Method for manufacturing shaped object by 3D printer, and 3D printer control program

Abstract

The invention provides a method for manufacturing a shaped object based on a 3D printer and a 3D printer control program. The shaped object with good transparency is manufactured. In a method for manufacturing a shaped object using a 3D printer, the shaped object is manufactured by repeating an uncured layer forming step (S1) for forming a single-layer amount of shaped layers from an uncured shaping material and an uncured layer curing step (S2) for curing the single-layer amount of shaped layers in this order. The uncured layer curing step (S2) is ended before the final curing of the one-layer amount of shaping layer formed by the last uncured layer forming step (S1), and the uncured layer forming step (S1) for forming the next one-layer amount of shaping layer is executed.

Description

Technical Field

[0001] The present invention belongs to the technical field of 3D printers that manufacture a shaped object by laminating and curing a shaping material. Background Art

[0002] In 3D printers of the MEX method (including material extrusion lamination method, food printers, etc.), FDM method (thermal melting lamination method), or LAM method (liquid lamination shaping method), it is configured to use resins such as PLA, ABS, PC, and TPE as the shaping material. The liquid resin is extruded from a nozzle and ejected onto a platform, and by appropriately controlling the movement of the nozzle in three-dimensional directions, it is gradually laminated layer by layer from the lower layer upward to form the target shaped object.

[0003] However, in a shaped object using such a resin raw material based on the MEX method, the outer ends of each layer formed during the lamination process remain in a shape bulging outward as they are, and on the outer surface of the presented shaped object, fine ridges formed continuously in the vertical direction and in the width direction appear continuously.

[0004] As a result, on the outer surface of the shaped object, fine ridges formed continuously in the vertical direction and in the width direction form so-called "lamination marks". Even in the case of a shaped object intended to be formed in a transparent color, the lamination marks cause the transparency to decrease, and as a result, there is a problem that the appearance of the shaped object is poor.

[0005] Prior Art Documents

[0006] Patent Documents

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 2017-226140 Summary of the Invention

[0008] Technical Problem to be Solved by the Invention

[0009] Therefore, the technical problem of the present invention is to provide a method for manufacturing a shaped object based on a 3D printer and a 3D printer control program that produce a shaped object with good transparency.

[0010] Solution for Solving the Above Technical Problem

[0011] The manufacturing method described in Technical Solution 1 is a manufacturing method of a shaped object based on a 3D printer. The uncured layer formation process and the uncured layer curing process are repeatedly performed in sequence in the stacking direction to fabricate the shaped object. In the uncured layer formation process, an uncured shaping material is ejected from a nozzle and stacked, and a shaping layer of one-layer quantity is formed from the uncured shaping material. In the uncured layer curing process, the shaping layer of one-layer quantity is cured. It is characterized in that the uncured layer curing process is ended before the curing of the shaping layer of one-layer quantity formed by the most recent uncured layer formation process, and the uncured layer formation process for forming the next shaping layer of one-layer quantity is executed, and the shaping layer of one-layer quantity in a sticky state is adhesively cured with the next shaping layer of one-layer quantity in a sticky state to fabricate the shaped object.

[0012] According to the manufacturing method described in Technical Solution 1, by utilizing the fact that a specified time is required until the shaping material is finally cured, both the upper and lower shaping layers that are in contact with each other, that is, the formed shaping layer and the next shaping layer to be formed, are adhesively bonded including the outer edge portion with the next sticky shaping layer before the formed shaping layer is cured. Thus, it is possible to minimize as much as possible the void portion that is the cause of forming a so-called "lamination mark". This void portion is usually formed between adjacent shaping layers on the end face portion of the shaped object by ejecting the shaping material from the nozzle to form the next shaping layer after the shaping layer is cured.

[0013] As a result, it is possible to avoid forming the "lamination mark" that was conventionally formed due to the voids generated between the outer edge portions of the respective shaping layers adjacent in the vertical direction. As a result, it is possible to fabricate a shaped object with a smoother and more transparent end face portion.

[0014] Furthermore, by adhesively bonding the end edge portions of the upper and lower shaping layers to each other, even for a shaped object having an overhang portion or an undercut portion, it is not necessary to provide a support member at this portion, which can avoid the complexity in the manufacturing process and improve the manufacturing efficiency.

[0015] The manufacturing method described in Technical Solution 2 is a manufacturing method of a shaped object based on a 3D printer. It is characterized in that, in the manufacturing method of a shaped object based on a 3D printer described in Technical Solution 1, the uncured layer formation process is as follows: while moving the nozzle in a manner of depicting concentric circles from the inside of the area for forming the shaping layer of one-layer quantity toward the outer edge portion, the uncured shaping material is ejected from the nozzle, and thus the shaping layer of one-layer quantity is formed from the uncured shaping material. The uncured layer curing process is executed in the following state: a state in which the outer edge portion of the shaping layer of one-layer quantity formed by the most recent uncured layer formation process is adhesively bonded to the outer edge portion of the shaping layer of one-layer quantity formed by the next uncured layer formation process.

[0016] According to this manufacturing method, especially in the case of manufacturing a shaped object having a planar portion or a disk-shaped portion protruding outward in the planar direction, the outer edge portions of the upper and lower shaping layers are bonded to each other in a state where the gap is reduced, whereby shaping can be performed without a support member.

[0017] That is, in the case of manufacturing a shaped object having a planar portion or a disk-shaped portion and having a shape in which the planar portion or the disk-shaped portion protrudes outward in the planar direction, the nozzle for ejecting the shaping material of the 3D printer is controlled to move from the inner portion to the outer portion. However, as in the past, when, after the outer edge portion of a certain shaping layer is completely cured, the shaping material equivalent to the upper shaping layer is ejected from the nozzle to form a shaping layer, the lower shaping layer cures and the viscosity becomes low. Therefore, the adhesiveness is low at the overhang portion of the upper shaping layer, and sometimes the shaping collapses. To prevent this, a support member is required.

[0018] However, in the present invention, before the outer edge portion of the shaping layer formed by the most recent uncured layer forming step is completely cured, in a state having adhesiveness, it is bonded to the outer edge portion of the shaping layer that becomes the upper layer formed by the next uncured layer forming step. Therefore, the adhesiveness is high, and even when no support member is provided at the overhang portion or the undercut portion, the shaping does not deform.

[0019] As a result, especially even in the case of manufacturing a shaped object having a planar portion or a disk-shaped portion and having a shape in which the planar portion or the disk-shaped portion protrudes outward in the planar direction, it is not necessary to provide a support member at the edge portion, the complexity in the manufacturing process can be avoided, and the manufacturing efficiency can be improved.

[0020] And at the same time, it is possible to avoid forming "layer lines" formed due to the gaps generated between the outer edge portions of the respective shaping layers adjacent in the vertical direction. As a result, a shaped object with a smoother and more transparent end face portion of the shaped object can be shaped.

[0021] The invention according to Technical Solution 3 is a method for manufacturing a shaped object by a 3D printer, characterized in that, in the manufacturing method according to Technical Solution 1 or 2, the uncured shaping material is an ultraviolet-curable liquid silicone rubber, and the uncured layer curing step is a step of irradiating the ultraviolet-curable liquid silicone rubber as the uncured shaping material with ultraviolet rays while controlling the time-dependent change in the viscosity of the ultraviolet-curable liquid silicone rubber, the intensity of ultraviolet rays, the irradiation time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement locus of the nozzle.

[0022] According to the manufacturing method of the present invention, by controlling the movement trajectory of the nozzle, the intensity of ultraviolet light, etc., the viscosity of the ultraviolet curable liquid silicone rubber used as the shaping material is adjusted, and the viscosity of the shaping layer is appropriately controlled, so that the edge portion of the shaping layer can be bonded to the edge portion of the upper shaping layer in a form with reduced voids therebetween, and the so-called "lamination marks" on the surface of the shaped object can be limited to a minimum, and a shaped object with high transparency and without a support member can be produced.

[0023] The manufacturing method described in Technical Solution 4 is a manufacturing method of a shaped object based on a 3D printer, characterized in that, in the manufacturing method described in Technical Solution 1 or 2, the uncured shaping material is heat curable liquid silicone rubber, and the uncured layer curing step is the following step: while controlling the time-dependent change of the viscosity of the heat curable liquid silicone rubber, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the heat curable liquid silicone rubber as the uncured shaping material is heated.

[0024] Therefore, according to the present invention, by controlling the movement trajectory of the nozzle, the heating temperature, etc., the viscosity of the ultraviolet curable liquid silicone rubber used as the shaping material is adjusted, and the viscosity of the shaping layer is appropriately controlled, so that the edge portion of the shaping layer can be bonded to the edge portion of the upper shaping layer in a form with reduced voids therebetween, and the so-called "lamination marks" on the surface of the shaped object can be limited to a minimum, and a shaped object with high transparency and without a support member can be produced.

[0025] The manufacturing method described in Technical Solution 5 is a manufacturing method of a shaped object based on a 3D printer, characterized in that, in the manufacturing method of a shaped object based on a 3D printer described in Technical Solution 4, the heat curable liquid silicone rubber is RTV (room temperature curable type) silicone rubber.

[0026] RTV silicone rubber is a shaping material that cures at room temperature. Therefore, in the shaping operation, the management of the movement trajectory of the nozzle, the shaping time, the ejection pressure from the nozzle, etc. is more important than in the case of ultraviolet curable shaping materials. However, by appropriately controlling these conditions, the viscosity of RTV silicone rubber can be adjusted, the viscosity of the shaping layer can be appropriately controlled, the edge portion of the shaping layer can be bonded to the edge portion of the upper shaping layer in a form with reduced voids therebetween, and the "lamination marks" on the surface of the shaped object can be limited to a minimum, and a shaped object with high transparency and without a support member can be produced.

[0027] The manufacturing method described in Technical Solution 6 is a manufacturing method of a shaped object based on a 3D printer, characterized in that, in the manufacturing method of a shaped object based on a 3D printer described in Technical Solution 1 or 2, the uncured shaping material is a thermoplastic resin, and the uncured layer curing process is the following process: while controlling the temporal change in the viscosity of the thermoplastic resin, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the thermoplastic resin as the uncured shaping material is heated.

[0028] Therefore, by appropriately controlling conditions such as the movement trajectory of the nozzle, the curing temperature and curing time of the thermoplastic resin, etc., it is possible to adjust the viscosity, etc. of the liquid resin used in the shaping material, appropriately control the viscosity of this shaping layer, bond the edge portion of this shaping layer and the edge portion of the shaping layer above in a form that reduces the gap between them, and limit the so-called "layer lines" on the surface of the shaped object to the minimum, and produce a shaped object with high transparency and without a support member.

[0029] The manufacturing method described in Technical Solution 7 is the manufacturing method of a shaped object based on a 3D printer described in Technical Solution 1 or 2, characterized in that the 3D printer is a 3D printer of the MEX method (material extrusion forming method).

[0030] The manufacturing method described in Technical Solution 8 is the manufacturing method of a shaped object based on a 3D printer described in Technical Solution 1 or 2, characterized in that the 3D printer is a 3D printer of the LAM method (liquid lamination forming method).

[0031] The invention described in Technical Solution 9 is a 3D printer control program, which is a program for executing the operation of the control device of a 3D printer. The 3D printer manufactures a shaped object by sequentially repeating the uncured layer forming process and the uncured layer curing process. In the uncured layer forming process, an uncured shaping material is ejected from a nozzle and laminated, and a shaping layer of one layer amount is formed by the uncured shaping material. In the uncured layer curing process, the shaping layer of one layer amount is cured. It is characterized in that the 3D printer is controlled by the 3D printer control program such that the uncured layer curing process ends before the final curing of the shaping layer of one layer amount formed by the most recent uncured layer forming process, and the uncured layer forming process for forming the next shaping layer of one layer amount is executed.

[0032] The 3D printer control program described in Technical Solution 10 is executed by the control device of the 3D printer in the 3D printer control program described in Technical Solution 9. The 3D printer manufactures a shaped object by repeatedly performing an uncured layer forming process of forming a shaped layer of a layer amount with uncured shaping material and an uncured layer curing process of curing the shaped layer of the layer amount in sequence. It is characterized in that the 3D printer is controlled by the 3D printer control program so that the uncured layer curing process ends before the final curing of the shaped layer of the layer amount formed by the most recent uncured layer forming process, and the uncured layer forming process for forming the next shaped layer of the layer amount is executed.

[0033] According to the 3D printer control program described in Technical Solution 10, by installing it on the control device (computer) of the 3D printer and executing it, the 3D printer that manufactures a shaped object by repeatedly performing an uncured layer forming process of forming a shaped layer of a layer amount with uncured shaping material and an uncured layer curing process of curing the shaped layer of the layer amount in sequence is controlled. Utilizing the fact that a specified time is required until the shaping material is finally cured, the upper and lower shaped layers that are in contact with each other are bonded to each other, and a shaped object with high transparency can be shaped without a support member.

[0034] The 3D printer control program described in Technical Solution 11 is characterized in that in the 3D printer control program described in Technical Solution 9, the uncured shaping material is ultraviolet curable liquid silicone rubber, and the uncured layer curing process is as follows: Based on parameters including the time-dependent change in the viscosity of the ultraviolet curable liquid silicone rubber, the intensity of ultraviolet light, the irradiation time, the ejection pressure of the shaping material from the nozzle or the timing of forming the next shaped layer, and the movement trajectory of the nozzle, ultraviolet light is irradiated on the ultraviolet curable liquid silicone rubber as the uncured shaping material.

[0035] The 3D printer control program described in Technical Solution 12 is characterized in that in the 3D printer control program described in Technical Solution 9, the uncured shaping material is a thermoplastic resin, and the uncured layer curing process is as follows: Based on parameters including the time-dependent change in the viscosity of the thermoplastic resin, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaped layer, or the movement trajectory of the nozzle, the thermoplastic resin as the uncured shaping material is heated.

[0036] The control program of the 3D printer according to Technical Solution 13 is characterized by having: a step of obtaining learning data, the learning data including data on shaping conditions related to the time-dependent change in the viscosity of various uncured shaping materials ejected, the ejection pressure from the nozzle, the heating time, the intensity of ultraviolet light, the irradiation time of ultraviolet light, the curing speed, the execution time of the uncured layer curing process, the timing of forming the next shaping layer, the shape conditions, or the movement trajectory of the nozzle, and shaping result data related to the quality of the transparency or the layer lamination marks of the shaped object when shaping is performed based on the data on the shaping conditions; a step of generating a learned model that optimizes the shaping conditions by performing machine learning using the obtained learning data; and a step of controlling the 3D printer based on the learned model.

[0037] Advantages of the Invention

[0038] According to the manufacturing method of the invention of the present application described in Technical Solutions 1 to 8, by utilizing the fact that it takes a specified time until the shaping material is finally cured, the edge portions of the upper and lower shaping layers that are in contact with each other, that is, the edge portions of the formed shaping layer and the next shaping layer to be formed, are bonded to the next shaping layer before the formed shaping layer is cured. Thus, it is possible to minimize the void portion that is the cause of the so-called "layer lamination marks". This void portion is usually formed between adjacent shaping layers on the end face of the shaped object when the next shaping layer is formed by ejecting the shaping material from the nozzle after the shaping layer is cured.

[0039] As a result, it is possible to avoid forming the "layer lamination marks" that were conventionally formed due to the voids generated between the shaping layers adjacent in the vertical direction. As a result, it is possible to shape a shaped object with a smoother end face and higher transparency.

[0040] Furthermore, by bonding the edge portions of the upper and lower shaping layers to each other, even for a shaped object having an overhang portion or an undercut portion, there is no need to provide a support member at this part, which can avoid the complexity in the manufacturing process and improve the manufacturing efficiency.

[0041] In addition, in order to manufacture a shaped object with reduced "layer lamination marks" and high transparency as described above, to manufacture a shaped object with a complex shape without using a support member, or a shaped object with a complex shape having overhang and undercut portions, condition settings such as information related to the time-dependent change in the viscosity of the shaping material ejected from the nozzle, the time for applying ultraviolet light or heat energy for curing the shaping material, and the timing of forming the next layer and the optimized movement trajectory of the ejection nozzle (referred to as the "shaping path") are very important.

[0042] Therefore, in order to solve the above technical problems, a slicing software capable of controlling the drive of a 3D printer in a manner that can meet the above conditions is required. However, in the conventional slicing software, the shaping conditions related to the temporal change in the viscosity of various uncured shaping materials ejected, the ejection pressure from the nozzle, the heating time, the intensity of ultraviolet rays, the irradiation time of ultraviolet rays, the curing speed, the execution time of the uncured layer curing process, the timing of forming the next shaping layer, the morphological conditions, or the movement trajectory of the nozzle are not considered.

[0043] As a result, the technical problems of the present invention could not be solved in the past, and it is only possible to solve them for the first time through the 3D printer control program of the present invention described in Technical Solutions 9 to 13.

[0044] In addition, especially in the control program of the 3D printer of the invention described in Technical Solution 13, it is configured to obtain and accumulate learning data by performing the shaping operation of the shaped object. The learning data includes data related to the shaping conditions such as the temporal change in the viscosity of various uncured shaping materials ejected, the ejection pressure from the nozzle, the heating time, the intensity of ultraviolet rays, the irradiation time of ultraviolet rays, the curing speed, the execution time of the uncured layer curing process, the timing of forming the next shaping layer, the morphological conditions, or the movement trajectory of the nozzle, as well as the shaping results related to the quality of the transparency or layer lines of the shaped object formed as a result, and perform machine learning based on AI (artificial intelligence). Thus, a learned model that optimizes the shaping conditions is formed, and the operation of the 3D printer is controlled based on this learned model. Therefore, it is possible to efficiently manufacture the target shaped object using the optimal shaping conditions. Description of the Drawings

[0045] Figure 1 It is a conceptual diagram of a 3D printer for manufacturing a shaped object by the manufacturing method of an embodiment of the present invention.

[0046] Figure 2 is Figure 1 a conceptual diagram of the dispenser unit and the moving mechanism of the 3D printer shown.

[0047] Figure 3 It is a flowchart of the manufacturing method of an embodiment of the present invention.

[0048] Figure 4 An embodiment of the manufacturing method of the present invention is shown, which is an example in the case where the shaping material is ultraviolet-curable liquid silicone rubber. Figure 4 (a) of is an explanatory diagram of the uncured layer forming process. Figure 4 (b) of is an explanatory diagram of the uncured layer curing process.

[0049] Figure 5Shows an embodiment of the manufacturing method of the present invention, Figure 5 (a) of Figure 5 is a cross-sectional schematic view showing the state of the outer edge portion of the shaped layer formed by the manufacturing method of an embodiment. Figure 5 (b) of Figure 5 is a cross-sectional schematic view showing the state of the outer edge portion of the shaped layer formed by the conventional manufacturing method.

[0050] Figure 6 Shows an embodiment of the manufacturing method of the present invention, and is a cross-sectional schematic view showing the state of the outer edge portion of the shaped layer formed by the manufacturing method of an embodiment. Detailed Embodiments

[0051] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Here, a 3D printer that uses an ultraviolet curable material (for example, ultraviolet curable liquid silicone rubber) as a shaping material and manufactures a shaped object by a liquid lamination shaping method will be described.

[0052] [Configuration of 3D Printer]

[0053] [3D Printer]

[0054] The 3D printer 10 used in the manufacturing method of the shaped object of the present embodiment is of the LAM type, as Figure 1 and Figure 2 shown, and includes a printer main body 60, a frame 70 that covers the printer main body 60 and shields ultraviolet rays, and a control device 80.

[0055] The printer main body 60 is composed of a dispenser unit 20 that emits an ultraviolet curable material M, a platform unit 30 that laminates the ultraviolet curable material M emitted from the dispenser unit 20, a moving mechanism unit 40 that relatively moves the dispenser unit 20 and the platform unit 30, and an ultraviolet irradiation unit 50 that irradiates the ultraviolet curable material M ejected onto the platform unit 30 with ultraviolet rays UV.

[0056] The printer main body 60 also has: a base 61 that constitutes the bottom of the 3D printer 10; and two support portions 62, 63 that extend upward from the base 61. The dispenser unit 20 is supported by one of the support portions 62, and the ultraviolet irradiation unit 50 is supported by the other support portion 63. The platform unit 30 is provided on the base 61.

[0057] The dispenser unit 20 has: a material cartridge 21 that houses the ultraviolet curable material M; a cartridge holding portion 22 that removably holds the material cartridge 21; and a compressed air supply portion (material ejection unit) 23 that ejects the ultraviolet curable material M from the material cartridge 21 held (mounted) on the cartridge holding portion 22.

[0058] The cassette holding part 22 is supported by the support part 62 via the lifting mechanism 41. The lifting mechanism 41 moves the cassette holding part 22 in the vertical direction (the direction indicated by the arrow Z).

[0059] The compressed air supply part 23 is fixedly arranged on the support part 62. The compressed air supply part 23 has: a compressed air ejection mechanism 23a that ejects compressed air; and a compressed air supply pipe 23b that supplies the compressed air ejected from the compressed air ejection mechanism 23a to the material cassette 21 mounted on the cassette holding part 22.

[0060] As Figure 2 shown, the material cassette 21 has a syringe-shaped material container part 21a and a piston part 21b inserted into the material container part 21a.

[0061] At the base end (upper end) of the material container part 21a, a compressed air inlet 21c connected to the compressed air supply pipe 23b is provided. The material cassette 21 presses the piston part 21b with the compressed air A supplied from the compressed air ejection mechanism 23a through the compressed air supply pipe 23b, so as to eject the ultraviolet curable material M from the nozzle 21d provided at the front end (lower end) of the material container part 21a. The material container part 21a and the piston part 21b are formed of an ultraviolet-shielding synthetic resin material.

[0062] As Figure 1 and Figure 2 shown, the platform part 30 is supported by the base part 61 via the horizontal movement mechanism 42. The horizontal movement mechanism 42 moves the platform part 30 in the left-right direction (the direction indicated by the arrow X) and the front-back direction (the direction indicated by the arrow Y).

[0063] The movement mechanism part 40 is composed of the lifting mechanism 41 and the horizontal movement mechanism 42. That is, the movement mechanism part 40 is configured to be able to move the dispenser part 20 and the platform part 30 in three mutually orthogonal axial directions (up and down, left and right, and front and back).

[0064] The ultraviolet irradiation part 50 has a UV lamp or a UV-LED as a light source. The ultraviolet irradiation part 50 is configured to be able to uniformly irradiate the ultraviolet curable material M laminated on the workpiece manufacturing area including the central part of the platform part 30 with ultraviolet rays.

[0065] In the present embodiment, whenever one layer amount of the ultraviolet curable material M is ejected onto the platform part 30, the platform part 30 is moved so that the workpiece manufacturing area of the platform part 30 enters the ultraviolet irradiation range of the ultraviolet irradiation part 50, and the ultraviolet curable material M on the platform part 30 is irradiated with ultraviolet rays UV.

[0066] The control device 80 controls the compressed air supply part 23, the movement mechanism part 40, and the ultraviolet irradiation part 50 based on the 3D data of the product to be manufactured.

[0067] That is, the control device 80 controls the ejection amount of the ultraviolet curable material M from the nozzle 21d, the relative movement amount between the nozzle 21d and the platform portion 30, the irradiation timing, irradiation amount, and irradiation time of the ultraviolet rays UV, etc., and drives and controls the movement locus (modeling path) of the nozzle 21d.

[0068] The control device 80 includes a processor that performs various operations, a storage device having a non-temporary storage medium that stores various information (programs, data), an input / output device that controls the input / output of data inside and outside the control device 80, etc. A 3D printer control program (so-called "slicing software") of the present invention is stored in the control device 80.

[0069] The 3D printer control program (slicing software) of the present embodiment is configured to, based on the three-dimensional image information of the object to be modeled to be produced, the dimensional information of each part, etc., and further based on the information on the time-dependent change in the viscosity of the ultraviolet curable liquid silicone rubber ejected from the nozzle 21d, appropriately set the intensity of the ultraviolet rays irradiated on the uncured layer of the amount formed by the ultraviolet curable liquid silicone rubber, the irradiation time of the ultraviolet rays, and set the ejection pressure of the modeling material ejected from the nozzle, the timing of forming the next modeling layer, and the movement locus (path) of the nozzle 21d that is most suitable for the production of the predetermined object to be modeled, and control the compressed air supply unit 23, the movement mechanism unit 40, and the ultraviolet irradiation unit 50 based on these parameters.

[0070] As a result, the control device 80 executes the 3D printer control program of the present invention, thereby realizing the manufacturing method of the object to be modeled W based on the 3D printer 10 of the present embodiment.

[0071] That is, in principle, the liquid silicone rubber in the present embodiment is a non-Newtonian fluid, and has the property of not immediately curing even after being ejected from the nozzle, but having a specified viscosity and slightly deforming.

[0072] Therefore, in the present embodiment, it is configured to utilize the property of the liquid silicone rubber. After ejecting the liquid silicone rubber from the nozzle of the 3D printer to form a certain layer, by controlling the ultraviolet irradiation, the layer is not completely cured, and the next layer is formed and bonded within the time when it has viscosity, and finally, each layer is cured as a whole to produce the object to be modeled.

[0073] That is, in this embodiment, the 3D printer control program installed in the control device 80 is configured to automatically calculate the timing of starting the shaping of the next shaping layer located above when one shaping layer is not completely cured but maintains a specified viscosity so that the two shaping layers can be bonded and cured by inputting various parameters such as data on the specific three-dimensional shape of the predetermined shaping object, various dimensional data that determine the three-dimensional size of the predetermined shaping object, data on the type of shaping material, data on the time change of the material until the shaping material is cured, and time data until the shaping is cured by UV cross-linking based on ultraviolet irradiation. The movement trajectory of the nozzle ("shaping path") is appropriately formed, and the nozzle is driven and controlled according to the shaping path, so that the desired shaping object can be produced.

[0074] [Method for manufacturing a shaped object using a 3D printer]

[0075] Then, refer to Figure 3 , Figure 4 and Figure 5 , a method for manufacturing a shape W based on the 3D printer 10 is described.

[0076] like Figure 3 As shown, in this embodiment, the 3D printer 10 is configured to manufacture a shape W by repeatedly performing an uncured layer forming process (step S1) and an uncured layer curing process (step S2) in sequence along the stacking direction. In the uncured layer curing process, the uncured layer is not completely cured but cured while maintaining a bonded state.

[0077] like Figure 4 As shown in (a) of FIG. 1 , the uncured layer forming step (step S1 ) is a step of forming a layer of a modeling layer L using a predetermined uncured ultraviolet curing material M on the stage 30 .

[0078] In the present embodiment, the uncured layer forming process (step S1) is the following process: while the nozzle 21d is moved along a predetermined movement trajectory (forming path) of the nozzle in a manner of drawing concentric circles from the inside (center) toward the outside (outer edge), for example in an area where a predetermined amount of forming layer L of a predetermined object is formed, uncured ultraviolet curing material M is ejected from the nozzle 21d, thereby forming a layer of forming layer L using the uncured ultraviolet curing material M.

[0079] In addition, the formation path is formed from the inside to the outside of the formation target object substantially in a manner of drawing concentric circles.

[0080] like Figure 4As shown in (b) thereof, the uncured layer curing process (step S2) is a process in which ultraviolet rays UV are irradiated onto a layer of the shaping layer L, and the irradiation time and irradiation intensity of the ultraviolet rays UV are controlled so that the shaping layer L is not completely cured, and the ultraviolet curable liquid silicone rubber as the ejected ultraviolet curable material M is cured in an incomplete state while maintaining a specified viscosity. Therefore, in this process, even after the ultraviolet irradiation, the shaping layer L is not completely cured and is in a viscous state.

[0081] The control device 80 controls the compressed air supply unit 23, the moving mechanism unit 40, and the ultraviolet irradiation unit 50 by using the slicing software of the present embodiment mounted thereon to perform the curing process S2 for incomplete curing so that a layer of the shaping layer L formed by the most recent uncured layer forming process (step S1) is not finally cured, and then, the uncured layer forming process S1 of the upper shaping layer L as the next process is performed.

[0082] That is, the slicing software mounted on the control device 80 is configured to control the 3D printer so that the curing process S2 ends before the final curing of a layer of the shaping layer L formed by the most recent uncured layer forming process, and the uncured layer forming process S1 for forming the next layer of the shaping layer L formed in the upper layer is performed.

[0083] As a result, by using the uncured layer curing process (step S2), the outer edge portion L1 of a layer of the shaping layer L formed by the most recent uncured layer forming process (step S1) and the outer edge portion L2 of a layer of the shaping layer L formed by the next uncured layer forming process (step S1) are adhesively bonded to each other. Then, the 3D printer 10 repeatedly performs the uncured layer forming process S1 and the curing process S2 for incompletely curing the uncured layer in a state of high viscosity, and drives the control nozzle upward to fabricate a shaped object.

[0084] [Function and Effect]

[0085] According to the manufacturing method of the present embodiment, by using the slicing software programmed to be capable of performing the manufacturing method of the present embodiment, irradiation is performed with ultraviolet rays whose intensity and irradiation time are appropriately controlled so that it is incompletely cured in a state of high viscosity. Therefore, within a specified time until the ultraviolet curable material M is finally cured, upper and lower shaping layers L that are in contact with each other are formed in the upper layer, and the lower shaping layer L1 formed previously and the upper shaping layer L2 formed subsequently are adhesively bonded to each other, so that the layer lamination marks (concavities, voids, etc.) on the end face portion of the shaped object W can be eliminated, and a shaped object W with high transparency can be fabricated.

[0086] In this case, regarding the final curing of the formed layers L1 and L2 after bonding, since the irradiation by the ultraviolet irradiation unit 50 is repeatedly performed only on the amount of the formed layer, as a result, the cured energy obtained by irradiation is supplied to all layers, and finally, curing involving all layers is performed to fabricate the shaped object.

[0087] More specifically, before the final curing of the amount of one layer of the formed layer L formed by the most recent uncured layer forming step (step S1), the curing step (step S2) is ended, and the uncured layer forming step (step S1) for forming the next amount of one layer of the formed layer L is executed. Thus, as Figure 5 shown in (a) of, in the ultraviolet curable material M of the formed layer L1 of a certain amount and the upper formed layer L2, viscosity remains. As a result, "sagging" occurs at the outer edge portion Le of each formed layer L, and the outer edge portions Le of the adjacent upper and lower formed layers L are bonded to each other.

[0088] As a result, in the present embodiment, the gap G (the main cause of the lamination mark) between the outer edge portions Le of each formed layer L becomes smaller. Therefore, it is possible to suppress a decrease in the transparency of the shaped object W caused by the lamination mark and diffuse reflection.

[0089] On the other hand, as in the conventional method, in the method of finally curing (fully curing) each formed layer L by the curing step (step S2) every time, as Figure 5 shown in (b) of, the gap G between the outer edge portions Le of the adjacent upper and lower formed layers L becomes larger. Therefore, the transparency of the shaped object is reduced due to the lamination mark and diffuse reflection. Thus, according to the manufacturing method of the present embodiment, such conventional drawbacks can be eliminated.

[0090] In addition, according to this manufacturing method, by using, for example, an ultraviolet curable liquid silicone rubber as the ultraviolet curable material M and adjusting its viscosity and the like, it is possible to fabricate a high-precision silicone rubber shaped object W comparable to a silicone rubber shaped object obtained by mold forming. In addition, the physical properties of the silicone rubber shaped object W manufactured by this manufacturing method, particularly regarding the tensile strength, elongation rate, etc., are of the same level as those of the silicone rubber shaped object obtained by mold forming.

[0091] In addition, according to this manufacturing method, by bonding the upper and lower formed layers L2 and L1 to each other, it is possible to execute a manufacturing method without a support member.

[0092] That is, as in Figure 6When the outer edge portion Le of the upper shaping layer L2 as shown is in a state of overhanging relative to the outer edge portion Le of the lower shaping layer L1, in the case of a manufacturing method in which ultraviolet rays are irradiated as in the past until the lower shaping layer L1 is completely cured, the outer edge portion Le of the shaping layer L1 is in a state without viscosity. Therefore, even when the upper shaping layer L2 is cured by ultraviolet rays, it may not be possible to maintain the strength of the outer edge portion Le and cause distortion. Therefore, in the past, a support member was required in such portions where overhangs, undercuts, etc. occurred, and the manufacturing operation was complicated.

[0093] However, in the manufacturing method of the present embodiment, by performing an uncured layer curing process (step S2) of irradiating the lower shaping layer L1 with ultraviolet rays UV in such a manner that the outer edge portions Le of the shaping layers L2 and L1 adjacent to each other in the vertical direction are bonded to each other in an uncured state, as Figure 6 shown, even under a shaping condition in which the outer edge portion Le of the upper shaping layer L2 protrudes more outward than the outer edge portion Le of the lower shaping layer L1, the outer edge portion Le of the lower shaping layer L1 is formed with a prescribed appropriate viscosity, so it has an adhesive force, and the outer edge portion Le of the upper shaping layer L2 is bonded and fixed to the lower shaping layer Le. Therefore, the outer edge portion Le of the upper shaping layer L2 does not distort. Therefore, in the present embodiment, the manufacturing operation of the shaped object can be smoothly performed without a support member.

[0094] In addition, by using machine learning based on AI (artificial intelligence), a shaped object can be manufactured by optimizing the shaping conditions based on parameters such as the viscosity of the uncured material ejected from the nozzle, the temporal change in viscosity, ultraviolet intensity, irradiation time, heating time, etc.

[0095] That is, the 3D printer control program of the present embodiment can also be configured to have: a step of obtaining learning data, the learning data including data on shaping conditions related to the temporal change in viscosity of various ejected uncured shaping materials, the ejection pressure from the nozzle, heating time, ultraviolet intensity, ultraviolet irradiation time, curing speed, the execution time of the uncured layer curing process, the timing of forming the next shaping layer, morphological conditions, or the movement trajectory of the nozzle, and shaping result data related to the quality of the transparency or layer lines of the shaped object when shaping is performed based on the data on the shaping conditions; a step of generating a learned model that optimizes the shaping conditions by performing machine learning using the obtained learning data; and a step of controlling the 3D printer based on the learned model.

[0096] In the case where machine learning is utilized for controlling various parameters like this, by performing the shaping of the shaped object W multiple times, for example, a large amount of learning data (data set) composed of shaping conditions (temporal change in the viscosity of various shaping materials ejected, curing speed, execution time of each uncured layer curing process, ultraviolet intensity, etc.) and shaping results (superiority or inferiority of the transparency of the shaped object, etc.) is obtained. By performing machine learning using the obtained learning data, a learned model that optimizes the shaping conditions is generated, and the function for controlling the 3D printer 10 based on this learned model is installed in the 3D printer control program. Thus, as the number of shaping times of the shaped object W increases, a higher-quality shaped object W can be manufactured.

[0097] [Other Embodiments]

[0098] The present invention is not limited to the above-described embodiments. For example, in the above-described embodiments, the dispenser unit 20 has a material cartridge 21 that houses the ultraviolet curable material M and a compressed air supply unit 23 that ejects the ultraviolet curable material M from the material cartridge 21. However, it is not limited to this configuration. For example, a dispenser unit 20 configured to mix two liquid silicone rubbers and extrude them through an extruder can also be employed.

[0099] Furthermore, in the above-described embodiments, the moving mechanism unit 40 includes a lifting mechanism 41 that moves the dispenser unit 20 up and down relative to the platform unit 30 and a horizontal moving mechanism 42 that moves the platform unit 30 horizontally relative to the dispenser unit 20. However, the lifting mechanism 41 can also be omitted, and a moving mechanism that moves the platform unit 30 relative to the dispenser unit 20 in three axial directions (up and down, left and right, and front and back) can be employed instead of the horizontal moving mechanism 42.

[0100] Furthermore, in the above-described embodiments, the ultraviolet irradiation unit 50 is fixed to the printer main body 60. However, the ultraviolet irradiation unit 50 can also be fixed to the dispenser unit 20.

[0101] Furthermore, in the above-described embodiments, a method of manufacturing a shaped object by using an ultraviolet curable material as a shaping material and by the liquid lamination shaping method has been described. However, the present invention can also be applied to a method of manufacturing a shaped object by using a thermosetting material (for example, thermosetting liquid silicone rubber) etc. as a shaping material and by the liquid lamination shaping method.

[0102] Furthermore, by using the slicing software related to the 3D printer control program of the present invention, it can also be applied to the case of manufacturing a shaped object using a shaping material such as (room temperature curable type) silicone rubber where the management of the shaping time is extremely important.

[0103] RTV (Room Temperature Vulcanizing) silicone rubber is a shaping material that cures at room temperature. Compared to the case of ultraviolet curing materials, etc., various parameters such as the shaping path, shaping order, shaping time, and ejection pressure of the shaping material from the nozzle for shaping need to be controlled more precisely.

[0104] The shaping of such a shaped object using RTV silicone rubber has been realized for the first time through the manufacturing method of the present invention and the slicing software with a 3D printer control program.

[0105] RTV silicone rubber has a one - component type and a two - component type. The one - component type reacts with moisture in the air, etc. when extruded from a container such as a cartridge and starts to cure at room temperature. The two - component type is a type in which the main agent and the curing agent are mixed and start to cure at room temperature or by heating.

[0106] When using such RTV silicone rubber to perform the shaping of a shaped object that reduces "layer lines" and does not require a support, the RTV silicone rubber (in the case of two - component) in the syringe - shaped material container part or the RTV silicone rubber at the nozzle tip (in the case of one - component) has not started to cure, so it has high fluidity and can smoothly perform shaping just after the start of shaping.

[0107] On the other hand, as it reaches the final stage of shaping, the RTV silicone rubber (in the case of two - component) in the material container or the RTV silicone rubber at the nozzle tip (in the case of one - component) starts to cure during the shaping process, so the fluidity decreases, and sometimes the ejection port at the nozzle tip gets blocked.

[0108] Therefore, in order to cope with such a situation, by implementing the manufacturing method of the present invention and the slicing software with a 3D printer control program, the ejection pressure and the shaping path can be appropriately controlled to manufacture a shaped object using a 3D printer.

[0109] In the case of a method of using a thermosetting material as a shaping material and manufacturing a shaped object by the liquid lamination shaping method, the 3D printer 10 and the manufacturing method of the shaping material based on the 3D printer 10 can be replaced with the following configuration.

[0110] The 3D printer 10 has: a dispenser unit 20 that ejects the thermosetting material M; a platform unit 30 that laminates the thermosetting material M ejected from the dispenser unit 20; a moving mechanism unit 40 that relatively moves the dispenser unit 20 and the platform unit 30 with respect to each other; a heating unit 50, such as a halogen lamp, that uses heat to cure the thermosetting material M ejected onto the platform unit 30; a printer main body 60; and a control device 80.

[0111] The uncured layer forming process (step S1) is a process of forming a layer of the shaping layer L from the uncured thermosetting material M. More specifically, the uncured layer forming process (step S1) is a process of ejecting the uncured thermosetting material M from the nozzle 21d while moving the nozzle 21d from the inside of the area where a layer of the shaping layer L is formed toward the outer edge portion, thereby forming a layer of the shaping layer L from the uncured thermosetting material M.

[0112] The curing process (step S2) is a process of incompletely curing a layer of the shaping layer L in a state with high viscosity by heating. The control device 80 is equipped with slicing software programmed to control each part of the 3D printer 10 such that the uncured layer curing process (step S2) ends before the final curing of the layer of the shaping layer L formed by the most recent uncured layer forming process (step S1), and the uncured layer forming process (step S1) for forming the next layer of the shaping layer L is executed.

[0113] As a result, by means of the uncured layer curing process (step S2), the outer edge portion Le of the layer of the shaping layer L formed by the most recent uncured layer forming process (step S1) and the outer edge portion Le of the layer of the shaping layer L formed by the next uncured layer forming process (step S1) are in a state of being bonded to each other in an uncured state, and the bonding state between the adjacent shaping layers L above and below is continuous, thereby manufacturing a shaped object.

[0114] Each component in the above embodiment is not limited to the above description within the scope of the gist of the present invention.

[0115] Industrial Applicability

[0116] The present invention relates to a method for manufacturing a shaped object based on a 3D printer and a 3D printer control program, and thus has wide industrial applicability.

[0117] Explanation of Reference Numerals

[0118] 10 3D printer

[0119] 20 Dispenser unit

[0120] 21d Nozzle

[0121] 30 Platform unit

[0122] 40 Moving mechanism unit

[0123] 50 Ultraviolet irradiation unit

[0124] 80 Control device

[0125] M Ultraviolet curable material (shaping material)

[0126] S1 Uncured layer forming process

[0127] Curing process of uncured layer of S2

[0128] UV ultraviolet ray

[0129] W shaped object.

Claims

1. A manufacturing method of a shaped object based on a 3D printer, in which an uncured layer forming process and an uncured layer curing process are repeatedly performed in sequence in the stacking direction to fabricate the shaped object. In the uncured layer forming process, an uncured shaping material is ejected from a nozzle and stacked, and a shaping layer of a single layer amount is formed by the uncured shaping material. In the uncured layer curing process, the shaping layer of a single layer amount is cured. It is characterized in that before the curing of the shaping layer of a single layer amount formed by the most recent uncured layer forming process is completed, the uncured layer curing process is ended, and the uncured layer forming process for forming the next shaping layer of a single layer amount is executed, and the shaping layer of a single layer amount in a viscous state is adhesively cured with the next shaping layer of a single layer amount in a viscous state to fabricate the shaped object.

2. The manufacturing method of a shaped object based on a 3D printer according to claim 1, It is characterized in that the uncured layer forming process is a process in which while moving the nozzle from the inside of the area where the shaping layer of a single layer amount is formed to the outer edge portion, the uncured shaping material is ejected from the nozzle, so that the shaping layer of a single layer amount is formed by the uncured shaping material. By using the uncured layer curing process, the outer edge portions of the shaping layer of a single layer amount in a viscous state formed by the most recent uncured layer forming process and the outer edge portions of the shaping layer of a single layer amount formed by the subsequent uncured layer forming process are adhesively cured with each other.

3. The manufacturing method of a shaped object based on a 3D printer according to claim 1 or 2, It is characterized in that the uncured shaping material is an ultraviolet-curable liquid silicone rubber, the uncured layer curing process is a process in which while controlling the time-dependent change of the viscosity of the ultraviolet-curable liquid silicone rubber, the intensity of ultraviolet light, the irradiation time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement locus of the nozzle, the ultraviolet-curable liquid silicone rubber as the uncured shaping material is irradiated with ultraviolet light.

4. The manufacturing method of a shaped object based on a 3D printer according to claim 1 or 2, It is characterized in that the uncured shaping material is a heat-curable liquid silicone rubber, the uncured layer curing process is a process in which while controlling the time-dependent change of the viscosity of the heat-curable liquid silicone rubber, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement locus of the nozzle, the heat-curable liquid silicone rubber as the uncured shaping material is heated.

5. The manufacturing method of a shaped object based on a 3D printer according to claim 4, It is characterized in that the heat-curable liquid silicone rubber is an RTV room temperature curing type silicone rubber.

6. The manufacturing method of a shaped object based on a 3D printer according to claim 1 or 2, It is characterized in that the uncured shaping material is a thermoplastic resin, The uncured layer curing process is as follows: while controlling the change over time of the viscosity of the thermoplastic resin, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the thermoplastic resin as the uncured shaping material is heated.

7. The method for manufacturing a shaped object based on a 3D printer according to claim 1 or 2, wherein, the 3D printer is a 3D printer in the MEX method, i.e., the material extrusion forming method.

8. The method for manufacturing a shaped object based on a 3D printer according to claim 1 or 2, wherein, the 3D printer is a 3D printer in the LAM method, i.e., the liquid lamination forming method.

9. A 3D printer control program that executes the operation of the control device of a 3D printer. The 3D printer manufactures a shaped object by sequentially repeating the uncured layer formation process and the uncured layer curing process. In the uncured layer formation process, an uncured shaping material is ejected from a nozzle and laminated, and a shaping layer of one layer amount is formed by the uncured shaping material. In the uncured layer curing process, the shaping layer of one layer amount is cured. wherein, the 3D printer is controlled by the 3D printer control program such that the uncured layer curing process ends before the final curing of the shaping layer of one layer amount formed by the most recent uncured layer formation process, and the uncured layer formation process for forming the next shaping layer of one layer amount is executed.

10. The 3D printer control program according to claim 9, wherein, the uncured shaping material is ultraviolet curable liquid silicone rubber, and the uncured layer curing process is as follows: based on parameters including the change over time of the viscosity of the ultraviolet curable liquid silicone rubber, the intensity of ultraviolet light, the irradiation time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the ultraviolet curable liquid silicone rubber as the uncured shaping material is irradiated with ultraviolet light.

11. The 3D printer control program according to claim 9, wherein, the uncured shaping material is heat curable liquid silicone rubber, and the uncured layer curing process is as follows: based on parameters including the change over time of the viscosity of the heat curable liquid silicone rubber, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the heat curable liquid silicone rubber as the uncured shaping material is heated.

12. The 3D printer control program according to claim 9, wherein, the uncured shaping material is a thermoplastic resin, and the uncured layer curing process is as follows: based on parameters including the change over time of the viscosity of the thermoplastic resin, the heating time, the ejection pressure of the shaping material from the nozzle, the timing of forming the next shaping layer, or the movement trajectory of the nozzle, the thermoplastic resin as the uncured shaping material is heated.

13. The 3D printer control program according to claim 9, characterized in that it has: a step of obtaining learning data, the learning data including data on the time-dependent change in the viscosity of various uncured modeling materials ejected, the ejection pressure from the nozzle, the heating time, the intensity of ultraviolet rays, the irradiation time of ultraviolet rays, the curing speed, the execution time of the uncured layer curing process, the timing of forming the next modeling layer, the shape conditions or the movement trajectory of the nozzle, and shaping result data related to the quality of the transparency or the layer lamination marks of the shaped object when shaping is performed based on the data of the shaping conditions; a step of generating a learned model that optimizes the shaping conditions by performing machine learning using the obtained learning data; and a step of controlling the 3D printer based on the learned model.

Images