Modeling method, modeling system, recording medium, and computer program product

Abstract

The invention relates to a modeling method, a modeling system, a recording medium, and a computer program product. The purpose of the present invention is to suppress deformation occurring in a molded object. This molding method comprises: a first molding step for molding a molded object (40); and a second molding step for molding the sacrificial molded object (60) above the molded object (40). The sacrificial modeling object (60) comprises a plurality of column parts (61); and a top section (62) formed above the column section (61).

Description

Technical Field

[0001] The present invention relates to a modeling method, a modeling system, a recording medium, and a computer program product. Background Art

[0002] As a modeling method for modeling a modeled object without using a mold or the like, there is known a method of causing a powdery modeling material to bind to form a modeling layer and modeling the modeled object by laminating the modeling layer.

[0003] In such a modeling method, in the modeling process of modeling the modeled object or in a subsequent process, there is a problem that the modeled object is deformed such as warping. In response to this problem, Patent Document 1 (U.S. Patent Application Publication No. 2014 / 0335313) proposes a method of previously modeling a support structure below a warped portion of the modeled object to suppress deformation of the modeled object.

[0004] [Prior Art Documents]

[0005] [Patent Documents]

[0006] Patent Document 1: U.S. Patent Application Publication No. 2014 / 0335313 Summary of the Invention

[0007] However, in the conventional method, deformation of the modeled object cannot sometimes be suppressed.

[0008] Therefore, an object of the present invention is to provide a new modeling method for suppressing deformation generated in a modeled object.

[0009] In order to achieve the above object, the modeling method according to the present invention is characterized by including: a first modeling process of modeling a modeled object; and a second modeling process of modeling a sacrificial modeled object above the modeled object, the sacrificial modeled object including: a plurality of column portions; and a top portion modeled above the column portions.

[0010] The effects of the present invention will be described below:

[0011] According to the present invention, deformation generated in the modeled object can be suppressed. Brief Description of the Drawings

[0012] Figure 1 is a schematic diagram of a modeling system according to a first embodiment of the present invention.

[0013] Figure 2 is a schematic diagram of a modeling device according to a first embodiment of the present invention.

[0014] Figure 3This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0015] Figure 4 This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0016] Figure 5 This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0017] Figure 6 This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0018] Figure 7 This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0019] Figure 8 This is a diagram for explaining the operation of the modeling device according to the first embodiment of the present invention.

[0020] Figure 9 This is a flowchart showing the modeling method of the modeled object of the modeling system according to the first embodiment of the present invention.

[0021] Figure 10 This is a diagram for explaining the mechanism of generating deformation in the modeled object.

[0022] Figure 11 This is a side view of the modeled object and the sacrificial modeled object modeled by the modeling method according to the first embodiment of the present invention.

[0023] Figure 12 This is a top view of the modeled object and the sacrificial modeled object modeled by the modeling method according to the first embodiment of the present invention.

[0024] Figure 13 This is a flowchart showing the modeling method of the modeled object of the modeling device according to the first embodiment of the present invention.

[0025] Figure 14 This is a diagram for explaining the mechanism of suppressing deformation of the modeled object.

[0026] Figure 15 This is a flowchart showing the modeling method according to the first embodiment of the present invention including a removal process (sacrificial modeled object removal process).

[0027] Figure 16 This is a side view of the modeled object and the sacrificial modeled object modeled by the modeling method according to the second embodiment of the present invention.

[0028] Figure 17 This is a top view of the modeled object and the sacrificial modeled object modeled by the modeling method according to the third embodiment of the present invention.

[0029] Figure 18 The top view of the molded object and the sacrificial molded object molded by the molding method of the fourth embodiment of the present invention.

[0030] Figure 19 The side view of the molded object and the sacrificial molded object molded by the molding method of the fifth embodiment of the present invention.

[0031] Figure 20 The side view of the molded object and the sacrificial molded object molded by the molding method of the sixth embodiment of the present invention.

[0032] Figure 21 The side view of the molded object and the sacrificial molded object molded by the molding method of the seventh embodiment of the present invention.

[0033] Figure 22 The side view of the molded object and the sacrificial molded object molded by the molding method of the eighth embodiment of the present invention.

[0034] Figure 23 The side view of the molded object and the sacrificial molded object molded by the molding method of the ninth embodiment of the present invention.

[0035] Figure 24 The side view of the molded object and the sacrificial molded object molded by the molding method of the tenth embodiment of the present invention.

[0036] Figure 25 The side view of the molded object and the sacrificial molded object molded by the molding method of the eleventh embodiment of the present invention.

[0037] Figure 26 The side view of the molded object and the sacrificial molded object molded by the molding method of the twelfth embodiment of the present invention.

[0038] Figure 27 The side view of the molded object and the sacrificial molded object molded by the molding method of the thirteenth embodiment of the present invention.

[0039] Figure 28 It shows Figure 23 The flowchart of the molding process of the embodiment.

[0040] Figure 29 It shows Figure 24 The flowchart of the molding process of the embodiment.

[0041] Figure 30 It shows Figure 25 The flowchart of the molding process of the embodiment.

[0042] Figure 31 It shows Figure 26Flow chart of the modeling process of the implementation form.

[0043] Figure 32 represents Figure 27 Flow chart of the modeling process of the implementation form.

[0044] Figure 33 is a diagram showing the results of a verification test for confirming the effects of the present invention.

[0045] Figure 34 is a block diagram showing an example of a control unit and a modeling data generation device of a modeling system according to each implementation form of the present invention.

[0046] Figure 35 is a diagram showing an example of modeling a plurality of modeled objects and sacrificial modeled objects in a modeling tank according to an implementation form of the present invention.

[0047] Figure 36 is a diagram showing an example of modeling a plurality of modeled objects and sacrificial modeled objects in a modeling tank according to another implementation form of the present invention.

[0048] Symbol explanations in the figure are as follows:

[0049] 9 Resin

[0050] 10 Modeling liquid

[0051] 20 Modeling material

[0052] 40 Modeled object

[0053] 60 Sacrificial modeled object

[0054] 61 Column part (first column part)

[0055] 61a Recessed part

[0056] 62 Top part

[0057] 63 Wall part

[0058] 64 Bottom plate part

[0059] 65 Column part (second column part)

[0060] 1000 Modeling system Detailed implementation manners

[0061] Hereinafter, embodiments for implementing the present invention will be described in detail with reference to the accompanying drawings. In each figure, for components and constituent elements such as components having the same function or shape, the same reference signs are given as long as they can be distinguished, and their descriptions are omitted after being described once.

[0062] <Overall structure of the modeling system>

[0063] Figure 1 is a schematic diagram of the modeling system 1000 according to the first embodiment of the present invention. First, based on Figure 1 , the overall structure of the modeling system 1000 to which the modeling method of the present invention is applied will be described.

[0064] The modeling system 1000 includes a modeling device 100, a drying device 200, a powder removing device 300, and a sintering device 400.

[0065] The modeling device 100 is a device that forms a powder layer containing a modeling material and imparts a modeling liquid to the powder layer to form a modeling layer. In addition, the modeling device 100 stacks the modeling layers to model a three-dimensional object. As the modeling material, in addition to metal powders containing aluminum, other metals, or metal alloys, powders containing ceramics, glass, etc. can also be used. In addition, the modeling liquid contains a solvent, resin, etc.

[0066] The drying device 200 is a device that dries the object modeled by the modeling device 100. Through the drying process, liquid components such as solvents remaining in the object are vaporized and removed.

[0067] The powder removing device 300 is a device that removes the remaining powder as the modeling material attached to the object after the drying process. As a method of removing the powder, methods such as removing the powder by blowing air and removing the powder by immersing the object in a removing liquid can be cited.

[0068] The sintering device 400 is a device that heats the object after removing the remaining powder, degreases the resin component contained in the object, and sinters the modeling material. By sintering the modeling material, a sintered body in which the modeling materials are integrated is obtained. The degreasing process and the sintering process can be continuously performed using the same device or using different devices.

[0069] In addition, the modeling system 1000 may also include a post-treatment device, etc. As the post-treatment device, there is no particular limitation, and it can be appropriately selected according to the purpose. For example, post-treatment devices such as a surface protection treatment device that performs a surface protection treatment on the object after removing the remaining powder, or a painting device that paints the object after removing the remaining powder can be cited. In addition, the modeling device 100, the drying device 200, the powder removing device 300, and the sintering device 400 can be separate units, or a part or all of them can be constituted by a single device.

[0070] <Structure of the Modeling Device>

[0071] Figure 2 is a schematic diagram of the modeling device 100 according to the first embodiment of the present invention. Based on Figure 2, the structure of the shaping device 100 will be described. For example, the shaping device 100 is an example of a device applicable to the BJ (Binder Jetting) method.

[0072] The shaping device 100 includes a shaping unit 1 and a shaping liquid supply mechanism 5.

[0073] (Shaping unit)

[0074] The shaping unit 1 forms a powder layer 31 containing a shaping material 20. The shaping unit 1 includes a powder tank 11 and a layer forming unit 16. The powder tank 11 includes a supply tank 21, a shaping tank 22, and a recovery tank 25. The supply tank 21 is a tank for storing the shaping material 20 supplied to the shaping tank 22. The shaping tank 22 is a tank for storing the powder layer 31 formed by supplying the shaping material 20 and the shaping layer 30 formed by binding the shaping material 20. The recovery tank 25 is a tank for recovering the remaining shaping material 20 that overflows from the shaping tank 22. The supply tank 21, the shaping tank 22, and the recovery tank 25 are all formed in a box shape with an open upper surface. In addition, the bottom 47 of the supply tank 21 is configured as a supply table 23 that can be lifted and lowered in the vertical direction ( Figure 2 the Z direction in). Similarly, the bottom 48 of the shaping tank 22 is also configured as a shaping table 24 that can be lifted and lowered in the vertical direction.

[0075] The layer forming unit 16 is a unit that supplies the shaping material 20 from the supply tank 21 to the shaping tank 22 to form the powder layer 31. The layer forming unit 16 includes a flattening mechanism 12 and a removing mechanism 13.

[0076] The flattening mechanism 12 moves in the horizontal direction ( Figure 2 the Y direction in), supplies the shaping material 20 from the supply tank 21 to the shaping tank 22, and flattens the supplied shaping material 20. In Figure 2 the example shown, as the flattening mechanism 12, a rotating body called a recoater is used. In addition, as the flattening mechanism 12, a plate-shaped blade or rod can also be used.

[0077] The removing mechanism 13 is a mechanism for removing the shaping material 20 attached to the flattening mechanism 12. In Figure 2 the example shown, as the removing mechanism 13, a plate-shaped member that contacts the flattening mechanism 12 and removes the shaping material 20 is used. The removing mechanism 13 is configured to be able to move together with the flattening mechanism 12 in a state of contacting the flattening mechanism 12.

[0078] (Shaping liquid supply mechanism)

[0079] The shaping liquid supply mechanism 5 is a mechanism for supplying the shaping liquid 10 to the powder layer 31 formed in the shaping tank 22 to form the shaping layer 30. The shaping liquid supply mechanism 5 includes a head 52 and a carriage 51.

[0080] The head 52 is a means for ejecting the shaping liquid 10 onto the powder layer 31. For example, the head 52 is an inkjet head having a nozzle array in which a plurality of nozzles are arranged. As a method of imparting the shaping liquid, in addition to the inkjet method, a dispenser method may also be used. Additionally, four nozzles 52 may be provided, and by imparting a cyan shaping liquid, a magenta shaping liquid, a yellow shaping liquid, a black shaping liquid, etc., a color-shaped object can be shaped.

[0081] The carriage 51 is a means for mounting the head 52 and moving the head 52 in two mutually orthogonal horizontal directions ( Figure 2 the X direction and the Y direction therein) and the vertical direction ( Figure 2 the Z direction therein).

[0082] <Operation of the Shaping Device>

[0083] Next, with reference to Figures 3 - 8 the operation of the shaping device 100 of the first embodiment of the present invention will be described.

[0084] First, when forming the first powder layer 31 on the shaping table 24 of the shaping tank 22, as Figure 3 shown, the supply table 23 of the supply tank 21 is raised so that the upper surface of the shaping material 20 is located above the upper surface of the supply tank 21 by a specified thickness. On the other hand, in the shaping tank 22, the shaping table 24 is adjusted to be located below the upper surface of the shaping tank 22, lower than the desired thickness of the powder layer 31.

[0085] Next, as Figure 4 shown, the flattening mechanism 12 is moved in the horizontal direction from the supply tank 21 toward the shaping tank 22, and the shaping material 20 on the supply table 23 is pushed toward the shaping tank 22 side by the flattening mechanism 12. Then, as Figure 5 shown, when the shaping material 20 pushed by the flattening mechanism 12 is supplied onto the shaping table 24, as Figure 6 shown, the first powder layer 31 with a uniform thickness is formed on the shaping table 24. At this time, the remaining shaping material 20 overflowing from the shaping tank 22 falls into the recovery tank 25 and is recovered. Then, as Figure 7 shown, by moving the flattening mechanism 12 in the opposite direction, the flattening mechanism 12 returns to its original initial position.

[0086] After forming the first powder layer 31, as Figure 8As shown, the head 52 is arranged at a position opposite to the powder layer 31, and the molding liquid 10 is ejected from the head 52 toward the powder layer 31. Thereby, the molding material 20 of the powder layer 31 to which the molding liquid 10 is imparted is combined to form a molding layer 30. Specifically, the resin-containing molding liquid 10 adheres to the molding material 20, and the molding materials 20 are combined via the resin to form the molding layer 30. As the resin contained in the molding liquid 10, for example, polyvinyl alcohol (PVA) or polyvinylpyrrolidone (PVP) is used. In addition, the molding liquid 10 is not limited to the molding liquid containing such a resin, and may contain a crosslinking agent and an organic solvent. When the molding liquid 10 contains a crosslinking agent and an organic solvent, by applying the molding liquid 10 to the molding material 20, the resin covering the molding material 20 is dissolved and crosslinked, so that the molding materials 20 are combined.

[0087] In this way, after the molding layer 30 is formed by applying the molding liquid to the first powder layer 31, the heights of the supply table 23 and the molding table 24 are adjusted again in the same manner, and the flattening mechanism 12 is reciprocated to form the second powder layer 31 on the molding table 24. Then, by applying the molding liquid 10 from the head 52 to the second powder layer 31, the second molding layer 30 is formed. Thereafter, by repeating the same process, a plurality of molding layers 30 are stacked to mold the molded object.

[0088] In addition, the remaining molding material 20 recovered into the recovery tank 25 can also be returned to the supply tank 21. For example, the molding material 20 in the recovery tank 25 is transferred to a molding material supply device provided above the supply tank 21 or the like. Further, the molding material 20 stored in the molding material supply device can be supplied to the supply tank 21 when the molding device 100 starts the molding operation or when the molding material 20 in the supply tank 21 decreases. As a mechanism for transferring the molding material 20 to the molding material supply device, a screw conveyor method using a screw, an air conveying method using air, or the like can be used.

[0089] <Manufacturing process of the molded object>

[0090] Figure 9 is a flowchart showing a molding method of a molded object of the molding system 1000 according to the first embodiment of the present invention.

[0091] As Figure 9 shown, in the manufacturing process, in addition to the molding process S0 performed by the molding device 100, it also includes a drying process S4 performed by the drying device 200, a remaining powder removing process S5 performed by the powder removing device 300, a debinding process S6 and a sintering process S7 performed by the sintering device 400.

[0092] In the molding process S0, it includes by Figures 3 - 8The steps of operating the shaping device 100. That is, in the shaping step S0, it includes: a powder layer forming step S1 of forming a powder layer 31 containing the shaping material 20; a shaping liquid applying step S2 of applying a shaping liquid to the powder layer 31; and a stacking step S3 of repeatedly performing the powder layer forming step S1 and the shaping liquid applying step S2. Thus, the shaped object is shaped.

[0093] After the shaping step S0 is performed, a drying step S4 of drying the shaped object is performed. In the drying step S4, by heating the shaped object using the drying device 200, the liquid components such as the solvent remaining in the shaped object are vaporized and removed. After that, a remaining powder removing step S5 of removing the remaining powder adhering to the shaped object is performed by the powder removing device 300. Then, after the remaining powder removing step S5 is performed, a debinding step S6 using the sintering device 400 is performed. In the debinding step S6, the resin in the shaped object is removed by heating the shaped object in an atmosphere containing an inert gas. Thus, a debound body is formed. Finally, a sintering step S7 using the sintering device 400 is performed to obtain a sintered body obtained by sintering the debound body.

[0094] <The problem of deformation occurring in the shaped object>

[0095] Here, with reference to Figure 10 The problem of deformation occurring in the shaped object will be described. Figure 10 This is a diagram for explaining the mechanism of deformation occurring in the shaped object. Figure 10 (a) shows the shaped object 40 before the drying step, Figure 10 (b) shows the resin segregation of the shaped object 40, Figure 10 (c) shows the deformation of the shaped object 40.

[0096] In a shaping system of the BJ method, if a drying step and a sintering step are performed on the shaped object, deformation of the shaped object 40 sometimes occurs. For example, as Figure 10 (c) shows, warping sometimes occurs in such a way that the center of the shaped object 40 protrudes upward more than the two ends. As a reason for this deformation, consider Figure 10 (a) and Figure 10 (b) show the mechanism.

[0097] First, as Figure 10 (a) shows, in the shaped object 40 before the drying step, the resin 9 contained in the shaping liquid applied through the shaping step is uniformly present throughout the shaped object 40. When the drying step of the shaped object 40 is performed from this state, the liquid components such as the solvent contained in the shaped object 40 are vaporized. In addition, as Figure 10As shown by the arrow in (b), the resin 9 in the molded object 40 moves from the lower part to the upper part of the molded object 40. As a result, the resin 9 is concentrated in the upper part of the molded object 40. Therefore, resin segregation occurs in which there is more resin in the upper part than in the lower part of the molded object 40. And if the sintering process of the molded object 40 is carried out in a state where resin segregation has occurred, it is difficult to promote the densification of sintering in the upper part where there is a lot of resin 9, while the densification of sintering is promoted in the lower part where there is less resin 9. Therefore, the balance of densification is disrupted. For the above reasons, as Figure 10 a deformation of the molded object 40 shown in (c), warping occurs in the upper part of the molded object 40.

[0098] In the past, as a method of suppressing the deformation of the molded object, there has been a method of previously molding a support structure below the part where deformation occurs, but in this method, it is difficult to suppress the deformation caused by resin segregation. Therefore, in the present invention, in order to suppress the deformation of the molded object, the following molding method is proposed.

[0099] <Molding method of the first embodiment of the present invention>

[0100] Figure 11 is a side view of the molded object 40 and the sacrificial molded object 60 molded by the molding method of the first embodiment of the present invention. Figure 12 is a top view of the molded object 40 and the sacrificial molded object 60 molded by the molding method of the first embodiment of the present invention. Refer to Figure 11 and Figure 12 , the molding method of the first embodiment of the present invention will be described.

[0101] In the molding method of the first embodiment of the present invention, in the molding tank 22, in addition to the molded object 40 finally obtained as the product, a sacrificial molded object 60 is also molded. The molded object 40 and the sacrificial molded object 60 are molded above the molding table 24 and are in a state of being embedded in the molding material 20 in the molding tank 22. The molded object 40 of the present invention is described as a cuboid, but various shapes such as a cube, a polyhedron, a cylinder, a prism, a polyhedron, a sphere, a shape with a concave part, and a shape with a convex part can also be applied. Different from the molded object 40, the sacrificial molded object 60 is not a molded object as a product, but a molded object molded incidentally to suppress the deformation of the molded object 40. Therefore, the sacrificial molded object 60 is molded in a state where it can be separated or separated from the molded object 40. The sacrificial molded object 60 is removed after the drying process. The sacrificial molded object 60 can be the same molding material 20 as the molded object 40 or a different molding material 20.

[0102] Specifically, the sacrificial molded object 60 includes a plurality of column parts 61 and a top part 62 molded above the column parts 61.

[0103] A plurality of column parts 61 are formed above the shaped object 40. The "above" of the shaped object 40 mentioned here refers to a position where at least a part of the column parts 61 is arranged in an overlapping manner with the shaped object 40 when observed in the vertical direction. In the first embodiment of the present invention, the plurality of column parts 61 are formed independently of each other and are spaced apart from each other. That is, the plurality of column parts 61 are evenly arranged on the rectangular upper surface of the shaped object 40. More specifically, the plurality of column parts 61 are arranged at equal intervals as a whole in the vicinity of the four sides constituting the outer periphery of the upper surface of the shaped object 40 and in the central part of the upper surface. In addition, the plurality of column parts 61 (all column parts 61) are formed in a manner of being connected to the upper surface of the shaped object 40. In addition, the part where the plurality of column parts 61 are connected may be any part including the upper part of the upper surface of the shaped object 40. The "upper part" of the shaped object 40 mentioned here refers to the part above the middle position of the overall height of the shaped object 40. For example, when the shaped object 40 is a sphere, the column part 61 may be connected to the surface (hemisphere) of the part above the center of the sphere. Figure 11 The heights of the plurality of column parts 61 shown are equal respectively, but they may also be different respectively. When the shaped object 40 is a sphere, among the plurality of column parts 61, the height of the outer column part 61 is the highest and the height of the column part 61 in the central part is the smallest. Here, the plurality of column parts 61 are shaped independently of each other and are spaced apart from each other, but at least two or more of the plurality of column parts 61 may also be shaped in contact with each other.

[0104] The top part 62 is formed above the plurality of column parts 61. The "above" mentioned here has the same meaning as the "above" of the shaped object 40. That is, when observed from the vertical direction, it is only necessary to be arranged in such a way that at least a part of the top part 62 overlaps with the plurality of column parts 61. In addition, the top part 62 is connected to the upper ends of the plurality of column parts 61. Therefore, the top part 62 is formed in a manner of being connected to the shaped object 40 via the plurality of column parts 61.

[0105] The top part 62 of the first embodiment of the present invention only needs to be located above the shaped object 40 in a manner of covering the shaped object 40, and it may not be the zenith. Figure 11 The upper part of the top part 62 shown is in a state where no shaping is performed, but it is also possible to further shape the sacrificial shaped object 60 above the top part 62. That is, it is also possible to Figure 11 further shape any one of the plurality of column parts 61, the top part 62, the plurality of column parts 61, and the top part 62 above the top part 62 shown.

[0106] As Figure 11 shown, the height of the plurality of column parts 61 is larger than the thickness of the top part 62. However, this is not limited thereto, and the height of the plurality of column parts 61 may be equal to the thickness of the top part 62, or the thickness of the top part 62 may be larger than the height of the column part 61. The larger the thickness of the top part 62, the more the deformation of the shaped object 40 can be suppressed.

[0107] <Modeling process>

[0108] Next, with reference to Figure 13 , a method for modeling a modeled object of the modeling device according to the first embodiment of the present invention will be described. Figure 13 It is a flowchart showing a method for modeling a modeled object of the modeling device according to the first embodiment of the present invention.

[0109] In the modeling method according to the first embodiment of the present invention, it includes a first modeling process for modeling the modeled object 40 and a second modeling process for modeling the sacrificial modeled object 60. In a modeling system of the BJ method, the modeled object is modeled sequentially from the lower side for each modeling layer. Therefore, first, the modeling of the modeled object 40 arranged on the lower side is performed (first modeling process). Then, after the modeling of the modeled object 40 is completed, the modeling of the sacrificial modeled object 60 is continued (second modeling process). In the modeling of the sacrificial modeled object 60 (second modeling process), first, the modeling of a plurality of column parts 61 is performed, and then the modeling of the top part 62 is performed. Thus, the sacrificial modeled object 60 having column parts 61 above the modeled object 40 and a top part 62 above the column parts 61 is modeled.

[0110] In this way, according to the modeling method of the first embodiment of the present invention, by modeling the sacrificial modeled object 60 above the modeled object 40, deformation of the modeled object 40 caused by resin segregation can be suppressed. In this case, as a mechanism for suppressing resin segregation causing deformation, the mechanism shown in Figure 14 can be considered. Figure 14 It is a diagram for explaining the mechanism of suppressing deformation of the modeled object 40. Figure 14 (a) is a diagram showing the movement of the resin 9 in the modeled object 40 during the drying process, Figure 14 (b) is a diagram showing the movement of the resin 9 in the sacrificial modeled object 60, Figure 14 (c) is a diagram showing the state of the resin 9 in the modeled object 40.

[0111] <Mechanism of deformation suppression>

[0112] After the modeled object 40 and the sacrificial modeled object 60 are modeled in the modeling tank 22, they are stored in the modeling tank 22 together with the modeling material 20, and the drying process is performed in this state. At this time, as shown by the arrow in Figure 14 (a), the resin 9 in the modeled object 40 moves from the bottom to the top along with the drying process. As a result, the resin 9 in the modeled object 40 accumulates in the sacrificial modeled object 60 at the upper part of the modeled object 40. And, as shown in Figure 14 (b), the resin 9 moves to the top part 62 through a plurality of column parts 61. Therefore, resin segregation where there is more resin in the upper part than in the lower part of the modeled object 40 is suppressed. For the above reasons, as shown in Figure 14As shown in (c), the resin 9 in the molded object 40 is distributed in a uniform or nearly uniform state. Additionally, the mechanism for suppressing such resin segregation is only speculative, and the possibility that other mechanisms are related to the suppression of resin segregation cannot be denied. Therefore, the present invention is not limited to this mechanism.

[0113] As described above, according to the molding method of the first embodiment of the present invention, resin segregation can be suppressed. Therefore, deformation of the molded object 40 in the sintering process can be suppressed. That is, since the deviation in the resin amount between the upper and lower parts of the molded object 40 is suppressed, densification promotion in the sintering process is uniformly performed on the upper and lower parts of the molded object 40, suppressing deformation such as warping of the molded object 40.

[0114] As an example of the column part 61, for example, a column part having a cylindrical shape with a diameter of 4 mm is listed, but the column part 61 is not limited to a cylindrical shape and may have a cross-sectional shape other than circular, such as a prismatic shape. Additionally, the column part 61 is not limited to the case where the length in the vertical direction is larger than the width in the horizontal direction. On the contrary, it may be the case where the width in the horizontal direction is larger than the length in the vertical direction. Additionally, the thickness (width in the horizontal direction) of the plurality of column parts 61 is not limited to all being the same, and it may be the case where the thickness of some column parts 61 is different from that of other column parts 61. Furthermore, in addition to the case where the plurality of column parts 61 are arranged at equal intervals, they may be arranged with different intervals.

[0115] As the top part 62, for example, an example of a flat plate shape with a thickness of 1 mm arranged horizontally can be listed, but the top part 62 is not limited to a planar shape and may be a curved shape, a shape with irregularities, a combined shape thereof, etc. Additionally, the thickness of the top part 62 may be uniform or non-uniform. Additionally, the top part 62 may also be rectangular in accordance with the shape of the molded object 40. Additionally, for the shape of the top part 62, various shapes such as a square, a rhombus, a polygon, an ellipse, and a perfect circle can be applied in addition to a rectangle. Additionally, the interval between the top part 62 and the molded object 40 is set to 5 mm, for example. However, the interval between the top part 62 and the molded object 40 is not limited to 5 mm and can be appropriately changed.

[0116] <Removal process>

[0117] In addition, the sacrificial molded object 60 is removed from the molded object 40 after the drying process and before the debinding process and the sintering process. Figure 15This is a flowchart of a modeling method including a removal process (sacrificial molding removal process) representing the first embodiment of the present invention. That is, after the modeling process S0 for modeling the molded object 40 and the sacrificial molding 60 is performed, the drying process S4 for the molded object 40 and the sacrificial molding 60 is carried out. Then, the removal process (sacrificial molding removal process) S10 for separating and removing the sacrificial molding 60 from the molded object 40 is performed. The removal process S10 of the sacrificial molding 60 can be carried out before the remaining powder removal process S5 for removing the remaining powder from the molded object 40, or can be carried out after the remaining powder removal process S5. In addition, the separation operation of the sacrificial molding 60 from the molded object 40 can be manually performed by an operator using tools or the like, or can be automatically performed using a device or the like.

[0118] Next, other embodiments different from the first embodiment of the present invention will be described. Hereinafter, mainly the parts different from the first embodiment of the present invention will be described, and the description of the same parts will be appropriately omitted.

[0119] <Second Embodiment of the Present Invention>

[0120] Figure 16 This is a side view of the molded object 40 and the sacrificial molding 60 modeled by the modeling method of the second embodiment of the present invention.

[0121] In the second embodiment of the present invention, the top portion 62 is composed of a plurality of divided top portions 62a. The divided top portions 62a can be connected to one column portion 61, or can be connected to a plurality of column portions 61. In this case, the vaporized components generated from the molded object 40 during the drying process are discharged upward through the gaps between the divided top portions 62a, and thus, it is expected to promote drying. In addition, the modeling of the divided top portions 62a can be omitted. That is, only a plurality of column portions 61 can be modeled as the sacrificial molding 60 above the molded object 40.

[0122] Similar to the first embodiment of the present invention, at least two or more of the plurality of column portions 61 can be modeled in contact with each other. In addition, the sacrificial molding 60 can be further modeled above the divided top portions 62a. Moreover, the height of the plurality of column portions 61 is larger than the thickness of the divided top portions 62a, but it is not limited thereto. The height of the plurality of column portions 61 can be equal to the thickness of the divided top portions 62a, or the thickness of the divided top portions 62a can be larger than the height of the column portions 61. The heights of the plurality of column portions 61 can be different from each other.

[0123] <Third Embodiment of the Present Invention>

[0124] Figure 17 This is a top view of the molded object 40 and the sacrificial molding 60 modeled by the modeling method of the third embodiment of the present invention.

[0125] In the third embodiment of the present invention, the column portion 61 is disposed only near the outer periphery except for the central portion of the upper surface of the shaped object 40. In this case, since the number of column portions 61 is reduced, the separation operation of the sacrificial shaped object 60 from the shaped object 40 can be reduced, and the amount of waste when the sacrificial shaped object 60 is discarded can be reduced.

[0126] <Fourth Embodiment of the Present Invention>

[0127] Figure 18 It is a plan view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method of the fourth embodiment of the present invention.

[0128] As in the fourth embodiment of the present invention, the column portion 61 may be disposed only near one of the four sides constituting the outer periphery of the upper surface of the shaped object 40. In this case, since the number of column portions 61 is further reduced, the separation operation of the sacrificial shaped object 60 and the amount of waste are further reduced.

[0129] <Fifth Embodiment of the Present Invention>

[0130] Figure 19 It is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method of the fifth embodiment of the present invention.

[0131] In the fifth embodiment of the present invention, the column portion 61 has a concave portion 61a. The concave portion 61a is provided at the lower end of the column portion 61, which is the connecting portion with respect to the shaped object 40. Therefore, the column portion 61 is formed to have a smaller width in the horizontal direction in the concave portion 61a than in other portions. As a result, the column portion 61 is easily separated from the shaped object 40 starting from the concave portion 61a, and thus the removal operation of the sacrificial shaped object 60 is easy. In addition, the concave portion 61a may be an annular groove continuously provided in the circumferential direction of the columnar column portion 61, or may be a plurality of intermittently provided grooves. The shape of the concave portion 61a can be appropriately changed. In addition, in order to easily separate the column portion 61, the column portion 61 may be formed to be thinner as a whole. For example, by forming the column portion 61 into a columnar shape with a diameter of 2 mm, the column portion 61 can be easily separated.

[0132] <Sixth Embodiment of the Present Invention>

[0133] Figure 20 It is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method of the sixth embodiment of the present invention.

[0134] As in the sixth embodiment of the present invention, a gap d1 may also exist between the plurality of column portions 61 and the top portion 62. That is, the plurality of column portions 61 and the top portion 62 may not be connected to each other. In this case, the molding material 20 is interposed between the plurality of column portions 61 and the top portion 62.

[0135] Thus, even when the plurality of column portions 61 and the top portion 62 are not connected to each other, deformation caused by resin segregation of the molded article 40 can be suppressed. In this case, it can be considered that the resin in the molded article 40 moves from the column portion 61 to the top portion 62 via the molding material 20 interposed between the column portion 61 and the top portion 62. Therefore, the resin amount in the upper portion of the molded article 40 decreases. The present invention is not limited to the mechanism described herein. The same applies to the embodiments described below.

[0136] <Seventh Embodiment of the Present Invention>

[0137] Figure 21 It is a side view of the molded article 40 and the sacrificial molded article 60 molded by the molding method of the seventh embodiment of the present invention.

[0138] In the seventh embodiment of the present invention, a gap d2 is provided between the plurality of column portions 61 and the molded article 40. Therefore, the plurality of column portions 61 are not connected to the molded article 40. Therefore, the molding material 20 is interposed between the plurality of column portions 61 and the molded article 40.

[0139] In this case, it can be considered that the resin in the molded article 40 moves from the molded article 40 to the column portion 61 and the top portion 62 via the molding material 20 interposed between the column portion 61 and the molded article 40, thereby suppressing deformation caused by resin segregation in the molded article 40. In addition, in this case, since the entire sacrificial molded article 60 including the column portion 61 and the top portion 62 is separated from the molded article 40, the separation operation of the sacrificial molded article 60 is not required.

[0140] <Eighth Embodiment of the Present Invention>

[0141] Figure 22 It is a side view of the molded article 40 and the sacrificial molded article 60 molded by the molding method of the eighth embodiment of the present invention.

[0142] In the eighth embodiment of the present invention, the gaps d1 and d2 are respectively provided between the plurality of column portions 61 and the top portion 62 and between the plurality of column portions 61 and the molded article 40. Therefore, the plurality of column portions 61 are not connected to the top portion 62 and the molded article 40. Therefore, the molding material 20 exists between the plurality of column portions 61 and the top portion 62 and between the plurality of column portions 61 and the molded article 40, respectively.

[0143] In this case, it can be considered that the resin in the molded object 40 moves toward the column portions 61 and the top portion 62 via the molding material 20 between the plurality of column portions 61 and the top portion 62, and between the plurality of column portions 61 and the molded object 40, thereby suppressing the deformation caused by resin segregation in the molded object 40. Further, in this case, since the sacrificial molded object 60 is separated from the molded object 40 as a whole, the separation operation of the sacrificial molded object 60 is not required either. Further, the plurality of column portions 61 may also be molded by combining two or more of the first, fifth to eighth embodiments of the present invention.

[0144] <Ninth Embodiment of the Present Invention>

[0145] Figure 23 FIG. 7 is a side view of the molded object 40 and the sacrificial molded object 60 molded by the molding method of the ninth embodiment of the present invention.

[0146] In the ninth embodiment of the present invention, the sacrificial molded object 60 includes, in addition to the column portions 61 and the top portion 62, a wall portion 63 molded on the side of the molded object 40. The wall portion 63 may be continuously arranged over the entire periphery of the molded object 40 as long as at least a part of the wall portion 63 overlaps the molded object 40 when viewed from any horizontal direction, or may be arranged on a part of the periphery of the molded object 40. Further, the wall portion 63 is not limited to a flat plate shape, and may also be a curved shape or a shape having irregularities.

[0147] In this way, it can be considered that the sacrificial molded object 60 includes the wall portion 63 in addition to the column portions 61 and the top portion 62, whereby the resin that moves from the molded object 40 toward the top portion 62 via the column portions 61 can further move toward the wall portion 63. Thereby, it can be considered that more resin in the molded object 40 can be moved to the sacrificial molded object 60, the amount of resin in the upper part of the molded object 40 can be reduced, and the deformation caused by resin segregation can be more effectively suppressed.

[0148] The column portions 61, the top portion 62, and the wall portion 63 may be connected to each other to form an integral body, or may be separated with a gap therebetween. Further, the column portions 61 and the molded object 40 may also be connected to each other, or may be separated with a gap therebetween.

[0149] <Tenth Embodiment of the Present Invention>

[0150] Figure 24 FIG. 8 is a side view of the molded object 40 and the sacrificial molded object 60 molded by the molding method of the tenth embodiment of the present invention.

[0151] In the tenth embodiment of the present invention, the sacrificial mold 60 includes, in addition to the column portion 61, the top portion 62, and the wall portion 63, a bottom portion 64 formed below the mold 40. The bottom portion 64 only needs to be arranged such that at least a part of the bottom portion 64 overlaps with the mold 40 when viewed in the vertical direction. In addition, the bottom portion 64 is not limited to a flat plate shape, and may also be a curved shape or a shape with irregularities.

[0152] Thus, since the sacrificial mold 60 includes the bottom portion 64 in addition to the column portion 61, the top portion 62, and the wall portion 63, it can be considered that the resin that moves from the mold 40 through the column portion 61 to the top portion 62 further moves to the bottom portion 64 through the wall portion 63. Thus, it can be considered that more resin in the mold 40 moves to the sacrificial mold 60, the amount of resin in the upper portion of the mold 40 can be reduced, and deformation caused by resin segregation can be more effectively suppressed.

[0153] The column portion 61, the top portion 62, the wall portion 63, and the bottom portion 64 may be connected to each other to form an integral body, or may be separated with a gap therebetween. In addition, the column portion 61 and the mold 40 may be connected to each other, or may be separated with a gap therebetween.

[0154] <The eleventh embodiment of the present invention>

[0155] Figure 25 It is a side view of the mold 40 and the sacrificial mold 60 formed by the molding method of the eleventh embodiment of the present invention.

[0156] In the eleventh embodiment of the present invention, the bottom portion 64 and the mold 40 are connected via a plurality of column portions 65. In this case, the sacrificial mold 60 includes, in addition to the top portion 62, the wall portion 63, and the bottom portion 64, a first column portion 61 formed between the top portion 62 and the mold 40, and a second column portion 65 formed between the bottom portion 64 and the mold 40.

[0157] Thus, since the bottom portion 64 and the mold 40 are connected via the second column portion 65, when the drying process is performed, the resin contained in the bottom portion 64 moves to the mold 40 through the second column portion 65. Thus, it can be considered that the resin is replenished to the lower portion of the mold 40. On the other hand, in the upper portion of the mold 40, the resin moves to the top portion 62 and the wall portion 63 through the first column portion 61, so the amount of resin decreases. That is, it can be considered that in the upper portion where the amount of resin increases during the drying process, the amount of resin can be reduced, and conversely, in the lower portion where the resin becomes less, the amount of resin can be increased. Therefore, deformation caused by resin segregation can be more effectively suppressed.

[0158] The arrangement of the second column portion 65 may be Figure 12 as shown in the column portion (first column portion) 61, and may be evenly arranged over the entire lower surface of the mold 40, or may beFigure 17 or Figure 18 Like the column part (first column part) 61 shown, it is only arranged near a part of the four sides on the outer periphery of the lower surface of the shaped object 40. In addition, similar to the first column part 61, in order to facilitate the separation operation of the shaped object 40, a concave part can also be provided at the connection part of the second column part 65 relative to the shaped object 40.

[0159] In addition, in Figure 25 , the first column part 61, the top part 62, the wall part 63, the bottom part 64 and the second column part 65 are connected to each other to form an integral body, but they can also be separated with a gap therebetween. In addition, the first column part 61 and the shaped object 40, and the second column part 65 and the shaped object 40 can also be connected to each other or can be separated with a gap therebetween.

[0160] <The Twelfth Embodiment of the Present Invention>

[0161] Figure 26 It is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method of the twelfth embodiment of the present invention.

[0162] In the twelfth embodiment of the present invention, the sacrificial shaped object 60 does not have the wall part 63 and the second column part 65, but only has the first column part 61, the top part 62 and the bottom part 64.

[0163] Since the bottom part 64 is not connected to the shaped object 40, there is a gap d3 between the bottom part 64 and the shaped object 40. In addition, the shaping material 20 exists in the gap d3.

[0164] In this case, it can be considered that when the drying process is performed, the resin contained in the bottom part 64 moves to the shaped object 40 through the shaping material 20 between the bottom part 64 and the shaped object 40. Thus, the resin is replenished to the lower part of the shaped object 40. On the other hand, in the upper part of the shaped object 40, the resin moves from the first column part 61 to the top part 62, so the amount of resin decreases. Thus, the deviation of the resin amount between the upper and lower parts of the shaped object 40 is suppressed, so it can be considered that deformation caused by resin segregation can also be effectively suppressed in this case.

[0165] In the fifth to twelfth embodiments of the present invention, similar to the first embodiment of the present invention, at least two or more of the plurality of column parts 61 can be shaped in contact with each other. In addition, the sacrificial shaped object 60 can be further shaped above the top part 62. Moreover, the height of the plurality of column parts 61 is larger than the thickness of the top part 62, but it is not limited thereto. The height of the plurality of column parts 61 can be equal to the thickness of the top part 62, or the thickness of the top part 62 can be larger than the height of the column part 61. The heights of the plurality of column parts 61 can also be different from each other.

[0166] <The thirteenth embodiment of the present invention>

[0167] Figure 27 It is a side view of the molded object 40 and the sacrificial molded object 60 molded by the molding method of the thirteenth embodiment of the present invention.

[0168] In the thirteenth embodiment of the present invention, the sacrificial molded object 60 has only the top portion 62. The top portion 62 is disposed above the molded object 40. That is, when viewed in the vertical direction, the top portion 62 is disposed such that at least a part of the top portion 62 overlaps the molded object 40.

[0169] Since the top portion 62 is not connected to the molded object 40, there is a gap d4 between the top portion 62 and the molded object 40. In addition, the molding material 20 exists in the gap d4.

[0170] In this case, it can be considered that when the drying process is performed, the resin in the molded object 40 moves toward the top portion 62 through the molding material 20 between the top portion 62 and the molded object 40. Therefore, the amount of resin accumulated in the upper portion of the molded product 40 can be reduced, and deformation due to resin segregation can be suppressed.

[0171] Figure 20 , Figure 21 , Figure 22 , Figure 26 and Figure 27 The sizes of the gaps d1, d2, d3, and d4 in

[0172] <The molding process related to other embodiments of the present invention>

[0173] Next, the molding process of each embodiment other than the first embodiment of the present invention will be described.

[0174] First, in Figures 16 - 22 each of the embodiments of Figure 13 , since the sacrificial molded object 60 is an embodiment including the column portion (first column portion) 61 disposed above the molded object 40 and the top portion 62, the molding process is basically the same as the molding process of the first embodiment of the present invention. That is, as

[0175] Figure 28 shows, first, the molded object 40 is molded, then the column portion (first column portion) 61 is molded, and then the top portion 62 is molded.

[0175] Figure 28 is a flowchart showing the molding process of the embodiment of Figure 23 of Figure 23In the embodiment as described above, when the sacrificial molding object 60 includes the wall portion 63, since the wall portion 63 is located on the side of the molding object 40, as Figure 28 shown, when molding the molding object 40, the wall portion 63 is also molded together. That is, for the portions of the molding object 40 and the wall portion 63 at the same height, by applying the molding liquid 10 to the same powder layer 31, the molding layers 30 of the molding object 40 and the wall portion 63 are formed respectively. Then, the molding layers 30 of the molding object 40 and the wall portion 63 are stacked to mold the molding object 40 and the wall portion 63. In addition, when a part of the wall portion 63 is located at a position lower than the molding object 40, the part located at a position lower than the molding object 40 is molded first, and then the other parts of the wall portion 63 and the molding object 40 are molded. On the contrary, when a part of the molding object 40 is located at a position lower than the wall portion 63, the part located at a position lower than the wall portion 63 is molded first, and then the other parts of the molding object 40 and the wall portion 63 are molded.

[0176] When the molding of the molding object 40 and the wall portion 63 is completed, next, the molding of the column portion (first column portion) 61 is performed, and then the molding of the top portion 62 is performed. In addition, when a part of the wall portion 63 is at the same height as the column portion 61, the wall portion 63 is also molded together with the molding of the column portion 61. In this way, the molding of the sacrificial molding object 60 including the wall portion 63 is performed.

[0177] Figure 29 is a flowchart showing the Figure 24 molding process of the embodiment. As in the Figure 24 embodiment, when the sacrificial molding object 60 includes the bottom portion 64, as Figure 29 shown, first, the molding of the bottom portion 64 is started. Then, when the molding of the bottom portion 64 is completed, the molding of the molding object 40 and the wall portion 63, the molding of the column portion (first column portion) 61, and the molding of the top portion 62 are performed in sequence. Regarding the molding of the portions other than the bottom portion 64, it is the same as the Figure 23 embodiment, so the detailed description is omitted.

[0178] Figure 30 is a flowchart showing the Figure 25 molding process of the embodiment. As in the Figure 25 embodiment, when the sacrificial molding object 60 includes the column portion (second column portion) 65 between the bottom portion 64 and the molding object 40, as Figure 30As shown, after the shaping of the bottom 64 is completed, the shaping of the column part (second column part) 65 is carried out. Additionally, when a part of the wall part 63 is at the same height as the column part (second column part) 65, the shaping of the wall part 63 is carried out together with the shaping of the column part (second column part) 65. Then, when the shaping of the column part (second column part) 65 is completed, the shaping of the shaped object 40 and the wall part 63, the shaping of the column part (first column part) 61, and the shaping of the top 62 are carried out in sequence.

[0179] Figure 31 is a flowchart showing Figure 26 the shaping process of the embodiment. As Figure 26 in the embodiment, when the sacrificial shaped object 60 only includes the top 62, the column part (first column part) 61, and the bottom 64, as Figure 31 shown, after the shaping of the bottom 64 is carried out, the shaping of the shaped object 40 is carried out, and then the shaping of the column part (first column part) 61 and the shaping of the top 62 are carried out in sequence.

[0180] Figure 32 is a flowchart showing Figure 27 the shaping process of the embodiment. In Figure 27 the embodiment, since the sacrificial shaped object 60 only includes the top 62, as Figure 32 shown, after the shaping of the shaped object 40 is carried out, the shaping of the top 62 is carried out.

[0181] As described above, the shaping processes of the embodiments of the present invention are carried out.

[0182] <Verification test>

[0183] Next, a verification test for confirming the effects of the present invention will be described. Figure 33 is a diagram showing the results of the verification test for confirming the effects of the present invention.

[0184] In the verification test, the shaped object 40 shaped together with the sacrificial shaped object 60 and the shaped object 40 not shaped together with the sacrificial shaped object 60 are dried after shaping, and the ratio of the resin in the upper part of each shaped object 40 to the resin in the lower part is calculated. The ratio of the resin can be quantitatively calculated, for example, by thermal analysis.

[0185] In Figure 33 this, Example 1 of the present invention is Figure 11 an example where the sacrificial shaped object 60 shown includes the column part (first column part) 61 and the top 62, and Example 2 of the present invention is Figure 27 an example where the sacrificial shaped object 60 only includes the top 62. On the other hand, the comparative example is an example where the sacrificial shaped object 60 is not shaped and only the shaped object 40 is shaped.

[0186] As Figure 33 shown, in the comparative example, the ratio of the resin in the upper part of the molded object 40 to the resin in the lower part exceeded 300 [%], resulting in significant resin segregation. In contrast, in the case of Example 1 and Example 2 of the present invention, the ratio of the resin in the upper part of the molded object 40 to the resin in the lower part was less than 200 [%], and resin segregation was suppressed. In particular, in Example 1 of the present invention, as a result, resin segregation was more effectively suppressed.

[0187] Thus, as in each embodiment of the present invention, when molding the molded object 40 and the sacrificial molded object 60 in the molding process, it can be said that resin segregation of the molded object 40 after drying can be suppressed as compared with the comparative example in which the sacrificial molded object 60 is not molded. In addition, particularly in Example 1 of the present invention, since resin segregation is effectively suppressed, it can be said that in order to suppress resin segregation, it is preferable that the top portion 62 is connected to the molded object 40 via the column portion 61. This is because the resin in the molded object 40 easily moves to the top portion 62 via the column portion 61.

[0188] <Structure of control unit and molding data generation device>

[0189] Next, the structure of the control unit and the molding data generation device of the molding system according to each embodiment of the present invention will be described.

[0190] Figure 34 is a block diagram showing an example of the control unit 500 and the molding data generation device 600 of the molding system 1000 according to each embodiment of the present invention.

[0191] As Figure 34 shown, the molding system 1000 includes a control unit 500 and a molding data generation device 600.

[0192] The control unit 500 includes a CPU 501 (central processing unit), a ROM 502 (read only memory), and a RAM 503 (random access memory). The ROM 502 stores a program for causing the molding data generation device 600 to perform a process of generating molding data when molding the molded object 40 and the sacrificial molded object 60, and other fixed data. The RAM 503 has a function of temporarily storing molding data and the like.

[0193] The modeling data generation device 600 is a computer or the like, and generates modeling data obtained by slicing the modeled object 40 and the sacrificial modeled object 60 for each modeling layer 30. The control unit 500 receives the modeling data from the modeling data generation device 600 and controls the modeling operation of each modeling layer 30 based on the modeling data. In addition, the modeling data generation device 600 may be separate from the modeling device 100 or may be integrally formed. In addition, the control unit 500 may be inside the modeling device 100 or outside the modeling device 100.

[0194] As described above, the embodiments of the present invention have been described. However, the modeling method, modeling system, and program for executing the modeling method of the present invention are not limited to the above embodiments, and design changes can be appropriately made without departing from the gist of the invention.

[0195] In the above embodiment, the case where one modeled object 40 and the sacrificial modeled object 60 arranged around it are modeled in the modeling tank 22 has been described as an example. However, the first modeling process for modeling the modeled object 40 and the second modeling process for modeling the sacrificial modeled object 60 may be performed multiple times. Figure 35 It is a diagram showing an example in which a plurality of modeled objects 40 and sacrificial modeled objects 60 are modeled in the modeling tank 22 according to an embodiment of the present invention. As Figure 35 shown in the example, the first modeling process and the second modeling process may be performed multiple times to model a plurality of modeled objects 40 and sacrificial modeled objects 60 in the modeling tank 22. In Figure 35 it, an example of modeling four sacrificial modeled objects 60 corresponding to the modeled object 40 is shown, but the number of modeled objects can be appropriately changed. The modeled objects 40 may have the same shape or may be one or more different.

[0196] Figure 36 It is a diagram showing an example in which a plurality of modeled objects 40 and sacrificial modeled objects 60 are modeled in the modeling tank 22 according to another embodiment of the present invention. The parts different from Figure 35 will be described, and the description of the same parts will be appropriately omitted. Figure 36 (a) is a diagram showing the top 62 and the connecting top 62b, Figure 36 (b) is a diagram in which a part of the top 62 is omitted, Figure 36 (c) is a diagram in which the connecting top 62b is provided and the top 62 is omitted. For the sake of simplicity of explanation, the case where the modeled object 40 is modeled into four modeled objects 40a, 40b, 40c, and 40d will be described. Similar to Figure 35 the above, the number and shape of the modeled objects can be appropriately changed.

[0197] Figure 36In (a), a molded object 40b is molded in the horizontal direction of the molded object 40a. A sacrificial molded object 60 is molded above the molded object 40a and the molded object 40b. Specifically, a plurality of column parts 61 are molded above the molded object 40a, and a top part 62 is molded above the plurality of column parts 61. In addition, similarly to the molded object 40a, a plurality of column parts 61 are molded above the molded object 40b, and a top part 62 is molded above the column parts 61. Above the sacrificial molded objects 60 corresponding to the molded object 40a and the molded object 40b respectively, a molded object 40c and a molded object 40d are also molded. Similarly to the molded object 40a and the molded object 40b, a plurality of column parts 61 are molded above the molded object 40c and the molded object 40d, but a connecting top part 62b is molded above the plurality of column parts 61. The connecting top part 62b is different from the top parts 62 of the molded object 40a and the molded object 40b, and becomes a common member with a plurality of column parts 61 in between.

[0198] Figure 36 (b) is different from Figure 36 (a). A plurality of column parts 61 are respectively molded above the molded object 40a and the molded object 40b, but the molding of the top part 62 is omitted above the plurality of column parts 61. That is, above the plurality of column parts 61, a molded object 40c and a molded object 40d are molded. In addition, a plurality of column parts 61 are molded above the molded object 40c and the molded object 40d, and a top part 62 is molded above the plurality of column parts 61. Figure 36 (b) is different from Figure 36 (a). The above-mentioned connecting top part 62b is not connected to the plurality of column parts 61 above the molded object 40c and the molded object 40d.

[0199] Figure 36 (c) is different from Figure 36 (a). A plurality of column parts 61 are respectively molded above the molded object 40a and the molded object 40b, but the molding of the top part 62 is omitted above the plurality of column parts 61. That is, above the plurality of column parts 61, a molded object 40c and a molded object 40d are molded. In addition, Figure 36 (c) is different from Figure 36 (b). A plurality of column parts 61 are molded above the molded object 40c and the molded object 40d, and a connecting top part 62b is molded above the plurality of column parts 61.

[0200] In addition, the molding method of the present invention only needs to include at least a molding process, and may not go through each process of a drying process, a residual powder removing process, a sacrificial molded object removing process (removing process), a degreasing process, and a sintering process, or may include one or more of them.

[0201] In addition, in the above-described embodiments, the case where the modeling method of the present invention is applied to a modeling system of the BJ method has been described as an example, but this description does not limit the application of the present invention to other methods. Therefore, as long as the present invention can be used to suppress the deformation of the modeled object, the present invention can also be applied to modeling systems of methods other than the BJ method.

[0202] Summarizing the embodiments of the present invention described above, the present invention at least includes the following embodiments:

[0203] [First Embodiment]

[0204] The first embodiment relates to a modeling method, characterized by including:

[0205] A first modeling process for modeling a modeled object; and

[0206] A second modeling process for modeling a sacrificial modeled object above the modeled object,

[0207] The sacrificial modeled object includes:

[0208] A plurality of column parts; and

[0209] A top part, which is modeled above the column parts.

[0210] [Second Embodiment]

[0211] In the second embodiment, in the first embodiment, after modeling the column parts, the top part is modeled.

[0212] [Third Embodiment]

[0213] In the third embodiment, in the first or second embodiment, the top part is connected to at least one of the column parts.

[0214] [Fourth Embodiment]

[0215] In the fourth embodiment, in the first or second embodiment, the top part is connected to all of the column parts.

[0216] [Fifth Embodiment]

[0217] In the fifth embodiment, in any one of the first to fourth embodiments, the column parts have concave parts.

[0218] [Sixth Embodiment]

[0219] In the sixth embodiment, in any one of the first to fifth embodiments, the sacrificial modeled object includes a wall part modeled on the side of the modeled object.

[0220] [Seventh Embodiment]

[0221] In the seventh embodiment, in any one of the first to sixth embodiments, the sacrificial modeled object includes a bottom part modeled below the modeled object.

[0222] [Eighth form]

[0223] The eighth form is that in the seventh form, the sacrificial object includes a plurality of column parts formed between the bottom and the object.

[0224] [Ninth form]

[0225] The ninth form is that in any one of the first to eighth forms, the first shaping process and the second shaping process are performed multiple times to shape a plurality of the objects and the sacrificial object.

[0226] [Tenth form]

[0227] The tenth form is that in any one of the first to ninth forms, the shaping method includes:

[0228] A powder layer forming process for forming a powder layer containing a shaping material; and

[0229] A shaping liquid imparting process for imparting a shaping liquid to the powder layer.

[0230] [Eleventh form]

[0231] The eleventh form is that in the tenth form, the shaping liquid contains resin.

[0232] [Twelfth form]

[0233] The twelfth form is that in any one of the first to eleventh forms, it includes a drying process for drying the object and the sacrificial object.

[0234] [Thirteenth form]

[0235] The thirteenth form is that in the twelfth form, it includes a removing process for removing the sacrificial object after the drying process.

[0236] [Fourteenth form]

[0237] The fourteenth form is that in the thirteenth form, it includes a sintering process for sintering the object after the removing process.

[0238] [Fifteenth form]

[0239] The fifteenth form relates to a shaping method, including:

[0240] A layer forming process for forming a powder layer containing a shaping material; and

[0241] A shaping liquid imparting process for imparting a shaping liquid to the powder layer,

[0242] The shaping method is characterized by including:

[0243] The first shaping process for shaping a shaped object; and

[0244] The second shaping process for shaping a sacrificial shaped object above the shaped object.

[0245] [Sixteenth form]

[0246] The sixteenth form relates to a shaping method, which includes:

[0247] In the first shaping process (S11, S100), shaping a shaped object (40);

[0248] In the second shaping process (S101), in order to form a sacrificial shaped object (60), in the stacking direction, shaping a plurality of column parts (61) above the shaped object (40); and

[0249] In the second shaping process (S101), in order to form a sacrificial shaped object (60), in the stacking direction, shaping a top part (62) above the plurality of column parts (61).

[0250] [Seventeenth form]

[0251] The seventeenth form relates to a shaping system for shaping a shaped object and a sacrificial shaped object after shaping and drying, characterized in that:

[0252] Including a shaping device, which performs:

[0253] The first shaping process for shaping the shaped object; and

[0254] The second shaping process for shaping the sacrificial shaped object above the shaped object,

[0255] The sacrificial shaped object includes:

[0256] A plurality of column parts; and

[0257] A top part shaped above the column parts.

[0258] [Eighteenth form]

[0259] The eighteenth form relates to a shaping system, including:

[0260] A shaping device, in the first shaping process, shaping a shaped object, and in the second shaping process, in the stacking direction, shaping a sacrificial shaped object above the shaped object; and

[0261] A drying device for drying the shaped object and the sacrificial shaped object.

[0262] [Nineteenth form]

[0263] The nineteenth form relates to a program, characterized in that it is used to cause a modeling data generation device to execute processing for generating modeling data when modeling the modeled object and the sacrificial modeled object by any one of the first to sixteenth forms of the modeling method.

[0264] [The twentieth form]

[0265] The twentieth form relates to a recording medium, characterized in that it stores computer instructions which, when executed by one or more processors of a computer, cause the one or more processors to execute the modeling method according to any one of the first to sixteenth forms.

[0266] [The twenty - first form]

[0267] The twenty - first form relates to a computer program product, characterized in that it includes computer instructions which, when executed by one or more processors of a computer, cause the one or more processors to execute the modeling method according to any one of the first to sixteenth forms.

Claims

1. A shaping method, characterized in that: include: The first shaping step is to shape the object; and The second shaping step is to shape a sacrificial shaping object on the top of the shaping object. The sacrificial molding comprises: a plurality of columns; and The top is formed above the column.

2. The molding method according to claim 1, characterized in that: After shaping the column, shape the top.

3. The molding method according to claim 1, characterized in that: The top portion is connected to at least one of the pillar portions.

4. The molding method according to claim 1, characterized in that: The top portion is connected to all of the column portions.

5. The molding method according to claim 1, characterized in that: The column portion has a recessed portion.

6. The molding method according to claim 1, characterized in that: The sacrificial object includes a wall portion formed on the side of the object.

7. The molding method according to claim 1, characterized in that: The sacrificial object includes a bottom portion formed below the object.

8. The molding method according to claim 7, characterized in that: The sacrificial molding includes a plurality of pillars molded between the bottom and the molding.

9. The molding method according to claim 1, characterized in that: The first shaping step and the second shaping step are performed multiple times to shape the shaped object and the sacrificial shaped object multiple times.

10. The molding method according to claim 1, characterized in that: The modeling method comprises: a powder layer forming step of forming a powder layer including a modeling material; and The modeling liquid applying step is to apply the modeling liquid to the powder layer.

11. The molding method according to claim 10, characterized in that: The modeling liquid contains resin.

12. The molding method according to claim 1, characterized in that: The method comprises a drying step of drying the shaped object and the sacrificial shaped object.

13. The molding method according to claim 12, characterized in that: The method comprises a removing step of removing the sacrificial molding after the drying step.

14. The molding method according to claim 13, characterized in that: The method further comprises a sintering step of sintering the shaped object after the removing step.

15. A modeling method comprising: a layer forming step of forming a powder layer including a modeling material; and a modeling liquid applying step of applying a modeling liquid to the powder layer, The modeling method is characterized in that it comprises: The first shaping step is to shape the object; and The second shaping step is to shape a sacrificial shaping object on the shaping object.

16. A molding system for molding a molded object and a sacrificial molded object after molding, characterized in that : Includes a modeling device that performs: A first shaping step is to shape the object; and The second shaping step is to shape the sacrificial shaping object above the shaping object. The sacrificial molding comprises: a plurality of columns; and A top portion of the molding is formed above the column portion.

17. A recording medium, characterized in that Computer instructions are stored, and when the computer instructions are executed by one or more processors of a computer, the one or more processors execute the modeling method described in any one of claims 1 to 15.

18. A computer program product, characterized in that The computer system comprises computer instructions, which, when executed by one or more processors of a computer, enable the one or more processors to execute the modeling method described in any one of claims 1 to 15.

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