Support member and shaped article manufacturing method

Abstract

To provide a shaped article manufacturing method for manufacturing a shaped article.SOLUTION: A shaped article manufacturing method includes a step of performing shaping operation without installing a support member as a recyclable support obtained by being separated from a model when manufacturing a shaped article. The shaped article manufacturing method includes a step of stopping the shaping operation immediately before shaping a support necessary part of the model once, and installing a support member. The shaped article manufacturing method includes a step of restarting the shaping operation in a state in which the support member is installed, and shaping the support necessary part of the model on the support member.SELECTED DRAWING: Figure 8

Description

Technical Field

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

Background Art

[0002] In recent years, as a manufacturing apparatus for manufacturing 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] And 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 the necessary support 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 necessary support 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 an object that can easily remove the support.

Means for Solving the Problems

[0007] The support member according to an embodiment of the present invention is a support member that supports a portion of a model that needs to be supported when manufacturing a shaped object using a shaped object manufacturing apparatus, and is a reusable support obtained by being separated from the model when the shaped object is manufactured.

[0008] The above support member may have a cylindrical portion.

[0009] The above support member may have a cylindrical portion and a plurality of extending portions that extend radially from the cylindrical portion.

[0010] The above support member may have a plate-shaped spiral portion.

[0011] The above support member may have a bottom portion and a plurality of cylindrical portions erected on the bottom portion.

[0012] The above support member may be shaped using a shaped object manufacturing apparatus of a thermal melting lamination method or a stereolithography method.

[0013] Further, a shaped object manufacturing method according to an embodiment of the present invention is a shaped object manufacturing method for manufacturing a shaped object using the above support member and a shaped object manufacturing apparatus, and includes a step of performing a shaping operation without installing the support member, a step of temporarily stopping the shaping operation immediately before a portion of the model that needs to be supported is shaped, installing the support member, and a step of restarting the shaping operation with the support member installed and shaping the portion of the model that needs to be supported on the support member.

[0014] Furthermore, a shaped object manufacturing method according to an embodiment of the present invention is a shaped object manufacturing method for manufacturing a shaped object using a shaped object manufacturing apparatus, and includes a shaping step of shaping a rough shaped object having a model that becomes the shaped object and a support that supports a portion of the model that needs to be supported, and a removing step of removing the support from the rough shaped object by separating the model and the support after the shaping step. The support removed in the removing step can be reused as a support member that supports a portion of the model that needs to be supported when manufacturing a shaped object.

[0015] Also, a modeling object manufacturing method according to an embodiment of the present invention is a modeling object manufacturing method for manufacturing a modeling object using a modeling object manufacturing apparatus, the method including: a modeling step of modeling a rough modeling object having a model that becomes the modeling object and a support that supports a portion of the model that requires support; and a removal step of removing the support from the rough modeling object by separating the model and the support after the modeling step, wherein the support removed in the removal step can be reused as a support member that supports a portion of the model that requires support when manufacturing a modeling object having the same shape as the modeling object.

Effects of the Invention

[0016] According to an embodiment of the present invention, the support can be easily removed.

Brief Description of the Drawings

[0017]

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Mode for Carrying Out the Invention

[0018] An embodiment of the present invention will be described with reference to the drawings.

[0019] In FIG. 1, reference numeral 1 denotes a fused deposition model 3D printer, which is a device for manufacturing objects. This fused deposition model 3D printer (hereinafter sometimes simply referred to as "3D printer 1") is a modeling machine that produces a three-dimensional object W by sequentially layering resin, which is a modeling material that has been melted (dissolved) by heat, one layer at a time based on 3D modeling data.

[0020] The resin, which is the modeling material used in the 3D printer 1, is, for example, a thermoplastic resin (filament, etc.), more specifically, for example, PLA, PLA with plant fiber, ABS, ABS with glass fiber, ABS with carbon fiber, PP, PP with glass fiber, PP with carbon fiber, PC, PC·ABS, ASA, TPE, TPU, cellulose acetate, PA, PETG, etc. In addition, the 3D printer 1 is, for example, of a single nozzle head type, and only one type of resin is required for modeling, and a resin dedicated to support (such as a water-soluble resin) is not required.

[0021] As shown in Figures 1(a) and (b), the 3D printer 1 includes, for example, a box-shaped main body 3 having a modeling chamber 2 inside, a modeling head 4 that is movable in the X-axis direction (horizontal, i.e., left-right direction) and the Z-axis direction (up-down, i.e., height direction) within the modeling chamber 2, and a modeling table 5 that is movable in the Y-axis direction (horizontal, i.e., front-back direction) within the modeling chamber 2.

[0022] Since the modeling head 4 can move in the X-axis and Z-axis directions and the modeling table 5 can move in the Y-axis direction, the modeling head 4 moves in three dimensions relative to the modeling table 5 (as will be described later, the 3D printer 1 is not limited to the configuration shown in Figure 1, and it is sufficient that the modeling head 4 moves in at least three dimensions relative to the modeling table 5).

[0023] 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.

[0024] 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. 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.

[0025] However, depending on the shape of the target shaped object W, as will be described later, a support 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.

[0026] That is, when the support S is required, after once shaping the 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.

[0027] Here, the shaping head 4 of the 3D printer 1 of the thermal melting 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) in the shaping head 4 from the discharge port 10.

[0028] That is, the resin heated and melted by a heating means such as a heater (not shown) is extruded by an extrusion means (not shown) such as a gear in the shaping head 4, and is discharged (ejected) downward from the discharge port 10 of one nozzle 11 for discharging the shaping material. Note that the heating means and the extrusion means may be provided outside the shaping head 4 instead of inside the shaping head 4.

[0029] Then, the opening diameter φ of the discharge port 10 having a circular shape that opens downward (the opening diameter of the nozzle 11) 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).

[0030] Next, a method for manufacturing a three-dimensional object W, for example, as shown in FIG. 2, using the above-described 3D printer 1 of the thermal melting lamination method will be described.

[0031] 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.

[0032] And, the disk-shaped portion 17 that constitutes a part of the object (model M) W is a portion that needs to be supported by the support S so as not to collapse under its own weight during the shaping (during shaping) by the 3D printer 1, that is, a portion that needs support MO, that is, a so-called overhang portion (a portion that floats in the air in the model M) (see FIG. 3).

[0033] Further, FIG. 3 is a diagram schematically showing a method for manufacturing an object W shown in FIG. 2 (an example of the manufacturing method according to this embodiment), (a) to (c) are diagrams of the shaping process, and (d) is a diagram of the removal process.

[0034] 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 and laminating it on the shaping table 5, finally, a three-dimensional rough object W1 having a model M that becomes the target object W and a support S that supports the portion MO that needs support of the model M from the lower side during shaping is shaped (formed) on the shaping table 5.

[0035] In the removal process, which is the second process, as shown in FIG. 3(d), after the shaping process, the model M and the support S are separated from each other, and the support S is removed from the rough object W1 to obtain the target object W.

[0036] In the method for manufacturing a shaped object according to the present embodiment, in the shaping process described above, while temporarily forming a predetermined gap 20 between the support S and the support-required part MO of the model M (while leaving a space), the support-required part MO is shaped.

[0037] More specifically, as shown in Fig. 4(a), during the shaping process, while temporarily forming a predetermined gap (constant gap) 20 in the height direction 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 support-required part MO of the model M being shaped, the layer of the lower surface (one layer that becomes the lower surface of the support-required part MO which is the disk-shaped part 17) of the support-required part MO is shaped.

[0038] Also, in the method for manufacturing a shaped object according to the present 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.

[0039] 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 within the range that is half or more of the opening diameter φ of the nozzle 11 that discharges the shaping material (molten resin) and is the same as or less than the opening diameter φ.

[0040] Here, as shown in Figs. 4(b) and 5, the gap 20 temporarily formed in the shaping process is filled substantially entirely by the resin sag because the resin deforms downward (sags) due to its own weight. Note that Fig. 3 is a figure in which the resin sag is omitted (the same applies to Fig. 12).

[0041] 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 will occur. However, since it takes a certain amount of time for the discharged molten resin to be cooled by the air in the modeling chamber 2 and hardened, basically, sagging occurs due to its own weight as shown in Fig. 4(b).

[0042] 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 21 of the support S (the upper surface of the hardened layer which is the hardened part), and is supported by the upper surface 21.

[0043] However, the contact part 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 modeling process becomes easy.

[0044] That is, in this modeling process, a support S that is easy to remove and is not firmly integrated with the model M at the end of modeling is modeled together with the model M from the same material.

[0045] Also, the dimension H of the predetermined gap 20 for not firmly integrating (adhering) the model M and the support S in this way 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 part MO that needs to support the model M collapses.

[0046] In short, when the relationship of φ / 2 ≦ H ≦ φ is satisfied, while preventing the collapse of the model M, the resin sag can be minimized, and the model M and the support S are not firmly integrated (adhered).

[0047] Therefore, it is easy to separate the model M and the support S in the removal process. For example, as shown in FIG. 3(d), on the modeling table 5, without using any tools (tool-less), an 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.

[0048] 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.

[0049] 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.

[0050] Also, in the modeling object manufacturing method according to the present embodiment, as shown in FIGS. 6 and 7, the support S of the rough-formed object W1 formed in the modeling process includes an inner cylindrical portion 31 that is annular in plan view, that is, a cylindrical portion that is, for example, annular in plan view, and an outer cylindrical portion 32 that is located at a predetermined distance away from the inner cylindrical portion 31 on the outer side of the inner cylindrical portion 31 and is in proximity to the inner peripheral surface 27 of the model M, and is annular in plan view having a shape corresponding to the inner peripheral surface 27 of the model M, that is, for example, annular in plan view centered on the center point P of the inner cylindrical portion 31, and a plurality of connecting portions (connecting plate-like portions) 33 that are linear and plate-like in plan view and extend radially from the inner cylindrical portion 31 to the outer side so as to radiate from the center point P of the inner cylindrical portion 31 and integrally connect the inner cylindrical portion 31 and the outer cylindrical portion 32.

[0051] Further, this support S is formed to have a smaller diameter than the inner cylindrical portion 31 and is an annular shape in a plan view located inside the inner cylindrical portion 31, that is, for example, a plurality of additional cylindrical portions such as an annular shape in a plan view centered on the center point P of the inner cylindrical portion 31, for example, two reduced-diameter cylindrical portions 36 and 37. 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.

[0052] And these 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 open and having an 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).

[0053] Also, each of the cylindrical portions 31, 32, 36, and 37, which is a short cylindrical shape with upper and lower surfaces open, forms a single closed curve that is a closed curve in a plan view (the same applies to the cylindrical 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 whose starting point and ending point coincide and that 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 polygons such as triangles and quadrilaterals, as well as cardioids (heart shapes), etc. Further, the closed curve is a curve whose starting point and 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.

[0054] As shown in FIG. 6, the angle θ formed between both connecting portions (extending portions) 33 adjacent to each other in the circumferential direction is, for example, 10°. Although all of the angles θ are equal in the illustrated example, they do not necessarily have to be all equal. The thickness (plate thickness dimension) t of the plate-shaped 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 cylindrical portions 36 and 37 is the same as the interval dimension between the small-diameter cylindrical portion 36 and the inner cylindrical portion 31 and is, for example, 0.8 mm. In this illustrated example, the number of small-diameter cylindrical portions 36 and 37 located on the inner side (inner circumferential side) of the inner cylindrical portion 31 is two, but it may be one or three or more, for example.

[0055] Then, as shown in FIG. 8(a), the support S after removal in the removal process has exactly the same shape as before removal and has the inner cylindrical portion 31, the outer cylindrical portion 32, the connecting portion 33, and the small-diameter cylindrical portions 36 and 37.

[0056] Therefore, the support S after removal can be reused as a support member (a spare piece) 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) as the shaped object W formed with the support S and the model M.

[0057] That is, when repeatedly manufacturing (modeling) the shaped object (model M) W shown in FIG. 2 by reusing the support S after removal shown in FIG. 8(a) as a spare piece, as shown in FIG. 8(b), immediately before the necessary support portion MO of the model M is modeled, the modeling operation is temporarily stopped, the support S as a spare piece (a base that supports the necessary support portion MO) is placed on the modeling table 5, and then the modeling operation is restarted to model the necessary support portion MO of the model M on the spare piece.

[0058] And, by reusing the support S as a spare piece in this way, even in the modeling process of support reuse in which only the model M is modeled without performing support modeling, a predetermined gap 20 is temporarily formed between the support S (spare piece) after removal and the necessary support portion MO of the model M, and the necessary support portion MO is modeled.

[0059] As a result, also in this case, the model M and the support (placement piece) S do not firmly integrate (adhere), and therefore, 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 support S after its removal can be used repeatedly any number of times.

[0060] And according to the modeling object manufacturing method according to the above-described present embodiment, a modeling step of modeling a rough modeling object W1 having a model M that becomes the modeling object W and a support S that supports the support-required part MO of this model M, and a removal step of removing the support S from the rough modeling object W1 by separating the model M and the support S after this modeling step are provided. In the modeling step, in order to perform the modeling of the support-required part MO 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 step becomes easy, and the support S can be easily removed from the rough modeling object W1. Therefore, the productivity of the modeling object W can be improved.

[0061] Moreover, support marks are less likely to remain on the support-required part MO of the modeling object (model M) W, and the quality of the modeling object W can also be improved.

[0062] Also, when the dimension of the predetermined gap 20 in the modeling step is H and the opening diameter of the nozzle 11 in the 3D printer 1 of the heat fusion lamination method is φ, by making φ / 2 ≦ H ≦ φ satisfied, not only can the collapse of the model M in the modeling step be appropriately prevented, but also the separation between the model M and the support S in the removal step becomes easy, and the support S can be easily and appropriately removed from the rough modeling object W1.

[0063] Furthermore, the support S for the rough-formed object W1 in the shaping process includes a cylindrical inner cylindrical portion 31 having an annular shape in plan view, a cylindrical outer cylindrical portion 32 having an annular shape in plan view and located outside the inner cylindrical portion 31 and corresponding to the cylindrical inner peripheral surface of the model M, and a plurality of flat plate-shaped connecting portions (extending portions) 33 having a linear shape in plan view and extending radially outward from the inner cylindrical portion 31 to 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.

[0064] In recent years, shaping software has evolved, and there may be 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 may occur. In the manufacturing method of this embodiment, such problems do not occur by using the support S with a predetermined shape.

[0065] Furthermore, in the manufacturing method of this 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, without depending on shaping software for support generation, 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 shaping machine using the fused deposition modeling method.

[0066] In addition, since there is no problem with the model M and the support S being made of the same shaping material, there is no limitation on the number of nozzles, and there is no problem with the single-head specification 3D printer 1.

[0067] 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).

[0068] 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.

[0069] 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, by simply lifting the model M by hand on the shaping table 5, the model M could be easily separated from the support S on the shaping table 5. Also, on the necessary support part MO of the model M, some support marks could be seen, but there were no irregularities in the form of protrusions and depressions, there were no problems with the quality of the shaped object W, and there were no lamination abnormalities (collapse). Furthermore, the separated support S could be reused as a spare piece.

[0070] 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, by simply lifting the model M by hand on the shaping table 5, the model M could be easily separated from the support S on the shaping table 5. Also, on the necessary support part MO of the model M, there were some signs of resin sagging, but there were no problems with the quality of the shaped object W, and there were no lamination abnormalities (collapse). Furthermore, the separated support S could be reused as a spare piece.

[0071] 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, it could not be separated by simply lifting the model M 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 were traces of deformation on the support S when pinched with the radio pliers, and this support S could not be reused as a spare piece.

[0072] Also, the prototype shown in Fig. 10(b) is the case where H = 0.5 mm and D = 0.4 mm. In this case, with no resistance at all, by simply lifting the model M by hand on the shaping table 5, the model M could be easily separated from the support S on the shaping table 5. However, partial lamination abnormalities (collapse) occurred in the necessary support part MO of the model M.

[0073] Furthermore, the prototype shown in Fig. 10(c) is the case without a support. In this case, lamination abnormalities (collapse) occurred in the necessary support part MO of the model M.

[0074] Therefore, it was confirmed by these prototypes that it is preferable to satisfy φ / 2 ≦ H ≦ φ.

[0075] In addition, in the above embodiment, the case of manufacturing the shaped object W shown in FIG. 2 has been described, but the present invention 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 as well, the support S can be easily removed, and the same operational effects can be achieved.

[0076] That is, the shaped object W shown in FIG. 11 is, for example, a lid having a stepped oblique cap shape, and includes a lower cylindrical portion 41, an upper cylindrical portion 42 that is integrally provided on the inner peripheral surface of the upper end portion of the lower cylindrical portion 41 and is formed to have a smaller diameter than the lower cylindrical portion 41, and an inclined disk-shaped portion 43 that is integrally provided on the inner peripheral surface of the upper end portion of the upper cylindrical portion 42.

[0077] And the upper cylindrical portion 42 and the disk-shaped portion 43 that constitute a part of the shaped object (model M) W are support-required portions (overhang portions) MO that need to be supported 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).

[0078] FIG. 12 is a diagram schematically showing a shaped object manufacturing method (an example of the manufacturing method according to the present embodiment) for manufacturing the shaped object W shown in FIG. 11, where (a) to (e) are diagrams of the shaping process, and (f) is a diagram of the removal process.

[0079] And 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 support-required portion MO of the model M so as to satisfy φ / 2 ≦ H ≦ φ, the shaping of the support-required portion MO is performed. Note that the predetermined gap 20 is substantially entirely filled by resin sagging due to its own weight (see FIG. 13).

[0080] In addition, the support S laminated and formed 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 small-diameter cylindrical portions 36 and 37, as shown in FIGS. 13 to 15, in the same manner as when manufacturing the shaped object W shown in FIG. 2 described above. 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.

[0081] Furthermore, the support (spare part) S after removal shown in FIG. 15 can also be reused as a spare part for supporting the support-required portion MO of the model M when manufacturing the same shaped object W, similar to the support S shown in FIG. 8.

[0082] 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 (e.g., Archimedean spiral shape, etc.) in plan view.

[0083] 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 composed of 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.

[0084] In addition, such a support (support pattern) S having a spiral (volute) shape can be designed by applying, for example, an Archimedean spiral, and the continuous function that forms the basis of the design is as follows in parametric representation.

[0085] X t =t·cos(t) Y t =t·sin(t)

[0086] And even with the support S shown in Fig. 16, a cap-shaped shaped object W as shown in Fig. 2 can be manufactured in the same way, and in this case as well, the support S can be easily removed, and the same effects can be obtained.

[0087] In addition, since such a spiral support pattern is the creation of a shape by a continuous function, support design can be performed in a short time, the operation of the nozzle 11 during shaping becomes smooth, and the shaping time can be shortened.

[0088] Note that the model M (the shaped object which is the object such as a product) and the support S (the placement piece which is a reusable support member) 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 same effects such as the support S can be easily removed can be obtained.

[0089] First, the model M shown in Figs. 17(a) and (b) is, for example, a lid having an elliptical shape, and includes 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. The continuous function that forms the basis of the support S design when shaping such an elliptical model M is as follows in parametric representation. However, a ≠ b in the following.

[0090] X t =at·cos(t) Y t =bt·sin(t)

[0091] And the disk-shaped portion (upper plate portion) 62 that constitutes a part of the model M is a support-required portion MO that requires support by the support S shown in Figs. 17(c) and (d) so as not to collapse by its own weight during shaping (during manufacturing) by the 3D printer 1.

[0092] The support S shown in Figs. 17(c) and (d) is different from the one composed of the circular plate-shaped spiral portion 51 having a perfect circular shape shown in Fig. 16 above, and is composed of an elliptical plate-shaped spiral portion 63.

[0093] Next, the model M shown in FIGS. 18(a) and (b) has a lid body in the shape of, for example, a hexagram (it may also be in the shape of a pentagram, an octagram, etc.), and includes a hexagonal cylindrical portion 66 and a hexagonal plate-like portion 67 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 66.

[0094] And the plate-like portion (upper plate portion) 67 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. 18(c) and (d) so as not to collapse due to its own weight during the shaping (during the shaping) by the 3D printer 1.

[0095] The support S shown in FIGS. 18(c) and (d) has a plate-like spiral portion 68 having a perfect circular shape and a hexagonal outer peripheral plate portion 69 integrally provided on the outer peripheral side of the spiral portion 68. Triangular through-holes 70 are formed through the upper and lower surfaces of this outer peripheral plate portion.

[0096] Next, the model M shown in FIGS. 19(a) and (b) is a lid body that is a structure using, for example, a three-dimensional Archimedes spiral shape, and includes a cylindrical portion 71 and a hole-forming portion 73 integrally provided on the inner peripheral side of the cylindrical portion 71 and having a spiral hole (spiral hole) 72 formed inside that opens downward.

[0097] And the hole-forming portion 73 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. 19(c) and (d) so as not to collapse due to its own weight during the shaping (during the shaping) by the 3D printer 1.

[0098] The support S shown in FIGS. 19(c) and (d) is composed of a plate-like spiral portion 75 whose width dimension (vertical dimension) gradually increases from the outer peripheral side toward the center side. As is apparent from FIG. 19(c), this spiral portion 75 has a perfect circular shape in plan view, but is not limited to this, and may have other shapes such as an elliptical shape.

[0099] Note that such a support (support pattern) S can be designed by applying, for example, Archimedes' spiral. The continuous function that forms the basis of the design is as follows in parametric form, and the specific design method is as shown in, for example, FIG. 20.

[0100] X t = t·cos(t) Y t = t·sin(t) Z t = t

[0101] Next, the model M shown in FIGS. 21(a) and (b) is, for example, a lid having a perfect circular shape. Similar to 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 of the cylindrical portion 81.

[0102] And the disk-shaped portion 77 that forms part of this model M is a support-required portion MO that needs to be supported by the support S shown in FIGS. 21(c) and (d) and FIG. 22 so as not to collapse under its own weight during shaping (during printing) by the 3D printer 1.

[0103] The support S shown in FIGS. 21(c) and (d) and FIG. 22, similar to the one shown in FIG. 6 etc., has an inner cylindrical portion (cylindrical portion) 81, an outermost outer cylindrical portion 82, and a plurality of plate-shaped connecting portions (extending portions) 83 that extend radially outward from the inner cylindrical portion 81 to connect the two cylindrical portions 81, 82.

[0104] Also, this support S has a plurality of, for example, two smaller-diameter cylindrical portions 86, 87 that are located inside the inner cylindrical portion 81. These cylindrical portions 86, 87 are connected to the inner cylindrical portion 81 via a connecting portion 88 that forms a cross shape in plan view.

[0105] Furthermore, this support S has a plurality, for example, three intermediate cylindrical portions 91, 92, 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 of the cylindrical portions 81, 82, 86, 87, 91, 92, 93 of this support S is cylindrical, but the cylindrical portion is not limited to this shape as will be described later.

[0106] 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 having a square tube 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.

[0107] And the plate-like portion 97 constituting a part of this model M is a support-required portion MO that requires support 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 shaping (during modeling) by the 3D printer 1.

[0108] The support S shown in FIGS. 23(c) and (d) and FIG. 24 is the same as that shown in FIG. 6 and the like, and has 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, 102.

[0109] Also, this support S has a plurality, that is, for example, two additional cylindrical portions 104, 105 located inside the inner cylindrical portion 101. 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.

[0110] 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 to this, and any cylindrical shape is acceptable.

[0111] 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.

[0112] 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.

[0113] 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 and connect the two cylindrical portions 116 and 117.

[0114] 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.

[0115] 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.

[0116] 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, a substantially cross-shaped bulging portion 124 is formed on the bottom plate 123 of the tubular portion 121 so as 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.

[0117] Then, the bulging portion 124 and the plate-like portion (flange portion) 122 that constitute 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.

[0118] 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.

[0119] Next, the model M shown in FIGS. 29(a) and (b) is, for example, a member (sculpture, 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.

[0120] And the plate-shaped part 132 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. 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-shaped object W1 composed of these model M and support S.

[0121] 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.

[0122] 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.

[0123] 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-shaped object W1 after shaping, but it is necessary to destroy 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.

[0124] 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 a general pellet-shaped thermoplastic resin (which may be a recycled pellet material or the like) that can be obtained at low cost as a shaping material instead of a dedicated filament resin.

[0125] Further, the modeling 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 a stereolithography method (DLP method or SLA method).

[0126] Furthermore, the three-dimensional modeling object modeled using the modeling 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 modeling object are arbitrary.

[0127] Also, the modeling object manufacturing apparatus is not limited to a configuration in which a modeling head (discharging means) having a nozzle for discharging a modeling material is movable in the X-axis direction and the Z-axis direction and a modeling table is movable in the Y-axis direction. Any configuration in which the modeling head is movable relative to the modeling table in at least three dimensions may be used. For example, a configuration in which the modeling head is movable in the X-axis direction and the Y-axis direction and the modeling table is movable in the Z-axis direction, or a configuration in which the modeling head is provided at the tip of a robot arm (for example, a robot arm of a 6-axis robot is preferable) and is movable in any direction including three directions of the X-axis direction, the Y-axis direction, and the Z-axis direction may be used.

[0128] Also, the dimension of a predetermined gap in the modeling process may be a clearance (a slight gap height dimension) such that the resin sag (sag of the modeling 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 do not firmly integrate (adhere) to each other.

[0129] Furthermore, the support of the rough modeling object in the modeling 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.

[0130] Also, the additional cylindrical portion located inside the inner cylindrical portion of the support may have either a configuration (integrated configuration) connected to the inner cylindrical portion or a configuration (separate configuration) not connected to the inner cylindrical portion, and the number, shape, etc. of the additional cylindrical portion are also arbitrary.

Explanation of Signs

[0131] 1 A 3D printer of the 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 support member that supports a portion of a model that requires support when a model is manufactured using a model manufacturing apparatus, Reusable supports that are separated from the model during manufacturing. A support member characterized by:

2. Has a cylindrical portion 2. The support member according to claim 1.

3. A cylindrical portion; a plurality of extending portions extending radially from the cylindrical portion; 2. The support member according to claim 1.

4. Has a plate-shaped spiral portion 2. The support member according to claim 1.

5. The bottom and A plurality of cylindrical portions are provided on the bottom.

2. The support member according to claim 1.

6. Created using a fused deposition modeling or stereolithography modeling device 6. The support member according to claim 1, wherein the support member is a support member having a first end and a second end.

7. A method for manufacturing a shaped object by using a shaped object manufacturing apparatus and a support member according to any one of claims 1 to 5, comprising the steps of: performing a modeling operation without installing the support member; a step of temporarily stopping a modeling operation immediately before a support-requiring portion of the model is modeled, and installing the support member; restarting a modeling operation with the support member installed, and modeling the support-requiring portion of the model on the support member; A method for manufacturing a shaped object, comprising:

8. A method for manufacturing a object by using a object manufacturing apparatus, comprising the steps of: a modeling step of forming a rough object having a model to be the object and supports for supporting portions of the model that require support; a removing step of removing the support from the rough object by separating the model and the support after the modeling step, The support removed in the removing step can be reused as a support member for supporting a part of the model that needs support when manufacturing a model. A method for manufacturing a shaped object, comprising:

9. A method for manufacturing a object by using a object manufacturing apparatus, comprising the steps of: a modeling step of forming a rough object having a model to be the object and supports for supporting portions of the model that require support; a removing step of removing the support from the rough object by separating the model and the support after the modeling step, The support removed in the removing step can be reused as a support member for supporting a part of a model that requires support when manufacturing a model having the same shape as the model. A method for manufacturing a shaped object, comprising:

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