Method for manufacturing three-dimensional molded object

Abstract

To provide a technology capable of molding a molded object with a low filling rate with high precision.SOLUTION: A method for manufacturing a three-dimensional molded object includes: a first step that is to obtain designation information that specifies a filling rate of the molded object; a second step of generating first molding data including information on a first discharge amount and a first discharge path and instructing a formation of the molded object in an outer region; a third step of generating second molding data, which includes information on a second discharge amount and a second discharge path and instructs formation of the molded object in the internal region, based on the designation information; a fourth step of generating third molding data including information on a third discharge amount and a third discharge path and instructing a formation of a support structure in the internal region; a fifth step of molding a three-dimensional molded object; and a sixth step of separating the support structure from the molded object. The fourth step includes a step of generating third molding data such that, in one layer, the third discharge paths are located in at least a part of a gap between the second discharge paths.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a three-dimensional object.

Background Art

[0002] For example, Patent Document 1 discloses a support arrangement determination device that calculates the centroid of a three-dimensional model of a target object and determines the surface of the three-dimensional model on which a support for supporting the target object is arranged using the position of the calculated centroid.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When forming an object with a low filling rate, since there are gaps inside the object, the position of the internal modeling material may shift due to gravity before it hardens, and the forming accuracy of the object may decrease. Therefore, there is a need for a technique that can form an object with a low filling rate with high precision.

Means for Solving the Problems

[0005] According to a first aspect of the present disclosure, a method for manufacturing a three-dimensional object is provided. The method for manufacturing a three-dimensional object manufactures a three-dimensional object having a shaped object and a support structure for supporting the shaped object by discharging a shaping material and a support material from a discharge unit toward a stage to stack layers, and includes: a first step of acquiring designation information for designating a filling rate of the shaped object; a second step of generating first shaping data including information on a first discharge amount which is a discharge amount per unit time of the shaping material by the discharge unit and information on a first discharge path which is a path through which the shaping material is discharged, and instructing formation of the shaped object in an outer peripheral region constituting an outer contour of the shaped object; a third step of generating second shaping data including information on a second discharge amount which is a discharge amount per unit time of the shaping material by the discharge unit and information on a second discharge path which is a path through which the shaping material is discharged, and instructing formation of the shaped object in an inner region which is inside the outer peripheral region, based on the designation information; a fourth step of generating third shaping data including information on a third discharge amount which is a discharge amount per unit time of the support material by the discharge unit and information on a third discharge path which is a path through which the support material is discharged, and instructing formation of the support structure in the inner region; a fifth step of shaping the three-dimensional object according to the first shaping data, the second shaping data, and the third shaping data; and a sixth step of separating the support structure from the shaped object. The fourth step includes a step of generating the third shaping data such that the third discharge path is located at least partially in a gap between the second discharge paths in one of the layers.

Brief Description of the Drawings

[0006]

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Mode for Carrying Out the Invention

[0007] A. First Embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of the three-dimensional modeling system 10 in the present embodiment. In FIG. 1, arrows indicating the X, Y, and Z directions orthogonal to each other are shown. The X direction and the Y direction are directions parallel to the horizontal plane. The Z direction is a direction parallel to the vertical direction. The X, Y, and Z directions in FIG. 1 indicate the same directions as the X, Y, and Z directions in other figures. When specifying a direction, the positive direction, which is the direction indicated by the arrow, is denoted as "+", and the negative direction, which is the direction opposite to the direction indicated by the arrow, is denoted as "-", and positive and negative signs are used in combination in the direction notation.

[0008] The three-dimensional modeling system 10 includes a three-dimensional modeling apparatus 100 and an information processing apparatus 400. The three-dimensional modeling apparatus 100 in the present embodiment is an apparatus that forms a three-dimensional object having a shaped object and a support structure that supports the shaped object by a material extrusion method. The three-dimensional modeling apparatus 100 includes a control unit 300 for controlling each part of the three-dimensional modeling apparatus 100. The control unit 300 and the information processing apparatus 400 are connected to be communicable with each other.

[0009] The three-dimensional modeling apparatus 100 includes a shaping unit 110 that generates and discharges a plasticized material, a shaping stage 210 that serves as a base of the three-dimensional object, and a moving mechanism 230 that controls the discharge position of the plasticized material.

[0010] Under the control of the control unit 300, the shaping unit 110 discharges the plasticized material obtained by plasticizing the solid-state material onto the stage 210. The shaping unit 110 includes a material supply unit 20 that is a supply source of the raw material before being converted into the plasticized material, a plasticizing unit 30 that converts the raw material into the plasticized material, and a discharge unit 60 that discharges the plasticized material.

[0011] The three-dimensional shaping apparatus 100 includes, as a shaping unit 110, a first shaping unit 110a and a second shaping unit 110b. The first shaping unit 110a includes a first material supply unit 20a as a material supply unit 20, a first plasticizing unit 30a as a plasticizing unit 30, and a first discharge unit 60a as a discharge unit 60. The second shaping unit 110b includes a second material supply unit 20b as a material supply unit 20, a second plasticizing unit 30b as a plasticizing unit 30, and a second discharge unit 60b as a discharge unit 60. The first shaping unit 110a and the second shaping unit 110b are arranged adjacent to each other in the X direction. The configuration of the first shaping unit 110a and the configuration of the second shaping unit 110b are the same. Hereinafter, when distinguishing the constituent members of both, the constituent members of the first shaping unit 110a are denoted with the symbol "a", and the constituent members of the second shaping unit 110b are denoted with the symbol "b". Note that the first shaping unit 110a and the second shaping unit 110b may be arranged adjacent to each other in the Y direction.

[0012] The first shaping unit 110a discharges a shaping material from the first discharge unit 60a toward the stage 210, and the second shaping unit 110b discharges a support material from the second discharge unit 60b toward the stage 210. Here, the shaping material is a material for forming a shaped object that is a product part of the three-dimensional shaped object, and the support material is a material for forming a support structure that supports the shaped object during shaping.

[0013] The first material supply unit 20a supplies the raw material M1 of the shaping material to the first plasticizing unit 30a. The first material supply unit 20a is constituted by, for example, a hopper. The first material supply unit 20a is connected to the first plasticizing unit 30a via a communication path 25a. The raw material M1 of the shaping material is introduced into the first material supply unit 20a in the form of pellets, powder, or the like. The raw material M1 of the shaping material is composed of a material that is insoluble in water or a solvent. As the raw material M1 of the shaping material, for example, an ABS resin, polylactic acid (PLA), polyetherimide (PEI), a material combining nylon 12 and carbon fiber, or the like can be used.

[0014] The second material supply unit 20b supplies the raw material M2 of the support material to the second plasticizing unit 30b. The second material supply unit 20b is constituted by, for example, a hopper. The second material supply unit 20b is connected to the second plasticizing unit 30b via the communication passage 25b. The raw material M2 of the support material is input into the second material supply unit 20b in the form of pellets, powder, or the like. The raw material M2 of the support material is composed of a material that is soluble in water or a solvent. As the raw material M2 of the support material, for example, HIPS (High Impact Polystyrene), polyvinyl alcohol (PVA), or the like can be used. In the following description, when the raw material M1 of the modeling material and the raw material M2 of the support material are not particularly distinguished, they are simply referred to as materials. Also, when the modeling material and the support material are not particularly distinguished, they are referred to as plasticized materials.

[0015] FIG. 2 is an explanatory diagram showing a schematic configuration of the modeling unit 110. Hereinafter, with reference to FIG. 2, the plasticizing unit 30 and the discharging unit 60 will be described.

[0016] The plasticizing unit 30 plasticizes at least a part of the material supplied from the material supply unit 20 and guides the plasticized plasticized material to the discharging unit 60. Here, "plasticizing" is a concept including melting, and is to change from a solid state to a state having fluidity. Specifically, in the case of a material in which glass transition occurs, plasticizing means raising the temperature of the material above the glass transition point. In the case of a material in which glass transition does not occur, plasticizing means raising the temperature of the material above the melting point. The plasticizing unit 30 includes a screw case 31, a drive motor 32, a screw 40, and a barrel 50.

[0017] The screw 40 is housed within the screw case 31. The upper surface side of the screw 40 is connected to the drive motor 32. The screw 40 rotates within the screw case 31 by the rotational driving force generated by the drive motor 32. The axial direction of the rotation axis RX of the screw 40 is along the Z direction. The rotational speed of the screw 40 is controlled by the control unit 300 controlling the rotational speed of the drive motor 32. Note that the screw 40 may be driven by the drive motor 32 via a speed reducer. The screw 40 is also called a rotor or a flat screw.

[0018] The barrel 50 is installed on the -Z direction side of the screw 40. The opposing surface 52, which is the upper surface of the barrel 50, faces the lower surface 48 of the screw 40. A communication hole 56 that communicates with the flow path 65 of the discharge portion 60 is formed at the center of the barrel 50. A heater 58 is provided inside the barrel 50. The temperature of the heater 58 is controlled by the control unit 300.

[0019] FIG. 3 is a perspective view showing the schematic configuration of the screw 40. The screw 40 has a substantially cylindrical shape in which the length in the direction along the rotation axis RX is smaller than the length in the direction perpendicular to the rotation axis RX. A spiral groove 42 is formed on the lower surface 48 of the screw 40 with the central portion 46 as the center. The groove 42 communicates with the material inlet 44 formed on the side surface of the screw 40. The material supplied from the material supply unit 20 is supplied to the groove 42 through the material inlet 44. The groove 42 is formed by being separated by the rib portion 43. FIG. 3 shows an example in which three grooves 42 are formed, but the number of grooves 42 may be one or two or more. Note that the groove 42 is not limited to a spiral shape, and may be a helical shape, an involute curve shape, or a shape that extends in an arc from the central portion 46 toward the outer periphery.

[0020] FIG. 4 is a schematic plan view of the barrel 50. A plurality of guide grooves 54 are formed around the communication hole 56 in the opposing surface 52. Each guide groove 54 has one end connected to the communication hole 56 and extends spirally from the communication hole 56 toward the outer periphery of the opposing surface 52. Note that one end of the guide groove 54 may not be connected to the communication hole 56. Further, the guide groove 54 may not be formed in the barrel 50.

[0021] The material supplied to the groove 42 of the screw 40 is plasticized in the groove 42 while flowing along the groove 42 by the rotation of the screw 40 and the heating of the heater 58, and is guided to the central portion 46 of the screw 40. The paste-like plasticized material that has flowed into the central portion 46 and exhibits fluidity is supplied to the discharge portion 60 through the communication hole 56. Note that in the plasticizing section 30, not all types of substances constituting the plasticized material need to be plasticized. The plasticized material only needs to be converted into a state having fluidity as a whole by plasticizing at least some types of substances among the substances constituting the plasticized material.

[0022] The discharge portion 60 discharges the material plasticized in the plasticizing portion 30. The discharge portion 60 includes a nozzle 61, a flow path 65, and a discharge control portion 70.

[0023] The nozzle 61 is connected to the communication hole 56 of the barrel 50 through the flow path 65. The nozzle 61 discharges the plasticized material from the nozzle opening 62 at the tip of the nozzle 61 toward the stage 210. Hereinafter, the nozzle 61 included in the first discharge portion 60a is also referred to as the first nozzle 61a, and the nozzle 61 included in the second discharge portion 60b is also referred to as the second nozzle 61b.

[0024] The discharge control portion 70 includes a discharge adjustment portion 71 that opens and closes the flow path 65 and a suction portion 72 that sucks and temporarily stores the plasticized material.

[0025] The discharge adjustment unit 71 is provided in the flow path 65 and changes the opening degree of the flow path 65 by rotating within the flow path 65. In the present embodiment, the discharge adjustment unit 71 is constituted by a butterfly valve. The discharge adjustment unit 71 is driven by a first drive unit 73 under the control of the control unit 300. The first drive unit 73 is constituted by, for example, a stepping motor. The control unit 300 can adjust the flow rate of the plasticized material flowing from the plasticizing unit 30 to the nozzle 61, that is, the discharge amount of the plasticized material discharged from the nozzle 61, by controlling the rotation angle of the butterfly valve using the first drive unit 73. The discharge adjustment unit 71 can adjust the discharge amount of the plasticized material and can control the on / off of the outflow of the plasticized material.

[0026] The suction unit 72 is connected in the flow path 65 between the discharge adjustment unit 71 and the nozzle opening 62. When the discharge of the plasticized material from the nozzle 61 stops, the suction unit 72 temporarily sucks the plasticized material in the flow path 65, thereby suppressing the trailing phenomenon in which the plasticized material drips from the nozzle opening 62 as if drawing a thread. In the present embodiment, the suction unit 72 is constituted by a plunger. The suction unit 72 is driven by a second drive unit 74 under the control of the control unit 300. The second drive unit 74 is constituted by, for example, a stepping motor or a rack and pinion mechanism that converts the rotational force of the stepping motor into the translational movement of the plunger.

[0027] The stage 210 shown in FIG. 1 is disposed at a position facing the nozzle opening 62 of the nozzle 61. The three-dimensional shaping apparatus 100 shapes a three-dimensional shaped object by discharging a plasticized material from the nozzle 61 onto the shaping surface 211, which is the upper surface of the stage 210, to laminate layers. The stage 210 may be provided with a heater for suppressing the rapid cooling of the plasticized material discharged onto the stage 210.

[0028] The moving mechanism 230 changes the relative position between the nozzle 61 and the stage 210. In this embodiment, the moving mechanism 230 moves the stage 210 relative to the nozzle 61 whose position is fixed. A change in the relative position of the nozzle 61 with respect to the stage 210 is simply referred to as the movement of the nozzle 61. The moving mechanism 230 is constituted by a three-axis positioner that moves the stage 210 in three axial directions of the X, Y, and Z directions by the driving force of three motors. Each motor of the moving mechanism 230 is driven under the control of the control unit 300. Note that the moving mechanism 230 may be configured to move the nozzle 61 with the position of the stage 210 fixed instead of moving the stage 210. Further, the moving mechanism 230 may be configured to move both the stage 210 and the nozzle 61.

[0029] The control unit 300 is a control device that controls the operation of the three-dimensional shaping apparatus 100 as a whole. The control unit 300 is constituted by a computer including one or a plurality of processors 310, a storage device 320, and an input / output interface that performs signal input / output with the outside. The processor 310 controls the three-dimensional shaping apparatus 100 according to the shaping data acquired from the information processing apparatus 400 and performs shaping of a three-dimensional shaped object on the stage 210 by executing a program stored in the storage device 320. Note that the control unit 300 may be realized by a configuration combining circuits instead of being constituted by a computer.

[0030] FIG. 5 is an explanatory diagram schematically showing a state in which the three-dimensional shaping apparatus 100 shapes the three-dimensional shaped object MD. In the three-dimensional shaping apparatus 100, as described above, the shaping material M3 and the support material M4 are generated. While maintaining the distance between the shaping surface 211 of the stage 210 and the first nozzle 61a, the control unit 300 discharges the shaping material M3 from the first nozzle 61a while changing the position of the first nozzle 61a with respect to the stage 210 in the direction along the shaping surface 211 of the stage 210. Further, while maintaining the distance between the shaping surface 211 of the stage 210 and a second nozzle 61b (not shown), the control unit 300 discharges the support material M4 from the second nozzle 61b while changing the position of the second nozzle 61b with respect to the stage 210 in the direction along the shaping surface 211 of the stage 210. The materials discharged from the nozzle 61 are continuously deposited in the moving direction of the nozzle 61.

[0031] The control unit 300 repeatedly moves the nozzle 61 to form the layer ML. One layer ML is formed by only the shaping material M3 or both the shaping material M3 and the support material M4. After forming one layer ML, the control unit 300 relatively moves the position of the nozzle 61 with respect to the stage 210 in the Z direction. Then, the shaped object MD1 and the support structure MD2 are shaped by stacking the layer ML on top of the layer MLs formed so far. Hereinafter, the lowermost layer ML is referred to as the first layer, and the nth layer ML (n is a natural number) counted from the first layer is referred to as the nth layer.

[0032] For example, when the control unit 300 switches the discharge of the modeling material M3 from the first nozzle 61a and the discharge of the support material M4 from the second nozzle 61b during the formation of one layer ML, or when moving the nozzle 61 in the Z direction after the formation of one layer of the layer ML is completed, or when there are a plurality of independent modeling regions in each layer ML, the discharge of the plasticized material from the nozzle 61 may be temporarily interrupted. In this case, the discharge control unit 70 closes the flow path 65 to stop the discharge of the plasticized material from the nozzle opening 62, and the suction unit 72 temporarily suctions the plasticized material in the nozzle 61. After changing the position of the nozzle 61, the control unit 300 opens the flow path 65 by the discharge control unit 70 while discharging the plasticized material in the suction unit 72, thereby restarting the deposition of the plasticized material from the changed position of the nozzle 61.

[0033] The shaped object MD1 has an outer region ZD1 and an inner region ZD2. The outer region ZD1 is a region that constitutes the outer contour of the shaped object MD1 and means a portion located on the outer contour of the shaped object MD1 whose shaping is completed. The inner region ZD2 is inside the outer region ZD1 and means a portion located inside the shaped object MD1 whose shaping is completed. The inner region ZD2 is also called an infill. In FIG. 5, in order to clearly show the outer region ZD1, the outer region ZD1 is hatched with oblique lines.

[0034] FIG. 6 is an explanatory diagram showing a schematic configuration of the information processing apparatus 400. The information processing apparatus 400 is configured as a computer in which a CPU 410, a memory 420, a storage device 430, a communication interface 440, and an input / output interface 450 are interconnected by a bus 460. An input device 470 such as a keyboard and a mouse and a display device 480 such as a liquid crystal display are connected to the input / output interface 450. The information processing apparatus 400 is connected to the control unit 300 of the three-dimensional shaping apparatus 100 via the communication interface 440.

[0035] The CPU 410 functions as an acquisition unit 411 and a data generation unit 412 by executing a program stored in the storage device 430.

[0036] The acquisition unit 411 acquires designation information for designating the filling rate of the shaped object MD1.

[0037] The data generation unit 412 generates shaping data, which is data for shaping the three-dimensional shaped object MD. The shaping data includes first shaping data, second shaping data, and third shaping data, which will be described later.

[0038] FIG. 7 is a process diagram of a method for manufacturing a three-dimensional shaped object. The processes from step S10 to step S70 are executed in the information processing apparatus 400, and the processes of step S80 and step S90 are executed in the three-dimensional shaping apparatus 100.

[0039] In step S10, the data generation unit 412 of the information processing apparatus 400 acquires shape data representing the three-dimensional shape of the shaped object MD1 from another computer, a recording medium, or the storage device 430. The shape data is data representing the shape of the shaped object MD1 created using three-dimensional CAD software, three-dimensional CG software, or the like. As the shape data, for example, data in the STL format, AMF format, or the like can be used.

[0040] In step S20, the data generation unit 412 generates slice data. The slice data refers to data representing the shape of the shaped object MD1 sliced into a plurality of layers. More specifically, the data generation unit 412 generates slice data by slicing the shape of the shaped object MD1 represented by the shape data into a plurality of layers along the XY plane.

[0041] In step S30, the data generation unit 412 receives from the user the setting of the shaping conditions for the three-dimensional shaped object MD. The user operates the setting screen displayed on the display device 480 using the input device 470 to set the shaping conditions. The shaping conditions are, for example, the line width, the shaping pattern, the filling rate of the shaped object, etc. The "line width" is the width of the plasticized material discharged from the nozzle 61. The "shaping pattern" is a pattern indicating the movement path of the nozzle 61 for filling the internal region ZD2 of each layer ML. The "filling rate of the shaped object" is the area ratio of the shaping material M3 that fills the internal region ZD2 according to the specified shaping pattern. Here, assume that the user sets a value less than 100% as the filling rate of the shaped object. Hereinafter, the shaping pattern is also referred to as the infill path pattern.

[0042] In step S40, the acquisition unit 411 acquires the specified information. The acquisition unit 411 acquires, as the specified information, the filling rate of the shaped object included in the shaping conditions received by the data generation unit 412 in step S30. Step S40 is also referred to as the first step.

[0043] In step S50, the data generation unit 412 generates first shaping data based on the slice data and the shaping conditions. The first shaping data is data instructing the formation of the shaped object MD1 in the outer contour region ZD1. The first shaping data includes information on the first discharge amount, which is the discharge amount per unit time of the shaping material M3 by the first discharge unit 60a, and information on the first discharge path, which is the path along which the shaping material M3 is discharged. Here, the path along which the shaping material M3 is discharged is the path along which the first nozzle 61a moves relatively along the shaping surface 211 of the stage 210. The first shaping data includes information on the first discharge amount and information on the first discharge path for each layer obtained by slicing the shape of the shaped object MD1 into a plurality of layers. It is preferable that the data generation unit 412 generates the first shaping data for each layer in order from the upper layer ML. Note that the data generation unit 412 may generate the first shaping data for each layer in order from the lower layer ML.

[0044] FIG. 8 is a diagram for explaining the discharge path of the plasticizing material in one layer ML. FIG. 8 shows a state of one layer ML viewed from above. In step S50, the data generation unit 412 determines a first discharge amount and a first discharge path R1 for forming the shaped object MD1 in the outer contour region ZD1 shown in FIG. 8. In FIG. 8, as the first discharge path R1, a path that goes around the outer contour of the shaped object MD1 once is shown. Note that the first discharge path R1 may be a path that goes around the outer contour of the shaped object MD1 two or more times. Step S50 is also called the second step.

[0045] In step S60 of FIG. 7, the data generation unit 412 generates second shaping data based on the slice data and the shaping conditions. The second shaping data is data for instructing the formation of the shaped object MD1 in the internal region ZD2. The second shaping data includes information on the second discharge amount, which is the discharge amount per unit time of the shaping material M3 by the first discharge unit 60a, and information on the second discharge path, which is the path along which the shaping material M3 is discharged. The second shaping data includes information on the second discharge amount and information on the second discharge path for each layer obtained by slicing the shape of the shaped object MD1 into a plurality of layers. The data generation unit 412 generates the second shaping data for each layer in order from the upper layer ML. Note that the data generation unit 412 may generate the second shaping data for each layer in order from the lower layer ML.

[0046] In step S60, the data generation unit 412 determines a second discharge amount and a second discharge path R2 for forming the shaped object MD1 in the internal region ZD2 shown in FIG. 8. At this time, the data generation unit 412 determines the second discharge amount and the second discharge path R2 based on the specified information acquired in step S40. Specifically, the data generation unit 412 determines the second discharge amount and the second discharge path R2 such that the filling rate of the shaping material M3 in each layer ML is equal to the specified information. The filling rate of the shaping material M3 in the layer ML is the area ratio of the shaping material M3 occupying the internal region ZD2 when the layer ML is viewed from above. Further, the data generation unit 412 generates the second shaping data such that at least a part of the second discharge path R2 in the internal region ZD2 and the first discharge path R1 in the outer peripheral region ZD1 are in contact with each other. Furthermore, when the shaping of the three-dimensional shaped object MD is completed, the data generation unit 412 generates the second shaping data such that a hole portion communicating with the internal region ZD2 is formed in the three-dimensional shaped object MD. Specifically, the data generation unit 412 generates the second shaping data such that the gap formed inside the shaped object MD1 communicates with the outside of the shaped object MD1. Step S60 is also referred to as the third step.

[0047] In step S70 of FIG. 7, the data generation unit 412 generates third shaping data based on the slice data and the shaping conditions. The third shaping data is data for instructing the formation of the support structure MD2 in the internal region ZD2. The third shaping data includes information on the third discharge amount, which is the discharge amount per unit time of the support material M4 by the second discharge unit 60b, and information on the third discharge path, which is the path along which the support material M4 is discharged. Here, the path along which the support material M4 is discharged is the path along which the second nozzle 61b relatively moves along the shaping surface 211 of the stage 210. The third shaping data includes information on the third discharge amount and information on the third discharge path for each layer obtained by slicing the shape of the shaped object MD1 into a plurality of layers. The data generation unit 412 generates the third shaping data for each layer in order from the upper layer ML. Step S70 includes step S71 and step S72. Step S70 is also referred to as the fourth step. Note that the data generation unit 412 may generate the third shaping data for each layer in order from the lower layer ML.

[0048] In step S71, the data generation unit 412 identifies a gap region ZD3 which is a region where the modeling material M3 is not discharged in the internal region ZD2. The data generation unit 412 identifies, as the gap region ZD3, a portion of the internal region ZD2 where the second discharge path R2 is not located.

[0049] In step S72, the data generation unit 412 generates third modeling data. As shown in FIG. 8, the data generation unit 412 generates the third modeling data such that the support material M4 is discharged into the gap region ZD3 identified in step S71. That is, the data generation unit 412 determines the third discharge amount and the third discharge path R3 such that the third discharge path R3 is located in at least a part of the gap between the second discharge paths R2. The data generation unit 412 preferably generates the third modeling data such that the sum of the filling rate of the modeling material M3 and the filling rate of the support material M4 in each layer ML is close to 100%.

[0050] In step S80, the control unit 300 of the three-dimensional modeling apparatus 100 acquires, from the information processing apparatus 400, modeling data including the first modeling data, the second modeling data, and the third modeling data generated by the information processing apparatus 400 in steps S50 to S70.

[0051] In step S90, the control unit 300 controls the first discharge unit 60a, the second discharge unit 60b, and the moving mechanism 230 according to the modeling data acquired from the information processing apparatus 400, and forms a three-dimensional object MD by forming a modeled object MD1 and a support structure MD2 on the modeling surface 211 of the stage 210. Step S90 is also referred to as the fifth step.

[0052] In step S100, the user separates the support structure MD2 from the modeled object MD1. For example, the user immerses the three-dimensional object MD in a liquid that dissolves only the support structure MD2 of the three-dimensional object MD that has been formed, such as water or a solvent, to dissolve the support structure MD2. Step S100 is also referred to as the sixth step.

[0053] According to the first embodiment described above, in one layer ML, the data generation unit 412 generates the third shaping data so that the third discharge path R3 is located at least partially in the gap between the second discharge paths R2. As a result, in the shaping of the three-dimensional shaped object MD, the support structure MD2 is formed in the gap existing inside the shaped object MD1. Therefore, it is possible to suppress the position of the shaping material M3 discharged above the support structure MD2 from shifting due to gravity before it hardens. Accordingly, even a shaped object MD1 with a low filling rate can be shaped with high precision.

[0054] Also, in the present embodiment, the data generation unit 412 identifies the gap region ZD3 and generates the third shaping data so that the support material M4 is discharged into the gap region ZD3. Therefore, in the shaping of the three-dimensional shaped object MD, it is possible to suppress the support material M4 from being discharged into the region where the shaping material M3 has already been discharged.

[0055] Also, in the present embodiment, the data generation unit 412 generates the second shaping data so that at least a part of the second discharge path R2 in the internal region ZD2 is in contact with at least a part of the first discharge path R1 in the outer peripheral region ZD1. Therefore, when the support structure MD2 is separated from the shaped object MD1, it is possible to suppress the shaped object MD1 in the outer peripheral region ZD1 and the shaped object MD1 in the internal region ZD2 from separating.

[0056] Also, in the present embodiment, the data generation unit 412 generates the second shaping data so that a hole portion communicating with the internal region ZD2 is formed in the three-dimensional shaped object MD. As a result, when the three-dimensional shaped object MD is immersed in a liquid that dissolves only the support structure MD2, the liquid flows into the inside of the three-dimensional shaped object MD. Therefore, the support structure MD2 can be easily separated from the shaped object MD1.

[0057] B. Second Embodiment: In the second embodiment, the process of step S72 of the method for manufacturing a three-dimensional shaped object is different from that of the first embodiment. The processes other than step S72 and the configuration of the three-dimensional shaping system 10 are the same as those of the first embodiment.

[0058] FIG. 9 is a diagram for explaining the discharge path of the plasticizing material in one layer ML in the second embodiment. FIG. 9 shows a state of one layer ML viewed from above. In the second embodiment, in step S72 of FIG. 7, the data generation unit 412 generates third modeling data so that the support material M4 is discharged into a part of the gap region ZD3 specified in step S71. As shown in FIG. 9, the data generation unit 412 preferably determines the third discharge path R3 so that the gap region ZD3 is divided by the support material M4. The data generation unit 412 generates third modeling data so that the sum of the filling rate of the modeling material M3 in each layer ML and the filling rate of the support material M4 is less than 100%.

[0059] According to the second embodiment described above, the data generation unit 412 generates third modeling data so that the third discharge path R3 is located in at least a part of the gap between the second discharge paths R2 in one layer ML. Therefore, similar to the first embodiment, even a shaped object MD1 with a low filling rate can be shaped with high precision.

[0060] C. Third Embodiment: In the third embodiment, the process of step S72 of the method for manufacturing a three-dimensional shaped object is different from that of the first embodiment. The processes other than step S72 and the configuration of the three-dimensional shaping system 10 are the same as those of the first embodiment.

[0061] FIGS. 10 and 11 are diagrams for explaining the discharge path of the plasticizing material in one layer ML in the third embodiment. FIG. 10 shows a state of the (n + 1)-th layer viewed from above. FIG. 11 shows a state of the (n + 2)-th layer viewed from above.

[0062] The data generation unit 412 generates third modeling data for each layer in order from the upper layer ML. In the third embodiment, in step S72 of FIG. 7, the data generation unit 412 generates the third modeling data for the (n + 1)-th layer such that the support material M4 is discharged into the region where the second discharge path R2 in the (n + 2)-th layer and the gap region ZD3 in the (n + 1)-th layer overlap in the vertical direction. In other words, the data generation unit 412 determines the third discharge path R3 of the (n + 1)-th layer such that the support material M4 is discharged into the region where the region where the modeling material M3 is discharged in the (n + 2)-th layer and the gap region ZD3 in the (n + 1)-th layer overlap in the vertical direction. When there is a region where the support material M4 is discharged in the (n + 2)-th layer, the data generation unit 412 generates the third modeling data for the (n + 1)-th layer such that the support material M4 is discharged into the region where the second discharge path R2 or the third discharge path R3 in the (n + 2)-th layer and the gap region ZD3 in the (n + 1)-th layer overlap in the vertical direction.

[0063] FIG. 12 is a view showing a part of the three-dimensional object MD formed by the method for manufacturing a three-dimensional object in the third embodiment. FIG. 12 shows a cross-sectional view of the three-dimensional object MD seen from the side. The data generation unit 412 generates the third modeling data for all the layers ML as described above. As a result, in the gap region ZD3 of the layer ML below the (n + 2)-th layer, the third discharge path R3 exists in the region that overlaps the second discharge path R2 of the (n + 2)-th layer in the vertical direction. Also, the third discharge path R3 in each layer ML exists in the region that overlaps the second discharge path R2 or the third discharge path R3 of the layer ML one layer below it in the vertical direction. In other words, the data generation unit 412 generates the third modeling data for the (n + 1)-th layer such that the support material M4 is discharged into the region that overlaps the second discharge path R2 or the third discharge path R3 in the n-th layer in the vertical direction among the regions where the second discharge path R2 in the (n + 2)-th layer and the gap region ZD3 in the (n + 1)-th layer overlap in the vertical direction.

[0064] According to the third embodiment described above, the data generation unit 412 generates the third modeling data of the (n + 1)-th layer such that the support material M4 is discharged into the region that vertically overlaps with the second discharge path R2 in the (n + 2)-th layer and the gap region ZD3 in the (n + 1)-th layer, and vertically overlaps with the second discharge path R2 or the third discharge path R3 in the n-th layer. Therefore, in the three-dimensional modeling of the three-dimensional molded object MD, the support material M4 can be disposed at a position that supports the modeling material M3 of the layer ML one layer above. Thereby, it is possible to suppress the position of the modeling material M3 discharged above the support structure MD2 from shifting due to gravity before it hardens, and even if the molded object MD1 has a low filling rate, it can be modeled with high precision.

[0065] Also, in the present embodiment, the data generation unit 412 generates the third modeling data in order from the upper layer ML. Therefore, the third modeling data of the (n + 1)-th layer can be generated using the information of the third discharge path R3 of the (n + 2)-th layer.

[0066] D. Fourth Embodiment: In the fourth embodiment, the processes of steps S60 and S70 of the method for manufacturing a three-dimensional molded object are different from those of the first embodiment. The processes other than steps S60 and S70, and the configuration of the three-dimensional modeling system 10 are the same as those of the first embodiment.

[0067] FIG. 13 is a process diagram showing a method for manufacturing a three-dimensional molded object according to the fourth embodiment. In FIG. 13, for the processes in which the same processes as those in FIG. 7 are executed, the same reference numerals as those in FIG. 7 are given, and the description thereof is omitted.

[0068] In step S61, the data generation unit 412 generates the second modeling data by using a part of the path of the infill path pattern P1 indicating the movement path of the discharge unit 60 for filling the internal region ZD2 as the second discharge path R2. FIG. 14 shows an example of the infill path pattern P1. The infill path pattern P1 is a movement path such that when the nozzle 61 is moved along the infill path pattern P1 and the plasticized material is discharged, the discharged plasticized material fills the entire internal region ZD2.

[0069] FIG. 15 is a diagram for explaining the discharge path of the plasticizing material in one layer ML in the fourth embodiment. FIG. 15 shows a state of viewing one layer ML from above. As shown in FIG. 15, the data generation unit 412 determines a part of the path of the infill path pattern P1 shown in FIG. 14 as the second discharge path R2. The data generation unit 412 determines the second discharge path R2 so that the filling rate of the modeling material M3 in each layer ML is equal to the specified information. Further, the data generation unit 412 determines the second discharge path R2 so that the center of gravity of the modeled object MD1 after separating the support structure MD2 is located near the center of the modeled object MD1.

[0070] In step S73 of FIG. 13, the data generation unit 412 generates third modeling data using the paths other than the second discharge path R2 in the infill path pattern P1 as the third discharge path R3. As shown in FIG. 15, the data generation unit 412 determines, as the third discharge path R3, the paths other than the path determined as the second discharge path R2 in step S61 among the infill path patterns P1 shown in FIG. 14.

[0071] According to the fourth embodiment described above, the data generation unit 412 generates second modeling data using a part of the paths in the infill path pattern P1 as the second discharge path R2, and generates third modeling data using the paths other than the second discharge path in the infill path pattern P1 as the third discharge path R3. Therefore, in the modeling of the three-dimensional modeled object MD, the support material M4 is discharged to the region in the internal region ZD2 where the modeling material M3 is not discharged. Thereby, it is possible to suppress the position of the modeling material M3 discharged above the support structure MD2 from shifting due to gravity before it hardens. Therefore, even a modeled object MD1 with a low filling rate can be modeled with high precision.

[0072] E. Fifth Embodiment: In the fifth embodiment, the process of step S70 of the method for manufacturing a three-dimensional modeled object is different from that of the first embodiment. The processes other than step S70 and the configuration of the three-dimensional modeling system 10 are the same as those of the first embodiment.

[0073] In the fifth embodiment, in step S70, the data generation unit 412 generates the third shaping data such that the infill path pattern P3 included in the third shaping data is different from the infill path pattern P2 included in the second shaping data. Specifically, the data generation unit 412 determines the third discharge path R3 such that the infill path pattern P3 of the third discharge path R3 is different from the infill path pattern P2 of the second discharge path R2.

[0074] FIGS. 16 and 17 are diagrams for explaining the infill path pattern. FIG. 16 shows the infill path pattern P2 of the second discharge path R2, and FIG. 17 shows the infill path pattern P3 of the third discharge path R3. The infill path pattern P2 is a pattern that obliquely crosses the internal region ZD2, and the infill path pattern P3 is a pattern that draws a rectangle in the internal region ZD2.

[0075] FIG. 18 is a diagram for explaining the discharge path of the plasticizing material in one layer ML in the fifth embodiment. FIG. 18 shows a state of viewing one layer ML from above. As shown in FIG. 18, since the infill path pattern P2 and the infill path pattern P3 are different, in one layer ML, the third discharge path R3 is located at least partially in the gap between the second discharge paths R2. Also, as shown in FIG. 18, in the fifth embodiment, there is a portion where the second discharge path R2 and the third discharge path R3 overlap in the same layer ML. Thereby, while the support material M4 is being discharged from the second nozzle 61b, the already discharged shaping material M3 is likely to adhere to the second nozzle 61b. Therefore, it is preferable to increase the frequency of cleaning the second nozzle 61b.

[0076] Note that the data generation unit 412 may determine the third discharge path R3 such that the infill path pattern P3 of the third discharge path R3 is the same as the infill path pattern P2 of the second discharge path R2. In this case, as shown in FIG. 19, the data generation unit 412 determines the third discharge path R3 such that the overlapping area of the second discharge path R2 and the third discharge path R3 in the same layer ML is reduced.

[0077] According to the fifth embodiment described above, the data generation unit 412 generates the third modeling data such that the infill path pattern P3 included in the third modeling data is different from the infill path pattern P2 included in the second modeling data. Since the infill path pattern P2 and the infill path pattern P3 are different, in one layer ML, the third discharge path R3 is located at least partially in the gap between the second discharge paths R2. Therefore, similar to the first embodiment, even a shaped object MD1 with a low filling rate can be shaped with high precision.

[0078] F. Other Embodiments: (F-1) In the above embodiment, the data generation unit 412 generates the second modeling data in step S60 of FIG. 7 such that a hole communicating with the internal region ZD2 is formed in the three-dimensional shaped object MD when the shaping of the three-dimensional shaped object MD is completed. In contrast, the data generation unit 412 may generate the first modeling data in step S50 of FIG. 7 such that a hole communicating with the internal region ZD2 is formed in the three-dimensional shaped object MD when the shaping of the three-dimensional shaped object MD is completed.

[0079] (F-2) In the above embodiment, the raw material M1 of the modeling material is composed of a material that does not dissolve in water or a solvent, and the raw material M2 of the support material is composed of a material that dissolves in water or a solvent. In contrast, the raw material M1 of the modeling material may be composed of a material containing metal powder and a binder, and the raw material M2 of the support material may be composed of a material containing resin. As the metal powder, a single metal such as magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or a powder containing two or more of these metals, or an alloy containing two or more of these metals is used. Examples of the above-mentioned alloys include maraging steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy, and the like. The binder contains resin and wax. As the resin, an acrylic resin, an epoxy resin, a silicone resin, a cellulose-based resin, or other synthetic resins, or thermoplastic resins such as PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) is used. According to such a form, by performing a degreasing treatment on the three-dimensional object MD after the modeling is completed, the support structure MD2 can be separated from the object MD1.

[0080] (F-3) In the above embodiment, the data generation unit 412 generates the first modeling data for all the layers ML in step S50 of FIG. 7, generates the second modeling data for all the layers ML in step S60, and generates the third modeling data for all the layers ML in step S70. In contrast, the data generation unit 412 may generate the first modeling data, the second modeling data, and the third modeling data layer by layer. In this case, it is preferable that the data generation unit 412 generates the modeling data in order from the lower layer ML.

[0081] (F-4) In the third embodiment, the data generation unit 412 generates the third modeling data for each layer in order from the upper layer ML. In contrast, the data generation unit 412 may generate the third modeling data for each layer in order from the lower layer ML.

[0082] (F-5) In the above-described embodiment, the three-dimensional modeling apparatus 100 includes two ejection units 60. In contrast, the three-dimensional modeling apparatus 100 may include one ejection unit 60, or may include three or more ejection units 60.

[0083] (F-6) In the above-described embodiment, the material extrusion method of laminating a plasticized material has been described as an example. However, the present disclosure can be applied to various methods such as an inkjet method, a DMD method (Direct Metal Deposition), and a binder jet method.

[0084] G. Other Forms: The present disclosure is not limited to the above-described embodiments, and can be realized in various forms without departing from the gist thereof. For example, the present disclosure can also be realized by the following forms. The technical features in the above-described embodiments corresponding to the technical features in each of the following forms can be appropriately replaced or combined in order to solve some or all of the problems of the present disclosure, or to achieve some or all of the effects of the present disclosure. Further, if the technical feature is not described as essential in this specification, it can be appropriately deleted.

[0085] (1) According to one aspect of the present disclosure, a method for manufacturing a three-dimensional object is provided. This method for manufacturing a three-dimensional object manufactures a three-dimensional object having a shaped object and a support structure that supports the shaped object by discharging a shaping material and a support material from a discharge unit toward a stage and laminating layers, and includes: a first step of obtaining designation information for designating a filling rate of the shaped object; a second step of generating first shaping data including information on a first discharge amount which is an amount of the shaping material discharged per unit time by the discharge unit and information on a first discharge path which is a path along which the shaping material is discharged, and instructing formation of the shaped object in an outer region that constitutes an outer contour of the shaped object; a third step of generating second shaping data including information on a second discharge amount which is an amount of the shaping material discharged per unit time by the discharge unit and information on a second discharge path which is a path along which the shaping material is discharged, and instructing formation of the shaped object in an inner region that is inside the outer region, based on the designation information; a fourth step of generating third shaping data including information on a third discharge amount which is an amount of the support material discharged per unit time by the discharge unit and information on a third discharge path which is a path along which the support material is discharged, and instructing formation of the support structure in the inner region; a fifth step of shaping the three-dimensional object according to the first shaping data, the second shaping data, and the third shaping data; and a sixth step of separating the support structure from the shaped object, wherein the fourth step includes a step of generating the third shaping data such that the third discharge path is located at least partially in a gap between the second discharge paths in one of the layers. According to such an aspect, in the shaping of a three-dimensional object, since a support structure is formed in a gap existing inside the shaped object, it is possible to suppress the position of the shaping material discharged above the support structure from shifting due to gravity before the shaping material hardens. Therefore, even a shaped object with a low filling rate can be shaped with high precision.

[0086] (2) In the above-described form, the fourth step includes a step of specifying a gap region, which is a region where the modeling material is not discharged in the internal region, based on the second modeling data, and a step of generating the third modeling data so that the support material is discharged into the gap region. According to such a form, in the modeling of a three-dimensional object, it is possible to suppress the discharge of the support material into a region where the modeling material has already been discharged.

[0087] (3) In the above-described form, in the fourth step, with the lowermost layer being defined as the first layer, among the regions where the second discharge path in the (n + 2)-th layer (n is a natural number) and the gap region in the (n + 1)-th layer overlap vertically, the third modeling data for the (n + 1)-th layer is generated such that the support material is discharged into the region where the second discharge path or the third discharge path in the n-th layer overlaps vertically with the vertical direction. According to such a form, in the modeling of a three-dimensional object, it is possible to arrange the support material at a position that supports the modeling material of the layer one above.

[0088] (4) In the above-described form, in the fourth step, the third modeling data is generated in order from the upper layer. According to such a form, the third modeling data for the (n + 1)-th layer can be generated using the information on the third discharge path of the (n + 2)-th layer.

[0089] (5) In the above-described form, among the infill path patterns indicating the movement paths of the discharge parts for filling the internal region, part of the paths are used as the second discharge paths to generate the second modeling data, and the paths other than the second discharge paths among the infill path patterns are used as the third discharge paths to generate the third modeling data. According to such a form, in the modeling of a three-dimensional object, the support material is discharged into a region where the modeling material is not discharged in the internal region. Therefore, it is possible to suppress the displacement of the position of the modeling material discharged above the support structure due to gravity before it hardens.

[0090] (6) In the above-described form, in the third step, the second shaping data is generated such that at least a part of the second discharge path in the internal region is in contact with the first discharge path in the outer peripheral region. According to such a form, when the support structure is separated from the shaped object, it is possible to suppress the separation of the shaped object in the outer peripheral region and the shaped object in the internal region.

[0091] (7) In the above-described form, in the second step, the first shaping data is generated such that a hole communicating with the internal region is formed in the three-dimensional shaped object, or in the third step, the second shaping data is generated such that a hole communicating with the internal region is formed in the three-dimensional shaped object. According to such a form, when the three-dimensional shaped object is immersed in a liquid that dissolves only the support structure, the liquid flows into the inside of the three-dimensional shaped object, so that the support structure can be easily separated from the shaped object.

Explanation of reference numerals

[0092] 10…Three-dimensional shaping system, 20…Material supply unit, 20a…First material supply unit, 20b…Second material supply unit, 25a…Communication path, 25b…Communication path, 30…Plasticizing unit, 30a…First plasticizing unit, 30b…Second plasticizing unit, 31…Screw case, 32…Drive motor, 40…Screw, 42…Groove, 43…Rib portion, 44…Material inlet, 46…Central portion, 48…Bottom surface, 50…Barrel, 52…Opposing surface, 54…Guide groove, 56…Communication hole, 58…Heater, 60…Discharge unit, 60a…First discharge unit, 60b…Second discharge unit, 61…Nozzle, 61a…First nozzle, 61b…Second nozzle, 62…Nozzle opening, 65…Flow path, 70…Discharge control unit, 71…Discharge adjustment unit, 72…Suction unit, 73…First drive unit, 74…Second drive unit, 100…Three-dimensional shaping device, 110…Shaping unit, 110a…First shaping unit, 110b…Second shaping unit, 210…Stage, 211…Shaping surface, 230…Moving mechanism, 300…Control unit, 310…Processor, 320…Memory device, 400…Information processing device, 410…CPU, 411…Acquisition unit, 412…Data generation unit, 420…Memory, 430…Memory device, 440…Communication interface, 450…Input / output interface, 460…Bus, 470…Input device, 480…Display device, M1…Raw material of shaping material, M2…Raw material of support material, M3…Shaping material, M4…Support material, MD…Three-dimensional shaped object, MD1…Shaped object, MD2…Support structure, ML…Layer, P1, P2, P3…Infill path pattern, R1…First discharge path, R2…Second discharge path, R3…Third discharge path, RX…Rotation axis, ZD1…Outer region, ZD2…Inner region, ZD3…Gap region

Claims

1. A method for manufacturing a three-dimensional object, which manufactures a three-dimensional object having a shaped object and a support structure for supporting the shaped object by discharging a shaping material and a support material from a discharge unit toward a stage to stack layers, comprising: a first step of obtaining designation information for designating a filling rate of the shaped object; a second step of generating first shaping data including information on a first discharge amount which is an amount of the shaping material discharged per unit time by the discharge unit and information on a first discharge path which is a path along which the shaping material is discharged, and instructing formation of the shaped object in an outer region constituting an outer contour of the shaped object; a third step of generating second shaping data including information on a second discharge amount which is an amount of the shaping material discharged per unit time by the discharge unit and information on a second discharge path which is a path along which the shaping material is discharged, and instructing formation of the shaped object in an inner region which is inside the outer region, based on the designation information; a fourth step of generating third shaping data including information on a third discharge amount which is an amount of the support material discharged per unit time by the discharge unit and information on a third discharge path which is a path along which the support material is discharged, and instructing formation of the support structure in the inner region; a fifth step of shaping the three-dimensional object according to the first shaping data, the second shaping data, and the third shaping data; a sixth step of separating the support structure from the shaped object, wherein the fourth step includes a step of generating the third shaping data such that the third discharge path is located in at least a part of a gap between the second discharge paths in one layer; A method for manufacturing a three-dimensional object.

2. The method for manufacturing a three-dimensional object according to Claim 1, wherein the fourth step includes a step of specifying a gap region which is a region where the shaping material is not discharged in the inner region, based on the second shaping data; and a step of generating the third shaping data such that the support material is discharged into the gap region. A method for manufacturing a three-dimensional object.

3. The method for manufacturing a three-dimensional object according to Claim 2, wherein In the fourth step, with the layer located at the bottommost position being defined as the first layer, in a region where the second discharge path in the (n + 2)-th layer (n is a natural number) and the gap region in the (n + 1)-th layer overlap vertically, the support material is discharged into a region where the second discharge path or the third discharge path in the n-th layer overlaps vertically, and the third shaping data for the (n + 1)-th layer is generated accordingly. Method for manufacturing a three-dimensional shaped object.

4. A method for manufacturing a three-dimensional shaped object according to claim 3, In the fourth step, the third shaping data is generated in order from the upper layer. Method for manufacturing a three-dimensional shaped object.

5. A method for manufacturing a three-dimensional shaped object according to claim 1, Among the infill path patterns indicating the movement path of the discharge part for filling the internal region, part of the paths are used as the second discharge path to generate the second shaping data, and the paths other than the second discharge path among the infill path patterns are used as the third discharge path to generate the third shaping data. Method for manufacturing a three-dimensional shaped object.

6. A method for manufacturing a three-dimensional shaped object according to claim 1, In the third step, the second shaping data is generated such that at least a part of the second discharge path in the internal region and the first discharge path in the outer contour region are in contact with each other. Method for manufacturing a three-dimensional shaped object.

7. A method for manufacturing a three-dimensional shaped object according to claim 1, In the second step, the first shaping data is generated such that a hole communicating with the internal region is formed in the three-dimensional shaped object, or in the third step, the second shaping data is generated such that a hole communicating with the internal region is formed in the three-dimensional shaped object. Method for manufacturing a three-dimensional shaped object.

Images