Method for manufacturing a three-dimensional shaped object

Abstract

Provided is a method for manufacturing a three-dimensional shaped object, which can reduce variation in the line width of a material that is ejected from a nozzle and accumulated on a table. A method for manufacturing a three-dimensional shaped object is a method for manufacturing a three-dimensional shaped object in a three-dimensional shaping device including a plasticizing section having a screw and a motor that rotates the screw to plasticize a material and generate a plasticized material; a flow path through which the plasticized material passes; a nozzle having a nozzle opening that ejects the plasticized material that has passed through the flow path from the nozzle opening toward a table; and a position changing section that changes the relative positions of the table and the nozzle, the method including a deceleration process that reduces the relative speed of the nozzle with respect to the table, in which the screw is reversed.

Description

Technical Field

[0001] This invention relates to a method for manufacturing three-dimensional objects. Background Technology

[0002] There is a known method for creating three-dimensional objects by spraying plasticized material from a nozzle toward a worktable and allowing it to solidify.

[0003] For example, Patent Document 1 describes a method for manufacturing a three-dimensional model in a three-dimensional modeling device, which includes: a nozzle having a nozzle opening from which modeling material is ejected toward a worktable; a position changing unit that changes the relative position of the nozzle and the worktable; and a pressure adjusting unit having a branch flow path connected to a flow path for supplying modeling material and a plunger that moves within the branch flow path.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2023-182086

[0005] In the aforementioned method of manufacturing three-dimensional objects, it is desirable to reduce the variation in the linewidth of the material ejected from the nozzle and deposited on the worktable. Summary of the Invention

[0006] One aspect of the method for manufacturing a three-dimensional object according to the present invention is a method for manufacturing a three-dimensional object in a three-dimensional modeling apparatus, the three-dimensional modeling apparatus comprising: a plasticizing unit having a spiral component and a motor for rotating the spiral component to plasticize material to generate a plasticized material; a flow path through which the plasticized material passes; a nozzle having a nozzle opening for ejecting the plasticized material that has passed through the flow path from the nozzle opening toward a worktable; and a position changing unit for changing the relative position of the worktable and the nozzle, the method for manufacturing the three-dimensional object including a deceleration step of reducing the relative speed of the nozzle relative to the worktable, wherein the spiral component is reversed in the deceleration step. Attached Figure Description

[0007] Figure 1 This is a schematic cross-sectional view of the three-dimensional modeling device of this embodiment.

[0008] Figure 2 This is a perspective view schematically showing the spiral component of the three-dimensional modeling device of this embodiment.

[0009] Figure 3 This is a schematic top view of the barrel of the three-dimensional modeling apparatus of this embodiment.

[0010] Figure 4 This is a flowchart illustrating the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0011] Figure 5 This is a cross-sectional view of the modeling process of the control unit of the three-dimensional modeling device used to explain this embodiment.

[0012] Figure 6 This is a flowchart illustrating the spiral rotation speed control process of the control unit of the three-dimensional modeling device in this embodiment.

[0013] Figure 7 This is a flowchart illustrating a modified example of the spiral rotation speed control process of the control unit of the three-dimensional modeling device in this embodiment.

[0014] Figure 8 It is a graph showing the rate of change of line width relative to the elapsed time.

[0015] Label Explanation

[0016] 10…Ejection section, 20…Worktable, 30…Position changing section, 32…First electric actuator, 34…Second electric actuator, 36…Third electric actuator, 40…Control section, 100…3D modeling device, 110…Material supply section, 112…Supply path, 120…Plasticizing section, 122…Spiral housing, 124…Drive motor, 126…Shaft, 130…Spiral, 131…Upper surface, 132…Gutter forming surface, 133…Side surface, 134…First groove, 135…Central section, 136…Connecting section, 137…Material inlet section, 140…Barrel, 142…Opposing surface, 144…Second groove, 146…Connecting hole, 150…Heater, 160…Nozzle, 162… Nozzle flow path, 164… Nozzle opening, 166… Flow path, 170… Pressure adjustment section, 172… Branch flow path, 174… Plunger, 176… Drive section. Detailed Implementation

[0017] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Furthermore, the embodiments described below are not intended to unduly limit the scope of the invention as defined in the claims. Additionally, the structures described below are not necessarily all essential components of the present invention.

[0018] 1. Three-dimensional modeling installation

[0019] 1.1. Overall Structure

[0020] First, the three-dimensional modeling device of this embodiment will be described with reference to the accompanying drawings. Figure 1 This is a schematic cross-sectional view of the three-dimensional modeling device 100 according to this embodiment. Additionally, in Figure 1In the diagram, the X-axis, Y-axis, and Z-axis are shown as three mutually orthogonal axes. The X-axis and Y-axis directions are, for example, horizontal. The Z-axis direction is, for example, vertical.

[0021] like Figure 1 As shown, the three-dimensional modeling device 100 includes, for example, an ejection unit 10, a worktable 20, a position changing unit 30, and a control unit 40.

[0022] The 3D modeling apparatus 100 sprays plasticized material from the ejector 10 toward the worktable 20 while simultaneously driving the position changing unit 30 to change the relative position of the ejector 10 and the worktable 20. As a result, the 3D modeling apparatus 100 layers the modeling material onto the worktable 20 to create a 3D object of the desired shape. The 3D modeling apparatus 100 is, for example, a FDM (Fused Deposition Modeling) type 3D modeling apparatus.

[0023] Additionally, although not shown, multiple ejector sections 10 may be provided. Two ejector sections 10 may also be provided. In this case, both ejector sections 10 may eject plastic material that constitutes the three-dimensional shape, or one may eject plastic material while the other ejects a support member that supports the three-dimensional shape. The two ejector sections 10 may also be arranged in the X-axis direction.

[0024] like Figure 1 As shown, the ejection section 10 includes, for example, a material supply section 110, a plasticizing section 120, a nozzle 160, and a pressure adjustment section 170.

[0025] The material supply section 110 stores granular and powdered materials. The material supply section 110 supplies materials to the plasticizing section 120. The material supply section 110 is, for example, composed of a hopper. The material supplied from the material supply section 110 is, for example, acrylonitrile butadiene styrene (ABS) resin.

[0026] The material supply unit 110 and the plasticizing unit 120 are connected by a supply path 112 located below the material supply unit 110. The material fed into the material supply unit 110 is supplied to the plasticizing unit 120 via the supply path 112.

[0027] The plasticizing section 120 includes, for example, a spiral housing 122, a drive motor 124, a spiral 130, a barrel 140, and a heater 150. The plasticizing section 120 plasticizes at least a portion of the solid material supplied from the material supply section 110 to generate a fluid paste-like plasticized material, which is then supplied to the nozzle 160.

[0028] Furthermore, plasticization includes the concept of melting, which is a change from a solid to a fluid state. Specifically, in the case of materials undergoing a glass transition, plasticization refers to raising the material's temperature above the glass transition point. In the case of materials not undergoing a glass transition, plasticization refers to raising the material's temperature above its melting point.

[0029] The spiral housing 122 is a housing for housing the spiral component 130. A barrel 140 is provided on the lower surface of the spiral housing 122. The spiral component 130 is housed in the space surrounded by the spiral housing 122 and the barrel 140.

[0030] A drive motor 124 is disposed on the upper surface of the spiral member housing 122. The drive motor 124 is, for example, a servo motor. The shaft 126 of the drive motor 124 is connected to the upper surface 131 of the spiral member 130. The drive motor 124 causes the spiral member 130 to rotate. The drive motor 124 is controlled by the control unit 40. Alternatively, the shaft 126 of the drive motor 124 and the upper surface 131 of the spiral member 130 can also be connected via a reducer.

[0031] The helical member 130 is, for example, a planar helical member with a generally cylindrical shape, having a size in the direction of the rotation axis R that is smaller than the size of the direction orthogonal to the rotation axis R. In the illustrated example, the rotation axis R is parallel to the Z-axis. The helical member 130 rotates about the rotation axis R using the torque generated by the drive motor 124.

[0032] The spiral member 130 has an upper surface 131, a groove forming surface 132 on the side opposite to the upper surface 131, and a side surface 133 connecting the upper surface 131 and the groove forming surface 132. A first groove 134 is formed on the groove forming surface 132. The side surface 133 is, for example, perpendicular to the groove forming surface 132. Figure 2 This is a schematic perspective view of the spiral component 130. Furthermore, for convenience, in Figure 2 The diagram shows the relationship between the upper and lower positions. Figure 1 The opposite of the state shown.

[0033] like Figure 2As shown, a first groove 134 is formed on the groove forming surface 132 of the auger 130. The first groove 134, for example, has a central portion 135, a connecting portion 136, and a material inlet portion 137. The central portion 135 faces a communicating hole 146 formed in the barrel 140. The central portion 135 communicates with the communicating hole 146. The connecting portion 136 connects the central portion 135 and the material inlet portion 137. In the illustrated example, the connecting portion 136 is arranged in a vortex shape from the central portion 135 toward the outer periphery of the groove forming surface 132. The material inlet portion 137 is provided on the outer periphery of the groove forming surface 132. That is, the material inlet portion 137 is provided on the side surface 133 of the auger 130. Material supplied from the material supply section 110 is introduced into the first groove 134 through the material inlet portion 137, and is conveyed through the connecting portion 136 and the central portion 135 to the communicating hole 146 formed in the barrel 140. For example, two first grooves 134 are formed.

[0034] Furthermore, the number of the first groove 134 is not particularly limited. Although not shown, the first groove 134 can be formed in more than three forms, or in only one form. In addition, although not shown, the helical member 130 may not be a planar helical member, but a long coaxial screw with helical grooves on the side.

[0035] like Figure 1 As shown, the barrel 140 is disposed below the auger 130. The barrel 140 has a counter surface 142 opposite to the groove forming surface 132 of the auger 130. A connecting hole 146 communicating with the first groove 134 is formed at the center of the counter surface 142. Figure 3 This is a schematic top view of the barrel 140.

[0036] like Figure 3 As shown, a second groove 144 and a connecting hole 146 are formed on the opposing surface 142 of the barrel 140. Multiple second grooves 144 are formed. In the illustrated example, six second grooves 144 are formed, but the number of second grooves 144 is not particularly limited. Viewed from the Z-axis direction, multiple second grooves 144 are formed around the connecting hole 146. One end of each second groove 144 is connected to the connecting hole 146 and extends in a vortex shape from the connecting hole 146 toward the outer periphery of the barrel 140. The second groove 144 functions to guide the plasticized material to the connecting hole 146.

[0037] Furthermore, although not shown in the figure, the shape of the second groove 144 is not particularly limited; for example, it can also be straight. Additionally, one end of the second groove 144 may not be connected to the connecting hole 146. Furthermore, the second groove 144 may not be formed on the opposing surface 142. However, if efficient guidance of the plasticized material into the connecting hole 146 is desired, it is preferable that the second groove 144 is formed on the opposing surface 142.

[0038] like Figure 1As shown, heater 150 is disposed in barrel 140. Heater 150 heats the material supplied between screw 130 and barrel 140. The output of heater 150 is controlled by control unit 40. Plasticizing unit 120 heats the material while conveying it toward connecting hole 146 via screw 130, barrel 140 and heater 150, thereby generating plasticized material. Then, plasticizing unit 120 causes the generated plasticized material to flow out from connecting hole 146.

[0039] Additionally, although not shown in the diagram, the heater 150 can also be annular when viewed from the Z-axis direction. Alternatively, the heater 150 can be located below the barrel 140 instead of being mounted on it.

[0040] A nozzle 160 is disposed below the barrel 140. A nozzle flow path 162 is formed in the nozzle 160. The nozzle flow path 162 communicates with a connecting hole 146. Plasticizing material is supplied to the nozzle flow path 162 from the connecting hole 146. The nozzle 160 ejects the plasticizing material supplied to the nozzle flow path 162 from the nozzle opening 164 toward the worktable 20. The nozzle flow path 162 and the connecting hole 146 constitute the flow path 166. The three-dimensional modeling apparatus 100 includes the flow path 166. In the illustrated example, the flow path 166 extends along the Z-axis direction. Plasticizing material passes through the flow path 166. The nozzle 160 ejects the plasticizing material passing through the flow path 166 from the nozzle opening 164 toward the worktable 20.

[0041] A pressure regulating section 170 is disposed to the side of the flow path 166. The pressure regulating section 170 includes, for example, a branch flow path 172, a plunger 174, and a drive section 176. The branch flow path 172 is connected to the flow path 166. The branch flow path 172 branches off from the flow path 166. In the illustrated example, the branch flow path 172 is connected to the nozzle flow path 162. The branch flow path 172 extends along the X-axis. Although not shown, the branch flow path 172 may also be connected to the connecting hole 146. The plunger 174 moves within the branch flow path 172. In the illustrated example, the plunger 174 moves along the X-axis. The drive section 176 moves the plunger 174. The drive section 176 is configured, for example, to include a motor. The drive section 176 is controlled by a control section 40.

[0042] The pressure regulating unit 170 adjusts the pressure of the flow path 166. Specifically, by moving the plunger 174 away from the flow path 166, the pressure of the flow path 166 can be reduced. Conversely, by moving the plunger 174 closer to the flow path 166, the pressure of the flow path 166 can be increased.

[0043] A worktable 20 is positioned below the nozzle 160. In the illustrated example, the worktable 20 is rectangular in shape. Plastic material ejected from the nozzle 160 is deposited on the worktable 20. The worktable 20 is made of a metal such as aluminum.

[0044] The position changing unit 30 supports the worktable 20. The position changing unit 30 changes the relative position of the ejector 10 and the worktable 20. That is, the position changing unit 30 changes the relative position of the nozzle 160 and the worktable 20. Through the position changing unit 30, the nozzle 160 moves relative to the worktable 20. In the illustrated example, the position changing unit 30 changes the relative position of the ejector 10 and the worktable 20 in the X-axis and Y-axis directions by moving the worktable 20 in both directions. Furthermore, the position changing unit 30 changes the relative position of the ejector 10 and the worktable 20 in the Z-axis direction by moving the ejector 10 in the Z-axis direction.

[0045] The position changing unit 30 includes, for example, a first electric actuator 32, a second electric actuator 34, and a third electric actuator 36. The first electric actuator 32 moves the worktable 20 in the X-axis direction. The second electric actuator 34 moves the worktable 20 in the Y-axis direction. The third electric actuator 36 moves the ejection unit 10 in the Z-axis direction. The electric actuators 32, 34, and 36 are controlled by the control unit 40.

[0046] Furthermore, the position changing unit 30 is not particularly limited in structure as long as it can change the relative position of the ejector 10 and the worktable 20. For example, the position changing unit 30 could be a structure that moves the worktable 20 in the Z-axis direction and moves the ejector 10 in the X-axis and Y-axis directions. Alternatively, the position changing unit 30 could be a structure that fixes the worktable 20 and moves the ejector 10 along the X-axis, Y-axis, and Z-axis directions. Alternatively, the position changing unit 30 could be a structure that fixes the ejector 10 and moves the worktable 20 along the X-axis, Y-axis, and Z-axis directions.

[0047] The control unit 40 may be configured as a computer, for example, having a processor, main memory, and an input / output interface for inputting and outputting signals to and from the outside. The control unit 40 performs various functions, for example, by executing programs loaded into the main memory via the processor. Specifically, the control unit 40 controls the ejection unit 10 and the position changing unit 30. Alternatively, the control unit 40 may not be a computer, but rather a combination of multiple circuits.

[0048] 1.2. Actions

[0049] 1.2.1. Overall Process

[0050] Figure 4 This is a flowchart illustrating the operation of the three-dimensional modeling device 100. Specifically, Figure 4 This is a flowchart illustrating the processing of the control unit 40 of the three-dimensional modeling device 100.

[0051] The user, for example, operates an operation unit (not shown) to output a processing start signal to the control unit 40 to begin processing. The operation unit may consist of, for example, a mouse, keyboard, or touch panel. The control unit 40 begins processing upon receiving the processing start signal.

[0052] First, such as Figure 4 As shown, as step S1, the control unit 40 performs a modeling data acquisition process to acquire modeling data for modeling a three-dimensional object.

[0053] The modeling data includes, for example, the type of material stored in the material supply section 110, information about the path of the nozzle 160 relative to the worktable 20, information about the relative speed of the nozzle 160 relative to the worktable 20 corresponding to the path, information about the rotational speed of the auger 130 corresponding to the relative speed, and information about the amount of plasticized material ejected from the nozzle 160 in the path.

[0054] The modeling data is created, for example, by reading shape data from slicing software installed on a computer connected to the 3D modeling device 100. Shape data represents the target shape of a 3D model created using 3D CAD (Computer Aided Design) software, 3D CG (Computer Graphics) software, etc. Shape data may be in formats such as STL (Standard Triangulated Language) or AMF (Additive Manufacturing File Format). The slicing software divides the target shape of the 3D model into layers of a specified thickness and creates modeling data for each layer. The modeling data is represented by G-code, M-code, etc. The control unit 40 acquires the modeling data from a computer connected to the 3D modeling device 100, a USB (Universal Serial Bus) memory, or other recording medium.

[0055] Next, as step S2, the control unit 40 controls the ejection unit 10 and the position change unit 30 based on the styling data to perform a styling layer forming process in which plasticizing material is ejected from the ejection unit 10 toward the worktable 20 and a styling layer is formed.

[0056] Specifically, the control unit 40 plasticizes the material supplied between the auger 130 and the barrel 140 to generate a plasticized material, and then ejects the plasticized material from the nozzle 160 of the ejection unit 10. The control unit 40 continues to generate the plasticized material, for example, until the molding layer forming process is completed.

[0057] Here, Figure 5 This is a cross-sectional view used to illustrate the modeling layer formation process performed by the control unit 40 of the three-dimensional modeling device 100.

[0058] like Figure 5 As shown, based on the acquired modeling data, the control unit 40 controls the position change unit 30 to change the relative position of the ejector unit 10 and the worktable 20, and controls the ejector unit 10 to eject the plasticized material from the nozzle 160 toward the worktable 20.

[0059] Specifically, before the shaping layer formation process begins, that is, before the formation of shaping layer L1, which is the first shaping layer, begins, the nozzle 160 is positioned at an initial position in the -X-axis direction further than the end of the worktable 20 in the -X-axis direction. When the shaping layer formation process begins, as... Figure 5 As shown, the control unit 40, through the control position changing unit 30, moves the nozzle 160 relative to the worktable 20 in the +X axis direction. When the nozzle 160 passes over the worktable 20, plasticizing material is ejected from the nozzle 160. This forms the molding layer L1. Figure 5 In the diagram, n is set to any natural number, and the design layer Ln up to the nth layer is illustrated.

[0060] Next, as Figure 4 As shown, as step S3, the control unit 40 performs a determination process based on the modeling data to determine whether the formation of all modeling layers has been completed.

[0061] If it is determined that the formation of all shaping layers is incomplete ("No" in step S3), the control unit 40 returns the process to step S2. The control unit 40 repeats steps S2 and S3 until it is determined in step S3 that the formation of all shaping layers is complete.

[0062] On the other hand, if it is determined that the formation of all modeling layers is complete ("Yes" in step S3), the control unit 40 ends the process.

[0063] 1.2.2. Deceleration treatment in the formation of the shaping layer

[0064] The control unit 40 performs nozzle deceleration processing to reduce the relative speed (hereinafter also referred to as "nozzle speed") of the nozzle 160 relative to the worktable 20 during the modeling layer forming process. Specifically, the control unit 40 controls the position change unit 30 to reduce the nozzle speed based on the nozzle speed information contained in the modeling data. For example, if the path of the nozzle 160 relative to the worktable 20 is curved, the control unit 40 reduces the nozzle speed near the curved portion.

[0065] In the nozzle deceleration process, the control unit 40 controls the drive motor 124 to perform helical rotation speed control processing based on the rotational speed information of the auger 130 corresponding to the nozzle speed contained in the shaping data. For example, when the nozzle speed decreases, the amount of plasticized material ejected from the nozzle increases and the line width becomes thicker when the rotational speed of the auger is constant. Therefore, the control unit 40 performs auger rotation speed control processing in the nozzle deceleration process.

[0066] Here, Figure 6 This is a flowchart illustrating the screw rotation speed control process of the control unit 40. After the nozzle deceleration process begins, the control unit 40 starts the screw rotation speed control process. The screw rotation speed control process of the control unit 40 will be explained below.

[0067] like Figure 6 As shown, in step S11, the control unit 40 controls the drive motor 124 based on the modeling data to change the rotational speed of the spiral member 130 from a first rotational speed to a second rotational speed with a different sign than the first rotational speed. That is, the control unit 40 reverses the rotation of the spiral member 130, which was rotating at the first rotational speed, and rotates it at the second rotational speed. The absolute value of the second rotational speed is, for example, greater than the absolute value of the first rotational speed. Immediately after reversing the rotation, there may be a delay in the movement of the spiral member 130 relative to the signal from the control unit 40. Therefore, by making the absolute value of the second rotational speed greater than the absolute value of the first rotational speed, the line width can be adjusted quickly. The control unit 40 continuously rotates the spiral member 130 at the second rotational speed for a predetermined period based on the modeling data.

[0068] Next, as step S12, the control unit 40 controls the drive motor 124 based on the modeling data to change the rotational speed of the spiral member 130 from a second rotational speed to a third rotational speed with the same sign as the first rotational speed. That is, the control unit 40 reverses the rotation of the spiral member 130, which is rotating at the second rotational speed, and causes it to rotate at the third rotational speed. The third rotational speed is, for example, greater than the first and fourth rotational speeds. The absolute value of the third rotational speed is, for example, greater than the absolute value of the second rotational speed. Based on the modeling data, the control unit 40 causes the spiral member 130 to rotate continuously at the third rotational speed for a predetermined period of time.

[0069] Next, as step S13, the control unit 40 controls the drive motor 124 based on the modeling data to change the rotational speed of the spiral member 130 from a third rotational speed to a fourth rotational speed with the same sign as the first rotational speed. The fourth rotational speed is less than both the first and third rotational speeds. The absolute value of the fourth rotational speed is, for example, less than the absolute value of the second rotational speed.

[0070] Then, the control unit 40 ends the spiral component speed control process.

[0071] While controlling the rotational speed of the screw, the control unit 40, for example, controls the drive unit 176 of the pressure adjustment unit 170 to move the plunger 174 away from the flow path 166 in the branch flow path 172. In other words, the control unit 40 causes the plunger 174 to draw back. For example, after the process in step S11 and before the process in step S12, the control unit 40 moves the plunger 174 away from the flow path 166. As a result, the linewidth can be finely adjusted.

[0072] For example, in the process of step S12, the control unit 40 controls the drive unit 176 to move the plunger 174 toward the flow path 166. This allows the plunger 174, which has moved away from the flow path 166, to return to a predetermined position.

[0073] The control unit 40 can also move the plunger 174 away from the flow path 166 based on the shape data. Alternatively, the control unit 40 can determine whether the line width is within a specified value based on an image captured by a camera (not shown), and if the line width exceeds the specified value, move the plunger 174 away from the flow path 166.

[0074] In the method for manufacturing a three-dimensional model in this embodiment, a three-dimensional modeling device 100 is used to manufacture the three-dimensional model.

[0075] 1.3. Effects

[0076] The method for manufacturing a three-dimensional model in this embodiment includes a deceleration step to reduce the relative speed of the nozzle 160 with respect to the worktable 20. In this deceleration step, the auger 130 is reversed. Therefore, in the method for manufacturing a three-dimensional model in this embodiment, by reversing the auger 130, the pressure of the flow path 166 can be rapidly reduced, and the time it takes for the pressure of the flow path 166 to reach a stable value can be shortened. This reduces the variation in the linewidth of the material ejected from the nozzle 160 and accumulated on the worktable 20. For example, even if the path of the nozzle 160 relative to the worktable 20 is complex, the linewidth of the material accumulated on the worktable 20 can be kept constant.

[0077] In the manufacturing method of the three-dimensional model of this embodiment, the deceleration process includes: changing the rotational speed of the auger 130 from a first rotational speed to a second rotational speed with a different sign than the first rotational speed; changing the rotational speed of the auger 130 from the second rotational speed to a third rotational speed with the same sign as the first rotational speed; and changing the rotational speed of the auger 130 from the third rotational speed to a fourth rotational speed with the same sign as the first rotational speed. The third rotational speed is greater than the fourth rotational speed. Therefore, in the manufacturing method of the three-dimensional model of this embodiment, the linewidth that has become thinner due to the change to the second rotational speed can be restored by changing to the third rotational speed.

[0078] In the manufacturing method of the three-dimensional model of this embodiment, the absolute value of the second rotational speed is greater than the absolute value of the first rotational speed. Therefore, in the manufacturing method of the three-dimensional model of this embodiment, by changing to the second rotational speed, the line width can be reduced in a short time.

[0079] In the manufacturing method of the three-dimensional model in this embodiment, the absolute value of the third rotational speed is greater than the absolute value of the second rotational speed. Therefore, in the manufacturing method of the three-dimensional model in this embodiment, by changing to the third rotational speed, it is possible to suppress the line width from becoming too thin.

[0080] In the manufacturing method of the three-dimensional model of this embodiment, during the nozzle deceleration process, the plunger 174 moves away from the flow path 166 in the branch flow path 172. Therefore, in the manufacturing method of the three-dimensional model of this embodiment, the line width can be reduced by means of the plunger 174.

[0081] 2. Variations in the processing of the control unit

[0082] Next, a modified example of the processing of the control unit 40 of the three-dimensional modeling device 100 of this embodiment will be described with reference to the accompanying drawings. Figure 7 This is a flowchart illustrating the processing of the control unit 40. Specifically, Figure 7 This is a flowchart illustrating the screw speed control process of the control unit 40.

[0083] Hereinafter, in a modified example of the processing of the control unit 40 of the three-dimensional modeling device 100 in this embodiment, the differences from the example of the processing of the control unit 40 of the three-dimensional modeling device 100 in this embodiment described above will be explained, and the similarities will be omitted.

[0084] In a modified example of the processing in the control unit 40, such as Figure 7 As shown, the processing steps S21 and S22 are performed. The processing steps S21 and S22 are basically the same as the processing steps S11 and S12 described above.

[0085] Next, as step S23, the control unit 40 controls the drive motor 124 based on the modeling data to change the rotational speed of the spiral member 130 from the third rotational speed to a fifth rotational speed with a different sign than the first rotational speed. That is, the control unit 40 reverses the rotation of the spiral member 130, which was rotating at the third rotational speed, and makes it rotate at the fifth rotational speed.

[0086] The absolute value of the fifth rotational speed is, for example, less than the absolute value of the second rotational speed. The linewidth variation tends to be large initially, then slow. Therefore, by making the absolute value of the second rotational speed greater than the absolute value of the fifth rotational speed, the pressure in the flow channel 166 can be controlled in accordance with the variation in linewidth. The absolute value of the fifth rotational speed is, for example, greater than the absolute values ​​of the first and fourth rotational speeds. The absolute value of the fifth rotational speed is, for example, less than the absolute value of the third rotational speed.

[0087] Based on the modeling data, the control unit 40 causes the auger 130 to rotate continuously at a fifth rotational speed for a predetermined period. The period during which the auger 130 rotates continuously at the fifth rotational speed is, for example, longer than the period during which the auger 130 rotates continuously at the second rotational speed and the period during which the auger 130 rotates continuously at the third rotational speed.

[0088] Next, as step S24, the control unit 40 controls the drive motor 124 based on the modeling data to change the rotational speed of the spiral member 130 from the fifth rotational speed to the fourth rotational speed, which has the same sign as the first rotational speed. That is, the control unit 40 reverses the rotation of the spiral member 130, which is rotating at the fifth rotational speed, and makes it rotate at the fourth rotational speed.

[0089] Then, the control unit 40 finishes processing the control of the rotational speed of the screw 130.

[0090] In the method for manufacturing a three-dimensional model in this embodiment, a variation of the processing of the control unit 40 of the three-dimensional modeling device 100 described above is used to manufacture the three-dimensional model.

[0091] In the manufacturing method of the three-dimensional model in this embodiment, the deceleration process includes a step between the step of changing to the third speed and the step of changing to the fourth speed, whereby the rotational speed of the auger 130 is changed from the third speed to a fifth speed with a different sign than the first speed. In the step of changing to the fourth speed, the rotational speed of the auger 130 is changed from the fifth speed to the fourth speed. Therefore, in the manufacturing method of the three-dimensional model in this embodiment, by changing to the fifth speed, the linewidth that became too thick in the step of changing to the third speed can be changed to an appropriate linewidth. 3. Example of material variation for the three-dimensional modeling device

[0092] Next, a variation example of the material of the three-dimensional modeling device 100 of this embodiment will be described.

[0093] In the aforementioned three-dimensional modeling apparatus 100, the material supplied from the material supply unit 110 to the plasticizing unit 120 is ABS resin. However, the material supplied from the material supply unit 110 to the plasticizing unit 120 may also be a material other than ABS resin, or a material in which other components have been added to ABS resin.

[0094] Materials supplied from the material supply unit 110 can include various materials primarily composed of thermoplastic, metallic, and ceramic materials. Here, "primary material" refers to the core material that forms the shape of the three-dimensional model manufactured by the three-dimensional modeling device 100, and is defined as a material comprising 50% or more by mass in the three-dimensional model. Among these materials are materials formed by melting these primary materials as monomers, and materials in which a portion of the components contained with the primary materials are melted into a paste.

[0095] Examples of thermoplastic materials include thermoplastic resins. Examples of thermoplastic resins include general-purpose plastics, general-purpose engineering plastics, and super engineering plastics.

[0096] Examples of general-purpose plastics include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), and polylactic acid (PLA).

[0097] Examples of general-purpose engineering plastics include polyacetal (POM), polyamide (PA), polycarbonate (PC), modified polyphenylene ether (m-PPE), polybutylene terephthalate (PBT), and polyethylene terephthalate (PET).

[0098] Examples of super engineering plastics include polysulfone (PSU), polyethersulfone (PES), polyphenylene sulfide (PPS), polyarylate (PAR), polyimide (PI), polyamide-imide (PAI), polyether-imide (PEI), and polyether-ether ketone (PEEK).

[0099] Pigments, metals, ceramics, and additives such as waxes, flame retardants, antioxidants, and heat stabilizers can also be mixed into thermoplastic materials. The thermoplastic material is plasticized in the plasticizing section 120 by the rotation of the screw 130 and the heating of the heater 150, transforming it into a molten state. Furthermore, the plasticized material thus generated, after being sprayed from the nozzle 160 and deposited on the worktable 20, solidifies due to a decrease in temperature.

[0100] In the plasticizing section 120, for example, a metal material can be used as the main material instead of the aforementioned thermoplastic material. In this case, it is preferable to mix the molten components from the formation of the plastic material into a powder material in which the metal material is made into powder, and then add it to the plasticizing section 120.

[0101] Examples of metallic materials include single metals such as magnesium (Mg), iron (Fe), cobalt (Co) or chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), and nickel (Ni), or alloys containing one or more of these metals, or maraging steel, stainless steel, cobalt-chromium-molybdenum alloys, titanium alloys, nickel alloys, aluminum alloys, cobalt alloys, and cobalt-chromium alloys.

[0102] In the plasticizing section 120, ceramic materials can be used as the main material to replace the aforementioned metal materials. Examples of ceramic materials include oxide ceramics such as silicon dioxide, titanium dioxide, alumina, and zirconium oxide, as well as non-oxide ceramics such as aluminum nitride.

[0103] The powder materials of metal and ceramic materials supplied from the material supply section 110 may also be a mixture of powders of a single metal or alloy, and powders of various ceramic materials. Alternatively, the powder materials of metal and ceramic materials may be coated with, for example, the aforementioned thermoplastic resin, or other thermoplastic resins. In this case, the thermoplastic resin may be melted in the plasticizing section 120 to exhibit fluidity.

[0104] Solvents can also be added to powdered metal and ceramic materials supplied from the material supply unit 110. Examples of solvents include: water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetates such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and isobutyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine solvents such as pyridine, γ-methylpyridine, and 2,6-dimethylpyridine; tetraalkylammonium acetate (e.g., tetrabutylammonium acetate); ionic liquids such as butyl carbitol acetate.

[0105] In addition, an adhesive may be added to the powdered metal or ceramic material supplied from the material supply unit 110. Examples of adhesives include acrylic resin, epoxy resin, silicone resin, cellulose resin or other synthetic resin, or PLA, PA, PPS, PEEK or other thermoplastic resins.

[0106] 4. Examples and Comparative Examples

[0107] When plastic material is sprayed from the nozzle of the three-dimensional modeling device corresponding to the three-dimensional modeling device 100 toward the worktable, and the rotation speed of the planar spiral component is changed from 5 rpm to 1.7 rpm, the line width of the material accumulated on the worktable is measured. Figure 8 It is a graph showing the rate of change of line width relative to the elapsed time.

[0108] In Example 1, the rotational speed of the planar helical component was changed from 5 rpm to -12 rpm and maintained for 40 ms, then changed to 25 rpm and maintained for 40 ms, then changed to -6 rpm and maintained for 120 ms, and then changed to 1.7 rpm.

[0109] In Example 2, the rotational speed of the planar helical component is the same as in Example 1 above, except that the rotational speed of the helical component is changed from 5 rpm to -12 rpm and maintained for 80 ms.

[0110] In Comparative Example 1, the rotational speed of the planar screw was changed directly from 5 rpm to 1.7 rpm.

[0111] In addition, in the above, the sign of the rotational speed when the planar helical component is reversed is set to negative.

[0112] like Figure 8 As shown, compared to Comparative Example 1, Examples 1 and 2 exhibit smaller variations in linewidth and a shorter time to stabilize. Compared to Example 2, Example 1 shows smaller variations in linewidth. However, compared to Example 1, the linewidth of Example 2 stabilizes in a shorter time.

[0113] As can be seen from the above, by reversing the spiral component, the variation in line width can be reduced.

[0114] The above-described embodiments and modifications are examples and are not intended to limit the scope. For instance, the embodiments and modifications can be appropriately combined.

[0115] This invention includes structures that are substantially the same as those described in the embodiments, such as structures with the same function, method, and result, or structures with the same purpose and effect. Additionally, this invention includes structures that replace non-essential parts of the structures described in the embodiments. Furthermore, this invention includes structures capable of achieving the same function or effect as the structures described in the embodiments, or structures that achieve the same purpose. Additionally, this invention includes structures incorporating known techniques into the structures described in the embodiments.

[0116] The following content is derived from the above implementation methods and variations.

[0117] One method for manufacturing a three-dimensional object is a method for manufacturing a three-dimensional object in a three-dimensional modeling apparatus, the three-dimensional modeling apparatus comprising: a plasticizing unit having a spiral component and a motor for rotating the spiral component to plasticize material to generate a plasticized material; a flow path through which the plasticized material passes; a nozzle having a nozzle opening for ejecting the plasticized material that has passed through the flow path from the nozzle opening toward a worktable; and a position changing unit for changing the relative position of the worktable and the nozzle, the method for manufacturing the three-dimensional object including a deceleration step of reducing the relative speed of the nozzle relative to the worktable, in which the spiral component is reversed.

[0118] According to the manufacturing method of this three-dimensional model, it is possible to reduce the variation in the linewidth of the material ejected from the nozzle and accumulated on the worktable.

[0119] In one method of manufacturing three-dimensional objects, it can also be... The deceleration process includes the following steps: changing the rotational speed of the screw from a first rotational speed to a second rotational speed with a different sign than the first rotational speed; changing the rotational speed of the screw from the second rotational speed to a third rotational speed with the same sign as the first rotational speed; and changing the rotational speed of the screw from the third rotational speed to a fourth rotational speed with the same sign as the first rotational speed, wherein the third rotational speed is greater than the fourth rotational speed.

[0120] According to the manufacturing method of this three-dimensional model, the line width that has become thinner due to the process of changing to the second speed can be restored by changing the process to the third speed.

[0121] In one method of manufacturing a three-dimensional object, the deceleration process may include the following step between the step of changing to the third speed and the step of changing to the fourth speed: changing the speed of the screw from the third speed to a fifth speed with a different sign than the first speed, and in the step of changing to the fourth speed, changing the speed of the screw from the fifth speed to the fourth speed.

[0122] According to the manufacturing method of this three-dimensional model, by changing to the fifth rotation speed, the line width that becomes too thick in the third rotation speed process can be changed to an appropriate line width.

[0123] In one method of manufacturing a three-dimensional object, the absolute value of the second rotational speed may also be greater than the absolute value of the first rotational speed.

[0124] According to the manufacturing method of this three-dimensional model, by changing to a second rotation speed, the line width can be reduced in a short time.

[0125] In one method of manufacturing a three-dimensional object, the absolute value of the third rotational speed may also be greater than the absolute value of the second rotational speed.

[0126] According to the manufacturing method of this three-dimensional model, by changing the process to the third rotation speed, it is possible to suppress the line width from becoming too thin.

[0127] In one embodiment of the method for manufacturing a three-dimensional model, the three-dimensional modeling device may include a pressure adjustment unit having a branch flow path connected to the flow path and a plunger moving in the branch flow path, wherein, during the deceleration process, the plunger moves in the branch flow path away from the flow path.

[0128] According to the manufacturing method of this three-dimensional object, the line width can be reduced by using a plunger.

Claims

1. A method for manufacturing a three-dimensional model, which is a method for manufacturing a three-dimensional model in a three-dimensional modeling device. The three-dimensional modeling device includes: The plasticizing section has a spiral component and a motor that rotates the spiral component, and plasticizes the material to generate a plasticized material; A flow path in which the plasticizing material passes; A nozzle having a nozzle opening that sprays the plasticized material that has passed through the flow path from the nozzle opening toward the worktable; as well as The position changing unit changes the relative position of the worktable and the nozzle. The method for manufacturing the three-dimensional model includes a deceleration process that reduces the relative speed of the nozzle with respect to the worktable. In the deceleration process, the spiral component is reversed.

2. The method for manufacturing a three-dimensional object according to claim 1, wherein, The deceleration process includes the following steps: The rotational speed of the spiral component is changed from a first rotational speed to a second rotational speed with a different sign from the first rotational speed; The rotational speed of the screw component is changed from the second rotational speed to a third rotational speed with the same sign as the first rotational speed; as well as The rotational speed of the screw component is changed from the third rotational speed to a fourth rotational speed with the same sign as the first rotational speed. The third rotational speed is greater than the fourth rotational speed.

3. The method for manufacturing a three-dimensional object according to claim 2, wherein, The deceleration process includes the following step between the step of changing to the third speed and the step of changing to the fourth speed: changing the speed of the screw from the third speed to a fifth speed with a different sign than the first speed. In the process of changing to the fourth speed, the speed of the screw is changed from the fifth speed to the fourth speed.

4. The method for manufacturing a three-dimensional object according to claim 2, wherein, The absolute value of the second rotational speed is greater than the absolute value of the first rotational speed.

5. The method for manufacturing a three-dimensional object according to claim 4, wherein, The absolute value of the third rotational speed is greater than the absolute value of the second rotational speed.

6. The method for manufacturing a three-dimensional model according to any one of claims 1 to 5, wherein, The three-dimensional modeling device includes a pressure adjustment unit, which has a branch flow path connected to the flow path and a plunger that moves in the branch flow path. During the deceleration process, the plunger moves in the branch flow path away from the flow path.

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