Modeling method, modeling system, and program

Abstract

To suppress a deformation occurring in a modeled object.SOLUTION: A method includes: a first modeling step of modeling a modeled object 40; and a second modeling step of modeling a sacrificial modeled object 60 above the modeled object 40. The sacrificial modeled object 60 includes a plurality of column portions 61 and a roof portion 62 modeled above the column portions 61.SELECTED DRAWING: Figure 11

Description

Technical Field

[0001] The present invention relates to a shaping method, a shaping system, and a program.

Background Art

[0002] As a shaping method for shaping an object without using a mold or the like, there is known a method of forming a shaping layer by binding a powdery shaping material and shaping the object by laminating the shaping layers.

[0003] In such a shaping method, there is a problem that deformation such as warping occurs in the object during the shaping process of shaping the object or in a subsequent process. In response to this problem, Patent Document 1 (U.S. Patent Application Publication No. 2014 / 0335313) proposes a method of suppressing deformation of the object by previously shaping a support structure below a portion where warping of the object occurs.

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the conventional method, deformation of the object may not be suppressed in some cases.

[0005] Therefore, an object of the present invention is to provide a new shaping method for suppressing deformation occurring in an object.

Means for Solving the Problems

[0006] In order to solve the above problems, the shaping method according to the present invention includes a first shaping step of shaping an object, and a second shaping step of shaping a sacrificial object above the object, wherein the sacrificial object includes a plurality of column portions and a roof portion shaped above the column portions.

Effects of the Invention

[0007] According to the present invention, deformation occurring in the object can be suppressed.

Brief Description of the Drawings

[0008]

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Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each drawing for explaining the present invention, components having the same function or shape, such as members and components, are given the same reference numerals as much as possible for discrimination, and the description thereof will be omitted after being explained once.

[0010] <Overall Configuration of the Modeling System> FIG. 1 is a schematic diagram of a modeling system 1000 according to a first embodiment of the present invention. First, based on FIG. 1, the overall configuration of the modeling system 1000 to which the modeling method according to the present invention is applied will be described.

[0011] The modeling system 1000 includes a modeling device 100, a drying device 200, a powder removing device 300, and a sintering device 400.

[0012] The shaping device 100 is a device that forms a powder layer containing a shaping material and applies a shaping liquid to the powder layer to form a shaping layer. Further, the shaping device 100 shapes a three-dimensional shaped object by laminating the shaping layers. As the shaping material, in addition to metal powders containing aluminum, other metals or metal alloys, powders containing ceramics, glass, etc. are used. Further, the shaping liquid contains a solvent, a resin, or the like.

[0013] The drying device 200 is a device that performs a drying process on the shaped object shaped by the shaping device 100. By the drying process, liquid components such as solvents remaining in the shaped object are vaporized and removed.

[0014] The powder removal device 300 is a device that removes excess powder, which is the shaping material adhering to the shaped object after the drying process. Examples of the method for removing the powder include a method of removing the powder by air blowing and a method of removing the powder by immersing the shaped object in a removal liquid.

[0015] The sintering device 400 is a device that heats the shaped object after the excess powder has been removed, thereby degreasing the resin component contained in the shaped object and sintering the shaping material. By sintering the shaping material, a sintered body in which the shaping materials are integrated is obtained. The degreasing process and the sintering process may be continuously performed using the same device, or may be performed using separate devices.

[0016] Further, the shaping system 1000 may include a post-treatment device or the like. The post-treatment device is not particularly limited and can be appropriately selected according to the purpose. For example, a surface protection treatment device that performs a surface protection treatment on the shaped object after the excess powder has been removed, or a post-treatment device such as a coating device that performs coating on the shaped object after the excess powder has been removed can be mentioned. Further, the shaping device 100, the drying device 200, the powder removal device 300, and the sintering device 400 may each be separate bodies, or some or all of them may be configured as one device.

[0017] <Configuration of the shaping device> FIG. 2 is a schematic view of a shaping apparatus 100 according to a first embodiment of the present invention. Based on FIG. 2, the configuration of the shaping apparatus 100 will be described. The shaping apparatus 100 is an example of an apparatus applied to, for example, the BJ (Binder Jetting) method.

[0018] The shaping apparatus 100 includes a shaping unit 1 and a shaping liquid applying means 5.

[0019] (Shaping unit) The shaping unit 1 forms a powder layer 31 containing a shaping material 20. The shaping unit 1 includes a powder tank 11 and a layer forming unit 16. The powder tank 11 includes a supply tank 21, a shaping tank 22, and a recovery tank 25. The supply tank 21 is a tank that stores the shaping material 20 to be supplied to the shaping tank 22. The shaping tank 22 is a tank that stores the powder layer 31 formed by supplying the shaping material 20 and the shaping layer 30 formed by binding the shaping material 20. The recovery tank 25 is a tank that recovers the excess shaping material 20 overflowing from the shaping tank 22. The supply tank 21, the shaping tank 22, and the recovery tank 25 are all formed in a box shape with an open top surface. Further, the bottom 47 of the supply tank 21 is configured as a supply stage 23 that can move up and down in the vertical direction (Z direction in FIG. 2). Similarly, the bottom 48 of the shaping tank 22 is also configured as a shaping stage 24 that can move up and down in the vertical direction.

[0020] The layer forming unit 16 is a unit that supplies the shaping material 20 from the supply tank 21 to the shaping tank 22 to form the powder layer 31. The layer forming unit 16 includes a flattening means 12 and a removing means 13.

[0021] The flattening means 12 is a means that moves in the horizontal direction (Y direction in FIG. 2), supplies the shaping material 20 from the supply tank 21 to the shaping tank 22, and flattens the supplied shaping material 20. In the example shown in FIG. 2, a rotating body called a recoater is used as the flattening means 12. Also, a plate-shaped blade or bar or the like may be used as the flattening means 12.

[0022] The removing means 13 is a means for removing the modeling material 20 attached to the flattening means 12. In the example shown in FIG. 2, as the removing means 13, a plate-like member that contacts the flattening means 12 and removes the modeling material 20 is used. The removing means 13 is configured to be movable together with the flattening means 12 while being in contact with the flattening means 12.

[0023] (Modeling liquid applying means) The modeling liquid applying means 5 is a means for applying the modeling liquid 10 to the powder layer 31 formed in the modeling tank 22 to form the modeling layer 30. The modeling liquid applying means 5 includes a head 52 and a carriage 51.

[0024] The head 52 is a means for discharging the modeling liquid 10 onto the powder layer 31. For example, the head 52 is an inkjet head and has a nozzle row in which a plurality of nozzles are arranged. As a method of applying the modeling liquid, in addition to the inkjet method, a dispenser method may also be used. Further, four heads 52 may be provided to apply a cyan modeling liquid, a magenta modeling liquid, a yellow modeling liquid, a black modeling liquid, etc., so that a color model can be formed.

[0025] The carriage 51 is a means for mounting the head 52 and moving the head 52 in two directions (the X direction and the Y direction in FIG. 2) perpendicular to each other in the horizontal direction and the vertical direction (the Z direction in FIG. 2).

[0026] <Operation of the modeling device> Subsequently, with reference to FIGS. 3 to 8, the operation of the modeling device 100 according to the first embodiment of the present invention will be described.

[0027] First, when forming the first-layer powder layer 31 on the modeling stage 24 of the modeling tank 22, as shown in FIG. 3, the supply stage 23 of the supply tank 21 is raised so that the upper surface of the modeling material 20 is positioned a predetermined thickness above the upper surface of the supply tank 21. On the other hand, in the modeling tank 22, the modeling stage 24 is adjusted to be positioned a desired thickness of the powder layer 31 below the upper surface of the modeling tank 22.

[0028] Next, as shown in FIG. 4, the flattening means 12 is horizontally moved from the supply tank 21 toward the shaping tank 22, and the shaping material 20 on the supply stage 23 is pushed toward the shaping tank 22 side by the flattening means 12. Then, as shown in FIG. 5, when the shaping material 20 pushed by the flattening means 12 is supplied onto the shaping stage 24, as shown in FIG. 6, a first powder layer 31 having a uniform thickness is formed on the shaping stage 24. At this time, the surplus shaping material 20 overflowing from the shaping tank 22 falls into the recovery tank 25 and is recovered. After that, as shown in FIG. 7, when the flattening means 12 moves in the opposite direction, the flattening means 12 is returned to its original initial position.

[0029] After the first powder layer 31 is formed, as shown in FIG. 8, the head 52 is disposed at a position facing the powder layer 31, and the shaping liquid 10 is discharged from the head 52 onto the powder layer 31. Thereby, the shaping materials 20 of the powder layer 31 to which the shaping liquid 10 is applied are bonded to form a shaping layer 30. Specifically, when the shaping liquid 10 containing the resin adheres to the shaping material 20, the shaping materials 20 are bonded to each other via the resin to form the shaping layer 30. As the resin contained in the shaping liquid 10, for example, polyvinyl alcohol (PVA) or polyvinylpyrrolidone (PVP) is used. Further, the shaping liquid 10 is not limited to those containing such a resin, and may contain a crosslinking agent and an organic solvent. When the shaping liquid 10 contains a crosslinking agent and an organic solvent, when the shaping liquid 10 is applied to the shaping material 20, the resin coating the shaping material 20 dissolves and crosslinks, and the shaping materials 20 are bonded.

[0030] Thus, after the shaping liquid is applied to the first powder layer 31 to form the shaping layer 30, again in the same manner, the heights of the supply stage 23 and the shaping stage 24 are adjusted, and the flattening means 12 is reciprocally moved to form a second powder layer 31 on the shaping stage 24. Then, when the shaping liquid 10 is applied from the head 52 to the second powder layer 31, a second shaping layer 30 is formed. After that, by repeating the same process, a plurality of shaping layers 30 are laminated to shape an object.

[0031] Also, the surplus modeling material 20 recovered in the recovery tank 25 may be returned to the supply tank 21. For example, the modeling material 20 in the recovery tank 25 is transferred to a modeling material supply device installed above the supply tank 21 or the like. Then, when the modeling operation by the modeling device 100 is started, or when the modeling material 20 in the supply tank 21 decreases, the modeling material 20 stored in the modeling material supply device may be supplied to the supply tank 21. As a means for transferring the modeling material 20 to the modeling material supply device, a screw conveyor method using a screw, a pneumatic transport method using air, or the like can be used.

[0032] <Manufacturing process of the molded object> FIG. 9 is a flowchart showing a method for molding a molded object by the molding system 1000 according to the first embodiment of the present invention.

[0033] As shown in FIG. 9, the manufacturing process includes, in addition to the molding process S0 by the molding device 100, a drying process S4 by the drying device 200, a surplus powder removal process S5 by the powder removal device 300, a debinding process S6 and a sintering process S7 by the sintering device 400.

[0034] The molding process S0 includes each process performed by the operation of the molding device 100 in FIGS. 3 to 8. That is, the molding process S0 includes a powder layer forming process S1 for forming a powder layer 31 containing the molding material 20, a molding liquid applying process S2 for applying a molding liquid to the powder layer 31, and a lamination process S3 in which the powder layer forming process S1 and the molding liquid applying process S2 are repeatedly performed. Thereby, the molded object is molded.

[0035] After the shaping process S0 is performed, a drying process S4 for drying the shaped object is performed. In the drying process S4, the shaped object is heated by the drying device 200, so that liquid components such as solvents remaining in the shaped object are vaporized and removed. Then, an excess powder removal process S5 is performed by the powder removal device 300 to remove excess powder adhering to the shaped object. After the excess powder removal process S5 is performed, a debinding process S6 by the sintering device 400 is performed. In the debinding process S6, the shaped object is heated in an atmosphere containing an inert gas, so that the resin in the shaped object is removed. Thereby, a debound body is formed. Finally, a sintering process S7 by the sintering device 400 is performed to obtain a sintered body in which the debound body is sintered.

[0036] <Problems of deformation occurring in the shaped object> Here, the problem of deformation occurring in the shaped object will be described with reference to FIG. 10. FIG. 10 is a diagram for explaining the mechanism by which the shaped object is deformed. FIG. 10(a) shows the shaped object 40 before the drying process is performed, FIG. 10(b) shows the resin segregation of the shaped object 40, and FIG. 10(c) shows the deformation of the shaped object 40.

[0037] In a shaping system using the BJ (Binder Jetting) method, when a drying process and a sintering process are performed on the shaped object, deformation of the shaped object 40 may occur. For example, as shown in FIG. 10(c), a warp may occur in which the center of the shaped object 40 protrudes upward more than both ends. The reason for such deformation may be the mechanism shown in FIGS. 10(a) and 10(b).

[0038] First, as shown in Fig. 10(a), in the shaped object 40 before the drying process, the resin 9 contained in the shaping liquid imparted by the shaping process is uniformly present throughout the shaped object 40. From this state, when the drying process of the shaped object 40 is performed, liquid components such as the solvent contained in the shaped object 40 vaporize. Further, as indicated by the arrow in Fig. 10(b), the resin 9 in the shaped object 40 moves from the bottom to the top of the shaped object 40. As a result, the resin 9 accumulates in the upper part of the shaped object 40, so that resin segregation occurs in which the resin 9 becomes more in the upper part than in the lower part of the shaped object 40. Then, when the sintering process of the shaped object 40 is performed in a state where resin segregation has occurred, it is difficult to promote the densification of sintering in the upper part where the resin 9 is abundant, while in the lower part where the resin 9 is less, the densification of sintering is promoted. Therefore, the balance of densification is disrupted. From the above, as a deformation of the shaped object 40 shown in Fig. 10(c), it is considered that warping occurs in the upper part of the shaped object 40.

[0039] Conventionally, as a method for suppressing the deformation of a shaped object, there is a method of shaping a support structure in advance below the portion where deformation occurs. However, it is considered difficult to suppress the deformation due to resin segregation by such a method. Therefore, in the present invention, in order to suppress the deformation of the shaped object, the following shaping method is proposed.

[0040] <Shaping method according to the first embodiment of the present invention> Fig. 11 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the first embodiment of the present invention. Fig. 12 is a plan view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the first embodiment of the present invention. While referring to Figs. 11 and 12, the shaping method according to the first embodiment of the present invention will be described.

[0041] In the modeling method according to the first embodiment of the present invention, in the modeling tank 22, in addition to the modeled object 40 finally obtained as the product, a sacrificial modeled object 60 is modeled. The modeled object 40 and the sacrificial modeled object 60 are modeled above the modeling stage 24 and are in a state of being buried in the modeling material 20 in the modeling tank 22. Note that although the modeled object 40 of the present invention will be described as being a rectangular parallelepiped, various shapes such as a cube, a polyhedron, a cylinder, a prism, a polygonal prism, a sphere, a shape having a concave portion, and a shape having a convex portion can be applied. Different from the modeled object 40, the sacrificial modeled object 60 is not a modeled object as a product but is modeled incidentally to suppress deformation of the modeled object 40. For this reason, the sacrificial modeled object 60 is modeled in a state separable from or separated from the modeled object 40. The sacrificial modeled object 60 is removed after the drying process. The sacrificial modeled object 60 may be the same modeling material 20 as the modeled object 40 or may be a different modeling material 20.

[0042] Specifically, the sacrificial modeled object 60 includes a plurality of column portions 61 and a roof portion 62 modeled above the column portions 61.

[0043] The plurality of column parts 61 are formed above the shaped object 40. The "above" of the shaped object 40 here means a position where at least a part of the column parts 61 is arranged so as to overlap the shaped object 40 when viewed from the vertical direction. In the first embodiment of the present invention, the plurality of column parts 61 are formed independently of each other and are spaced apart from each other. That is, the plurality of column parts 61 are evenly arranged on the rectangular upper surface of the shaped object 40. More specifically, the plurality of column parts 61 are arranged at equal intervals overall across the vicinity of the four sides constituting the outer periphery of the upper surface of the shaped object 40 and the central part of the upper surface. Also, the plurality of column parts 61 (all column parts 61) are formed so as to be connected to the upper surface of the shaped object 40. Note that the location where the plurality of column parts 61 are connected may be any part of the upper part including the upper surface of the shaped object 40. The "upper part" of the shaped object 40 here means a part above the intermediate position of the overall height of the shaped object 40. For example, when the shaped object 40 is a sphere, the column parts 61 may be connected to the surface (hemispherical surface) of the part above the center of the sphere. The heights of the plurality of column parts 61 shown in FIG. 11 are all equal, but they may also be different from each other. When the shaped object 40 is a sphere, among the plurality of column parts 61, the height of the outer column parts 61 is the highest, and the height of the column parts 61 in the central part is the smallest. Here, although the plurality of column parts 61 are formed independently of each other and are spaced apart from each other, at least two or more of the plurality of column parts 61 may be formed in contact with each other.

[0044] The roof part 62 is formed above the plurality of column parts 61. The "above" here has the same meaning as the "above" of the shaped object 40. That is, when viewed from the vertical direction, at least a part of the roof part 62 may be arranged so as to overlap the plurality of column parts 61. Also, the roof part 62 is connected to the upper ends of the plurality of column parts 61. Therefore, the roof part 62 is formed so as to be connected to the shaped object 40 via the plurality of column parts 61.

[0045] The roof part 62 according to the first embodiment of the present invention may be positioned above the shaped object 40 so as to cover the shaped object 40, and it does not have to be at the zenith. Although there is no shaping above the roof part 62 shown in FIG. 11, a sacrificial shaped object 60 may be further shaped above the roof part 62. That is, above the roof part 62 shown in FIG. 11, any one of a plurality of column parts 61, the roof part 62, a plurality of column parts 61, and the roof part 62 may be further shaped.

[0046] As shown in FIG. 11, the height of the plurality of column parts 61 is greater than the thickness of the roof part 62. Not limited to this, the height of the plurality of column parts 61 and the thickness of the roof part 62 may be made equal, or the thickness of the roof part 62 may be made greater than the height of the column part 61. The greater the thickness of the roof part 62, the more the deformation of the shaped object 40 can be suppressed.

[0047] <Shaping process> Subsequently, with reference to FIG. 13, a method for shaping a shaped object by the shaping device according to the first embodiment of the present invention will be described. FIG. 13 is a flowchart showing a method for shaping a shaped object by the shaping device according to the first embodiment of the present invention.

[0048] In the shaping method according to the first embodiment of the present invention, a first shaping step of shaping the shaped object 40 and a second shaping step of shaping the sacrificial shaped object 60 are included. In a BJ type shaping system, since the shaped object is shaped in order from the lower side for each shaping layer, first, the shaping of the shaped object 40 arranged on the lower side (the first shaping step) is performed. Then, when the shaping of the shaped object 40 is completed, the shaping of the sacrificial shaped object 60 (the second shaping step) is subsequently performed. In the shaping of the sacrificial shaped object 60 (the second shaping step), first, the shaping of the plurality of column parts 61 is performed, and then the shaping of the roof part 62 is performed. Thereby, a sacrificial shaped object 60 having column parts 61 above the shaped object 40 and a roof part 62 above the column parts 61 is shaped.

[0049] Thus, according to the shaping method according to the first embodiment of the present invention, by shaping the sacrificial shaped object 60 above the shaped object 40, deformation of the shaped object 40 due to resin segregation can be suppressed. In this case, as a mechanism for suppressing resin segregation as deformation, the mechanism shown in FIG. 14 is conceivable. FIG. 14 is a diagram for explaining the mechanism by which deformation of the shaped object 40 is suppressed. FIG. 14(a) is a diagram showing the movement of the resin 9 in the shaped object 40 during the drying process, FIG. 14(b) is a diagram showing the movement of the resin 9 through the sacrificial shaped object 60, and FIG. 14(c) is a diagram showing the state of the resin 9 in the shaped object 40.

[0050] <Deformation suppression mechanism> After the shaped object 40 and the sacrificial shaped object 60 are shaped in the shaping tank 22, the drying process is performed while they are still accommodated in the shaping tank 22 together with the shaping material 20. At this time, as indicated by the arrow in FIG. 14(a), the resin 9 in the shaped object 40 moves upward from the bottom along with the drying process. As a result, the resin 9 in the shaped object 40 gathers at the sacrificial shaped object 60 at the upper part of the shaped object 40. Then, as shown in FIG. 14(b), it is considered that the resin 9 moves through the plurality of column portions 61 to the roof portion 62. Thereby, resin segregation in which the resin 9 becomes more in the upper part than the lower part of the shaped object 40 is suppressed. From the above, as shown in FIG. 14(c), it is considered that the resin 9 in the shaped object 40 is distributed in a uniform or nearly uniform state. Note that such a mechanism for suppressing resin segregation is only a speculation, and the possibility that other mechanisms are involved in the suppression of resin segregation cannot be denied. Therefore, the present invention is not limited to this mechanism.

[0051] As described above, according to the shaping method according to the first embodiment of the present invention, resin segregation can be suppressed, so that deformation of the shaped object 40 in the sintering process can be suppressed. That is, since the variation in the resin amount between the upper and lower parts of the shaped object 40 is suppressed, densification promotion in the sintering process is uniformly performed in the upper and lower parts of the shaped object 40, and deformation such as warping of the shaped object 40 is suppressed.

[0052] As an example of the column portion 61, for example, a column portion having a cylindrical shape with a diameter of 4 mm can be cited. However, the column portion 61 is not limited to the case of having a cylindrical shape, and may have a cross-sectional shape other than circular, such as a prismatic shape. Further, the column portion 61 is not limited to the case where the length in the vertical direction is larger than the width in the horizontal direction. On the contrary, it may be the case where the width in the horizontal direction is larger than the length in the vertical direction. Further, the thicknesses (widths in the horizontal direction) of the plurality of column portions 61 are not limited to the case where they are all the same, and the thicknesses of some of the column portions 61 may be different from the thicknesses of the other column portions 61. Furthermore, in addition to the case where the plurality of column portions 61 are arranged at equal intervals, they may be arranged so that the intervals are different.

[0053] As the roof portion 62, for example, an example of a flat plate shape with a thickness of 1 mm arranged horizontally can be cited. However, the roof portion 62 is not limited to the planar shape, and may be a curved shape, a shape having irregularities, a shape combining these, or the like. Further, the thickness of the roof portion 62 may be uniform or non-uniform. Further, the roof portion 62 may be rectangular according to the shape of the shaped object 40. Further, various shapes such as a square, a rhombus, a polygon, an ellipse, and a perfect circle may be applied to the shape of the roof portion 62 in addition to a rectangle. Further, the interval between the roof portion 62 and the shaped object 40 is set to, for example, 5 mm. However, the interval between the roof portion 62 and the shaped object 40 is not limited to the case of being 5 mm and can be changed as appropriate.

[0054] <Removal process> Further, after the drying process and before the degreasing process and the sintering process are performed, the sacrificial shaped object 60 is removed from the shaped object 40. FIG. 15 is a flowchart showing a shaping method including a removal process (sacrificial shaped object removal process) according to the first embodiment of the present invention. That is, after the shaping process S0 for shaping the shaped object 40 and the sacrificial shaped object 60 is performed, the drying process S4 for the shaped object 40 and the sacrificial shaped object 60 is performed. Thereafter, a removal process (sacrificial shaped object removal process) S10 for separating and removing the sacrificial shaped object 60 from the shaped object 40 is performed. The removal process S10 of the sacrificial shaped object 60 may be performed before the surplus powder removal process S5 for removing surplus powder from the shaped object 40, or may be performed after the surplus powder removal process S5. Further, the separation operation of the sacrificial shaped object 60 from the shaped object 40 may be performed manually by an operator using a tool or the like, or may be performed automatically using a device or the like.

[0055] Subsequently, another embodiment different from the first embodiment of the present invention will be described. Hereinafter, mainly the parts different from the first embodiment of the present invention will be described, and the same parts will be omitted as appropriate.

[0056] <Second Embodiment of the Present Invention> FIG. 16 is a side view of a shaped object 40 and a sacrificial shaped object 60 shaped by a shaping method according to the second embodiment of the present invention.

[0057] In the second embodiment of the present invention, the roof portion 62 is composed of a plurality of divided roofs 62a that are divided. The divided roof 62a may be connected to one column portion 61, or may be connected to a plurality of column portions 61. In this case, it is considered that the vaporized components generated from the shaped object 40 during the drying process are released upward through the gaps between the divided roofs 62a, so that promotion of drying is expected. Note that the shaping of the divided roof 62a may be omitted. That is, only a plurality of column portions 61 may be shaped as the sacrificial shaped object 60 above the shaped object 40.

[0058] Similar to the first embodiment of the present invention, at least two or more of the plurality of column portions 61 may be shaped in contact with each other. Further, a sacrificial shaped object 60 may be shaped above the divided roof 62a. Furthermore, although the height of the plurality of column portions 61 is greater than the thickness of the divided roof 62a, it is not limited thereto, and the height of the plurality of column portions 61 and the thickness of the divided roof 62a may be made equal, or the thickness of the divided roof 62a may be made greater than the height of the column portions 61. The heights of the plurality of column portions 61 may be made different from each other.

[0059] <The third embodiment of the present invention> FIG. 17 is a plan view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the third embodiment of the present invention.

[0060] In the third embodiment of the present invention, the column portions 61 are arranged only in the vicinity of the outer periphery, excluding the central portion of the upper surface of the shaped object 40. In this case, since the number of column portions 61 is reduced, the separation work of the sacrificial shaped object 60 with respect to the shaped object 40 is reduced, and the amount of waste when the sacrificial shaped object 60 is discarded can be reduced.

[0061] <The fourth embodiment of the present invention> FIG. 18 is a plan view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the fourth embodiment of the present invention.

[0062] As in the fourth embodiment of the present invention, the column portions 61 may be arranged only in the vicinity of one side among the four sides constituting the outer periphery of the upper surface of the shaped object 40. In this case, since the number of column portions 61 is further reduced, the separation work of the sacrificial shaped object 60 and the amount of waste are further reduced.

[0063] <The fifth embodiment of the present invention> FIG. 19 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the fifth embodiment of the present invention.

[0064] In the fifth embodiment of the present invention, the column portion 61 has a concave portion 61a. The concave portion 61a is provided at the lower end which is the connection portion of the column portion 61 to the shaped article 40. For this reason, the column portion 61 is formed such that the horizontal width is smaller in the concave portion 61a than in other portions. Thereby, since the column portion 61 is likely to be separated from the shaped article 40 starting from the concave portion 61a, the removal work of the sacrificial shaped article 60 becomes easy. Further, the concave portion 61a may be an annular groove provided continuously in the circumferential direction of the columnar column portion 61, or may be a plurality of grooves provided intermittently. The shape of the concave portion 61a can be changed as appropriate. Note that, in order to make it easy to separate the column portion 61, the entire column portion 61 may be formed thin. For example, by making the column portion 61 into a column shape with a diameter of 2 mm, it becomes easy to separate the column portion 61.

[0065] <Sixth Embodiment of the Present Invention> FIG. 20 is a side view of the shaped article 40 and the sacrificial shaped article 60 shaped by the shaping method according to the sixth embodiment of the present invention.

[0066] As in the sixth embodiment of the present invention, there may be a gap d1 between the plurality of column portions 61 and the roof portion 62. That is, the plurality of column portions 61 and the roof portion 62 may not be connected to each other. In this case, the shaping material 20 is interposed between the plurality of column portions 61 and the roof portion 62.

[0067] Thus, even when the plurality of column portions 61 and the roof portion 62 are not connected to each other, deformation due to resin segregation in the shaped article 40 can be suppressed. In this case, it is considered that the amount of resin in the upper part of the shaped article 40 decreases due to the resin in the shaped article 40 moving from the column portion 61 to the roof portion 62 through the shaping material 20 interposed between the column portion 61 and the roof portion 62. Note that the present invention is not limited to the mechanism described here. This also applies to the embodiments described below.

[0068] <Seventh Embodiment of the Present Invention> FIG. 21 is a side view of the shaped article 40 and the sacrificial shaped article 60 shaped by the shaping method according to the seventh embodiment of the present invention.

[0069] In the seventh embodiment of the present invention, a gap d2 is provided between the plurality of column portions 61 and the shaped object 40. Therefore, the plurality of column portions 61 are not connected to the shaped object 40. For this reason, the shaping material 20 is interposed between the plurality of column portions 61 and the shaped object 40.

[0070] In this case, it is considered that the deformation due to resin segregation in the shaped object 40 is suppressed by the resin in the shaped object 40 moving from the shaped object 40 to the column portion 61 and the roof portion 62 through the shaping material 20 interposed between the column portion 61 and the shaped object 40. Further, in this case, since the sacrificial shaped object 60 including the column portion 61 and the roof portion 62 is entirely separated from the shaped object 40, the separation work of the sacrificial shaped object 60 becomes unnecessary.

[0071] <The eighth embodiment of the present invention> FIG. 22 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the eighth embodiment of the present invention.

[0072] In the eighth embodiment of the present invention, gaps d1 and d2 are provided between the plurality of column portions 61 and the roof portion 62 and between the plurality of column portions 61 and the shaped object 40, respectively. Therefore, the plurality of column portions 61 are not connected to the roof portion 62 and the shaped object 40. For this reason, the shaping material 20 is interposed between the plurality of column portions 61 and the roof portion 62 and between the plurality of column portions 61 and the shaped object 40, respectively.

[0073] In this case, it is considered that the deformation due to resin segregation in the shaped object 40 is suppressed by the resin in the shaped object 40 moving to the column portion 61 and the roof portion 62 through the shaping material 20 interposed between the plurality of column portions 61 and the roof portion 62 and between the plurality of column portions 61 and the shaped object 40. Further, also in this case, since the sacrificial shaped object 60 is entirely separated from the shaped object 40, the separation work of the sacrificial shaped object 60 becomes unnecessary. Note that the plurality of column portions 61 may be shaped by combining two or more of the first, fifth to eighth embodiments of the present invention.

[0074] <The ninth embodiment of the present invention> Figure 23 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the ninth embodiment of the present invention.

[0075] In the ninth embodiment of the present invention, the sacrificial shaped object 60 includes a wall portion 63 shaped on the side of the shaped object 40 in addition to the column portion 61 and the roof portion 62. The wall portion 63 may be continuously arranged over the entire periphery of the shaped object 40 or arranged on a part of the periphery of the shaped object 40 as long as at least a part of the wall portion 63 overlaps the shaped object 40 when viewed from any horizontal direction. Further, the wall portion 63 is not limited to the case of being flat, and may have a curved shape or a shape having irregularities.

[0076] Thus, by including the wall portion 63 in addition to the column portion 61 and the roof portion 62 in the sacrificial shaped object 60, it is considered that the resin that has moved from the shaped object 40 to the roof portion 62 via the column portion 61 can be further moved to the wall portion 63. As a result, more resin in the shaped object 40 can be moved to the sacrificial shaped object 60, the amount of resin at the upper part of the shaped object 40 can be reduced, and it is considered that deformation due to resin segregation can be more effectively suppressed.

[0077] Note that the column portion 61, the roof portion 62, and the wall portion 63 may be connected to each other and integrally formed, or may be separated via a gap. Also, the column portion 61 and the shaped object 40 may be connected to each other or may be separated via a gap.

[0078] <The Tenth Embodiment of the Present Invention> Figure 24 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the tenth embodiment of the present invention.

[0079] In the tenth embodiment of the present invention, the sacrificial shaped object 60 includes, in addition to the column portion 61, the roof portion 62, and the wall portion 63, a floor portion 64 shaped below the shaped object 40. The floor portion 64 only needs to be arranged such that at least a part of the floor portion 64 overlaps with the shaped object 40 when viewed in the vertical direction. Further, the floor portion 64 is not limited to a flat plate shape, and may have a curved shape or a shape with irregularities.

[0080] Thus, by including the floor portion 64 in addition to the column portion 61, the roof portion 62, and the wall portion 63 in the sacrificial shaped object 60, it is considered that the resin that has moved from the shaped object 40 to the roof portion 62 via the column portion 61 can be further moved to the floor portion 64 via the wall portion 63. As a result, more resin in the shaped object 40 can be moved to the sacrificial shaped object 60, the amount of resin in the upper part of the shaped object 40 can be reduced, and it is considered that deformation due to resin segregation can be more effectively suppressed.

[0081] Note that the column portion 61, the roof portion 62, the wall portion 63, and the floor portion 64 may be connected to each other and integrally formed, or may be separated via a gap. Also, the column portion 61 and the shaped object 40 may be connected to each other or may be separated via a gap.

[0082] <The eleventh embodiment of the present invention> FIG. 25 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the eleventh embodiment of the present invention.

[0083] In the eleventh embodiment of the present invention, the floor portion 64 and the shaped object 40 are connected via a plurality of column portions 65. In this case, the sacrificial shaped object 60 includes, in addition to the roof portion 62, the wall portion 63, and the floor portion 64, a first column portion 61 shaped between the roof portion 62 and the shaped object 40, and a second column portion 65 shaped between the floor portion 64 and the shaped object 40.

[0084] Thus, since the floor portion 64 and the shaped article 40 are connected via the second pillar portion 65, when the drying process is performed, the resin contained in the floor portion 64 moves to the shaped article 40 via the second pillar portion 65. Accordingly, it is considered that the resin is replenished to the lower part of the shaped article 40. On the other hand, in the upper part of the shaped article 40, since the resin moves to the roof portion 62 and the wall portion 63 via the first pillar portion 61, the amount of the resin is reduced. That is, in the upper part where the amount of the resin increases with the drying process, the amount of the resin can be reduced, and conversely, in the lower part where the resin becomes less, the amount of the resin can be increased. Therefore, it is considered that the deformation due to the resin segregation can be more effectively suppressed.

[0085] The second pillar portion 65 may be arranged evenly over the entire lower surface of the shaped article 40, like the pillar portion (first pillar portion) 61 shown in FIG. 12, or may be arranged only in the vicinity of a part of the four sides constituting the outer periphery of the lower surface of the shaped article 40, like the pillar portion (first pillar portion) 61 shown in FIG. 17 or FIG. 18. Further, similar to the first pillar portion 61, in order to facilitate the separation operation with respect to the shaped article 40, a recess may be provided at the connection portion of the second pillar portion 65 with respect to the shaped article 40.

[0086] Further, in FIG. 25, the first pillar portion 61, the roof portion 62, the wall portion 63, the floor portion 64, and the second pillar portion 65 are connected to each other and integrally formed, but they may be separated via a gap. Further, the first pillar portion 61 and the shaped article 40, and the second pillar portion 65 and the shaped article 40 may also be connected to each other or may be separated via a gap.

[0087] <The 12th Embodiment of the Present Invention> FIG. 26 is a side view of the shaped article 40 and the sacrificial shaped article 60 shaped by the shaping method according to the 12th embodiment of the present invention.

[0088] In the 12th embodiment of the present invention, the sacrificial shaped article 60 does not have the wall portion 63 and the second pillar portion 65, and has only the first pillar portion 61, the roof portion 62, and the floor portion 64.

[0089] Since the bed portion 64 is not connected to the shaped object 40, a gap d3 is present between the bed portion 64 and the shaped object 40. Also, the shaping material 20 is present in the gap d3.

[0090] In this case, when the drying process is performed, it is considered that the resin contained in the bed portion 64 moves to the shaped object 40 through the shaping material 20 between the bed portion 64 and the shaped object 40. Thereby, the lower part of the shaped object 40 is replenished with resin. On the other hand, in the upper part of the shaped object 40, since the resin moves to the roof portion 62 through the first pillar portion 61, the amount of resin is reduced. Thereby, the variation in the resin amount between the upper and lower parts of the shaped object 40 is suppressed. Therefore, also in this case, it is considered that deformation due to resin segregation can be effectively suppressed.

[0091] Also in the fifth to twelfth embodiments of the present invention, similar to the first embodiment of the present invention, at least two or more of the plurality of pillar portions 61 may be in contact with each other and shaped. Further, a sacrificial shaped object 60 may be shaped above the roof portion 62. Furthermore, although the height of the plurality of pillar portions 61 is greater than the thickness of the roof portion 62, it is not limited thereto, and the height of the plurality of pillar portions 61 and the thickness of the roof portion 62 may be made equal, or the thickness of the roof portion 62 may be made greater than the height of the pillar portion 61. The heights of the plurality of pillar portions 61 may be made different from each other.

[0092] <The 13th Embodiment of the Present Invention> FIG. 27 is a side view of the shaped object 40 and the sacrificial shaped object 60 shaped by the shaping method according to the 13th embodiment of the present invention.

[0093] In the 13th embodiment of the present invention, the sacrificial shaped object 60 has only the roof portion 62. The roof portion 62 is disposed above the shaped object 40. That is, the roof portion 62 is disposed such that at least a part of the roof portion 62 overlaps the shaped object 40 when viewed from the vertical direction.

[0094] Since the roof portion 62 is not connected to the shaped object 40, a gap d4 is present between the roof portion 62 and the shaped object 40. Also, the shaping material 20 is present in the gap d4.

[0095] In this case, when the drying process is performed, it is considered that the resin in the molded object 40 moves to the roof portion 62 through the molding material 20 between the roof portion 62 and the molded object 40. Thereby, it is considered that the amount of resin gathering at the upper part of the molded object 40 can be reduced, and deformation due to resin segregation can be suppressed.

[0096] The sizes of the gaps d1, d2, d3, d4 in FIGS. 20, 21, 22, 26, and 27 can be appropriately changed, but are preferably 10 mm or less, and preferably about 20 mm at maximum.

[0097] <The molding process according to another embodiment of the present invention> Subsequently, the molding process according to each embodiment other than the first embodiment of the present invention will be described.

[0098] First, in each of the embodiments shown in FIGS. 16 to 22, as in the first embodiment of the present invention, the sacrificial molded object 60 includes a column portion (first column portion) 61 and a roof portion 62 disposed above the molded object 40. Therefore, the molding process is basically the same as the molding process according to the first embodiment of the present invention. That is, as shown in FIG. 13, first, after the molded object 40 is molded, the column portion (first column portion) 61 is molded, and then the roof portion 62 is molded.

[0099] FIG. 28 is a flowchart showing the shaping process according to the embodiment of FIG. 23. As in the embodiment of FIG. 23, when the sacrificial shaped object 60 includes the wall portion 63, since the wall portion 63 is located on the side of the shaped object 40, as shown in FIG. 28, when the shaped object 40 is shaped, the shaping of the wall portion 63 is also performed accordingly. That is, for the portions of the shaped object 40 and the wall portion 63 at the same height, the shaping liquid 10 is applied to the same powder layer 31, whereby the respective shaping layers 30 of the shaped object 40 and the wall portion 63 are formed. Then, the shaping layers 30 of the shaped object 40 and the wall portion 63 are laminated, and the shaped object 40 and the wall portion 63 are shaped. When a part of the wall portion 63 is at a position lower than the shaped object 40, the shaping of the portion at a position lower than the shaped object 40 is performed first, and then the shaping of the other portion of the wall portion 63 and the shaped object 40 is performed. Conversely, when a part of the shaped object 40 is at a position lower than the wall portion 63, the shaping of the portion at a position lower than the wall portion 63 is performed first, and then the shaping of the other portion of the shaped object 40 and the wall portion 63 is performed.

[0100] When the shaping of the shaped object 40 and the wall portion 63 is completed, subsequently, the shaping of the column portion (first column portion) 61 is performed, and then the shaping of the roof portion 62 is performed. When a part of the wall portion 63 is at the same height as the column portion 61, the shaping of the wall portion 63 is also performed together with the shaping of the column portion 61. In this way, the shaping of the sacrificial shaped object 60 including the wall portion 63 is performed.

[0101] FIG. 29 is a flowchart showing the shaping process of the embodiment of FIG. 24. As in the embodiment of FIG. 24, when the sacrificial shaped object 60 includes the floor portion 64, as shown in FIG. 29, first, the shaping of the floor portion 64 is performed. Then, when the shaping of the floor portion 64 is completed, the shaping of the shaped object 40, the wall portion 63, the column portion (first column portion) 61, and the roof portion 62 are sequentially performed. Since the shaping of the portions other than the floor portion 64 is the same as that in the embodiment of FIG. 23, detailed description thereof is omitted.

[0102] FIG. 30 is a flowchart showing the modeling process of the embodiment of FIG. 25. When the sacrificial model 60 includes the column part (second column part) 65 between the floor part 64 and the model 40 as in the embodiment of FIG. 25, as shown in FIG. 30, after the modeling of the floor part 64 is completed, the modeling of the column part (second column part) 65 is performed. When a part of the wall part 63 is at the same height as the column part (second column part) 65, the modeling of the wall part 63 is also performed together with the modeling of the column part (second column part) 65. Then, when the modeling of the column part (second column part) 65 is completed, the modeling of the model 40 and the wall part 63, the modeling of the column part (first column part) 61, and the modeling of the roof part 62 are sequentially performed.

[0103] FIG. 31 is a flowchart showing the modeling process of the embodiment of FIG. 26. When the sacrificial model 60 includes only the roof part 62, the column part (first column part) 61, and the floor part 64 as in the embodiment of FIG. 26, as shown in FIG. 31, after the modeling of the floor part 64 is performed, the modeling of the model 40 is performed, and then, the modeling of the column part (first column part) 61 and the modeling of the roof part 62 are sequentially performed.

[0104] FIG. 31 is a flowchart showing the modeling process of the embodiment of FIG. 27. In the case of the embodiment of FIG. 27, since the sacrificial model 60 includes only the roof part 62, as shown in FIG. 32, after the modeling of the model 40 is performed, the modeling of the roof part 62 is performed.

[0105] As described above, the modeling process according to each embodiment of the present invention is performed.

[0106] <Verification test> Subsequently, a verification test for confirming the effects of the present invention will be described. FIG. 33 is a diagram showing the results of the verification test for confirming the effects of the present invention.

[0107] In the verification test, the model 40 modeled together with the sacrificial model 60 and the model 40 not modeled together with the sacrificial model 60 were dried after modeling, and the ratio of the upper resin to the lower part of each model 40 after the drying process was calculated. The resin ratio can be quantitatively calculated, for example, by thermal analysis or the like.

[0108] In FIG. 33, Example 1 of the present invention is an example in which the sacrificial object 60 shown in FIG. 11 includes a column part (first column part) 61 and a roof part 62, and Example 2 of the present invention is an example in which the sacrificial object 60 shown in FIG. 27 includes only the roof part 62. On the other hand, in the comparative example, the sacrificial object 60 is not formed, and only the object 40 is formed.

[0109] As shown in FIG. 33, in the comparative example, the ratio of the upper resin to the lower part of the object 40 exceeded 300 [%], resulting in significant resin segregation. On the other hand, in the cases of Example 1 and Example 2 of the present invention, the ratio of the upper resin to the lower part of the object 40 was less than 200 [%], and resin segregation was suppressed. In particular, in Example 1 of the present invention, resin segregation was more effectively suppressed.

[0110] Therefore, when the object 40 and the sacrificial object 60 are formed in the forming process as in each example of the present invention, it can be said that resin segregation of the object 40 after drying can be suppressed as compared with the comparative example in which the sacrificial object 60 is not formed. Further, particularly in Example 1 of the present invention, since resin segregation was effectively suppressed, it can be said that it is preferable that the roof part 62 is connected to the object 40 via the column part 61 in order to suppress resin segregation. This is presumably because the resin in the object 40 easily moves to the roof part 62 via the column part 61.

[0111] <Configuration of control unit and object data creation device> Subsequently, the configuration of the control unit and the object data creation device of the forming system according to each embodiment of the present invention will be described.

[0112] FIG. 34 is a block diagram showing an example of the control unit 500 and the object data creation device 600 of the forming system 1000 according to each embodiment of the present invention.

[0113] As shown in FIG. 34, the forming system 1000 includes a control unit 500 and an object data creation device 600.

[0114] The control unit 500 includes a CPU 501 (Central Processing Unit), a ROM 502 (Read Only Memory), and a RAM 503 (Random Access Memory). The ROM 502 stores a program for causing the shaping data creation device 600 to perform a process of creating shaping data when shaping the shaped object 40 and the sacrificial shaped object 60, and other fixed data. The RAM 503 has a function of temporarily storing shaping data and the like.

[0115] The shaping data creation device 600 is a computer or the like, and creates shaping data obtained by slicing the shaped object 40 and the sacrificial shaped object 60 for each shaping layer 30. The control unit 500 receives the shaping data from the shaping data creation device 600, and controls the shaping operation for each shaping layer 30 based on the shaping data. Note that the shaping data creation device 600 may be separate from or integrated with the shaping device 100. Also, the control unit 500 may be inside or outside the shaping device 100.

[0116] As described above, the embodiments of the present invention have been described. However, the shaping method, shaping system, and program for executing the shaping method according to the present invention are not limited to the above embodiments, and can be appropriately designed and changed without departing from the gist of the invention.

[0117] In the above embodiment, the case where one shaped object 40 and the sacrificial shaped object 60 arranged around it are shaped in the shaping tank 22 has been described as an example. However, the first shaping step of shaping the shaped object 40 and the second shaping step of shaping the sacrificial shaped object 60 may be performed a plurality of times. FIG. 35 is a diagram showing an example in which a plurality of shaped objects 40 and sacrificial shaped objects 60 are shaped in the shaping tank 22 according to an embodiment of the present invention. As shown in the example shown in FIG. 35, the first shaping step and the second shaping step may be performed a plurality of times to shape a plurality of shaped objects 40 and sacrificial shaped objects 60 in the shaping tank 22. FIG. 35 shows an example in which four sacrificial shaped objects 60 corresponding to the shaped object 40 are shaped, but the number of shaped objects can be appropriately changed. The shaped objects 40 may have the same shape or one or more of them may be different.

[0118] FIG. 36 is a diagram showing an example in which a plurality of shaped objects 40 and sacrificial shaped objects 60 are shaped in the shaping tank 22 according to another embodiment of the present invention. Differences from FIG. 35 will be described, and descriptions of the same parts will be omitted as appropriate. FIG. 36(a) is a diagram showing the roof portion 62 and the connecting roof portion 62b, FIG. 36(b) is a diagram in which a part of the roof portion 62 is omitted, and FIG. 36(c) is a diagram in which the connecting roof portion 62b is provided and the roof portion 62 is omitted. For the sake of simplicity, the case where four shaped objects 40a, 40b, 40c, and 40d are shaped will be described. The number and shape of the shaped objects can be appropriately changed as in FIG. 35.

[0119] In FIG. 36(a), the shaped object 40b is shaped in the horizontal direction of the shaped object 40a. The sacrificial shaped object 60 is shaped above the shaped object 40a and the shaped object 40b. Specifically, a plurality of pillar portions 61 are shaped above the shaped object 40a, and a roof portion 62 is shaped above the plurality of pillar portions 61. Similarly, a plurality of pillar portions 61 are shaped above the shaped object 40b as in the shaped object 40a, and a roof portion 62 is shaped above the pillar portion 61. Above the sacrificial shaped object 60 corresponding to each of the shaped object 40a and the shaped object 40b, the shaped object 40c and the shaped object 40d are further shaped. Similar to the shaped object 40a and the shaped object 40b, a plurality of pillar portions 61 are also shaped above the shaped object 40c and the shaped object 40d, but a connecting roof portion 62b is shaped above the plurality of pillar portions 61. The connecting roof portion 62b is a common member via a plurality of pillar portions 61, different from the roof portion 62 of the shaped object 40a and the shaped object 40b.

[0120] In FIG. 36(b), different from FIG. 36(a), a plurality of pillar portions 61 are shaped above the shaped object 40a and the shaped object 40b respectively, but the shaping of the roof portion 62 is omitted above the plurality of pillar portions 61. That is, the shaped object 40c and the shaped object 40d are shaped above the plurality of pillar portions 61. Also, a plurality of pillar portions 61 are shaped above the shaped object 40c and the shaped object 40d, and a roof portion 62 is shaped above the plurality of pillar portions 61. Different from FIG. 36(a), in FIG. 36(b), the connecting roof portion 62b is not connected to the plurality of pillar portions 61 above the shaped object 40c and the shaped object 40d.

[0121] Unlike FIG. 36(a), a plurality of column portions 61 are respectively formed above the shaped objects 40a and 40b in FIG. 36(c), but the formation of the roof portion 62 is omitted above the plurality of column portions 61. That is, above the plurality of column portions 61, the shaped objects 40c and 40d are formed. Further, unlike FIG. 36(b), in FIG. 36(c), a plurality of column portions 61 are formed above the shaped objects 40c and 40d, and a connecting roof portion 62b is formed above the plurality of column portions 61.

[0122] In addition, as long as the shaping method according to the present invention includes at least a shaping step, it does not have to go through the steps of a drying step, an excess powder removing step, a sacrificial shaped object removing step (removing step), a degreasing step, and a sintering step, or it may include one or more of these steps.

[0123] In the above embodiment, the case where the shaping method according to the present invention is applied to a BJ-type shaping system has been described as an example, but this description does not limit the application of the present invention to other systems. Therefore, as long as the deformation of the shaped object can be suppressed using the present invention, the present invention may be applied to a shaping system of a method other than the BJ method.

[0124] In addition, summarizing the aspects of the present invention described above, the present invention includes at least the following aspects.

[0125] [First aspect] The first aspect is a shaping method including a first shaping step of shaping a shaped object and a second shaping step of shaping a sacrificial shaped object above the shaped object, wherein the sacrificial shaped object includes a plurality of column portions and a roof portion formed above the column portions.

[0126] [Second aspect] The second aspect is the first aspect, wherein after the column portions are shaped, the roof portion is shaped.

[0127] [Third aspect] In the third aspect, in the first or second aspect, the roof portion is connected to at least one of the column portions.

[0128] [Fourth Aspect] In the fourth aspect, in the first or second aspect, the roof portion is connected to all of the column portions.

[0129] [Fifth Aspect] In the fifth aspect, in any one of the first to fourth aspects, the column portion has a concave portion.

[0130] [Sixth Aspect] In the sixth aspect, in any one of the first to fifth aspects, the sacrificial shaped object includes a wall portion shaped on the side of the shaped object.

[0131] [Seventh Aspect] In the seventh aspect, in any one of the first to sixth aspects, the sacrificial shaped object includes a floor portion shaped below the shaped object.

[0132] [Eighth Aspect] In the eighth aspect, in the seventh aspect, the sacrificial shaped object includes a plurality of column portions shaped between the floor portion and the shaped object.

[0133] [Ninth Aspect] In the ninth aspect, in any one of the first to eighth aspects, the first shaping step and the second shaping step are performed a plurality of times to shape a plurality of the shaped objects and the sacrificial shaped objects.

[0134] [Tenth Aspect] In the tenth aspect, in any one of the first to ninth aspects, the shaping method includes a powder layer forming step of forming a powder layer containing a shaping material, and a shaping liquid applying step of applying a shaping liquid to the powder layer.

[0135] [Eleventh Aspect] In the eleventh aspect, in the tenth aspect, the shaping liquid contains a resin.

[0136] [Aspect 12] Aspect 12 includes a drying step of drying the shaped object and the sacrificial shaped object in any one of Aspects 1 to 11.

[0137] [Aspect 13] Aspect 13 includes a removing step of removing the sacrificial shaped object after the drying step in Aspect 12.

[0138] [Aspect 14] Aspect 14 includes a sintering step of sintering the shaped object after the removing step in Aspect 13.

[0139] [Aspect 15] Aspect 15 is a shaping method including a layer forming step of forming a powder layer containing a shaping material and a shaping liquid applying step of applying a shaping liquid to the powder layer, the shaping method including a first shaping step of shaping a shaped object and a second shaping step of shaping a sacrificial shaped object above the shaped object.

[0140] [Aspect 16] Aspect 16 is a shaping system for shaping a shaped object and a sacrificial shaped object that are dried after shaping, including a first shaping step of shaping the shaped object and a second shaping step of shaping the sacrificial shaped object above the shaped object, the sacrificial shaped object including a plurality of column parts and a roof part shaped above the column parts.

[0141] [Aspect 17] Aspect 17 is a program for causing a shaping data creation device to perform a process of creating shaping data when shaping the shaped object and the sacrificial shaped object by the shaping method according to any one of Aspects 1 to 15.

Explanation of Signs

[0142] 9 Resin 10 Shaping liquid 20 Shaping material 40 Shaped object 60 Sacrificial shaped object 61 Column part (first column part) 61a Concave part 62 Roof part 63 Wall part 64 Floor part 65 Column part (second column part) 1000 Shaping system

Prior art documents

Patent documents

[0143]

Patent Document 1

Claims

1. A first shaping step of shaping an object, A second shaping step of shaping a sacrificial object above the object, and The sacrificial object, Includes a plurality of column parts, And a roof part shaped above the column part, and is characterized in that it is a shaping method.

2. The shaping method according to claim 1, wherein the roof part is shaped after the column part is shaped.

3. The shaping method according to claim 1, wherein the roof part is connected to at least one of the column parts.

4. The shaping method according to claim 1, wherein the roof part is connected to all of the column parts.

5. The shaping method according to claim 1, wherein the column part has a concave part.

6. The shaping method according to claim 1, wherein the sacrificial object includes a wall part shaped on the side of the object.

7. The shaping method according to claim 1, wherein the sacrificial object includes a floor part shaped below the object.

8. The shaping method according to claim 7, wherein the sacrificial object includes a plurality of column parts shaped between the floor part and the object.

9. The shaping method according to claim 1, wherein the first shaping step and the second shaping step are performed a plurality of times to shape a plurality of the objects and the sacrificial objects.

10. The shaping method, Includes a powder layer forming step of forming a powder layer containing a shaping material, And a shaping liquid applying step of applying a shaping liquid to the powder layer, and is the shaping method according to claim 1.

11. The shaping method according to claim 10, wherein the shaping liquid contains a resin.

12. The shaping method according to claim 1, including a drying step of drying the object and the sacrificial object.

13. The shaping method according to claim 12, including a removing step of removing the sacrificial object after the drying step.

14. The shaping method according to claim 13, including a sintering step of sintering the object after the removing step.

15. A layer forming step of forming a powder layer containing a shaping material, And a shaping liquid applying step of applying a shaping liquid to the powder layer, and is a shaping method, Including a first shaping step of shaping an object, And a second shaping step of shaping a sacrificial object above the object, and is characterized in that it is a shaping method.

16. A shaping system for shaping an object and a sacrificial object that are dried after shaping, Including a first shaping step of shaping the object, And a second shaping step of shaping the sacrificial object above the object, The sacrificial object, Includes a plurality of column parts, A shaping system, characterized by including a roof portion shaped above the column portion.

17. A program for causing a shaping data creation device to perform a process of creating shaping data when shaping the shaped object and the sacrificial shaped object by the shaping method according to Claim 1 or 15.

Images