Production method of formed object

Abstract

To provide a production method of a formed object and the like capable of preventing a laminated body before curing from being buckled or destructed.SOLUTION: A production method of a formed object in accordance with an embodiment of the present invention is provided with: a formation process forming a formed object body and infill arranged so as to project from an outer wall of the formed object body by discharging and laminating forming material of powder or paste material mineralized through hydration reaction, polymerization reaction, or calcination, from a 3D printer; and a separation process separating the infill from the formed object body.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a shaped object. [Background technology]

[0002] As disclosed in Patent Document 1, a method of forming a component having a certain height by discharging and layering concrete or mortar using a 3D printer is well known. In addition, a method of forming a reinforcing part during the forming process (Patent Documents 2 and 3) and a method of using a jig are also known (see Patent Document 4). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2023-68666 A [Patent Document 2] JP 2020-26099 A [Patent Document 3] Special Publication No. 2022-551175 [Patent Document 4] JP 2023-151847 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the modeling method of Patent Document 1, after the modeling material is layered, the layered body may buckle or collapse due to its own weight before the modeling material hardens. In response to this, as disclosed in Patent Document 2 or Patent Document 3, buckling or collapse can be suppressed by providing a reinforcing part extending between the two walls, but these methods impose limitations on the design of the model. In addition, as disclosed in Patent Document 4, when a jig is used to support the model, an increase in labor hours is unavoidable.

[0005] In view of the above circumstances, the present invention provides a method for manufacturing a shaped object that can suppress buckling and / or collapse of a laminate before curing. [Means for solving the problem]

[0006] According to one aspect of the present invention, there is provided a method for manufacturing a molded object, comprising: a formation process for forming a molded object body and an infill arranged to protrude from an outer wall of the molded object body by ejecting and stacking a molding material, which is a powder or paste material that mineralizes via a hydration reaction, a polymerization reaction, or a calcination, from a 3D printer; and a separation process for severing the infill from the molded object body.

[0007] According to this aspect, by forming the infill together with the main body of the object, it is possible to prevent the laminated body before hardening from buckling or collapsing under its own weight. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a schematic plan view of a shaped object 101 obtained by the manufacturing method of a shaped object according to the present embodiment. [Diagram 2] FIG. 2 is a schematic side view of the model 101 of FIG. [Diagram 3] FIG. 2 is a flow diagram of a method for manufacturing a shaped object according to the first embodiment. [Figure 4] 2 is a schematic diagram showing an example of a discharge path R of the model 101 in FIG. [Diagram 5] FIG. 1 is a schematic diagram showing modeling using a 3D printer. [Figure 6] FIG. 2 is a schematic plan view of a shaped object 201 obtained by the manufacturing method of a shaped object according to the present embodiment. [Figure 7] 7 is a schematic cross-sectional view of the model 201 taken along line VII-VII in FIG. 6. [Figure 8] FIG. 7 is a diagram showing an example of a discharge path R of the model 201 in FIG. 6. [Figure 9] 8 is a schematic cross-sectional view of a model 201 having a shape different from that of FIG. 7. [Figure 10] FIG. 3 is a schematic plan view of a shaped object 301 obtained by the manufacturing method of a shaped object according to the present embodiment. [Figure 11]FIG. 11 is a schematic side view of the model 301 in FIG. 10. [Figure 12] FIG. 11 is a flow diagram of a method for manufacturing a shaped object according to a third embodiment. [Figure 13] 11 is a diagram showing an example of a discharge path R of the model 301 in FIG. 10. FIG. [Figure 14] 5A to 5C are schematic side views showing examples of shapes of a main body of a model that can be applied to any embodiment. [Figure 15] 11A to 11C are schematic plan views showing examples of other shapes of the main body of the object that can be applied to any of the embodiments. [Figure 16] FIG. 13 is a diagram showing an example of a wall on which a pattern is formed in which recesses and protrusions are alternately arranged both vertically and horizontally. [Figure 17] 1 is an example of a discharge path R of a cord that controls a 3D printer in an embodiment. [Figure 18] 1 is an example of a graph showing the change over time in penetration resistance. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the drawings. Various characteristic features shown in the following embodiments can be combined with each other.

[0010] <Model 101 of the First Embodiment> Fig. 1 is a schematic plan view of a shaped object 101 obtained by the manufacturing method of a shaped object according to this embodiment. Fig. 2 is a schematic side view of the shaped object 101 in Fig. 1. The shaped object 101 is a civil engineering structure or an architectural structure. Examples of the shaped object 101 include gutters, blocks, walls, and buildings. The shaped object 101 is made of concrete, mortar, or a ceramic material. The shaped object 101 has a multi-layer structure formed by a material dispensed from a 3D printer (printed by a 3D printer).

[0011] The object 101 may be a civil engineering structure. Civil engineering structures are often constructed in harsher environments than architectural structures. In other words, there is a high need for civil engineering structures to be constructed in accordance with the on-site environment, such as where the site is not leveled. Therefore, the manufacturing method can be used to construct a civil engineering structure that does not buckle and / or collapse during construction while reducing the number of steps required for on-site pouring and custom-made manufacturing.

[0012] The object 101 has an object main body 102, a plurality of infills 103, and a base 104. The object main body 102 is a framework of a civil engineering structure or an architectural structure. The object main body 102 has a first outer wall 102A and a second outer wall 102B that are spaced apart from each other. The second outer wall 102B faces the first outer wall 102A.

[0013] 2, the first outer wall 102A extends so as to be inclined with respect to the vertical direction. Specifically, the inner surface of the first outer wall 102A is inclined so as to be inward (closer to the second outer wall 102B) as it extends upward. Therefore, the inner portion of the first outer wall 102A forms an overhang 102C below which there is a space.

[0014] The infill 103 is connected to the first outer wall 102A and the second outer wall 102B of the object main body 102. This makes it possible to suppress the first outer wall 102A and the second outer wall 102B from buckling and / or collapsing during modeling. In addition, the first outer wall 102A and the second outer wall 102B support each other via the infill 103, which promotes the effect of suppressing the buckling and / or collapse of the object main body 102 during modeling.

[0015] Moreover, the infill 103 is connected to the overhang 102C. As a result, the overhang 102C, which is particularly prone to collapse, is supported by the infill 103, which promotes the effect of suppressing buckling and / or collapse of the main body 102 of the object being modeled.

[0016] Infill 103 is connected to the range from the lower end of first outer wall 102A to the upper end of first outer wall 102A. That is, infill 103 is connected to surface SF (inner surface of first outer wall 102A) of overhang 102C over the entire vertical direction. Note that surface SF of overhang 102C may be a flat surface, a curved surface, a bent surface, or a composite surface that is a combination of these.

[0017] 1, a plurality of infills 103 are provided in a model 101. The shape and number of the infills 103 are designed to increase the second radial moment of area in a cross section perpendicular to the vertical direction (i.e., a horizontal cross section) of the model 101. Note that the shape of the infills 103 is not particularly limited, and the number of infills 103 may be one.

[0018] Specifically, assuming that the object 101 has a simple shape that can be mathematically analyzed, the critical height Hc at which the object 101 buckles and / or collapses due to its own weight is proportional to the Young's modulus E and the cross-sectional secondary radius i of the object 101, and inversely proportional to the specific gravity ρ. Therefore, in order to increase the resistance to buckling, it is effective to increase the Young's modulus E, increase the cross-sectional secondary radius i, or decrease the specific gravity ρ.

[0019] The radius of area i is determined by the minimum moment of area Imin in the horizontal cross section and the cross-sectional area A of the horizontal cross section, i = (Imin / A) 1 / 2 Therefore, by maximizing the minimum second area moment Imin, it is possible to suppress collapse of the main body 102 of the object being modeled. Note that the minimum second area moment refers to the minimum of the second area moment in the X-axis direction and the second area moment in the Y-axis direction in the horizontal cross section.

[0020] The base 104 is a base for stacking the object main body 102 and the infill 103. In other words, the base 104 connects the lower end of the object main body 102 and the lower end of the infill 103.

[0021] <Manufacturing method of the first embodiment> 3 is a flow diagram of the method for manufacturing a shaped object according to the first embodiment. The manufacturing method is a method for manufacturing a shaped object 101 made of concrete, mortar, or a ceramic material.

[0022] The manufacturing method includes a shape design step S110, a cord design step S120, a forming step S130, and a finishing step S140.

[0023] <Shape design process> In the shape design process S110, the overall shape of the object 101 is designed. Specifically, the shape of the object main body 102 is designed based on the shape of the desired structure, and the shape of the infill 103 is designed to prevent buckling and / or collapse of the object main body 102 before hardening.

[0024] As described above, the infill 103 is designed to reduce the second moment of area in a cross section perpendicular to the vertical direction of the object 101 (i.e., a horizontal cross section) so that the overhang 102C of the object main body 102 does not buckle and / or collapse. For example, the infill 103 connected to the overhang 102C is designed to be densely arranged in the horizontal cross section of the object 101. Typically, the overhangs 102C are arranged more densely than the level that satisfies the structural strength required of the object 101 after manufacture.

[0025] <Code design process> In the code design process S120, code for controlling a 3D printer is designed in order to model the object 101 designed in the shape design process S110.

[0026] Examples of the code format include STL, G-code, OBJ, 3MF, etc. The code designed in this process includes a continuous discharge path spanning the object body 102 and the infill 103. This promotes the effect of suppressing buckling and / or collapse of the object body 102 during modeling, since the infill 103 is formed simultaneously with the object body 102.

[0027] Fig. 4 is a schematic diagram showing an example of the discharge path R of the model 101 in Fig. 1. Fig. 5 is a schematic diagram showing modeling by a 3D printer. As shown in Fig. 4, the discharge path R is a single continuous path on a plane, and the modeling material is discharged along the discharge path R. A discharge nozzle N of the 3D printer moves back and forth or circulates along the discharge path R, thereby forming a laminate of the modeling material CM.

[0028] The discharge path R has a turn back at the connection portion 103A of the infill 103 with the main body 102 of the molded object. Specifically, the discharge path R includes an outgoing path R1 from the second outer wall 102B toward the first outer wall 102A, a return path R2 from the connection portion 103A between the infill 103 and the first outer wall 102A toward the second outer wall 102B, and a return path R3 that connects the outgoing path R1 and the return path R2 at the connection portion 103A. The infill 103 extending from the first outer wall 102A is formed by stacking the molding material on the outgoing path R1 and the return path R2. In addition, the infill 103 and the first outer wall 102A are connected by stacking the molding material on the return path R3.

[0029] As a result, the folded back portion of the discharge path R is disposed inside the main body 102 of the molded object, thereby improving the dimensional accuracy of the main body 102 of the molded object. In addition, deterioration of functions such as water resistance caused by the folded back portion being disposed on the outside is also suppressed.

[0030] In modeling using a 3D printer, unevenness may occur on the surface of the modeled object 101 due to the lamination of modeling materials. For this reason, the outer surface of the modeled object 101 is smoothed by flattening with plastering or by filling with an adhesive material (concrete, mortar, or ceramic-based material) when joining with other members. Therefore, in the shape design step S110 and / or the cord design step S120, the shape or cord of the modeled object 101 is designed taking into account dimensional changes caused by such smoothing.

[0031] In addition, the code can be added, edited, or the like in a later process according to the environment or conditions of the modeling site. In addition, in the formation process S130, the code (for example, input information such as modeling speed other than the path) may be adjusted in real time during modeling.

[0032] <Formation process> In the formation step S130, the modeling material CM, which is a powder or paste material that is mineralized via a hydration reaction, a polymerization reaction, or a firing, is discharged from a 3D printer and layered to form the modeled object main body 102 and the infill 103 that prevents the modeled object main body 102 from buckling and / or collapsing before hardening. Here, "mineralization" means that the main component (the component that is contained most abundantly on a mass basis) is changed into a hardened material that is an inorganic material. Typically, the modeled object main body 102 is made of concrete, mortar, or ceramics.

[0033] Specifically, the code designed in the code design step S120 is input to a 3D printer to form a model 101. As shown in Fig. 5A, the modeling material CM is discharged from a discharge nozzle N of the 3D printer moving along a discharge path R, and a model main body 102 and an infill 103 are simultaneously formed.

[0034] The hardening time of the molding material CM is preferably 1.0 hour or more, more preferably 1.5 hours or more, and even more preferably 2.0 hours or more. The "hardening time" is the time from immediately after mixing water is added to the raw material of the molding material CM to the initial strength (penetration resistance value of 3.5 N / mm) in accordance with the concrete setting time test specified in JIS-A-1147. 2) is reached. This makes it possible to manufacture a highly strong object 101 by hardening the main body 102 of the object at a relatively slow hardening speed while preventing the main body 102 of the object from buckling and / or collapsing before hardening.

[0035] Moreover, the hardening time of the modeling material CM is, for example, preferably 8 hours or less, more preferably 6 hours or less, and even more preferably 4 hours or less, which can reduce the risk of buckling during modeling.

[0036] The specific gravity of the molding material CM is 1.2t / m 3 More than 1.4t / m is preferable. 3 More preferably, 1.6t / m 3 This makes it possible to manufacture a molded object 101 that has high strength due to its high specific gravity, while preventing buckling and / or collapse of the molded object main body 102 before hardening.

[0037] The specific gravity of the molding material CM is, for example, 3.0t / m 3 Less than 2.5t / m is preferable. 3 The following is more preferable. This can reduce the risk of buckling during modeling.

[0038] When the object 101 is a civil engineering structure, in the formation step S130, it is preferable to discharge and layer the modeling material CM at the construction site P of the civil engineering structure. This makes it possible to directly model the civil engineering structure at the construction site P while preventing buckling and / or collapse during modeling, thereby making it possible to reduce the number of construction steps while constructing the civil engineering structure in accordance with the on-site environment.

[0039] 5B, in the formation step S130, the fluid F or granules may be filled around the object main body 102. As a result, the object main body 102 is supported by the fluid F or the granules, and a synergistic effect with the infill 103 promotes the effect of suppressing buckling and / or collapse of the object main body 102 during modeling.

[0040] For example, the model 101 is modeled in a container C, and the fluid F or granules are supplied into the container C at the same time as the modeling material CM is discharged, so that the fluid F or granules can be filled around the model main body 102. The fluid F or granules are continuously supplied so that the filling height follows the stacking height of the modeling material CM.

[0041] Examples of the fluid F include water, a liquid having a certain viscosity, a clay material, etc. In the case of a highly viscous fluid, the fluid F may be discharged and layered by a separate 3D printer simultaneously with the modeling material CM. This allows the fluid F to be filled only around the main body 102 of the model.

[0042] Examples of the granules include sand, soil, polymer resin balls, etc. By using a hydrophobic polymer resin as the granules, it is possible to suppress the dissipation of moisture from the surface of the main body 102 of the model during modeling. In addition, by using a clay material to which a highly water-absorbent polymer resin containing moisture is added as the granules, a water retention or moisture-retaining curing effect can be obtained for the main body 102 of the model during modeling.

[0043] Furthermore, a support material that solidifies by drying may be used as the granules. By using such a support material, the object main body 102 can be cured until after the object is modeled. After the curing, the support material can be easily removed by washing it away with water or the like. Furthermore, the support material can be reused by drying the slurry recovered by washing it away.

[0044] <Finishing process> In the finishing step S140, the exterior portion of the object 101 formed in the forming step S130 is processed to perform finishing. The processing includes cutting off unnecessary portions, smoothing the outer surface, and the like.

[0045] <Model 201 of the Second Embodiment> Fig. 6 is a schematic plan view of a molded object 201 obtained by the manufacturing method of a molded object according to this embodiment. Fig. 7 is a schematic cross-sectional view of the molded object 201 taken along line VII-VII in Fig. 6. The molded object 201 is a civil engineering or architectural structure similar to the molded object 101 in Fig. 1. The molded object 201 is made of concrete, mortar, or a ceramic material. The molded object 201 has a multi-layer structure formed by a material dispensed from a 3D printer (printed by a 3D printer).

[0046] The object 201 may be a civil engineering structure. This makes it possible to reduce the number of steps involved in on-site pouring and custom-made manufacturing, and to build a civil engineering structure that does not buckle and / or collapse during construction.

[0047] The object 201 has an object main body 202, an infill 203, and a base 204. The object main body 202 is a framework of a civil engineering structure or an architectural structure. The object main body 202 has at least one outer wall 202A.

[0048] As shown in Fig. 7, the outer wall 202A extends so as to be inclined with respect to the vertical direction. Specifically, of the outer and inner surfaces of the outer wall 202A, at least the outer surface (both the outer and inner surfaces in the example of Fig. 7) is inclined so as to move outward (away from the center of the object main body 202) as it goes upward. Therefore, the outer wall 202A forms an overhang with a space therebelow. In other words, the object main body 202 has an overhang (the outer wall 202A) with a space therebelow.

[0049] The infill 203 is connected to the inner surface of the outer wall 202A of the object main body 202. In other words, the infill 203 is connected to the surface (i.e., the inner surface) opposite to the surface (i.e., the outer surface) facing the space below the overhang. As a result, the outer wall 202A is pulled inward by the infill 203, so that buckling and / or collapse of the object main body 202 during modeling can be suppressed. In addition, since the infill 203 is provided inside the object main body 202, the object main body 202 can be modeled in any outer shape (design shape) while suppressing buckling and / or collapse of the object main body 202.

[0050] The infill 203 is connected to the range from the lower end of the inner surface of the outer wall 202A to the upper end of the inner surface. In other words, the infill 203 is connected to the surface SF of the overhang (the inner surface of the outer wall 202A) over the entire vertical direction. The surface SF of the overhang may be a flat surface, a curved surface, a bent surface, or a composite surface that is a combination of these. Although not shown in FIG. 6, the shaped object 201 may be provided with multiple infills 203. Furthermore, multiple infills 203 may be connected to one outer wall 202A (overhang).

[0051] The infill 203 may be connected to two opposing outer walls of the object main body 202. This can prevent the two outer walls from buckling and / or collapsing during modeling. In addition, since the two outer walls support each other via the infill 203, the effect of preventing the buckling and / or collapse of the object main body 202 during modeling is promoted.

[0052] The base 204 is a base for stacking the object main body 202 and the infill 203. In other words, the base 204 connects the lower end of the object main body 202 and the lower end of the infill 203.

[0053] The manufacturing method of the object 201 in Fig. 6 is similar to the manufacturing method of the object 101 in Fig. 1. That is, the manufacturing method of the object 201 in Fig. 6 includes a shape designing step S110, a cord designing step S120, a forming step S130, and a finishing step S140, which are shown in Fig. 3.

[0054] <Shape design process> In the shape design step S110, the overall shape of the object 201 is designed. Details of the shape design step S110 are the same as those of the manufacturing method of the object 101 in FIG.

[0055] <Code design process> In the cord design process S120, a cord for controlling a 3D printer is designed to form the object 201 designed in the shape design process S110. The cord includes a continuous discharge path spanning the object main body 202 and the infill 203. This promotes the effect of suppressing buckling and / or collapse of the object main body 202 during modeling, since the infill 203 is formed simultaneously with the object main body 202. Details of the cord design process S120 are the same as those in the manufacturing method of the object 101 in FIG. 1.

[0056] Fig. 8 is a diagram showing an example of the discharge path R of the model 201 of Fig. 6. As shown in Fig. 8, the discharge path R is a single continuous path on a plane. The discharge path R has a turn back at a portion (tip) of the infill 203 that is the furthest from the connection portion with the model main body 202 (outer wall 202A). Specifically, the discharge path R includes an outgoing path R1 from the outer wall 202A toward the tip of the infill 203, a return path R2 from the tip of the infill 203 toward the outer wall 202A, and a return path R3 that connects the outgoing path R1 and the return path R2 at the tip of the infill 203.

[0057] As a result, the folded back portion of the discharge path R is disposed inside the main body 202 of the molded object, thereby improving the dimensional accuracy of the main body 202 of the molded object. In addition, deterioration of functions such as water resistance caused by the folded back portion being disposed on the outside is also suppressed.

[0058] <Formation process> In the formation process S130, a modeling material CM, which is a powder or paste material that mineralizes via a hydration reaction, polymerization reaction, or sintering, is ejected from a 3D printer and layered to form a modeled object main body 202 and an infill 203 that prevents buckling and / or collapse of the modeled object main body 202 before hardening.

[0059] When the object 201 is a civil engineering structure, in the formation step S130, it is preferable to discharge and layer the modeling material at the construction site of the civil engineering structure. This makes it possible to directly model the civil engineering structure at the construction site while preventing buckling and / or collapse during modeling, thereby reducing the number of construction steps while constructing the civil engineering structure in accordance with the on-site environment.

[0060] In the formation step S130, the fluid F or granules may be filled around the object main body 202. As a result, the object main body 202 is supported by the fluid F or the granules, and a synergistic effect with the infill 203 promotes the effect of suppressing buckling and / or collapse of the object main body 202 during modeling. Other details of the formation step S130 are the same as those in the manufacturing method of the object 101 in FIG. 1.

[0061] <Finishing process> In the finishing step S140, the outer portion of the object 201 formed in the forming step S130 is processed to perform finishing. Details of the finishing step S140 are the same as those in the manufacturing method of the object 101 in FIG.

[0062] <Modification of the second embodiment> Fig. 9 is a schematic cross-sectional view of a modeled object 201 having a shape different from that of Fig. 7. As in the example of Fig. 9, an overhang (outer wall 202A) of the modeled object 201 may have a lower overhang 202B whose outer surface is inclined outward (away from the center of the modeled object body 202) as it extends upward, and an upper overhang 202C whose outer surface is inclined inward (closer to the center of the modeled object body 202) as it extends upward. The upper overhang 202C is located above the lower overhang 202B, and typically extends upward from the upper end of the lower overhang 202B.

[0063] In the example of Figure 9, the infill 203 is connected to at least the inner surface of the lower overhang 202B, and may also be connected to the inner surface of the upper overhang 202C (the surface facing the space below the overhang) if necessary.

[0064] <Model 301 of the Third Embodiment> Fig. 10 is a schematic plan view of a molded object 301 obtained by the manufacturing method of a molded object according to this embodiment. Fig. 11 is a schematic side view of the molded object 301 in Fig. 10. The molded object 301 is a civil engineering structure or architectural structure similar to the molded object 101 in Fig. 1 and the molded object 201 in Fig. 6. The molded object 301 is made of concrete, mortar, or a ceramic material. The molded object 301 has a multi-layer structure formed by a material dispensed from a 3D printer (printed by a 3D printer). The molded object 301 is preferably a civil engineering structure.

[0065] The object 301 has a main body 302, a plurality of infills 303, and a base 304. The main body 302 is a framework of a civil engineering structure or an architectural structure. The main body 302 has a plurality of outer walls 302A.

[0066] 11, the outer wall 302A extends so as to be inclined with respect to the vertical direction. Specifically, at least the outer surface of the outer wall 302A is inclined so as to be outward (away from the center of the object main body 302) as it goes upward. Therefore, the outer wall 302A forms an overhang below which there is a space. In other words, the object main body 302 has an overhang (the outer wall 302A) below which there is a space.

[0067] Each of the multiple infills 303 is connected to the outer surface of the outer wall 302A of the object main body 302. That is, the infills 303 are connected to the surface (i.e., the outer surface) facing the space below the overhang. This makes it possible to prevent the outer wall 302A from buckling and / or collapsing during modeling.

[0068] The infill 303 is formed so as to protrude from the outer wall 302A. As shown in FIG. 10, the infill 303 has an auxiliary wall 303A and a plurality of connecting portions 303B. The auxiliary wall 303A is a portion disposed on the outer side of the outer wall 302A so as to face the outer wall 302A. The connecting portions 303B are portions that connect the auxiliary wall 303A and the outer surface of the outer wall 302A. In the example of FIG. 10, three connecting portions 303B are provided, but the number of connecting portions 303B is not limited to this and can be set arbitrarily.

[0069] Infill 303 (specifically, connecting portion 303B) is connected to the range from the lower end of the inner surface of outer wall 302A to the upper end of the inner surface. In other words, infill 303 is connected to overhang surface SF (inner surface of outer wall 302A) over the entire vertical direction. Note that overhang surface SF may be a flat surface, a curved surface, a bent surface, or a composite surface that is a combination of these.

[0070] The base 304 is a base for stacking the object main body 302 and the infill 303. In other words, the base 304 connects the lower end of the object main body 302 and the lower end of the infill 303.

[0071] 12 is a flow diagram of a method for manufacturing a shaped object according to the third embodiment. This manufacturing method is a method for manufacturing a shaped object 301 made of concrete, mortar, or a ceramic material.

[0072] The manufacturing method includes a shape designing step S110, a cord designing step S120, a forming step S130, a cutting step S150, and a finishing step S160.

[0073] <Shape design process> In the shape design process S110, the overall shape of the object 301 is designed. The details of the shape design process S110 are the same as those in the manufacturing method of the object 101 in FIG.

[0074] <Code design process> In the cord design process S120, a cord for controlling a 3D printer is designed to form the object 301 designed in the shape design process S110. The cord includes a continuous discharge path spanning the object main body 302 and the infill 303. This promotes the effect of suppressing buckling and / or collapse of the object main body 302 during modeling, since the infill 303 is formed simultaneously with the object main body 302. Details of the cord design process S120 are the same as those in the manufacturing method of the object 101 in FIG. 1.

[0075] FIG. 13 is a diagram showing an example of the discharge path R of the model 301 of FIG. 10. As shown in FIG. 13, the discharge path R is a single continuous path on a plane. The discharge path R has a turn back at a connecting portion 303B of the infill 303 that is connected to the model main body 302 (outer wall 302A). That is, the discharge path R has a turn back at a connecting portion of the infill 303 with the model main body 302. Specifically, the discharge path R includes an outgoing path R1 from the auxiliary wall 303A of the infill 303 toward the outer wall 302A, a return path R2 from the outer wall 302A toward the auxiliary wall 303A of the infill 303, and a return path R3 that connects the outgoing path R1 and the return path R2 at the connecting portion 303B of the infill 303.

[0076] As a result, the folded portion of the discharge path R is included in the connecting portion between the main body 302 of the object and the infill 303, thereby improving the dimensional accuracy of the main body 302 of the object. In addition, the provision of the folded portion in the main body 302 of the object also suppresses deterioration of functions such as water resistance.

[0077] <Formation process> In the formation process S130, a modeling material CM, which is a powder or paste material that mineralizes via a hydration reaction, polymerization reaction, or sintering, is ejected from a 3D printer and layered to form a modeled object main body 302 and an infill 303 that is arranged to protrude from the outer wall 302A of the modeled object main body 302.

[0078] When the object 301 is a civil engineering structure, in the formation step S130, it is preferable to discharge and layer the modeling material at the construction site of the civil engineering structure. This makes it possible to directly model the civil engineering structure at the construction site while preventing buckling and / or collapse during modeling, thereby reducing the number of construction steps while constructing the civil engineering structure in accordance with the on-site environment.

[0079] In the formation step S130, the fluid F or granules may be filled around the object main body 302. As a result, the object main body 302 is supported by the fluid F or the granules, and this promotes an effect of suppressing buckling and / or collapse of the object main body 302 during modeling due to a synergistic effect with the infill 303. Other details of the formation step S130 are the same as those of the manufacturing method for the object 101 in FIG. 1.

[0080] <Separation process> In the separation step S150, the infill 303 provided on the outer side of the object main body 302 formed in the formation step S130 is separated from the object main body 302. This makes it possible to form the object main body 302 into any outer shape (design shape) while suppressing buckling and / or collapse of the object main body 302 during modeling by the infill 303.

[0081] In the example of Fig. 10, separation is performed at the boundary between the outer wall 302A and the connecting portion 303B of the infill 303, which is indicated by a dashed line (i.e., the surface SF of the overhang shown in Fig. 11). The separated infill 303 is removed from the object 301. In other words, the object 301 produced by this production method does not include the infill 303. It is to be noted that the infill 303 may be separated, for example, before the object main body 302 hardens.

[0082] <Finishing process> In the finishing step S160, finishing is performed by processing the exterior portion of the shaped object 301 from which the infill 303 has been separated. The processing includes cutting off unnecessary portions other than the infill 303, smoothing the outer surface (particularly the separated surface of the infill 303), and the like.

[0083] 4. Effect The effects of this embodiment can be summarized as follows: That is, by forming the infill 103 together with the main body 102 of the object, it is possible to prevent the laminated body before hardening from buckling or collapsing under its own weight.

[0084] Although the embodiment of the present invention has been described above, the present invention is not limited to this, and can be modified as appropriate without departing from the technical concept of the invention.

[0085] 5.Other The shapes of the objects 101, 201, and 301 described above are examples. Fig. 14 is a schematic side view showing an example of the shape of the object body applicable to any embodiment. The object body 402 shown in Fig. 14 has a first outer wall 402A whose outer surface is inclined so as to turn inward (approaching the center of the object body 402) as it goes upward, a second outer wall 402B whose outer surface is inclined so as to turn outward (away from the center of the object body 402) as it goes upward, and a third outer wall 402C connecting the first outer wall 402A and the second outer wall 402B. The upper edge of the third outer wall 402C has a first portion 402D that is inclined so as to rise (increase in height) from the upper end of the first outer wall 402A toward the second outer wall 402B, and a second portion 402E that is inclined so as to rise from the upper end of the second outer wall 402B toward the first outer wall 402A. That is, the upper edge of the third outer wall 402C is bent so as to be convex upward. By forming the upper edge of the third outer wall 402C in such a shape, the upper edge can pull together the first outer wall 402A and the second outer wall 402B, each of which has an overhang. As a result, the effect of suppressing buckling and / or collapse of the main body 402 of the object during modeling can be enhanced.

[0086] FIG. 15 is a schematic plan view showing another example of the shape of the object body applicable to any embodiment. The object body 502 shown in FIG. 15 has a first outer wall 502A and a second outer wall 502B arranged to face each other. The first outer wall 502A and the second outer wall 502B are each curved so as to be convex outward in a plan view. The second outer wall 502B is arranged inside the first outer wall 502A. Furthermore, a plurality of infills 503 are arranged in a truss shape in a plan view between the first outer wall 502A and the second outer wall 502B. The infills 503 are connected to the inner surface of the first outer wall 502A and the outer surface of the second outer wall 502B. With this structure, when the first outer wall 402A and / or the second outer wall 402B have an overhang, the infills 503 can suppress buckling and / or collapse of the object body 502 during modeling.

[0087] The present invention may include a method for manufacturing a molded object, comprising a forming step of forming a molded object main body having walls formed with a pattern in which concave portions and convex portions are alternately arranged both vertically and horizontally by discharging and stacking a molding material, which is a powder or paste material that is mineralized via a hydration reaction, a polymerization reaction, or a firing, from a 3D printer. According to such a manufacturing method, the concave-convex pattern of the walls can suppress buckling and / or collapse of the molded object main body during modeling.

[0088] FIG. 16 is a diagram showing an example of a wall on which a pattern is formed in which concave and convex portions are alternately arranged both vertically and horizontally. The wall 602A shown in FIG. 16A has an overhang, and a rectangular concave and convex pattern is formed on the entire outer surface of the wall 602A. In addition, at least one infill 603 is connected to the inner surface of the wall 602A (the surface opposite to the surface on which the concave and convex pattern is formed). In the example of the wall 602A in FIG. 16A, as shown in FIG. 16B, a discharge path R is designed that includes a path along the concave and convex pattern of the wall 602A, a path that fills the inside of the wall 602A, and a path that forms the infill 603.

[0089] In addition, in the present invention, in the forming step, buckling and / or collapse of the laminate may be suppressed by filling the periphery of the shaped object main body 102 with fluid or granules, without forming the infill 103.

[0090] 6. Working Example Fig. 17 shows an example of the discharge path R of the code that controls the 3D printer in the embodiment. Fig. 17A shows the discharge path R of one layer in a plan view, and Fig. 17B shows the discharge paths R of all layers superimposed in a plan view. Fig. 17C shows the discharge path R as seen from the side.

[0091] A 3D printer discharged a modeling material (mortar) obtained by the following procedure along this discharge path R. First, various raw materials were mixed according to the following formula, and each component was mixed for 5 minutes using a Hobart mixer to obtain a powdered composition. This composition was mixed with tap water in an amount of 15% by mass relative to the total mass of the binder and fine aggregate, and the mixture was kneaded to obtain a mortar material. Portland cement: 70 parts by weight Ground granulated blast furnace slag: 20 parts by weight Silica fume: 8.5 parts by weight Inorganic expanding agent: 1.5 parts by weight Fine aggregate: 100% by volume of the total binder Rheology modifier: 0.160% by weight based on the total weight of the binder Short fibre: 0.2% by volume based on the total volume of binder and fine aggregate Viscosifier: 0.070% by weight based on the total weight of binder and fine aggregate

[0092] The resulting mortar material was subjected to a measurement of penetration resistance in accordance with the concrete setting time test prescribed in JIS-A-1147. Figure 18 is an example of a graph showing the change in penetration resistance over time. As shown in Figure 18, the hardening time of the mortar material (penetration resistance value of 3.5 N / mm 2 The time required to reach 100% was more than one hour. The specific gravity of the mortar material was 2.09 to 2.1 t / m 3 It was.

[0093] When the obtained mortar material was discharged and layered along the discharge path R in FIG. 17, a structure up to a height of 40 layers (0.4 m) could be created without buckling or collapsing.

[0094] It may be provided in any of the following ways:

[0095] (1) A method for manufacturing a molded object, comprising: a forming step of forming a molded object body and an infill arranged to protrude from an outer wall of the molded object body by ejecting and stacking a molding material, which is a powder or paste material that is mineralized via a hydration reaction, a polymerization reaction, or a sintering reaction, from a 3D printer; and a separating step of separating the infill from the molded object body.

[0096] (2) The method for manufacturing a shaped object described above in (1), wherein the shaped object main body has an overhang below which there is a space, and the infill is connected to the overhang.

[0097] (3) A method for manufacturing a molded object, comprising a forming step of forming a molded object body and an infill that prevents buckling and / or collapse of the molded object body before hardening by ejecting and stacking a molding material, which is a powder or paste material that mineralizes via a hydration reaction, a polymerization reaction, or a calcination, from a 3D printer, wherein the molded object body has an overhang with a space below it, and the infill is connected to a surface of the overhang opposite to the surface facing the space.

[0098] (4) A method for manufacturing a shaped object described in any one of (1) to (3) above, wherein the infill is connected to a first outer wall of the shaped object body and a second outer wall opposite to the first outer wall.

[0099] (5) A method for manufacturing a molded object according to any one of (1) to (4) above, further comprising a code design step of designing a code for controlling the 3D printer, the code including an ejection path spanning the molded object body and the infill.

[0100] (6) The method for manufacturing a shaped object according to (5) above, wherein the discharge path has a turn back at a connection portion of the infill with the main body of the shaped object.

[0101] (7) The method for manufacturing a molded object according to any one of (1) to (6) above, wherein the hardening time of the molding material is 1.0 hour or longer.

[0102] (8) In the method for manufacturing a shaped object according to any one of (1) to (7) above, the specific gravity of the shaping material is 1.2 t / m 3 This is the above method for manufacturing a molded object.

[0103] (9) The method for manufacturing a shaped object according to any one of (1) to (8) above, wherein in the forming step, a fluid or granules is filled around the main body of the shaped object.

[0104] (10) The method for manufacturing a shaped object according to any one of (1) to (9) above, wherein the shaped object is a civil engineering structure.

[0105] (11) The method for manufacturing a shaped object according to (10) above, wherein in the forming step, the shaping material is discharged and layered at a construction site of the civil engineering structure. Of course, this is not the case.

[0106] Finally, although various embodiments according to the present disclosure have been described, these are presented as examples and are not intended to limit the scope of the invention. The novel embodiment can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. The embodiments and their modifications are included within the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0107] 101: Modeled object 102: Main body of the sculpture 102A: First exterior wall 102B: Second exterior wall 102C: Overhang 103: Infill 103A: Connecting part 104: Foundation 201: Modeled object 202: Main body of sculpture 202A: Exterior wall 202B: Lower overhang 202C: Upper overhang 203: Infill 204: Foundation 301: Modeled object 302: Main body of sculpture 302A: Exterior wall 303: Infill 303A: Auxiliary wall 303B:Connection part 304: Foundation 402: Main body of sculpture 402A: First exterior wall 402B: Second exterior wall 402C: 3rd exterior wall 402D: 1st part 402E: 2nd part 502: Main body of sculpture 502A: First exterior wall 502B: 2nd outer wall 503: Infill 602A: Wall 603: Infill C: Container CM: Modeling material F:Fluid N: Discharge nozzle P: Construction location R: Discharge route R1: Outbound R2:Return trip R3: Turnaround SF: surface

Claims

1. A method for manufacturing a shaped object, comprising the steps of: A forming process for forming a main body of a molded object and an infill arranged to protrude from an outer wall of the main body of the molded object by discharging and layering a molding material, which is a powder or paste material that is mineralized via a hydration reaction, a polymerization reaction, or a firing reaction, from a 3D printer; a separation step of separating the infill from the main body of the object; A method for manufacturing a shaped object, comprising:

2. The method for producing a shaped object according to claim 1 , The object body has an overhang below which there is a space, The infill is connected to the overhang.

3. A method for manufacturing a shaped object, comprising the steps of: A forming process is provided for forming a main body of a molded object and an infill for preventing buckling and / or collapse of the main body of the molded object before hardening by discharging and stacking a molding material, which is a powder or paste material that is mineralized via a hydration reaction, a polymerization reaction, or a sintering reaction, from a 3D printer; The object body has an overhang below which there is a space, The infill is connected to a surface of the overhang opposite the surface facing the space. A method for manufacturing a sculpture.

4. The method for producing a shaped object according to claim 1 or 3, The infill is connected to a first outer wall of the object body and a second outer wall opposite to the first outer wall.

5. The method for producing a shaped object according to claim 1 or 3, Further comprising a code design step of designing a code for controlling the 3D printer, The cord includes a discharge path extending across the main body of the object and the infill.

6. The method for producing a shaped object according to claim 5 , The method for manufacturing a shaped object, wherein the discharge path has a turn back at a portion of the infill that is connected to a main body of the shaped object.

7. The method for producing a shaped object according to claim 1 or 3, A method for manufacturing a molded object, wherein the hardening time of the molding material is 1.0 hour or longer.

8. The method for producing a shaped object according to claim 1 or 3, The specific gravity of the molding material is 1.2 t / m ３ This is the above method for manufacturing a molded object.

9. The method for producing a shaped object according to claim 1 or 3, In the forming step, a fluid or granular material is filled around the main body of the object.

10. The method for producing a shaped object according to claim 1 or 3, The method for manufacturing a shaped object, wherein the shaped object is a civil engineering structure.

11. The method for producing a shaped object according to claim 10, In the forming step, the modeling material is ejected and layered at a construction site of the civil engineering structure.

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