Shaped article manufacturing method

Abstract

To provide a shaped article manufacturing method capable of easily removing a support.SOLUTION: A shaped article manufacturing method includes a shaping step and a removing step. The shaping step is a step of shaping a roughly shaped article W1 having a model M formed into a shaped article and a support S for supporting a support necessary part MO of the model M. The removing step is a step of separating the model M and the support S after the shaping step, and thereby removing the support S from the roughly shaped article W1. The shaping step shapes the support necessary part MO while forming a predetermined gap 20 between the support S and the support necessary part MO of the model M.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a three-dimensional object and a manufacturing apparatus for a three-dimensional object used in the manufacturing method.

Background Art

[0002] In recent years, as a manufacturing apparatus for a three-dimensional object, for example, a 3D printer using a fused deposition modeling method is widely known (see, for example, Patent Document 1).

[0003] When manufacturing a three-dimensional object having a desired shape using the fused deposition modeling method 3D printer, depending on the shape of the target object, a support (support material) for supporting a support-required part (overhang part) of the model to be the object may be required.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, since the support for supporting the support-required part of the model during modeling is unnecessary after modeling, it is necessary to separate the two and remove the support, but the removal is often difficult.

[0006] Therefore, one of the problems of the present invention is to provide a method for manufacturing a three-dimensional object and a manufacturing apparatus for a three-dimensional object that can easily remove the support.

Means for Solving the Problems

[0007] The method for manufacturing a shaped object according to an embodiment of the present invention is a method for manufacturing a three-dimensional shaped object using a shaped object manufacturing apparatus, the method including a shaping step of shaping a rough shaped object having a model to be the shaped object and a support that supports a portion of the model that requires support, and a removing step of removing the support from the rough shaped object by separating the model and the support after the shaping step. In the shaping step, the shaping of the portion that requires support is performed while forming a predetermined gap between the support and the portion of the model that requires support.

[0008] In the above method for manufacturing a shaped object, when the dimension of the predetermined gap in the shaping step is H and the opening diameter of the nozzle in the shaped object manufacturing apparatus is φ, it may satisfy φ / 2 ≦ H ≦ φ.

[0009] In the above method for manufacturing a shaped object, the support of the rough shaped object in the shaping step may have a cylindrical portion and a plurality of extending portions that extend radially from the cylindrical portion.

[0010] In the above method for manufacturing a shaped object, the support of the rough shaped object in the shaping step may have an inner cylindrical portion, an outer cylindrical portion, and a connecting portion that connects the inner cylindrical portion and the outer cylindrical portion.

[0011] In the above method for manufacturing a shaped object, the support of the rough shaped object in the shaping step may have an additional cylindrical portion located inside the cylindrical portion.

[0012] In the above method for manufacturing a shaped object, the cylindrical portion may form a closed curve.

[0013] In the above method for manufacturing a shaped object, the support of the rough shaped object in the shaping step is formed by a continuous function.

[0014] In the above method for manufacturing a shaped object, the support of the rough shaped object in the shaping step may have a plate-like spiral portion.

[0015] In the above-described method for manufacturing a shaped article, the support for the rough shaped article in the shaping step may have a cylindrical portion.

[0016] In the above-described method for manufacturing a shaped article, the support for the rough shaped article in the shaping step may have a bottom portion and a plurality of cylindrical portions erected on the bottom portion.

[0017] In the above-described method for manufacturing a shaped article, the support removed in the removing step may be reusable as a support member for supporting a portion that requires support of the model when manufacturing the same shaped article.

[0018] In the above-described method for manufacturing a shaped article, the shaped article manufacturing apparatus may be a 3D printer using a fused deposition modeling method.

[0019] Also, the shaped article manufacturing apparatus according to an embodiment of the present invention is used in the above-described method for manufacturing a shaped article.

Advantages of the Invention

[0020] According to an embodiment of the present invention, the support can be easily removed.

Brief Description of the Drawings

[0021]

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Embodiments for Carrying Out the Invention

[0022] An embodiment of the present invention will be described with reference to the drawings.

[0023] In FIG. 1, reference numeral 1 denotes a 3D printer of a thermal melting lamination method, which is a shaping apparatus. This 3D printer of the thermal melting lamination method (hereinafter sometimes simply referred to as "3D printer 1") is a shaping machine for manufacturing a three-dimensional shaped object W by sequentially laminating layers of resin, which is a shaping material melted (melted) by heat, based on 3D shaping data.

[0024] The resin, which is a shaping material used in the 3D printer 1, is, for example, a thermoplastic resin (such as a filament), and more specifically, for example, PLA, PLA containing plant fibers, ABS, ABS containing glass fibers, ABS containing carbon fibers, PP, PP containing glass fibers, PP containing carbon fibers, PC, PC·ABS, ASA, TPE, TPU, cellulose acetate, PA, PETG, etc. Further, the 3D printer 1 is, for example, of a single nozzle head specification, and only one type of resin used for shaping may be sufficient, and a resin dedicated to support (such as a water-soluble resin) is not required.

[0025] As shown in FIGS. 1(a) and (b), the 3D printer 1 includes, for example, a box-shaped main body 3 having a shaping chamber 2 inside, a shaping head 4 movable in the X-axis direction (left-right direction, which is the horizontal direction) and the Z-axis direction (up-down direction, which is the height direction) in the shaping chamber 2, and a shaping table 5 movable in the Y-axis direction (front-back direction, which is the horizontal direction) in the shaping chamber 2.

[0026] Note that since the shaping head 4 is movable in the X-axis direction and the Z-axis direction and the shaping table 5 is movable in the Y-axis direction in this way, the shaping head 4 moves three-dimensionally relative to the shaping table 5 (as will be described later, the 3D printer 1 is not limited to the configuration illustrated in FIG. 1, and any configuration in which the shaping head 4 moves at least three-dimensionally relative to the shaping table 5 is acceptable).

[0027] Further, the 3D printer 1 includes a first drive unit 6 that moves the shaping head 4 in the X-axis direction and the Z-axis direction within the shaping chamber 2, a second drive unit 7 that moves the shaping table 5 in the Y-axis direction within the shaping chamber 2, and a control unit 8 that controls both drive units 6, 7, etc. based on 3D shaping data such as STL data.

[0028] Then, based on the control by the control unit 8, while the shaping head 4 moves three-dimensionally relative to the shaping table 5, resin (melted resin) is discharged from the nozzle 11 of the moving shaping head 4, and the discharged resin hardens and solidifies, so that the resin is laminated on the shaping table 5 and a three-dimensional shaped object W of a desired shape is shaped.

[0029] However, depending on the shape of the target shaped object W, as will be described later, a support (support material) S for supporting the support required part (overhang part) MO of the model M that finally becomes the target shaped object W may be required. In this case, a rough shaped object W1 composed of the model M and the support S is shaped.

[0030] That is, when the support S is required, after once shaping a rough shaped object W1 composed of the model M and the support S, the support S is removed from the rough shaped object W1 to obtain the target shaped object W.

[0031] Here, the shaping head 4 of the 3D printer 1 of the hot melt lamination method with a single nozzle head specification is, for example, of the melted resin extrusion type, and has a single nozzle 11 that discharges the resin melted by the heat from a heating means (not shown) within the shaping head 4 from the discharge port 10.

[0032] That is, the resin melted by heating means such as a heater (not shown) is extruded by extrusion means (not shown) such as gears in the modeling head 4, and is discharged (ejected) downward from the discharge port 10 of one nozzle 11 for discharging the modeling material. Note that the heating means and the extrusion means may be provided outside the modeling head 4 instead of inside the modeling head 4.

[0033] And the opening diameter φ of the circular discharge port 10 (the opening diameter of the nozzle 11) that opens downward is, for example, 0.2 mm to 1.0 mm, and in this embodiment, it is, for example, 0.4 mm (φ = 0.4 mm).

[0034] Next, a method for manufacturing a three-dimensional object W using the above-described 3D printer 1 of the heat melting and laminating method will be described. For example, the three-dimensional object W shown in FIG. 2 will be manufactured.

[0035] The object W shown in FIG. 2 is, for example, a cap-shaped lid body, and includes a cylindrical portion 16 and a disk-shaped portion 17 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 16.

[0036] And the disk-shaped portion 17 that constitutes a part of the object (model M) W is a portion MO that needs to be supported by the support S so as not to collapse under its own weight during modeling (during the modeling process) by the 3D printer 1, that is, a so-called overhang portion (a portion of the model M that floats in the air) (see FIG. 3).

[0037] FIG. 3 is a diagram schematically showing a method for manufacturing an object W (an example of the manufacturing method according to this embodiment) shown in FIG. 2. (a) to (c) are diagrams of the modeling process, and (d) is a diagram of the removal process.

[0038] In the shaping process which is the first process, as shown in FIGS. 3(a) to (c), while discharging resin (molten resin made of one type of shaping material) from the discharge port 10 of the nozzle 11 of the shaping head 4 that moves three-dimensionally relative to the shaping table 5, by laminating on the shaping table 5, a three-dimensional rough-shaped object W1 having a model M that ultimately becomes the target shaped object W and a support S that supports the necessary part MO of the model M from below during shaping is shaped (formed) on the shaping table 5.

[0039] In the removal process which is the second process, as shown in FIG. 3(d), after the shaping process, by separating the model M and the support S from each other, the support S is removed from the rough-shaped object W1 to obtain the target shaped object W.

[0040] And in the shaping object manufacturing method according to this embodiment, in the above-described shaping process, while temporarily forming a predetermined gap 20 between the support S and the necessary part MO to be supported of the model M (while leaving a space), the shaping of the necessary part MO to be supported is performed.

[0041] More specifically, as shown in FIG. 4(a), during the shaping process, between the upper surface 21 of the already shaped support S and the lower surface (the lower surface of the linear molten resin immediately after being discharged from the discharge port 10 of the nozzle 11 during horizontal movement) 22 of the necessary part MO to be supported of the model M being shaped, while temporarily forming a predetermined gap (constant gap) 20 in the height direction, the shaping of the layer on the lower surface of the necessary part MO to be supported (one layer that becomes the lower surface of the necessary part MO to be supported which is the disk-shaped part 17) is performed.

[0042] Also, in the shaping object manufacturing method according to this embodiment, when the dimension (gap height dimension) of the predetermined gap 20 in the shaping process is H and the opening diameter (nozzle diameter) of the nozzle 11 in the 3D printer 1 using the thermal melting lamination method is φ, it satisfies φ / 2 ≦ H ≦ φ.

[0043] Therefore, for example, when φ is 0.4 mm as in the present embodiment, H is a dimension within the range of 0.2 mm to 0.4 mm. In other words, the dimension H of the predetermined gap 20 in the shaping process is a dimension that is not less than half of the opening diameter φ of the nozzle 11 that discharges the shaping material (molten resin) and is not greater than the same opening diameter φ.

[0044] Here, as shown in FIGS. 4(b) and 5, the gap 20 temporarily formed in the shaping process is filled substantially entirely by the sagging of the resin due to its own weight as the resin deforms (sags) downward. Note that FIG. 3 is a diagram in which the resin sagging is omitted (the same applies to FIG. 12).

[0045] That is, if the molten resin discharged from the discharge port 10 of the nozzle 11 moving in the horizontal direction cools and hardens simultaneously with the discharge, no sagging occurs. However, since it takes a certain amount of time for the discharged molten resin to cool and harden with the air in the shaping chamber 2, basically, sagging occurs due to its own weight as shown in FIG. 4(b).

[0046] As a result, the resin discharged from the discharge port 10 of the nozzle 11 moving in the horizontal direction sags due to its own weight by the amount of the gap 20, and its lower surface 22 comes into contact with the upper surface (the upper surface of the hardened layer which is the hardened portion) 21 of the support S and is supported by the upper surface 21.

[0047] However, the contact portion of the resin supported by the upper surface 21 (the lower surface of the resin sag) does not firmly integrate (adhere) with the upper surface 21 of the support S even after hardening and solidifying. Therefore, the removal of the support S in the removal process after the shaping process becomes easy.

[0048] That is, in this shaping process, a support S that is easy to remove and is not firmly integrated with the model M at the end of shaping is shaped together with the model M from the same material.

[0049] In addition, the dimension H of the predetermined gap 20 for not firmly integrating (adhering) the model M and the support S as described above preferably satisfies φ / 2 ≤ H ≤ φ in relation to the opening diameter φ of the nozzle 11. This is because, for example, when H is smaller than φ / 2, the model M and the support S are relatively firmly integrated. On the other hand, for example, when H is larger than φ, the support S has no meaning and at least a part of the support-required part MO of the model M collapses.

[0050] In short, when the relationship of φ / 2 ≤ H ≤ φ is satisfied, while preventing the collapse of the model M, resin sag can be minimized, and the model M and the support S are not firmly integrated (adhered).

[0051] Therefore, the separation of the model M and the support S in the removal process is easy. For example, as shown in Fig. 3(d), on the modeling table 5, without using any tools (tool-less), the operator can simply lift the model M upward by hand, and the model M can be easily separated from the support S (the support laminated and formed in a state of directly contacting the upper surface of the modeling table 5) on the modeling table 5. That is, the support S can be extremely easily removed from the model M with just one action of lifting the model M, and the removal of the support S from the rough-formed object W1 is easy.

[0052] In addition to the above-described gap 20, as shown in Figs. 4 and 5, in the modeling process, a predetermined horizontal gap (constant gap) 25 is formed over the entire circumference between the outer peripheral surface (the outer peripheral surface of the outer cylindrical portion 32) 26 of the support S and the inner peripheral surface (the inner peripheral surface of the cylindrical portion 16) 27 of the model M.

[0053] The dimension D of this gap 25 is, for example, the same as the opening diameter φ of the nozzle 11, for example, 0.4 mm. However, it is not necessarily required that D = φ. For example, the dimension D of the gap 25 may be, for example, 0.5 mm.

[0054] In addition, in the modeling object manufacturing method according to the present embodiment, as shown in FIGS. 6 and 7, the support S of the rough modeling object W1 modeled in the modeling process is an annular shape in plan view, that is, an inner cylindrical portion 31 which is, for example, a cylindrical portion in an annular shape in plan view, and an outer cylindrical portion 32 which is located on the outer side of the inner cylindrical portion 31 at a predetermined distance from the inner cylindrical portion 31 and is in a close proximity to the inner peripheral surface 27 of the model M and has an annular shape in plan view corresponding to the inner peripheral surface 27 of the model M, that is, for example, an annular shape in plan view centered on the center point P of the inner cylindrical portion 31. The support S also has a plurality of connecting portions (connecting plate-like portions) 33 which are linear and plate-like in plan view and extend radially outward from the inner cylindrical portion 31 so as to integrally connect the inner cylindrical portion 31 and the outer cylindrical portion 32 with the center point P of the inner cylindrical portion 31 as the center.

[0055] In addition, this support S is formed to have a smaller diameter than the inner cylindrical portion 31 and has a plurality of, for example, two reduced-diameter cylindrical portions 36 and 37 which are annular in plan view and are located on the inner side of the inner cylindrical portion 31, that is, for example, annular in plan view centered on the center point P of the inner cylindrical portion 31. That is, the planar shape (support pattern) of this support S is not restricted to being drawn in one stroke, and the reduced-diameter cylindrical portions 36 and 37 on the central side are not connected to the inner cylindrical portion 31.

[0056] The reduced-diameter cylindrical portions 36 and 37, the inner cylindrical portion 31, and the outer cylindrical portion 32 are concentric, and are all formed in a cylindrical shape (a cylindrical shape with upper and lower surfaces opened in the axial direction in the vertical direction) centered on a central axis L extending in the vertical direction (Z-axis direction) passing through the same center point P (see FIG. 5).

[0057] In addition, each of the short cylindrical tubular portions 31, 32, 36, and 37 with openings on the upper and lower surfaces forms a single closed curve that is a closed curve in a plan view (the same applies to the tubular portions and the like described later). A single closed curve (Jordan closed curve) is a closed curve that does not intersect itself. To explain further, it is a curve where the starting point and the ending point coincide and does not contact or intersect itself from the starting point to the ending point. The single closed curve includes a circle and an ellipse. Also, the single closed curve includes, for example, polygons such as triangles and quadrilaterals, as well as cardioids (heart shapes), etc. Furthermore, a closed curve is a curve where the starting point and the ending point coincide (for example, a lemniscate, etc.), and since the lemniscate divides the region into three parts, it is not a single closed curve.

[0058] As shown in FIG. 6, the angle θ formed by both connecting portions (extending portions) 33 adjacent to each other in the circumferential direction is, for example, 10°. Although all are equal in the illustrated example, the angle θ does not necessarily have to be equal for all. The thickness (plate thickness dimension) t of the plate-like connecting portion 33 is the same as the opening diameter φ of the nozzle 11 and is, for example, 0.4 mm. The interval dimension between both small-diameter tubular portions 36 and 37 is the same as the interval dimension between the small-diameter tubular portion 36 and the inner tubular portion 31 and is, for example, 0.8 mm. In this illustrated example, the number of small-diameter tubular portions 36 and 37 located on the inner side (inner circumferential side) of the inner tubular portion 31 is two, but it may be one or three or more, for example.

[0059] And the support S after removal removed in the removal process has exactly the same shape as before removal as shown in FIG. 8(a), and has an inner tubular portion 31, an outer tubular portion 32, a connecting portion 33, and small-diameter tubular portions 36 and 37.

[0060] Therefore, the support S after removal can be reused as a support member (a spare part) that supports the necessary support portion MO of the model M during modeling when manufacturing the same shaped object W (a three-dimensional shaped object of the same shape) W as the shaped object W formed with the support S together with the model M.

[0061] That is, when the support S after removal shown in Fig. 8(a) is reused as a placement piece and the shaped object (model M) W shown in Fig. 2 is repeatedly manufactured (shaped), as shown in Fig. 8(b), immediately before the support-required part MO of the model M is shaped, the shaping operation is temporarily stopped, the support S as a placement piece (base for supporting the support-required part MO) is placed on the shaping table 5, and then the shaping operation is resumed to shape the support-required part MO of the model M on the placement piece.

[0062] And by reusing the support S as a placement piece in this way, without performing support shaping, also in the shaping process of support reuse where only the model M is shaped, similar to the above-mentioned shaping process, while temporarily forming a predetermined gap 20 between the removed support (placement piece) S and the support-required part MO of the model M, the support-required part MO is shaped.

[0063] As a result, also in this case, the model M and the support (placement piece) S do not firmly integrate (adhere), so that even when the support S is reused as a placement piece, the separation between the model M and the support (placement piece) S in the removal process becomes easy. And the removed support S can be repeatedly used any number of times.

[0064] And according to the shaped object manufacturing method according to the above-described embodiment, a shaping process of shaping a rough shaped object W1 having a model M that becomes the shaped object W and a support S that supports the support-required part MO of this model M, and a removal process of removing the support S from the rough shaped object W1 by separating the model M and the support S after this shaping process are provided. In the shaping process, since the support-required part MO is shaped while forming a slight predetermined gap 20 between the support S and the support-required part MO of the model M, the separation between the model M and the support (support structure) S in the removal process becomes easy, and the support S can be easily removed from the rough shaped object W1. Therefore, the manufacturability of the shaped object W can be improved.

[0065] Moreover, support marks are less likely to remain on the support-required part MO of the shaped object (model M) W, and the quality of the shaped object W can also be improved.

[0066] Also, when the dimension of a predetermined gap 20 in the shaping process is H and the opening diameter of the nozzle 11 in the 3D printer 1 using the fused deposition modeling method is φ, by satisfying φ / 2 ≤ H ≤ φ, not only can the collapse of the model M in the shaping process be appropriately prevented, but also the separation between the model M and the support S in the removal process becomes easy, and the support S can be easily and appropriately removed from the rough-formed object W1.

[0067] Furthermore, the support S of the rough-formed object W1 in the shaping process has a cylindrical inner cylindrical portion 31 forming an annular shape in plan view, a cylindrical outer cylindrical portion 32 located on the outer side of the inner cylindrical portion 31 and having an annular shape in plan view corresponding to the cylindrical inner peripheral surface of the model M, and a plurality of flat plate-shaped connecting portions (extending portions) 33 that extend radially outward from the inner cylindrical portion 31 and connect the inner cylindrical portion 31 and the outer cylindrical portion 32. Therefore, the separation between the model M and the support S in the removal process becomes even easier, and the support S can be removed from the rough-formed object W1 even more easily.

[0068] In recent years, shaping software has evolved, and there are cases where a support structure that is relatively easy to remove can be selected. However, since it is easy to remove, problems such as the support being prone to collapse during shaping occur. In the manufacturing method of the present embodiment, such problems do not occur by using the support S having a predetermined shape.

[0069] Furthermore, in the manufacturing method of the present embodiment, a support S that can be easily removed in the removal process can be obtained without being limited by shaping software, a shaping machine, etc. That is, for example, since support generation does not depend on shaping software, a desired support shape (support material) corresponding to the model shape (model material) can be modeled and embedded in the 3D shaping data, so it can be applied to any 3D printer using the fused deposition modeling method.

[0070] In addition, since there is no problem when the model M and the support S are made of the same shaping material, there is no limitation on the number of nozzles, and there is no problem with a single-head specification 3D printer 1.

[0071] Here, FIGS. 9(a) and (b) are photographs of a prototype of the shaped object W (satisfying φ / 2 ≦ H ≦ φ), and FIGS. 10(a) to (c) are photographs of a prototype of the shaped object W (not satisfying φ / 2 ≦ H ≦ φ).

[0072] Note that the lid of the shaped object (model M) W has a diameter of 53 mm, a height of 10 mm, and a thickness of 1.5 mm. Also, the nozzle diameter φ of the 3D printer 1 is 0.4 mm.

[0073] And the prototype shown in FIG. 9(a) is the case where H = 0.2 mm and D = 0.4 mm. In this case, with almost no resistance, the model M could be easily separated from the support S on the shaping table 5 just by lifting the model M by hand on the shaping table 5. Also, although some support marks can be seen on the necessary support part MO of the model M, there are no irregularities, there is no problem with the quality of the shaped object W, and there is no lamination abnormality (collapse). Furthermore, the separated support S can be reused as a spare piece.

[0074] Also, the prototype shown in FIG. 9(b) is the case where H = 0.4 mm and D = 0.4 mm. In this case, with no resistance at all, the model M could be easily separated from the support S on the shaping table 5 just by lifting the model M by hand on the shaping table 5. Also, although there are some signs of resin sagging on the necessary support part MO of the model M, there is no problem with the quality of the shaped object W, and there is no lamination abnormality (collapse). Furthermore, the separated support S can be reused as a spare piece.

[0075] On the other hand, the prototype shown in FIG. 10(a) is the case where H = 0.1 mm and D = 0.4 mm. In this case, the model M could not be separated just by lifting it by hand. After removing the rough shaped object W1 from the shaping table 5, the model M and the support S were separated using a radio pliers as a tool, but there was some resistance at that time. Also, there are traces of deformation on the support S when it was pinched with the radio pliers, and this support S cannot be reused as a spare piece.

[0076] Moreover, the prototype shown in Fig. 10(b) is the case where H = 0.5 mm and D = 0.4 mm. In this case, the model M could be easily separated from the support S on the shaping table 5 just by lifting the model M by hand on the shaping table 5 without any resistance. However, lamination abnormalities (collapse) occurred partially in the support-required part MO of the model M.

[0077] Furthermore, the prototype shown in Fig. 10(c) is the case without a support. In this case, lamination abnormalities (collapse) occurred in the support-required part MO of the model M.

[0078] Therefore, it was confirmed by these prototypes that it is preferable to satisfy φ / 2 ≦ H ≦ φ.

[0079] In addition, in the above embodiment, the case of manufacturing the shaped object W shown in Fig. 2 has been described, but it is not limited to this. For example, the shaped object W shown in Fig. 11 can also be manufactured by the same method, and in this case, the support S can be easily removed, and the same operational effects can be achieved.

[0080] That is, the shaped object W shown in Fig. 11 is, for example, a stepped oblique cap-shaped lid body, and includes a lower cylindrical part 41, an upper cylindrical part 42 that is integrally provided on the inner peripheral surface of the upper end part of the lower cylindrical part 41 and is formed to have a smaller diameter than the lower cylindrical part 41, and an inclined disk-shaped part 43 that is integrally provided on the inner peripheral surface of the upper end part of the upper cylindrical part 42.

[0081] And the upper cylindrical part 42 and the disk-shaped part 43 that constitute a part of the shaped object (model M) W are support-required parts (overhang parts) MO that require support by the support S so as not to collapse due to their own weight during shaping (during the shaping process) by the 3D printer 1 (see Fig. 12).

[0082] Fig. 12 is a diagram schematically showing a shaped object manufacturing method (an example of the manufacturing method according to this embodiment) for manufacturing the shaped object W shown in Fig. 11. (a) to (e) are diagrams of the shaping process, and (f) is a diagram of the removal process.

[0083] Then, similar to the case of manufacturing the shaped object W shown in FIG. 2 described above, also in the shaping process shown in FIG. 12, while temporarily forming a predetermined gap 20 between the support S and the portion MO to be supported of the model M so as to satisfy φ / 2 ≦ H ≦ φ, the shaping of the portion MO to be supported is performed. Note that the entire predetermined gap 20 is substantially filled by the resin sag due to its own weight (see FIG. 13).

[0084] Also, the support S laminated and shaped in the shaping process shown in FIG. 12 also has an inner cylindrical portion 31, an outer cylindrical portion 32, a connecting portion 33, and diameter-reduced cylindrical portions 36, 37, as shown in FIGS. 13 to 15, similar to the case of manufacturing the shaped object W shown in FIG. 2 described above. Note that the outer cylindrical portion 32 having a shape corresponding to the inner peripheral surface 27 of the model M is composed of a cylindrical lower cylindrical portion 32a corresponding to the lower cylindrical portion 41 and a cylindrical upper cylindrical portion 32b corresponding to the upper cylindrical portion 42.

[0085] Furthermore, the support (spare piece) S after removal shown in FIG. 15 can also be reused as a spare piece for supporting the portion MO to be supported of the model M when manufacturing the same shaped object W, similar to the support S shown in FIG. 8.

[0086] Note that the support S according to the present embodiment is not limited to those shown in FIGS. 8 and 15, and for example, as shown in FIG. 16, it may have a plate-shaped spiral portion (spiral plate-shaped portion) 51 having a spiral shape in plan view (for example, an Archimedean spiral shape, etc.).

[0087] That is, the support S shown in FIG. 16 is composed of only one continuous plate-shaped spiral portion 51 and has a cross-sectional shape formed by a figure that can be drawn in one stroke. That is, this support S is formed by a seamless nozzle operation (continuous movement of the nozzle 11) that traces a curve (the same applies to the spiral portion and the like described later). Note that the thickness (plate thickness dimension) of the spiral portion 51 is the same as the opening diameter φ of the nozzle 11 and is, for example, 0.4 mm.

[0088] In addition, such a support (support pattern) S having a spiral (volute) shape can be designed by applying, for example, Archimedes' spiral, and the continuous function that forms the basis of the design is as follows in parametric representation.

[0089] X t = t·cos(t) Y t = t·sin(t)

[0090] Also, with the support S shown in FIG. 16, a cap-shaped modeled object W as shown in FIG. 2 can be manufactured in the same manner, and in this case as well, the support S can be easily removed, and the same effects can be achieved.

[0091] In addition, since such a spiral support pattern is created based on a continuous function, support design can be performed in a short time, the operation of the nozzle 11 during modeling becomes smooth, and the modeling time can be shortened.

[0092] Note that the model (modeled object such as a product) M and the support (spare part that is a reusable support member) S according to the manufacturing method of the present embodiment are not limited to the above-described shapes, and various shapes are conceivable. For example, those shown in FIGS. 17 to 32 may be used, and in any case, the support S can be easily removed, and the same effects can be achieved.

[0093] First, the models M shown in FIGS. 17(a) and (b) are, for example, lid bodies having an elliptical shape, and include an elliptical cylindrical portion 61 and an elliptical disk-shaped portion 62 provided integrally on the inner peripheral surface of the upper end portion of the cylindrical portion 61. Note that the continuous function that forms the basis of the design of the support S when modeling such an elliptical model M is as follows in parametric representation. However, a ≠ b in the following.

[0094] X t = at·cos(t) Y t = bt·sin(t)

[0095] And the disk-shaped part (upper plate part) 62 that constitutes part of the model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 17(c) and 17(d) so as not to collapse under its own weight during the shaping (during the shaping) by the 3D printer 1.

[0096] The support S shown in FIGS. 17(c) and 17(d) is composed of a plate-shaped spiral part 63 having an elliptical shape, different from the plate-shaped spiral part 51 having a perfect circular shape shown in FIG. 16 above.

[0097] Next, the model M shown in FIGS. 18(a) and 18(b) is a lid having, for example, a hexagonal star shape (it may also be a pentagonal star shape, an octagonal star shape, etc.), and includes a hexagonal star-shaped cylindrical part 66 and a hexagonal star-shaped plate part 67 integrally provided on the inner peripheral surface of the upper end part of the cylindrical part 66.

[0098] And the plate-shaped part (upper plate part) 67 that constitutes part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 18(c) and 18(d) so as not to collapse under its own weight during the shaping (during the shaping) by the 3D printer 1.

[0099] The support S shown in FIGS. 18(c) and 18(d) has a plate-shaped spiral part 68 having a perfect circular shape and a hexagonal star-shaped outer peripheral plate part 69 integrally provided on the outer peripheral side of the spiral part 68, and triangular through-holes 70 are formed through the upper and lower surfaces of this outer peripheral plate part.

[0100] Next, the model M shown in FIGS. 19(a) and 19(b) is a lid that is a structure using, for example, a three-dimensional Archimedes spiral shape, and includes a cylindrical part 71 and a hole-forming part 73 integrally provided on the inner peripheral side of the cylindrical part 71 and having a spiral hole (spiral hole) 72 formed inside that opens downward.

[0101] And the hole-forming part 73 that constitutes part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 19(c) and 19(d) so as not to collapse under its own weight during the shaping (during the shaping) by the 3D printer 1.

[0102] The support S shown in FIGS. 19(c) and (d) is composed of a plate-shaped spiral portion 75 whose width dimension (vertical dimension) changes so as to gradually increase from the outer peripheral side toward the center side. As is apparent from FIG. 19(c), this spiral portion 75 is circular in a plan view, but it is not limited thereto, and it may have other shapes such as an elliptical shape.

[0103] Such a support (support pattern) S can be designed by applying, for example, Archimedes' spiral, and the continuous function that forms the basis of the design is as follows in parametric representation, and the specific design method is as shown in FIG. 20, for example.

[0104] X t =t·cos(t) Y t =t·sin(t) Z t =t

[0105] Next, the model M shown in FIGS. 21(a) and (b) is, for example, a lid having a circular shape, and like the one shown in FIG. 2, it includes a cylindrical portion 76 and a disk-shaped portion 77 integrally provided on the inner peripheral surface of the upper end portion of this cylindrical portion 81.

[0106] And the disk-shaped portion 77 that constitutes a part of this model M is a support-required portion MO that requires support by the support S shown in FIGS. 21(c) and (d) and FIG. 22 so as not to collapse due to its own weight during shaping (during modeling) by the 3D printer 1.

[0107] The support S shown in FIGS. 21(c) and (d) and FIG. 22 has, like the one shown in FIG. 6 and the like, an inner cylindrical portion (cylindrical portion) 81, an outer cylindrical portion 82 located on the outermost side, and a plurality of plate-shaped connecting portions (extending portions) 83 that extend radially outward from the inner cylindrical portion 81 and connect both cylindrical portions 81, 82.

[0108] Further, this support S has a plurality of, for example, two additional cylindrical portions 86 and 87 with a smaller diameter, which are located inside the inner cylindrical portion 81. These cylindrical portions 86 and 87 are connected to the inner cylindrical portion 81 via a connecting portion 88 that forms a cross shape in plan view.

[0109] Furthermore, this support S has a plurality of, for example, three intermediate cylindrical portions 91, 92, and 93 located between the inner cylindrical portion 81 and the outer cylindrical portion 82 so as to intersect each connecting portion 83. Note that each cylindrical portion 81, 82, 86, 87, 91, 92, and 93 of this support S is cylindrical, but the cylindrical portion is not limited to this shape as will be described later.

[0110] Next, the model M shown in FIGS. 23(a) and (b) is, for example, a lid having a square shape, and includes a cylindrical portion 96 with a four-cornered cylinder shape and a square plate-like portion 97 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 96.

[0111] And the plate-like portion 97 that constitutes a part of this model M is a support-required portion MO that needs to be supported by the support S shown in FIGS. 23(c) and (d) and FIG. 24 so as not to collapse due to its own weight during the shaping (during the shaping) by the 3D printer 1.

[0112] The support S shown in FIGS. 23(c) and (d) and FIG. 24 has, similar to that shown in FIG. 6 and the like, an inner cylindrical portion (cylindrical portion) 101, an outer cylindrical portion 102 located on the outermost side, and a plurality of plate-like connecting portions (extending portions) 103 that extend radially outward from the inner cylindrical portion 101 and connect the two cylindrical portions 101 and 102.

[0113] Also, this support S has a plurality of, that is, for example, two additional cylindrical portions 104 and 105 located inside the inner cylindrical portion 101. And the additional cylindrical portion 104 is connected to the inner cylindrical portion 101 via a plurality of radially located connecting portions 108. On the other hand, the additional cylindrical portion 105 is not connected to the additional cylindrical portion 104 and is disposed separately inside the additional cylindrical portion 104.

[0114] Furthermore, this support S has a plurality, for example, two intermediate cylindrical portions 106 and 107 located between the inner cylindrical portion 101 and the outer cylindrical portion 102 so as to intersect with each connecting portion 103. In this support S, the additional cylindrical portions 104 and 105 are triangular cylindrical, the inner cylindrical portion 101 is cylindrical, and the outer cylindrical portion 102 and the intermediate cylindrical portions 106 and 107 are quadrangular cylindrical. However, here too, the illustrated shape is not limited, and any cylindrical shape is acceptable.

[0115] Next, the model M shown in FIGS. 25(a) and (b) is, for example, a lid having a circular shape, and includes a short cylindrical columnar portion 111 and an annular plate-like portion 112 integrally provided on the outer peripheral surface of the upper end portion of the columnar portion 111.

[0116] And the plate-like portion (flange portion) 112 constituting a part of this model M is a support-required portion MO that requires support by the support S shown in FIGS. 25(c) and (d) and FIG. 26 so as not to collapse under its own weight during shaping (during modeling) by the 3D printer 1.

[0117] The support S shown in FIGS. 25(c) and (d) and FIG. 26 has, similar to that shown in FIG. 6 and the like, an inner cylindrical portion (cylindrical portion) 116, an outer cylindrical portion 117 located on the outermost side, and a plurality of plate-like connecting portions (extending portions) 118 that extend radially outward from the inner cylindrical portion 116 to connect the two cylindrical portions 116 and 117.

[0118] Also, this support S has one additional cylindrical portion 119 located inside the inner cylindrical portion 116. However, this additional cylindrical portion 119 is not connected to the inner cylindrical portion 116 and is separate from the inner cylindrical portion 116. And the inner peripheral surface of this additional cylindrical portion 119 is formed in a shape corresponding to the outer peripheral surface of the columnar portion 111 of the model M.

[0119] Furthermore, this support S has one intermediate cylindrical portion 120 located between the inner cylindrical portion 116 and the outer cylindrical portion 117 so as to intersect with each connecting portion 118. In this support S, each of the cylindrical portions 116, 117, 119, and 120 is cylindrical.

[0120] Next, the model M shown in FIGS. 27(a) and (b) is, for example, a grease trap body having a box shape with an upper surface opening, and includes a bottomed cylindrical tubular portion 121 having a quadrangular shape and a quadrangular annular plate-like portion (flange portion) 122 integrally provided on the outer peripheral surface of the upper end portion of the tubular portion 121. Further, on the bottom plate 123 of the tubular portion 121, a substantially cross-shaped bulging portion 124 is formed to bulge upward, and the lower end portion of an oil-water separation member 125, which is a mounting member, is attached to the bulging portion 124 by fitting.

[0121] Then, the bulging portion 124 and the plate-like portion (flange portion) 122 that form a part of the model M are support-required portions MO that need to be supported by two separate supports S (S1, S2) shown in FIGS. 27 and 28 so as not to collapse under their own weight during the shaping (during the shaping) by the 3D printer 1.

[0122] Further, the support S1 has a plate-like bottom portion (base) 126 having a shape corresponding to the bulging portion 124 of the model M and a plurality (for example, 10 or more) of cylindrical portions 127 erected on the upper surface of the bottom portion 126. Furthermore, the support S2 has a quadrangular annular plate-like bottom portion (base) 128 having a shape corresponding to the plate-like portion (flange portion) 122 of the model M and a plurality (for example, 5 or more) of cylindrical portions 129 erected on the upper surface of the bottom portion 128. That is, each of the supports S1 and S2 has a support shape that does not have a radial element (extending portion) extending radially from the cylindrical portion.

[0123] Next, the model M shown in FIGS. 29(a) and (b) is, for example, a member (statue, pet tomb, etc.) imitating an animal such as a seal, and includes a cylindrical portion 131 and a dome-shaped plate-like portion 132 integrally provided on the upper end side of the cylindrical portion 131.

[0124] And the plate-shaped part 132 that constitutes a part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 29(c) to (e) and FIG. 30 so as not to collapse under its own weight during shaping (during the shaping process) by the 3D printer 1. Note that FIG. 31 shows the rough-formed object W1 composed of these model M and support S.

[0125] This support S has, similar to what is shown in FIG. 6 and the like, an inner cylindrical part (cylindrical part) 136, an outermost outer cylindrical part 137, and a plurality of plate-shaped connecting parts (extending parts) 138 that extend radially outward from the inner cylindrical part 136 to connect the two cylindrical parts 136 and 137.

[0126] Also, this support S has an additional cylindrical part 139 located inside the inner cylindrical part 136, and a rod-shaped part (which may be, for example, a cylindrical part or a square cylindrical part such as a cylindrical part) 140 that is a round bar-shaped central axis part located inside this additional cylindrical part 139. In this support S, each of the cylindrical parts 136, 137, and 139 is a cylindrical shape. Also, the shape of the upper surface part of this support S is a dome shape corresponding to the plate-shaped part 132 of the model M.

[0127] Next, the model M shown in FIG. 32 has an undercut shape, and the support-required part MO of this model M is supported by the support S and shaped. And also in such a case, according to the shaped object manufacturing method according to the present embodiment, the support S can be easily removed from the rough-formed object W1 after shaping, but it is necessary to break a part of the support S during this removal. Therefore, the support S after its removal cannot be reused as a spare part, unlike what was described above.

[0128] Note that the thermo-melting lamination type 3D printer, which is a shaped object manufacturing apparatus for manufacturing (shaping) the various shaped objects (models) described above, may be, for example, a pellet type large 3D printer with a nozzle diameter φ of 10 mm or more. In this large 3D printer, it is possible to use an inexpensive and generally available pellet-shaped thermoplastic resin (which may be a recycled pellet material or the like) as a shaping material instead of a dedicated filament resin.

[0129] Moreover, the shaped object manufacturing apparatus is not limited to a 3D printer using the fused deposition modeling method, and may be, for example, a 3D printer using the stereolithography method (DLP method or SLA method).

[0130] Furthermore, the three-dimensional shaped object formed using the shaped object manufacturing apparatus is not limited to those described above, and may be, for example, a housing, a joint, a box, etc. The type, shape, size, etc. of the shaped object are arbitrary.

[0131] Also, the shaped object manufacturing apparatus is not limited to a configuration in which a shaping head (discharging means) having a nozzle for discharging a shaping material is movable in the X-axis direction and the Z-axis direction and a shaping table is movable in the Y-axis direction. Any configuration in which the shaping head is movable relative to the shaping table in at least three dimensions may be used. For example, a configuration in which the shaping head is movable in the X-axis direction and the Y-axis direction and the shaping table is movable in the Z-axis direction, or a configuration in which the shaping head is provided at the tip of a robot arm (for example, the robot arm of a 6-axis robot is preferable) and is movable in any direction including the three directions of the X-axis direction, the Y-axis direction, and the Z-axis direction may be used.

[0132] Also, the dimension of a predetermined gap in the shaping process should be such that the resin sag (sag of the shaping material) based on its own weight is minimized, and the lower surface of the portion of the model that needs to be supported and the upper surface of the support that supports the portion that needs to be supported are not firmly integrated (adhered) to each other, i.e., a clearance (a slight gap height dimension) is sufficient.

[0133] Furthermore, the support for the rough shaped object in the shaping process may have, for example, a configuration without an outer cylindrical portion, a configuration without an additional cylindrical portion, a configuration without a radially extending portion, etc.

[0134] Also, the additional cylindrical portion located inside the inner cylindrical portion of the support may have either a configuration connected to the inner cylindrical portion (an integral configuration) or a configuration not connected (a separate configuration). Also, the number, shape, etc. of the additional cylindrical portion are arbitrary.

Explanation of Reference Numerals

[0135] 1 A 3D printer using a fused deposition modeling method, which is a shaped object manufacturing device 11 Nozzle 20 Predetermined gap 31, 81, 101, 116, 136 Inner cylindrical part, which is a cylindrical part 32, 82, 102, 117, 137 Outer cylindrical part 33, 83, 103, 118, 138 Connecting part, which is an extending part 36, 37, 86, 87, 104, 105, 119, 139 Additional cylindrical part 51, 63, 68, 75 Spiral part 126, 128 Bottom part 127, 129 Cylindrical part H Dimension of the predetermined gap (gap height dimension) φ Opening diameter of the nozzle (nozzle diameter) W Shaped object W1 Rough shaped object M Model MO Part requiring support (overhang part) S Support

Claims

1. A method for manufacturing a three-dimensional shaped object using a shaped object manufacturing apparatus, comprising: a shaping step of shaping a rough shaped object having a model to be the shaped object and a support for supporting a portion of the model that requires support; a removing step of removing the support from the rough shaped object by separating the model and the support after the shaping step; in the shaping step, while forming a predetermined gap between the support and the portion of the model that requires support, shaping the portion that requires support A method for manufacturing a shaped object, characterized in that.

2. When the dimension of the predetermined gap in the shaping step is H and the opening diameter of the nozzle in the shaped object manufacturing apparatus is φ, φ / 2 ≤ H ≤ φ is satisfied A method for manufacturing a shaped object according to claim 1, characterized in that.

3. The support of the rough shaped object in the shaping step has a cylindrical portion; and a plurality of extending portions extending radially from the cylindrical portion A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

4. The support of the rough shaped object in the shaping step has an inner cylindrical portion and an outer cylindrical portion; and a connecting portion connecting the inner cylindrical portion and the outer cylindrical portion A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

5. The support of the rough shaped object in the shaping step has an additional cylindrical portion located inside the cylindrical portion A method for manufacturing a shaped object according to claim 3, characterized in that.

6. The cylindrical portion forms a closed curve A method for manufacturing a shaped object according to claim 3, characterized in that.

7. The support of the rough shaped object in the shaping step is formed by a continuous function A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

8. The support of the rough shaped object in the shaping step has a plate-like spiral portion A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

9. The support of the rough shaped object in the shaping step has a cylindrical portion A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

10. The support of the rough shaped object in the shaping step has a bottom portion; and a plurality of cylindrical portions erected on the bottom portion A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

11. The support removed in the removing step can be reused as a support member for supporting a portion of the model that requires support when manufacturing the same shaped object A method for manufacturing a shaped object according to claim 1 or 2, characterized in that.

12. The shaped object manufacturing apparatus is a 3D printer using a thermal melting lamination method The method for manufacturing a shaped object according to claim 1 or 2, characterized by the above.

13. Used in the method for manufacturing a shaped object according to claim 1 or 2 A shaped object manufacturing apparatus, characterized by the above.

Images