrusion molding (materials whose main component is waste material of articles formed by extrusion molding, or material particles manufactured from such waste material) contain less crystallization accelerator and filler compared to, for example, blow molding and injection molding. This is because extrusion molding can produce products even at a slower crystallization rate compared to blow molding and injection molding. Therefore, by actively utilizing waste materials derived from extrusion molding, the amount of additional crystallization retarders and fillers required in the manufacture of AM materials can be reduced, resulting in lower manufacturing costs for both AM materials and products.

[0127] Another example of a method for identifying waste materials originating from extrusion molding is a method based on the shape of the waste material. Extruded products are mostly elongated shapes, so identification methods based on this characteristic are effective. Furthermore, as one method for automatic identification, for example, analyzing images of waste materials captured by a CCD (Charge Coupled Device) camera is considered.

[0128] In addition, other identification methods include providing information such as the composition of waste materials received from waste material suppliers or recycling stations, and the forming methods related to the products before they became waste materials. Furthermore, dedicated management of waste materials from suppliers or recycling stations that primarily supply waste materials derived from extrusion molding is also effective.

[0129] <Transformation>

[0130] The above describes this embodiment. Furthermore, the following variations are considered in this embodiment.

[0131] *The main components of AM materials and waste materials can also be components other than resin. For example, they can be metals, graphite fibers, carbon fibers, ceramics, inorganic materials, and rubber.

[0132] *Additional manufacturing methods other than SLS can also be used for modeling. For example, material extrusion deposition, material jetting, binder jetting, and photomapping.

[0133] *The property conditioning device 10 can also be used to condition materials that have deteriorated due to preheating in the AM device more than once, and then resend them to the AM device user as recycled AM materials. In this case, the property conditioning device 10 adds additives to restore the thermally deteriorated properties.

[0134] *AM materials shipped to AM device users may include, in addition to AM materials derived from waste materials, materials mixed with the aforementioned recycled AM materials or AM materials derived from virgin material particles. This is suitable for situations where AM materials derived solely from waste materials cannot be fully adjusted to the appropriate quality.

[0135] Furthermore, the present invention is not limited to the embodiments and modifications described above, and includes various modifications within the scope of the same technical concept. For example, the embodiments described above are examples that have been explained in detail for the purpose of easily understanding the present invention, and are not necessarily limited to having all the structures described. In addition, a part of the structure of a certain embodiment can be replaced with the structure of another embodiment, and it is also possible to add the structure of another embodiment to the structure of a certain embodiment. Furthermore, with respect to a part of the structure of each embodiment, other structures can be added, deleted, or replaced.

[0136] Furthermore, in the above description, control lines and information lines refer to the lines deemed necessary for the description, but may not represent all control lines and information lines on the product. In reality, almost all structures can be considered interconnected.

[0137] Explanation of reference numerals in the attached figures

[0138] 100... Processor system, 30... Processor, 40... Memory resources, 50... NI (Network Interface Device), 60... UI (User Interface Device), 110... Structure information DB, 120... Correspondence record DB, 130... Product shape information DB, 140... Physical property value information DB, 150... Manufacturing parameter information DB, 160... Manufacturing auxiliary program, 10... Physical property adjustment device, 20... Physical property measuring device, N... Network.

Claims

1. A manufacturing method, characterized in that, The first physical property value is the correlation between the physical property value of the first material, which is a waste material or a material made from waste material, and the amount of warpage. Based on the first physical property value, generate first manufacturing parameters for use when manufacturing an auxiliary manufacturing material from the first material; and Based on the first manufacturing parameters, the additional manufacturing material is manufactured from the first material. The additional manufacturing process involves powder sintering and lamination, and the material used in the additional manufacturing process comprises powdered resin. The correlation is calculated based on at least one of the following physical properties of the first material, namely crystallization rate, solidification shrinkage, powder particle size, and density, as determined in advance, and the warpage of the molded product when attempting to sinter and stack powder.

2. The manufacturing method according to claim 1, characterized in that, The first manufacturing parameters are generated according to the manufacturing batch of the manufacturing management unit that serves as the additional manufacturing material. The first physical property value is determined according to the waste material batch, which is the management unit of the first material corresponding to the manufacturing batch.

3. The manufacturing method according to claim 1, characterized in that, The manufacture of the additional manufacturing material includes at least one of the following: *Addition of crystallization delaying agents with properties that delay crystallization rate *Addition of packing material, The first manufacturing parameter includes at least one of the following: *Values ​​related to the amount of the added crystallization retarder. * Values ​​related to the amount of packing added.

4. The manufacturing method according to claim 3, characterized in that, The first material is a material whose main component is waste material of articles formed by extrusion molding, or material particles manufactured whose main component is waste material of articles formed by extrusion molding.

5. The manufacturing method according to claim 1, characterized in that, Obtain the physical property value of the additional manufacturing material, i.e., the second physical property value. Based on the second physical property value, a second manufacturing parameter is generated for use when performing additional manufacturing using the additional manufacturing material.

6. The manufacturing method according to claim 5, characterized in that, The second manufacturing parameter includes at least one of the following: *The output of a laser for heating materials used in the additional manufacturing apparatus for performing the additional manufacturing; *The temperature of the preheater for the materials used in the additional manufacturing process, which is provided in the additional manufacturing apparatus for performing the additional manufacturing.

7. The manufacturing method according to claim 5, characterized in that, The second manufacturing parameter includes at least one of the following: The thickness of the disc-shaped layer of the object manufactured by the aforementioned additional manufacturing; The shape angle of the object manufactured through the aforementioned additional manufacturing; The maximum length of the object manufactured through the additional manufacturing process; and The position of the object on the modeling base.

8. A system having one or more processors and one or more memory resources, characterized in that, The memory resource storage manufacturing auxiliary program. The processor, by executing the manufacturing assistance program, obtains a first material property value, which is the correlation between the physical property value of a first material (either as waste material or material manufactured from waste material) and the amount of warpage. Based on the first material property value, it generates a first manufacturing parameter to be used when manufacturing additional manufacturing materials from the first material. The additional manufacturing process involves powder sintering and lamination, and the material used in the additional manufacturing process comprises powdered resin. The correlation is calculated based on at least one of the following physical properties of the first material, namely crystallization rate, solidification shrinkage, powder particle size, and density, as determined in advance, and the warpage of the molded product when attempting to sinter and stack powder.

9. A system having one or more processors and one or more memory resources, characterized in that, The memory resource storage manufacturing auxiliary program. The processor, by executing the manufacturing assistance program, obtains a first property value, which is a correlation between the physical property value of a first material (either waste material or material manufactured from waste material) and the amount of warpage. Based on the first property value, it generates a first manufacturing parameter used when manufacturing an auxiliary manufacturing material from the first material. It then obtains a second property value, which is a physical property value of the auxiliary manufacturing material manufactured from waste material or material manufactured from waste material. Based on the second property value, it generates a second manufacturing parameter used when performing the auxiliary manufacturing process from the auxiliary manufacturing material. The additional manufacturing process involves powder sintering and lamination, and the material used in the additional manufacturing process comprises powdered resin. The correlation is calculated based on at least one of the following physical properties of the first material, namely crystallization rate, solidification shrinkage, powder particle size, and density, as determined in advance, and the warpage of the molded product when attempting to sinter and stack powder.

10. The system according to claim 9, characterized in that, The second manufacturing parameter includes at least one of the following: *The output of a laser for heating materials used in the additional manufacturing apparatus for performing the additional manufacturing; *The temperature of the preheater for the materials used in the additional manufacturing process, which is provided in the additional manufacturing apparatus for performing the additional manufacturing.

11. The system according to claim 9, characterized in that, The second manufacturing parameter includes at least one of the following: The thickness of the disc-shaped layer of the object manufactured by the aforementioned additional manufacturing; The shape angle of the object manufactured through the aforementioned additional manufacturing; The maximum length of the object manufactured through the additional manufacturing process; and The position of the object on the modeling base.

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