Method for manufacturing a three-dimensional shaped object

Abstract

Provided is a method for manufacturing a three-dimensional shaped object, which can balance the productivity and accuracy of the three-dimensional shaped object. The method for manufacturing a three-dimensional shaped object, which shapes a three-dimensional shaped object by layering a modeling material from a nozzle to a table, includes: a path information acquisition step of acquiring path information including a movement path of the nozzle relatively moving with respect to the table while discharging the modeling material toward the table; a speed decision step of deciding a speed of the nozzle with respect to the table based on a bending angle of the movement path included in the path information and a distance for bringing the speed of the nozzle with respect to the table to a prescribed value; and a shaping step of layering a modeling layer by discharging the modeling material from the nozzle while moving the nozzle with respect to the table based on the path information and the decided speed of the nozzle.

Description

Technical Field

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

[0002] There are known methods 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, which includes: a first step, determining the movement speed of the ejector in each local path based on the configuration of the endpoints representing the start and end points of the multiple local paths contained in the path information representing the movement path of the ejector while ejecting modeling material toward the worktable through multiple local paths; and a second step, layering the modeling material by ejecting it from the ejector while moving the ejector at the determined movement speed.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2023-121204

[0005] In the manufacturing method of three-dimensional objects as described above, it is desirable to balance the productivity and accuracy of the three-dimensional objects. Summary of the Invention

[0006] One method for manufacturing a three-dimensional object according to the present invention is to create a three-dimensional object by layering modeling material from a nozzle onto a worktable. The method includes the following steps: a path information acquisition step, wherein the path information includes a movement path of the nozzle moving relative to the worktable while spraying the modeling material toward the worktable; a speed determination step, wherein the speed of the nozzle relative to the worktable is determined based on the bending angle of the movement path included in the path information and the distance for achieving a predetermined speed of the nozzle relative to the worktable; and a modeling step, wherein the modeling material is sprayed from the nozzle to layer modeling layers while moving the nozzle relative to the worktable based on the path information and the determined speed of the nozzle. 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 planar 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 the embodiment of this invention.

[0012] Figure 6 This is a table showing the data used in the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0013] Figure 7 This is a flowchart illustrating the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0014] Figure 8 This is a flowchart illustrating the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0015] Figure 9 This is a flowchart illustrating the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0016] Figure 10 This is a flowchart illustrating the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0017] Figure 11 This is a diagram illustrating the movement path of the nozzle of the three-dimensional modeling device relative to the worktable in this embodiment.

[0018] Figure 12 This is a diagram illustrating the movement path of the nozzle of the three-dimensional modeling device relative to the worktable in this embodiment.

[0019] Figure 13 This is a diagram illustrating the movement path of the nozzle of the three-dimensional modeling device relative to the worktable in this embodiment.

[0020] Figure 14 This is a flowchart illustrating a variation of the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0021] Figure 15 This is a flowchart illustrating a variation of the processing of the control unit of the three-dimensional modeling device in this embodiment.

[0022] Figure 16 This is a diagram illustrating the movement path of the nozzle of the three-dimensional modeling device relative to the worktable in this embodiment.

[0023] Figure 17 This is a diagram illustrating the movement path of the nozzle of the three-dimensional modeling device relative to the worktable in this embodiment.

[0024] Label Explanation

[0025] 10 Ejection section; 20 Worktable; 30 Position changing section; 32 First electric actuator; 34 Second electric actuator; 36 Third electric actuator; 40 Control section; 42 Storage section; 100 Three-dimensional modeling device; 110 Material supply section; 112 Supply path; 120 Plasticizing section; 122 Spiral housing; 124 Drive motor; 126 Shaft; 130 Planar spiral component; 131 Upper surface; 132 Groove 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. Detailed Implementation

[0026] 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.

[0027] 1. Three-dimensional modeling installation

[0028] 1.1. Overall Structure

[0029] 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 1 In 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.

[0030] 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.

[0031] The 3D modeling apparatus 100 sprays plasticized modeling 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 model of the desired shape. The 3D modeling apparatus 100 is, for example, a FDM (Fused Deposition Modeling) type 3D modeling apparatus. Furthermore, although not shown, multiple ejector 10s may be provided. Two ejector 10s may also be provided. In this case, both ejector 10s may spray modeling material that constitutes the 3D model, or one may spray modeling material while the other sprays support material supporting the 3D model. The two ejector 10s may also be arranged in the X-axis direction.

[0032] like Figure 1 As shown, the ejection section 10 includes, for example, a material supply section 110, a plasticizing section 120, and a nozzle 160.

[0033] 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.

[0034] 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.

[0035] The plasticizing section 120 includes, for example, a spiral housing 122, a drive motor 124, a flat 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 molding material, which is then supplied to the nozzle 160.

[0036] 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.

[0037] The spiral housing 122 is a housing for housing the planar spiral component 130. A barrel 140 is provided on the lower surface of the spiral housing 122. The planar spiral component 130 is housed in the space surrounded by the spiral housing 122 and the barrel 140.

[0038] A drive motor 124 is disposed on the upper surface of the helical component 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 planar helical component 130. 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 planar helical component 130 can also be connected via a reducer.

[0039] The planar helical member 130 has an approximately cylindrical shape, with the magnitude of the direction along the rotation axis R being smaller than the magnitude of the direction orthogonal to the rotation axis R. In the illustrated example, the rotation axis R is parallel to the Z-axis. The planar helical member 130 rotates about the rotation axis R using the torque generated by the drive motor 124.

[0040] The planar helical 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 planar helical 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.

[0041] like Figure 2 As shown, a first groove 134 is formed on the groove forming surface 132 of the planar spiral member 130. The first groove 134 has, for example, a central portion 135, a connecting portion 136, and a material inlet portion 137. The central portion 135 is opposite to 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 planar spiral member 130. The 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, the first groove 134 has two forms.

[0042] Furthermore, the number of first grooves 134 is not particularly limited. Although not shown, there may be three or more first grooves 134, or only one. Additionally, although not shown, the plasticizing section 120 may not have a flat helical member 130, but instead have a long coaxial screw with helical grooves on its side. Moreover, the plasticizing section 120 can also plasticize the material by rotating the coaxial screw.

[0043] like Figure 1 As shown, the barrel 140 is disposed below the planar auger 130. The barrel 140 has a counter surface 142 opposite to the groove forming surface 132 of the planar 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.

[0044] 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 towards the outer periphery of the barrel 140. The second groove 144 functions to guide the plasticized molding material to the connecting hole 146.

[0045] 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.

[0046] like Figure 1 As shown, a heater 150 is disposed in the barrel 140. The heater 150 heats the material supplied between the planar auger 130 and the barrel 140. The output of the heater 150 is controlled by the control unit 40. The plasticizing unit 120 heats the material while conveying it toward the connecting hole 146 via the planar auger 130, the barrel 140, and the heater 150, thereby generating a plasticized molding material. Then, the plasticizing unit 120 causes the generated molding material to flow out from the connecting hole 146.

[0047] 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.

[0048] A nozzle 160 is positioned below the material cylinder 140. A nozzle flow path 162 is formed in the nozzle 160. The nozzle flow path 162 communicates with a connecting hole 146. Molding material is supplied from the connecting hole 146 to the nozzle flow path 162. The nozzle 160 ejects the molding material supplied to the nozzle flow path 162 toward the worktable 20. In the three-dimensional molding apparatus 100, a three-dimensional object is molded by layering molding material from the nozzle 160 onto the worktable 20.

[0049] A worktable 20 is positioned below the nozzle 160. In the illustrated example, the worktable 20 is rectangular in shape. The molding material ejected from the nozzle 160 is deposited on the worktable 20. The worktable 20 is made of a metal such as aluminum.

[0050] 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. The nozzle 160 moves relative to the worktable 20 via the position changing unit 30. In the illustrated example, the position changing unit 30 changes the relative position of the nozzle 160 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 nozzle 160 and the worktable 20 in the Z-axis direction by moving the ejector 10 in the Z-axis direction.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] The control unit 40 includes, for example, a storage unit 42. The storage unit 42 is composed of, for example, RAM (Random Access Memory) or ROM (Read Only Memory). The storage unit 42 stores, for example, data used in the processing of the control unit 40.

[0055] 1.2. Actions

[0056] 1.2.1. Overall Process

[0057] 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.

[0058] 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.

[0059] 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.

[0060] The styling data includes, for example, the type of material stored in the material supply unit 110, path information including the movement path of the nozzle 160 moving relative to the worktable 20 while spraying styling material toward the worktable 20, and information on the amount of styling material sprayed from the nozzle 160 in the movement path.

[0061] 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.

[0062] Next, as step S2, the control unit 40 performs a speed determination process, in which the speed of the nozzle 160 relative to the worktable 20 is determined based on the bending angle of the movement path contained in the acquired path information and the distance required to make the nozzle 160 reach a predetermined speed relative to the worktable 20. The details of the speed determination process will be described later.

[0063] Next, as step S3, the control unit 40 controls the position change unit 30 to move the nozzle 160 relative to the worktable 20 based on the path information contained in the modeling data and the speed of the nozzle 160 determined by the speed determination process, and controls the ejection unit 10 to perform the modeling process of ejecting modeling material from the nozzle 160 to stack modeling layers.

[0064] Specifically, the control unit 40 plasticizes the material supplied between the planar auger 130 and the barrel 140 to generate molding material, and then ejects the molding material from the nozzle 160 of the ejection unit 10. The control unit 40, for example, continuously generates molding material until the molding process is completed. Figure 5 This is a cross-sectional view used to illustrate the modeling process performed by the control unit 40 of the three-dimensional modeling device 100.

[0065] 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 ejection unit 10 and the worktable 20, and controls the ejection unit 10 to eject the plasticized modeling material from the nozzle 160 toward the worktable 20.

[0066] Specifically, before the shaping process begins, that is, before the formation of the shaping layer M1, 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 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, molding material is ejected from the nozzle 160. This forms the molding layer M1. Figure 5 In this diagram, n is set to any natural number, and the design layer up to the nth layer, Mn, is illustrated. The stacking direction of multiple design layers is the Z-axis direction.

[0067] Next, as Figure 4 As shown, as step S4, 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.

[0068] If it is determined that the formation of all shaping layers is incomplete (No in step S4), the control unit 40 returns the process to step S2. The control unit 40 repeats steps S3 and S4 until it is determined in step S4 that the formation of all shaping layers is complete.

[0069] On the other hand, if it is determined that the formation of all the modeling layers is complete ("Yes" in step S4), the control unit 40 ends the process.

[0070] 1.2.2. Speed ​​determines processing

[0071] (1) Data used in speed determination processing

[0072] The storage unit 42 of the 3D modeling device 100 stores the data used in the speed determination process. Figure 6 This is a table showing the data stored in storage unit 42 that is used in the speed determination process. Figure 6 The table below shows the data in Tables 1 through n.

[0073] exist Figure 6 In this context, "movement speed" refers to the movement speed of nozzle 160 relative to worktable 20 (hereinafter also referred to as "nozzle speed"). V1 is the slowest, increasing in the order of V2, V3, ..., Vn-1, Vn. That is, V2 is faster than V1, V3 is faster than V2, and Vn is faster than Vn-1. When the control unit 40 performs a process to increase the nozzle speed, it performs a process to increase the nozzle speed step by step. For example, when increasing the nozzle speed from speed V1 to speed V3, after performing a process to increase from speed V1 to speed V2, it performs a process to increase from speed V2 to speed V3. Similarly, when the control unit 40 performs a process to decrease the nozzle speed, it performs a process to decrease the nozzle speed step by step.

[0074] The "minimum assurance distance" is the minimum distance that must be ensured for the nozzle 160 to accelerate and stably spray the molding material relative to the worktable 20; it is the distance required to achieve the specified nozzle speed. The minimum assurance distance is set based on the nozzle speed.

[0075] The "threshold angle" is a threshold angle relative to the nozzle speed within the movement path (hereinafter also referred to as the "movement path") of the nozzle 160 relative to the worktable 20. The threshold angle is set based on the nozzle speed. For example, when the nozzle speed is Vn, if the bending angle is θn or greater, the nozzle 160 can stably spray molding material while bending. On the other hand, if the bending angle is less than θn, the nozzle 160 cannot stably spray molding material while bending at a speed Vn. θ1 is the smallest, and it increases in the order of θ2, θ3, ..., θn-1, θn.

[0076] "Deceleration distance" is the distance that should be ensured when it is determined that deceleration is necessary. The deceleration distance is the distance of the deceleration range. The deceleration distance is set based on the nozzle speed.

[0077] "Search distance" is the distance within the range used to determine the cumulative angle for deceleration. The search distance is set based on the nozzle speed.

[0078] (2) Overall process

[0079] Figures 7-10 This is a flowchart illustrating the speed determination process of the control unit 40. Specifically, Figure 7 This is a flowchart illustrating the overall process of speed determination in the control unit 40. Figure 8 This is a flowchart illustrating the process of setting the speed V1 in the control unit 40. Figure 9 This is a flowchart illustrating the processing after the control unit 40 determines the speed V2. Figure 10 This is a flowchart illustrating the process by which the control unit 40 determines whether deceleration is necessary.

[0080] After completing the aforementioned modeling data acquisition process, the control unit 40 performs speed determination processing. In the speed determination processing, firstly, as... Figure 7 As shown, as step S10, the control unit 40 processes the setting speed V1.

[0081] Next, as step S20, the control unit 40 performs processing after determining the speed V2. For example, the control unit 40 sequentially determines the speeds V2, V3, ..., Vn-1, and Vn.

[0082] Then, the control unit 40 finishes the speed determination process.

[0083] (3) Setting the speed V1

[0084] Here, Figures 11-13 This is a diagram illustrating the movement path of nozzle 160 relative to the worktable 20. The following will explain... Figures 11-13 The arrow shown is used to illustrate the case where the movement path is represented.

[0085] like Figure 11 As shown, the movement path is formed in one stroke. The movement path consists of straight, single paths. In the example shown, the movement path consists of two single paths, P1 and P2. The movement path includes a bend angle θ. The bend angle θ is greater than 0° and less than 180°. The bend angle θ can also be less than 180°. The larger the bend angle θ, the gentler the bend in the movement path. The smaller the bend angle θ, the steeper the bend in the movement path. The bend angle θ is located at the connecting part of single paths P1 and P2.

[0086] Figure 8 This is a flowchart illustrating the process of setting the speed V1 in the control unit 40.

[0087] like Figure 8 As shown, in step S11, the control unit 40 sets the nozzle speed in the single path of focus to speed V1. Specifically, the control unit 40 sets the speed V1 as single path P1. Figure 8 As shown in "Loop 1", the control unit 40 repeats step S11 for all single paths from the start to the end of the movement path. Figure 11 In the example shown, the movement path consists of single paths P1 and P2. Therefore, after setting the nozzle speed of single path P1 to V1, the control unit 40 sets the nozzle speed of single path P2 to V2.

[0088] Then, the control unit 40 ends the processing of the set speed V1, as follows: Figure 7 As shown, the process transitions to the step after determining speed V2.

[0089] (4) Decisions after speed V2

[0090] Figure 9 This is a flowchart illustrating the process after the control unit 40 determines the speed V2. Below, the process of the control unit 40 determining the speed V2 will be explained first.

[0091] like Figure 9 As shown, in step S21, the control unit 40 performs the process of setting the start and end points of the area of ​​interest. For example, the control unit 40 sets the entire movement path as the area of ​​interest. That is, the control unit 40 sets the start point of the area of ​​interest as the start point of the movement path and the end point of the area of ​​interest as the end point of the movement path. The area of ​​interest includes a bending angle θ.

[0092] Next, as step S30, the control unit 40 performs a process to determine whether it is necessary to reduce the nozzle speed. Figure 10 This is a flowchart illustrating the process of determining whether a reduction in nozzle speed is required (step S30).

[0093] like Figure 10 As shown, as step S31, the control unit 40 performs a process to determine whether the position of the end point of a single path is the same as the position of the end point of the region of interest.

[0094] Specifically, the control unit 40 first sets single path P1 as the single path of interest, and determines whether the position of the end point of single path P1 is the same as the position of the end point of the interest interval. For example... Figure 12As shown, the endpoint of single path P1 is located at the bend angle θ, which differs from the endpoint of the region of interest. Therefore, control unit 40 determines that the endpoint of single path P1 is different from the endpoint of the region of interest (in...). Figure 10 (No in step S31).

[0095] Next, as step S32, the control unit 40 performs a process to determine whether the bending angle θ in the interest interval is less than the threshold angle θn. Hereinafter, the bending angle θ is set to an angle greater than θ2 and less than θ3. Therefore, when n=2, it is determined that the bending angle θ is greater than θ2 (in...). Figure 10 (No in step S32).

[0096] Next, in step S33, the control unit 40 sets "no deceleration" as the determination result of the process (step S30) for determining whether deceleration of the nozzle speed is required. Then, the control unit 40 ends the process of step S30.

[0097] Next, as Figure 9 As shown, in step S40, the control unit 40 determines whether "no deceleration" was set in step S30. As described above, for single path P1, "no deceleration" was set in step S33, therefore the control unit 40 determines that "no deceleration" was set (in...). Figure 9 (In step S40, the answer is "Yes").

[0098] As Figure 9 The "loop 30" shown refers to the control unit 40 repeating step S30 and step S40 on all single paths from the start to the end of the region of interest. Figure 12 In the example shown in A, since there is a remaining single path P2, the control unit 40 performs step S30 on the single path P2.

[0099] like Figure 10 As shown, in step S31, the control unit 40 determines whether the position of the endpoint of the single path P2 is the same as the position of the endpoint of the region of interest. Figure 12 As shown in Figure A, the endpoint of single path P2 is at the same position as the endpoint of the region of interest. Therefore, the control unit 40 determines that the endpoint of single path P2 is at the same position as the endpoint of the region of interest (in...). Figure 10 (In step S31, the answer is "Yes").

[0100] Next, in step S34, the control unit 40 sets "deceleration due to focus on the endpoint position" as the determination result of step S30. Then, the control unit 40 ends the processing of step S30.

[0101] Next, as Figure 9As shown, in step S40, the control unit 40 determines whether "no deceleration" was set in step S30. As described above, for the single path P2, "deceleration due to focus on the destination position" is set in step S34; therefore, the control unit 40 determines that "no deceleration" was not set (in...). Figure 10 (No in step S40).

[0102] Next, as step S41, the control unit 40 performs the process of setting the position where deceleration is required as the target. As described above, in the single path P2, "decelerate due to focus on the destination position" is set, therefore... Figure 12 As shown in A, the control unit 40 sets the endpoint of the single path P2 as the target.

[0103] Next, as Figure 9 As shown, as step S42, the control unit 40 performs the process of calculating the cumulative distance from the starting point of the region of interest to the target. Figure 12 In the example shown in A, since the target's location is the end point of the interest interval, the cumulative distance is the distance from the start point to the end point of the interest interval.

[0104] Next, as step S43, the control unit 40 performs the process of subtracting Ln-1 from the cumulative distance obtained in step S42. When n=2, the control unit 40 reads the distance L1 from the storage unit 42, and... Figure 12 As shown in B, subtract the distance L1 from the starting point of the region of interest.

[0105] Next, in step S44, the control unit 40 determines whether "deceleration due to focus on the finish line position" is set as the determination result of step S30. As described above, "deceleration due to focus on the finish line position" is set in step S34, therefore the control unit 40 determines that "deceleration due to focus on the finish line position" is set (in...). Figure 9 (In step S44, the answer is "Yes").

[0106] Next, as step S45, the control unit 40 performs the process of subtracting Ln-1 from the cumulative distance obtained in step S42. When n=2, the control unit 40 reads the distance L1 from the storage unit 42, as follows: Figure 12 As shown in B, the distance L1 is subtracted from the target's location. In the example illustrated, the distance L1 is subtracted from the endpoint of the region of interest.

[0107] Next, as step S46, the control unit 40 determines whether the remaining distance within the region of interest is greater than or equal to distance Ln. When n=2, the control unit 40 reads distance L2 from the storage unit 42 and determines whether the remaining distance is greater than or equal to L2. Here, it is assumed that the remaining distance is greater than or equal to L2. Therefore, the control unit 40 determines that the remaining distance is greater than or equal to L2 (in...). Figure 9 (In step S46, the answer is "Yes").

[0108] Next, as step S47, the control unit 40 performs the process of dividing the region of interest at a position where it has advanced a distance of Ln-1 from the starting point of the region of interest. When n=2, the control unit 40 divides the movement path at a position where it has advanced a distance of L1 from the starting point of the region of interest.

[0109] Next, as step S48, the control unit 40 performs the process of dividing the region of interest at a position returned from the end of the region of interest to a distance of Ln-1. When n=2, the control unit 40 divides the movement path at a position returned from the end of the region of interest to a distance of L1.

[0110] Next, as step S49, the control unit 40 performs the process of registering the nozzle speed of the interval divided in steps S47 and S48 as speed V2. For example, the control unit 40 causes the storage unit 42 to store speed V2.

[0111] Next, as in step S50, such as Figure 12 As shown in C, the control unit 40 performs the following processing: registers the position divided in step S47 as the starting point of the next interest interval, and registers the position divided in step S48 as the ending point of the next interest interval. For example, the control unit 40 causes the storage unit 42 to store the starting and ending points of the interest interval.

[0112] Control unit 40 is designed for use as Figure 9 The “Loop 30” shown is a single path from the start point to the end point of the interest interval. The processing of steps S21, S30, S40 to S52 is repeated until the entire interest interval is confirmed as “Loop 20”. The processing of steps S21, S30, S40 to S52 is repeated until the process of “Loop 10” is completed from Table 2 to Table n.

[0113] Since the processing for n=2 has ended, the control unit 40 processes single path P1 with n=3. The control unit 40 sets n=3 for single path P1 and determines whether deceleration is needed (step S30).

[0114] like Figure 10As shown, in step S31, the control unit 40 determines whether the position of the end point of the single path P1 is the same as the position of the end point of the region of interest. The position of the end point of the single path P1 is the position of the bending angle θ, therefore the control unit 40 determines that the position of the end point of the single path P1 is different from the position of the end point of the region of interest (in...). Figure 10 (No in step S31).

[0115] Next, in step S32, the control unit 40 performs a process to determine whether the bending angle θ in the interest area is less than the threshold angle θn. The bending angle θ is set to be greater than θ2 and less than θ3, therefore the control unit 40 determines that the bending angle θ is less than θ3 (in...). Figure 10 (In step S32, the answer is "Yes").

[0116] Next, as step S35, the control unit 40 sets "deceleration due to θ < θn" as the determination result of step S30. Then, the control unit 40 ends the processing of step S30.

[0117] Next, as Figure 9 As shown, in step S41, the control unit 40 performs the process of setting the position requiring deceleration as the target. As described above, in step S35, it is set that "deceleration is due to θ < θn", therefore, as... Figure 13 As shown in A, the control unit 40 sets the position of the bending angle θ as the target.

[0118] Next, as step S42, the control unit 40 performs the process of calculating the cumulative distance from the starting point of the region of interest to the target.

[0119] Next, as step S43, the control unit 40 performs the process of subtracting Ln-1 from the cumulative distance obtained in step S42. When n=3, the control unit 40 reads the distance L2 from the storage unit 42, as follows: Figure 13 As shown in B, subtract the distance L2 from the starting point of the region of interest.

[0120] Next, in step S44, the control unit 40 determines whether "deceleration due to focus on the endpoint position" is set as the determination result of step S30. As described above, "deceleration due to θ < θn" is set in step S35, therefore the control unit 40 determines that "deceleration due to focus on the endpoint position" is not set (in...). Figure 9 (No in step S44).

[0121] Next, as step S51, the control unit 40 performs the process of subtracting Dn from the cumulative distance obtained in step S42. When n=3, the control unit 40 reads the distance D3 from the storage unit 42, as follows: Figure 13 As shown in B, subtract the distance D3 from the target's position.

[0122] Next, as step S46, the control unit 40 determines whether the remaining distance of the region of interest is greater than or equal to distance Ln. When n=3, the control unit 40 reads distance L3 from the storage unit 42 and determines whether the remaining distance is greater than or equal to L3. Here, it is assumed that the remaining distance is greater than or equal to L3. Therefore, the control unit 40 determines that the remaining distance is greater than or equal to L3 (in...). Figure 9 (In step S46, the answer is "Yes").

[0123] Next, as step S47, the control unit 40 performs the process of dividing the movement path at a position where it has advanced a distance of Ln-1 from the starting point of the region of interest. When n=3, the control unit 40 divides the movement path at a position where it has advanced a distance of L2 from the starting point of the region of interest.

[0124] Next, as step S48, the control unit 40 performs the process of dividing the movement path at a distance of Ln-1 from the end of the region of interest. When n=3, the control unit 40 divides the movement path at a distance of L2 from the end of the region of interest.

[0125] Next, as step S49, the control unit 40 performs the process of registering the nozzle speed of the interval divided in steps S47 and S48 as speed V3. For example, the control unit 40 causes the storage unit 42 to store speed V3.

[0126] Next, as step S50, the control unit 40 performs the following processing: registers the position divided in step S47 as the starting point of the next interest interval, and registers the position divided in step S48 as the ending point of the next interest interval. For example, the control unit 40 causes the storage unit 42 to store the starting point and ending point of the interest interval.

[0127] Next, the control unit 40 repeats steps S21 to S46 for single path P1 with n=4, similar to the example described above. Here, in step S46, it is assumed that the remaining distance is less than L4. Therefore, the control unit 40 determines that the remaining distance is less than L4 (in...). Figure 9 (No in step S46). The control unit 40 does not perform the process of increasing the nozzle speed from V3 to V4.

[0128] Next, as in step S52, such as Figure 13 As shown in Figure C, the control unit 40 performs the process of setting the target as the starting point of the next interest interval. In the example shown, the starting point of the interest interval is the starting point of the single path P2.

[0129] Next, the control unit 40 performs steps S21 to S46 for single path P2 in the same manner as in the example described above. Here, in step S46, as... Figure 13As shown in D, assume the remaining distance is less than L3. Therefore, the control unit 40 determines that the remaining distance is less than L3 (in Figure 9 (No in step S46).

[0130] Next, as Figure 13 As shown in D, the control unit 40 performs the process of setting the target as the starting point of the next interest zone. In the next interest zone, the nozzle speed is determined to be V1, so the control unit 40 determines in loop 30 that the end point of the interest zone has been reached. Then, in loops 20 and 10, the control unit 40 determines that the processing up to table n has been performed in all interest zones, and ends the processing after determining speed V2.

[0131] In the method for manufacturing a three-dimensional model in this embodiment, for example, the control unit 40 of the three-dimensional modeling device 100 described above is used to manufacture the three-dimensional model.

[0132] 1.3. Effects

[0133] The method for manufacturing a three-dimensional model in this embodiment includes: a path information acquisition step, wherein the path information includes a movement path in which a nozzle 160 moves relative to a worktable 20 while ejecting modeling material toward the worktable 20; a speed determination step, wherein the speed of the nozzle 160 relative to the worktable 20 is determined based on the bending angle θ of the movement path included in the path information and the distance Ln used to make the speed of the nozzle 160 relative to the worktable 20 reach a predetermined value; and a modeling step, wherein the nozzle 160 is moved relative to the worktable 20 while ejecting modeling material from the nozzle 160 to stack modeling layers based on the path information and the determined speed of the nozzle 160.

[0134] In this embodiment of the method for manufacturing three-dimensional models, since the nozzle speed is determined based on the bending angle θ and the distance Ln, the nozzle speed is increased when it can be increased and decreased when it should be decreased. Therefore, both the productivity and accuracy of the three-dimensional models can be balanced.

[0135] In the manufacturing method of a three-dimensional model in this embodiment, during the speed determination process, a region of interest is set in the movement path. It is determined whether the bending angle θ within the region of interest is less than a threshold angle θn. If the bending angle θ is determined to be less than the threshold angle θn, a deceleration region is set within the region of interest. Therefore, in the manufacturing method of a three-dimensional model in this embodiment, the nozzle speed can be decelerated near the bending angle θ. This allows for the determination of appropriate deceleration relative to the bending movement path.

[0136] In the manufacturing method of a three-dimensional model in this embodiment, when it is determined that the bending angle θ is greater than or equal to a threshold angle θn, in the speed determination step, it is determined whether the remaining distance of the subtraction interval between the position obtained by subtracting a distance Ln-1 (a first distance) from the starting point of the region of interest and the position obtained by subtracting a distance Ln-1 from the ending point of the region of interest is greater than or equal to a distance Ln (a second distance greater than distance Ln-1). Distances Ln-1 and Ln are set based on the speed of the nozzle 160. Therefore, in the manufacturing method of a three-dimensional model in this embodiment, it is possible to determine whether the nozzle speed can be increased within the subtraction interval.

[0137] In the manufacturing method of the three-dimensional model in this embodiment, when it is determined that the bending angle θ is less than the threshold angle θn, in the speed determination step, it is determined whether the remaining distance of the subtraction interval between the position obtained by subtracting the distance Ln-1 from the starting point of the interest interval and the position obtained by subtracting the distance Dn of the deceleration interval from the position of the bending angle θ is greater than or equal to the distance Ln-1. The distance Ln-1 and the distance Dn of the deceleration interval are set based on the speed of the nozzle 160. Therefore, in the manufacturing method of the three-dimensional model in this embodiment, it is possible to determine whether the nozzle speed can be increased within the subtraction interval.

[0138] In the manufacturing method of a three-dimensional model according to this embodiment, during the speed determination step, if it is determined that the remaining distance of the subtraction interval is greater than or equal to the distance Ln, the speed of the nozzle 160 in the subtraction interval is set to a second speed Vn, which is greater than the first speed Vn-1. If it is determined that the remaining distance of the subtraction interval is less than the distance Ln, the speed of the nozzle 160 in the subtraction interval is set to speed Vn. Therefore, in the manufacturing method of a three-dimensional model, it is possible to determine whether the nozzle speed can be increased based on the remaining distance of the subtraction interval.

[0139] In the manufacturing method of the three-dimensional model in this embodiment, during the speed determination process, the next area of ​​interest is set starting from the position of the bending angle θ. Therefore, in the manufacturing method of the three-dimensional model, interruption of the area of ​​interest can be prevented.

[0140] 2. Variations in the processing of the control unit

[0141] 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 14 and Figure 15 This is a flowchart illustrating the processing of the control unit 40. Specifically, Figure 14 This is a flowchart illustrating the process by which the control unit 40 determines whether deceleration is necessary. Figure 15 This is a flowchart illustrating the process by which the control unit 40 determines the cumulative angle Φ. Figure 16 This is a diagram illustrating the movement path of the nozzle 160 of the three-dimensional modeling device 100 relative to the worktable 20.

[0142] 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 control unit 40 of the three-dimensional modeling device 100 in this embodiment described above will be explained, and the similarities will be omitted.

[0143] like Figure 14 As shown, in step S32, if the control unit 40 determines that the bending angle θ in the region of interest is greater than or equal to the threshold angle θn (in... Figure 14 If step S32 is "No", then step S60 is performed to determine the cumulative angle Φ.

[0144] Here, as Figure 16 As shown, the movement path is configured to include single path P1 and single paths Q1 to Q5. Single path Q1 is connected to single path P1 at a single path angle α1. Single path Q2 is connected to single path Q1 at a single path angle α2. Single path Q3 is connected to single path Q2 at a single path angle α3. Single path Q4 is connected to single path Q3 at a single path angle α4. Single path Q5 is connected to single path Q4 at a single path angle α5. Single paths Q1 to Q5 are inclined in the same direction relative to the previous single path. The single path angle is related to the bending angle θ. The single path angle is, for example, the angle obtained by subtracting the bending angle θ from 180°. For example, when the bending angle θ is 160°, the single path angle is 20°. Single path angles α1 to α5 are within the search distance Sn in the movement path from the end position of single path Q1.

[0145] In the process of determining the cumulative angle Φ, the control unit 40, such as Figure 15 As shown, in step S61, the cumulative search distance is added to the distance of the next single path of the single path of interest. Specifically, the control unit 40 sets the distance of the next single path Q1 of the single path P1 of interest as the cumulative search distance. That is, the cumulative search distance becomes the distance of single path Q1.

[0146] Next, as step S62, the control unit 40 performs processing to add the angle of the single path of interest to the accumulated angle Φ. Specifically, the control unit 40 adds the single-path angle α1 of the single path Q1 to the accumulated angle Φ. Thus, the accumulated angle Φ becomes angle α1.

[0147] Next, the control unit 40 performs a process in step S63 to determine whether the cumulative angle Φ is greater than the cumulative threshold angle Φn. The cumulative threshold angle Φn is set based on the nozzle speed. The cumulative threshold angle Φn is related to the threshold angle θn. For example, the cumulative threshold angle Φn is the angle obtained by subtracting the threshold angle θn from 180°.

[0148] Specifically, the control unit 40 determines whether the cumulative angle α1 is greater than the cumulative threshold angle Φn. Here, the cumulative threshold angle Φn is set to be an angle greater than angle (α1+α2+α3) and less than angle (α1+α2+α3+α4). Therefore, the control unit 40 determines that the cumulative angle α1 is less than or equal to the cumulative threshold angle Φn (in...). Figure 15 (No in step S63).

[0149] Next, as step S64, the control unit 40 performs a process to determine whether the cumulative search distance is less than the search distance Sn. Specifically, the control unit 40 determines whether the cumulative search distance Q1 is less than the search distance Sn. Here, the search distance Sn is set to a distance greater than (Q1+Q2+Q3+Q4) and less than (Q1+Q2+Q3+Q4+Q5). Therefore, the control unit 40 determines that the cumulative search distance Q1 is less than the search distance Sn (in...). Figure 15 (In step S64, the condition is "Yes"). Then, the control unit 40 returns the process to step S61.

[0150] Next, the control unit 40 sets the cumulative search distance to (Q1+Q2) and the cumulative angle to (α1+α2), and repeats the processing steps S61 to S64.

[0151] Next, the control unit 40 sets the cumulative search distance to (Q1+Q2+Q3) and the cumulative angle to (α1+α2+α3), and repeats the processing steps S61 to S64.

[0152] Next, in step S61, the control unit 40 adds the distance of the single path Q4 to the cumulative search distance and sets the cumulative search distance to (Q1+Q2+Q3+Q4).

[0153] Next, in step S62, the control unit 40 adds the single-path angle α4 of the single-path Q4 to the cumulative angle, and sets the cumulative angle to (α1+α2+α3+α4).

[0154] Next, in step S63, the control unit 40 performs a process to determine whether the accumulated angle (α1+α2+α3+α4) is greater than the accumulated threshold angle Φn. As described above, the accumulated threshold angle Φn is less than the angle (α1+α2+α3+α4). Therefore, the control unit 40 determines that the accumulated angle (α1+α2+α3+α4) is greater than the accumulated threshold angle Φn (in Figure 15(In step S63, the answer is "Yes").

[0155] Next, as step S65, the control unit 40 performs the process of setting the initial position of interest to the position where deceleration is required. Figure 16 In the example shown, the control unit 40 sets the starting position of the single path Q1 to the position where deceleration is required.

[0156] Next, as step S66, the control unit 40 performs the process of setting the next focus start position. Figure 16 In the example shown, the control unit 40 sets the starting position of the single path Q5 as the next focus start position.

[0157] Next, as step S67, the control unit 40 processes the result of the determination that "deceleration is required because Φ>Φn" is set as the decision on whether deceleration is necessary (step S30). Then, the control unit 40 ends the processing of step S30.

[0158] Here, when the cumulative threshold angle Φn is greater than the angle (α1+α2+α3+α4+α5), as step S64, the control unit 40 performs a process to determine whether the cumulative search distance is greater than the search distance Sn. As described above, the distance (Q1+Q2+Q3+Q4+Q5) is greater than the search distance Sn, therefore the control unit 40 determines that the cumulative search distance (Q1+Q2+Q3+Q4+Q5) is greater than the search distance Sn (in Figure 15 (No in step S64).

[0159] Next, as step S68, the control unit 40 performs a process to determine whether the position of the end point of the next focus single path is the same as the position of the end point of the focus interval.

[0160] If the location of the endpoint of the next focus path is different from the location of the endpoint of the focus interval (in... Figure 15 If step S68 is "No", the control unit 40 returns the process to step S61. On the other hand, if the position of the endpoint of the next focus path is determined to be the same as the position of the endpoint of the focus interval (in... Figure 15 If "Yes" is selected in step S68, the control unit 40 ends the process of determining the cumulative angle Φ (step S60). Specifically, if the position of the end point of the single path Q5 is the same as the position of the end point of the interest interval, the control unit 40 ends the process of determining the cumulative angle Φ.

[0161] Then, as Figure 14 As shown, in step S33, the control unit 40 sets "no deceleration" as the determination result of step S30.

[0162] In addition, such as Figure 17As shown, when single path Q1 is tilted to one side relative to single path P1 and single path Q2 is tilted to the other side relative to single path Q1, in step S62, the control unit 40 sets the sign of single path angle α1 to positive and the sign of single path angle α2 to negative, and adds the single path angle of the single path of interest to the cumulative angle Φ. In the illustrated example, single path Q3 is tilted to one side relative to single path Q2, single path Q4 is tilted to the other side relative to single path Q3, and single path Q5 is tilted to one side relative to single path Q4. In this case, the control unit 40 sets the signs of single path angles α1, α3, and α5 to positive and the signs of single path angles α2 and α4 to negative, and calculates the sum of multiple single path angles, i.e., the cumulative angle. In step S63, the control unit 40, for example, determines that the cumulative angle (α1+α2+α3+α4+α5) is below the cumulative threshold angle Φn (within... Figure 15 (No in step S63).

[0163] 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.

[0164] In the manufacturing method of a three-dimensional model according to this embodiment, when it is determined that the bending angle θ is greater than or equal to a threshold angle θn, in the speed determination process, if multiple bending angles θ exist within a search distance Sn in the range of interest, and if the sum of the single-path angles related to the bending angle θ exceeds a cumulative threshold angle Φn, a deceleration range Dn is set in the range of interest. Therefore, in the manufacturing method of a three-dimensional model, the nozzle speed can be decelerated near the single-path angle.

[0165] In the manufacturing method of a three-dimensional model according to this embodiment, when the single-path angle α1, which is a first single-path angle among multiple single-path angles, and the single-path angle α2, which is a second single-path angle, bend in different directions, the sign of the single-path angle α1 is set to positive, and the sign of the single-path angle α2 is set to negative, and the sum of the multiple single-path angles is calculated. Therefore, in the manufacturing method of a three-dimensional model according to this embodiment, the nozzle speed is not decelerated near the single-path angle α1.

[0166] 3. Examples of material deformation in three-dimensional modeling devices

[0167] Next, a variation example of the material of the three-dimensional modeling device 100 of this embodiment will be described.

[0168] 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.

[0169] 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.

[0170] Examples of thermoplastic materials include thermoplastic resins. Examples of thermoplastic resins include general-purpose plastics, general-purpose engineering plastics, and super engineering plastics.

[0171] Examples of general-purpose plastics include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), and polylactic acid (PLA).

[0172] 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).

[0173] 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).

[0174] 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 planar spiral 130 and the heating of the heater 150, transforming it into a molten state. Furthermore, the resulting molding material solidifies due to a decrease in temperature after being ejected from the nozzle 160 and deposited on the worktable 20.

[0175] 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 that are formed during the molding process into a powder material in which the metal material is made into powder, and then add it to the plasticizing section 120.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] 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.

[0181] 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.

[0182] 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.

[0183] The following content is derived from the above implementation methods and variations.

[0184] One method for manufacturing a three-dimensional object involves creating the object by layering modeling material from a nozzle onto a worktable. The method includes the following steps: a path information acquisition step, acquiring path information including a movement path of the nozzle relative to the worktable while ejecting the modeling material towards it; a speed determination step, determining the speed of the nozzle relative to the worktable based on the bending angle of the movement path included in the path information and a distance for achieving a predetermined speed of the nozzle relative to the worktable; and a modeling step, layering modeling layers by ejecting the modeling material from the nozzle while moving it relative to the worktable, based on the path information and the determined nozzle speed.

[0185] The manufacturing method of this three-dimensional model can balance the productivity and accuracy of the three-dimensional model.

[0186] In one embodiment of the method for manufacturing the three-dimensional model, in the speed determination step, a focus zone is set in the movement path, and it is determined whether the bending angle in the focus zone is less than a threshold. If it is determined that the bending angle is less than the threshold, a deceleration zone is set in the focus zone.

[0187] According to the manufacturing method of this three-dimensional model, the speed of the nozzle relative to the worktable can be reduced near the bending angle.

[0188] In one embodiment of the method for manufacturing the three-dimensional model, if it is determined that the bending angle is greater than or equal to the threshold, in the speed determination step, it is determined whether the distance of the subtraction interval between the position obtained by subtracting the first distance from the starting point of the interest interval and the position obtained by subtracting the first distance from the ending point of the interest interval is greater than or equal to a second distance greater than the first distance, wherein the first distance and the second distance are set according to the speed of the nozzle.

[0189] Based on the manufacturing method of this three-dimensional model, it can be determined whether the speed of the nozzle relative to the worktable can be increased within the subtraction range.

[0190] In one embodiment of the method for manufacturing the three-dimensional model, if it is determined that the bending angle is less than the threshold, in the speed determination step, it is determined whether the distance of the deduction interval between the position obtained by subtracting a first distance from the starting point of the interest interval and the position obtained by subtracting the distance of the deceleration interval from the position of the bending angle is greater than a second distance greater than the first distance. The first distance and the distance of the deceleration interval are set according to the speed of the nozzle.

[0191] Based on the manufacturing method of this three-dimensional model, it can be determined whether the speed of the nozzle relative to the worktable can be increased within the subtraction range.

[0192] In one embodiment of the method for manufacturing the three-dimensional model, in the speed determination step, if it is determined that the distance of the subtraction interval is greater than the second distance, the speed of the nozzle in the subtraction interval is set to a second speed greater than the first speed; if it is determined that the distance of the subtraction interval is less than the second distance, the speed of the nozzle in the subtraction interval is set to the first speed.

[0193] According to the manufacturing method of this three-dimensional model, it is possible to determine whether the speed of the nozzle relative to the worktable can be increased based on the remaining distance of the deducted section.

[0194] In one embodiment of the method for manufacturing the three-dimensional object, the next focus area may be set starting from the position of the bending angle during the speed determination process.

[0195] The manufacturing method of this three-dimensional model can prevent the interruption of the area of ​​interest.

[0196] In one embodiment of the method for manufacturing the three-dimensional model, if it is determined that the bending angle is above the threshold, in the speed determination step, if there are multiple bending angles within a specified distance in the range of interest and the sum of the single-path angles related to the bending angles exceeds the threshold, a deceleration range is set in the range of interest.

[0197] According to the manufacturing method of this three-dimensional model, in the manufacturing method of the three-dimensional model, the speed of the nozzle relative to the worktable can be reduced at the near point of the single path angle.

[0198] In one embodiment of the method for manufacturing the three-dimensional model, if the first single-path angle and the second single-path angle among the plurality of single-path angles bend in different directions, in the speed determination step, the sign of the first single-path angle is set to positive, the sign of the second single-path angle is set to negative, and the sum of the plurality of single-path angles is calculated.

[0199] According to the manufacturing method of this three-dimensional model, the speed of the nozzle relative to the worktable can be prevented from slowing down near the first single-path angle.

Claims

1. A method for manufacturing a three-dimensional object, wherein the method shapes the three-dimensional object by layering shaping material from a nozzle onto a worktable. The manufacturing method of the three-dimensional model includes the following steps: The path information acquisition process involves obtaining path information, among which... The path information includes the movement path of the nozzle as it sprays the molding material toward the worktable while moving relative to the worktable; The speed-determining process is based on the bending angle of the movement path contained in the path information and the distance required to make the nozzle reach a predetermined speed relative to the worktable, thus determining the speed of the nozzle relative to the worktable; and In the shaping process, based on the path information and the determined speed of the nozzle, the shaping material is ejected from the nozzle to stack shaping layers while the nozzle is moved relative to the worktable.

2. The method for manufacturing a three-dimensional object according to claim 1, wherein, In the speed determination process, A region of interest is defined within the movement path. Determine whether the bending angle within the area of ​​interest is less than a threshold. If it is determined that the bending angle is less than the threshold, a deceleration zone is set in the range of interest.

3. The method for manufacturing a three-dimensional object according to claim 2, wherein, If it is determined that the bending angle is above the threshold value. In the speed determination process, it is determined whether the distance of the subtraction interval between the position obtained by subtracting a first distance from the starting point of the interest interval and the position obtained by subtracting the first distance from the ending point of the interest interval is greater than or equal to a second distance that is greater than the first distance. The first distance and the second distance are set according to the speed of the nozzle.

4. The method for manufacturing a three-dimensional object according to claim 2, wherein, If it is determined that the bending angle is less than the threshold, In the speed determination process, Determine whether the distance of the subtraction interval between the position obtained by subtracting a first distance from the starting point of the interest interval and the position obtained by subtracting the distance of the deceleration interval from the position of the bending angle is greater than or equal to a second distance that is greater than the first distance. The first distance and the distance of the deceleration zone are set according to the speed of the nozzle.

5. The method for manufacturing a three-dimensional object according to claim 3 or 4, wherein, In the speed determination process, If it is determined that the distance of the deduction interval is greater than the second distance, the speed of the nozzle in the deduction interval is set to a second speed that is greater than the first speed. If it is determined that the distance of the deduction interval is less than the second distance, the speed of the nozzle in the deduction interval is set to the first speed.

6. The method for manufacturing a three-dimensional object according to claim 4, wherein, In the speed determination process, the next focus area is set starting from the position of the bending angle.

7. The method for manufacturing a three-dimensional object according to claim 2, wherein, If it is determined that the bending angle is above the threshold value. In the speed determination process, if there are multiple bending angles within a specified distance in the range of interest and the sum of the single-path angles related to the bending angles exceeds a threshold, a deceleration range is set in the range of interest.

8. The method for manufacturing a three-dimensional object according to claim 7, wherein, When the first single-path angle and the second single-path angle among the multiple single-path angles bend in different directions, in the speed determination process, the sign of the first single-path angle is set to positive, the sign of the second single-path angle is set to negative, and the sum of the multiple single-path angles is calculated.

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