Manufacturing method of three-dimensional molding

Abstract

To provide a technique capable of shortening molding time in testing molding of a three-dimensional molding.SOLUTION: Provided herein is a three-dimensional molding manufacturing method for manufacturing a three-dimensional molding by laminating layers through discharging a molding material from a discharge part toward a stage. This manufacturing method includes: a first step of displaying a three-dimensional molding on a display based on shape data representing a three-dimensional shape of the three-dimensional molding; a second step of determining a molding target region among the three-dimensional molding displayed on the display based on a first region that defines a range of a face perpendicular to a lamination direction of the layers; a third step of generating first molding data based on data of a portion corresponding to the molding target region among the shape data, or generating third molding data by selecting data on a portion corresponding to the molding target region from second molding data generated based on the shape data; and a fourth step of molding the three-dimensional molding based on the first molding data or the third molding data.SELECTED DRAWING: Figure 6

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a method for manufacturing a three-dimensional object by discharging a modeling material from a discharge unit toward a stage to laminate layers.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When a three-dimensional object is test-modeled to confirm the actual modeled state of a part of the three-dimensional object, such as an overhang part or a support structure, parts other than the parts that need to be confirmed are also modeled, resulting in a problem that the modeling time becomes long, or a problem that the amount of modeling material used increases. Such problems are particularly prominent when test-modeling a three-dimensional object of a large size.

Means for Solving the Problems

[0005] According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object by discharging a modeling material from a discharge unit toward a stage and laminating layers to manufacture the three-dimensional object. This manufacturing method includes a first step of displaying the three-dimensional object on a display unit based on shape data representing the three-dimensional shape of the three-dimensional object, and a first area defining a range of a plane perpendicular to the lamination direction of the layers. A second step of determining a modeling target area among the three-dimensional objects displayed on the display unit based on the above, and generating first modeling data based on data of a portion corresponding to the modeling target area among the shape data, or selecting data of a portion corresponding to the modeling target area from second modeling data generated based on the shape data to generate third modeling data. And a fourth step of modeling a three-dimensional object based on the first modeling data or the third modeling data.

Brief Description of the Drawings

[0006]

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Modes for Carrying Out the Invention

[0007] A. First Embodiment: FIG. 1 is an explanatory drawing showing the schematic configuration of a three-dimensional modeling system 10 in the first embodiment. In FIG. 1, arrows indicating the X, Y, and Z directions orthogonal to each other are shown. The X direction and the Y direction are directions parallel to the horizontal plane, and the Z direction is a direction along the vertically upward direction. The arrows indicating the X, Y, and Z directions are also appropriately shown in other figures so that the illustrated directions correspond to those in FIG. 1. In the following description, when specifying the direction, the direction indicated by the arrow in each figure is defined as “+” and the opposite direction as “−”, and positive and negative signs are used together in the direction notation. Hereinafter, the +Z direction is also referred to as “up” and the -Z direction as “down”.

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

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

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

[0011] The material supply unit 20 supplies the raw material MR to the plasticizing unit 30. The material supply unit 20 is constituted by, for example, a hopper that stores the raw material MR. The material supply unit 20 is connected to the plasticizing unit 30 via a communication path 22. The raw material MR is introduced into the material supply unit 20 in the form of powder or pellets. As the raw material MR, for example, thermoplastic resins such as acrylonitrile-butadiene-styrene resin (ABS), polypropylene resin (PP), polyethylene resin (PE), and polyacetal resin (POM) are used.

[0012] The plasticizing unit 30 plasticizes the raw material MR supplied from the material supply unit 20 to generate a paste-like shaping material that exhibits fluidity, and guides it to the discharge unit 60. In the present embodiment, "plasticization" is a concept including melting, and is to change from a solid state to a state having fluidity. Specifically, in the case of a material in which glass transition occurs, plasticization is to raise the temperature of the material above the glass transition point. In the case of a material in which glass transition does not occur, plasticization is to raise the temperature of the material above the melting point.

[0013] The plasticizing unit 30 has a screw case 31, a drive motor 32, a flat screw 40, and a barrel 50. The flat screw 40 is also called a rotor or a scroll. The barrel 50 is also called a screw opposing surface.

[0014] The flat screw 40 is housed in the screw case 31. The upper surface 47 of the flat screw 40 is connected to the drive motor 32, and the flat screw 40 rotates within the screw case 31 by the rotational driving force generated by the drive motor 32. The drive motor 32 operates under the control of the control unit 300. Note that the flat screw 40 may be driven by the drive motor 32 via a speed reducer.

[0015] Figure 2 is a perspective view showing a schematic configuration on the lower surface 48 side of the flat screw 40. The flat screw 40 shown in Figure 2 is shown with the positional relationship between the upper surface 47 and the lower surface 48 shown in Figure 1 reversed in the vertical direction for ease of understanding of the technology. The flat screw 40 has a substantially cylindrical shape with a length in the axial direction, which is the direction along its central axis, smaller than the length in the direction perpendicular to the axial direction. The flat screw 40 is arranged such that its rotation axis RX, which is the center of rotation, is parallel to the Z direction.

[0016] On the lower surface 48 of the flat screw 40, which is a plane intersecting the rotation axis RX, a spiral groove portion 42 is formed. The communication passage 22 of the above-described material supply unit 20 communicates with the groove portion 42 from the side surface of the flat screw 40. In the present embodiment, the groove portion 42 is formed in three sections separated by ridge portions 43. Note that the number of groove portions 42 is not limited to three, and may be one, or two or more. The groove portion 42 is not limited to a spiral shape, and may be a helical shape, an involute curve shape, or a shape extending in an arc from the central portion toward the outer periphery.

[0017] As shown in Figure 1, the lower surface 48 of the flat screw 40 faces the upper surface 52 of the barrel 50, and a space is formed between the groove portion 42 on the lower surface 48 of the flat screw 40 and the upper surface 52 of the barrel 50. Raw material MR is supplied from the material supply unit 20 through the material inlet 44 shown in Figure 2 into this space between the flat screw 40 and the barrel 50.

[0018] The barrel 50 is embedded with a barrel heater 58 for heating the raw material MR supplied into the groove 42 of the rotating flat screw 40. A communication hole 56 is provided at the center of the barrel 50.

[0019] Figure 3 is a schematic plan view showing the upper surface 52 side of the barrel 50. A plurality of guide grooves 54 are formed on the upper surface 52 of the barrel 50, which are connected to the communication hole 56 and extend spirally from the communication hole 56 toward the outer periphery. Note that one end of the guide groove 54 may not be connected to the communication hole 56. Also, the guide groove 54 can be omitted.

[0020] The raw material MR supplied into the groove 42 of the flat screw 40 is plasticized in the groove 42 and flows along the groove 42 by the rotation of the flat screw 40, and is guided as a modeling material to the central portion 46 of the flat screw 40. The paste-like modeling material that has flowed into the central portion 46 and exhibits fluidity is supplied to the discharge portion 60 through the communication hole 56 provided at the center of the barrel 50. Note that in the modeling material, not all types of substances constituting the modeling material need to be plasticized. The modeling material only needs to be converted into a state having fluidity as a whole by plasticizing at least some types of substances among the substances constituting the modeling material.

[0021] The discharge portion 60 in FIG. 1 includes a nozzle 61 for discharging the modeling material, a flow path 65 of the modeling material provided between the flat screw 40 and the nozzle opening 62, and a discharge control portion 77 for controlling the discharge of the modeling material.

[0022] The nozzle 61 is connected to the communication hole 56 of the barrel 50 through the flow path 65. The nozzle 61 discharges the modeling material generated in the plasticizing portion 30 from the nozzle opening 62 at the tip toward the stage 210.

[0023] The discharge control portion 77 includes a discharge adjustment portion 70 for opening and closing the flow path 65, and a suction portion 75 for sucking and temporarily storing the modeling material.

[0024] The discharge adjustment unit 70 is provided in the flow path 65 and changes the opening degree of the flow path 65 by rotating within the flow path 65. In the present embodiment, the discharge adjustment unit 70 is constituted by a valve. The discharge adjustment unit 70 is driven by a first drive unit 74 under the control of the control unit 300. The first drive unit 74 is constituted by, for example, a stepping motor. The control unit 300 can adjust the flow rate of the modeling material flowing from the plasticizing unit 30 to the nozzle 61, that is, the discharge amount of the modeling material discharged from the nozzle 61, by controlling the rotation angle of the discharge adjustment unit 70 using the first drive unit 74. The discharge adjustment unit 70 can adjust the discharge amount of the modeling material and can control the on / off of the outflow of the modeling material.

[0025] The suction unit 75 is connected in the flow path 65 between the discharge adjustment unit 70 and the nozzle opening 62. When the discharge of the modeling material from the nozzle 61 stops, the suction unit 75 temporarily sucks the modeling material in the flow path 65, thereby suppressing the trailing phenomenon in which the modeling material hangs from the nozzle opening 62 like a thread. In the present embodiment, the suction unit 75 is constituted by a plunger. The suction unit 75 is driven by a second drive unit 76 under the control of the control unit 300. The second drive unit 76 is constituted by, for example, a stepping motor or a rack and pinion mechanism that converts the rotational force of the stepping motor into the translational movement of the plunger.

[0026] The stage 210 is arranged at a position facing the nozzle opening 62 of the nozzle 61. In the first embodiment, the modeling surface 211 of the stage 210 facing the nozzle opening 62 of the nozzle 61 is arranged to be parallel in the X and Y directions, that is, the horizontal direction. The stage 210 is provided with a stage heater 212 for suppressing the rapid cooling of the modeling material discharged onto the stage 210. The stage heater 212 is controlled by the control unit 300.

[0027] The moving mechanism 230 changes the relative position between the stage 210 and the nozzle 61 under the control of the control unit 300. In the present embodiment, the position of the nozzle 61 is fixed, and the moving mechanism 230 moves the stage 210. The moving mechanism 230 is constituted by a three-axis positioner that moves the stage 210 in three axial directions of the X, Y, and Z directions by the driving force of three motors. In this specification, unless otherwise specified, the movement of the nozzle 61 means moving the nozzle 61 or the discharge unit 60 relative to the stage 210.

[0028] In other embodiments, instead of the configuration in which the moving mechanism 230 moves the stage 210, a configuration may be adopted in which the moving mechanism 230 moves the nozzle 61 relative to the stage 210 with the position of the stage 210 fixed. Further, a configuration in which the moving mechanism 230 moves the stage 210 in the Z direction and moves the nozzle 61 in the X and Y directions, or a configuration in which the moving mechanism 230 moves the stage 210 in the X and Y directions and moves the nozzle 61 in the Z direction may be adopted. Even with these configurations, the relative positional relationship between the nozzle 61 and the stage 210 can be changed.

[0029] In FIG. 1, only one shaping unit 110 is shown, but the three-dimensional shaping apparatus 100 may include a plurality of shaping units 110. By providing a plurality of shaping units 110, different types of shaping materials can be discharged from each shaping unit 110. Therefore, for example, the main body of the shaped object and the support structure for supporting the shaped object can be shaped with different types of shaping materials.

[0030] The control unit 300 is a control device that controls the operation of the entire three-dimensional shaping apparatus 100. The control unit 300 is composed of a computer including one or a plurality of processors 310, a storage device 320 including a main storage device and an auxiliary storage device, and an input / output interface that performs input / output of signals with the outside. The processor 310 controls the shaping unit 110 and the moving mechanism 230 according to the shaping data acquired from the information processing device 400 by executing the program stored in the storage device 320, and shapes a shaped object on the stage 210. Note that the control unit 300 may be realized by a configuration combining circuits instead of being composed of a computer.

[0031] FIG. 4 is an explanatory diagram schematically showing a state in which the three-dimensional shaping apparatus 100 shapes a shaped object. In the three-dimensional shaping apparatus 100, as described above, the raw material MR in a solid state is plasticized to generate the shaping material MM. The control unit 300 discharges the shaping material MM from the nozzle 61 while changing the position of the nozzle 61 with respect to the stage 210 in the direction along the shaping surface 211 of the stage 210 while maintaining the distance between the shaping surface 211 of the stage 210 and the nozzle 61. The shaping material MM discharged from the nozzle 61 is continuously deposited in the moving direction of the nozzle 61.

[0032] The control unit 300 repeatedly moves the nozzle 61 to form a layer ML. After forming one layer ML, the control unit 300 relatively moves the position of the nozzle 61 with respect to the stage 210 in the Z direction, which is the stacking direction of the layers ML. Then, the shaped object is shaped by further stacking the layer ML on the layer ML formed so far.

[0033] When, for example, the control unit 300 moves the nozzle 61 in the Z direction when a layer ML of one layer is completed, or when there are a plurality of modeling regions independent of each other in each layer, it may temporarily interrupt the discharge of the modeling material from the nozzle 61. In this case, the discharge adjustment unit 70 closes the flow path 65 to stop the discharge of the modeling material MM from the nozzle opening 62, and the suction unit 75 temporarily sucks the modeling material in the nozzle 61. After changing the position of the nozzle 61, the control unit 300 resumes the deposition of the modeling material MM from the changed position of the nozzle 61 by discharging the modeling material in the suction unit 75 and opening the flow path 65 by the discharge adjustment unit 70.

[0034] FIG. 5 is an explanatory diagram showing a schematic configuration of the information processing apparatus 400. The information processing apparatus 400 is configured as a computer in which a CPU 410, a memory 420, a storage device 430, a communication interface 440, and an input / output interface 450 are interconnected by a bus 460. An input device 470 such as a keyboard and a mouse and a display unit 480 such as a liquid crystal display are connected to the input / output interface 450. The information processing apparatus 400 is connected to the control unit 300 of the three-dimensional modeling apparatus 100 via the communication interface 440.

[0035] The CPU 410 functions as a data generation unit 411 by executing a program stored in the storage device 430. The data generation unit 411 generates modeling data used by the three-dimensional modeling apparatus 100 to model a three-dimensional object.

[0036] FIG. 6 is a flowchart of a modeling process executed in the three-dimensional modeling system 10. The modeling process is a process for realizing a method for manufacturing a three-dimensional object. The processes of steps S10 to S50 shown in FIG. 6 are executed in the information processing apparatus 400, and the processes of steps S60 to S70 are executed in the three-dimensional modeling apparatus 100.

[0037] In step S10, the data generation unit 411 of the information processing apparatus 400 acquires shape data representing the three-dimensional shape of a three-dimensional object from another computer, a recording medium, or the storage device 430. The shape data is data representing the shape of a three-dimensional object created using three-dimensional CAD software, three-dimensional CG software, or the like. As the shape data, for example, data in the STL format, AMF format, or the like is used.

[0038] In step S20, the data generation unit 411 displays the three-dimensional shape of the three-dimensional object on the display unit 480 based on the shape data acquired in step S10. Step S20 corresponds to the first step in the present disclosure.

[0039] FIGS. 7 and 8 are diagrams showing examples in which the three-dimensional shape of a three-dimensional object is displayed on the display unit 480. FIGS. 7 and 8 each show an example in which the three-dimensional shape of a donut-shaped three-dimensional object MD1 is displayed. FIG. 7 shows a display example of the three-dimensional object MD1 viewed from above. FIG. 8 shows a display example of the three-dimensional object MD1 viewed obliquely from above.

[0040] In step S30 of FIG. 6, the data generation unit 411 determines the first region AR1. The first region AR1 is a region that defines the range of a plane perpendicular to the stacking direction, that is, a plane along the X-Y plane. In the first embodiment, the data generation unit 411 determines the first region AR1 by receiving a specification of the range of the first region AR1 from the user via the input device 470. In FIG. 7, the range shown by the rectangle is the first region AR1. FIG. 8 shows a display example in which the range of the first region AR1 shown in FIG. 7 is viewed in three dimensions. As shown in FIG. 8, in the first embodiment, when the range of the first region AR1 is viewed in three dimensions, the range is columnar. The first region AR1 is specified, for example, when the user numerically inputs coordinates representing the range of the first region AR1 using a keyboard or drags and selects the range of the first region AR1 by operating a mouse.

[0041] In step S40, the data generation unit 411 determines the modeling target region MA. The modeling target region MA is a region of the three-dimensional model MD1 represented by the shape data that is actually modeled by the three-dimensional modeling apparatus 100. In the first embodiment, the first region AR1 received in step S30 is determined as the modeling target region MA as it is. Steps S30 and S40 correspond to the second step in the present disclosure. FIG. 9 shows an example in which a portion MD2 within the modeling target region MA of the three-dimensional model MD1 is displayed on the display unit 480.

[0042] In step S50, the data generation unit 411 generates modeling data. Step S50 corresponds to the third step in the present disclosure. In the first embodiment, the data generation unit 411 generates modeling data based on the data of the portion corresponding to the modeling target region MA among the shape data representing the shape of the three-dimensional model MD1. The modeling data generated in the first embodiment is referred to as first modeling data. Hereinafter, the portion corresponding to the modeling target region among the three-dimensional model is referred to as the "modeling target portion".

[0043] FIG. 10 is an explanatory diagram of a method for generating first modeling data. On the left side of the figure, a cross-section of the modeling target portion MP1 is shown, and on the right side of the figure, the visualized first modeling data DA1 corresponding to the cross-section is shown. In generating the first modeling data DA1, the data generation unit 411 generates the first modeling data DA1 by generating modeling paths for an outer shell region SA representing the outer shell of the modeling target portion MP1 and an infill region IA existing inside the outer shell region SA, respectively. More specifically, the data generation unit 411 analyzes the shape data acquired in step S10 and slices the modeling target portion MP1 into a plurality of layers along the X-Y plane. Then, the data generation unit 411 determines modeling paths for forming the outer shell region SA and the infill region IA existing inside the outer shell region SA for each layer to model them. The modeling path is path information representing the movement path of the nozzle 61. The path information includes data representing a plurality of linear movement paths. Each movement path included in the path information includes discharge amount information representing the discharge amount of the modeling material discharged in the movement path. The data generation unit 411 generates a modeling path by generating path information and discharge amount information for all the layers within the modeling target region MA. The line width of the modeling path is determined based on the length of the movement path represented by the modeling path and the discharge amount of the modeling material discharged in the movement path. In FIG. 10, as the modeling path for modeling the outer shell region SA, two rounds of modeling paths along the contour of the modeling target portion MP1 are shown. Also, as the modeling path for modeling the infill region IA, a concentric infill pattern with an infill rate of 100% is shown. The concentric infill pattern refers to a pattern that gradually decreases toward the center of the contour shape of the modeled object. The number of rounds of the modeling path for modeling the outer shell region SA, the infill pattern, and the infill rate for modeling the infill region IA may be arbitrarily set by the user.

[0044] The first shaping data DA1 may include support data. When the overhang portion is included in the shaping target portion MP1, the data generation unit 411 generates support data for supporting the shaping target portion from below. The overhang portion refers to a protruding portion without support below in the three-dimensional shaped object. In the present embodiment, the meaning of the overhang portion includes a bridge portion. The bridge portion refers to a bridge-shaped portion supported at both ends in the three-dimensional shaped object. The data generation unit 411 generates support data by specifying the space region below the overhang portion and generating a shaping path according to predetermined conditions for the space region.

[0045] In step S60 of FIG. 6, the control unit 300 of the three-dimensional shaping apparatus 100 acquires the first shaping data DA1 generated in step S50 from the information processing apparatus 400.

[0046] In step S70, the control unit 300 controls the discharge unit 60 and the movement mechanism 230 according to the first shaping data DA1 acquired from the information processing apparatus 400, and shapes a three-dimensional shaped object on the shaping surface 211 of the stage 210. Since the first shaping data DA1 is shaping data for shaping the shaping target portion MP1, in step S70, the portion corresponding to the shaping target region MA in the three-dimensional shaped object MD1 is shaped as the three-dimensional shaped object. Step S70 corresponds to the fourth step in the present disclosure.

[0047] In the first embodiment described above, the modeling target area MA is determined based on the first area AR1 specified by the user, and the first modeling data DA1 is generated based on the data of the part corresponding to the modeling target area MA in the shape data representing the three-dimensional shape of the three-dimensional model MD1. Then, based on the first modeling data DA1, the part corresponding to the modeling target area MA in the three-dimensional model MD1 is modeled as a three-dimensional model. Therefore, when performing a test modeling to check the actual modeling state of a part of the three-dimensional model, such as an overhang part or a support structure, the modeling of parts other than the parts that need to be checked is suppressed. Therefore, the modeling time during the test modeling can be shortened, and the amount of modeling material used can be reduced. Such an effect is particularly remarkable when performing a test modeling of a three-dimensional model of a large size.

[0048] Also, in the first embodiment, the first modeling data DA1 is generated by generating a modeling path for each of the outer shell area SA representing the outer shell of the part corresponding to the modeling target area MA in the shape data representing the three-dimensional model MD1 and the infill area IA existing inside the outer shell area SA. Therefore, the infill area IA is surrounded by the outer shell area SA, and the modeling target part MP1 in the three-dimensional model MD1 can be accurately modeled.

[0049] Also, in the first embodiment, the range of the first area AR1 is received, and the modeling target area MA is determined based on the specification. Therefore, the user can specify the first area AR1 within an arbitrary range.

[0050] Also, in the first embodiment, since a part of the three-dimensional model can be modeled without modifying the shape data representing the shape of the three-dimensional model, it is not necessary to edit the shape data using three-dimensional CAD software or three-dimensional CG software. Therefore, even in an environment without these software, a part of the three-dimensional model can be easily tested.

[0051] FIG. 11 is an explanatory diagram of another method for generating the modeling data in the first embodiment. In step S50 of the modeling process shown in FIG. 6, the data generation unit 411 may not generate a modeling path for surrounding the cutting surface CS where the three-dimensional shape of the three-dimensional model MD1 is cut by the modeling target region MA. That is, for the contour portion originally existing in the three-dimensional model MD1, the outer shell region SA is generated, and for the surface generated by being cut by the modeling target region MA, it may not be necessary to generate the outer shell region SA. In this case, for the infill region IA, a modeling path is generated in the same manner as the method shown in FIG. 10. By generating the first modeling data DA1 in this way, the outer shell region SA of the modeling target portion MP1 can be modeled with the same modeling path as when the entire three-dimensional model MD1 is modeled.

[0052] B. Second Embodiment: The configuration of the three-dimensional modeling system 10 in the second embodiment is the same as that of the three-dimensional modeling system 10 in the first embodiment. In the second embodiment, the method for generating the modeling data in step S50 of the modeling process shown in FIG. 6 is different from that in the first embodiment. Since the processing contents of steps S10 to S40 and steps S60 to S70 are the same as those in the first embodiment, only the processing content of step S50 will be described below.

[0053] FIG. 12 is an explanatory diagram of a method for generating modeling data in the second embodiment. In the second embodiment, the data generation unit 411 selects data of a portion corresponding to the modeling target region MA from the second modeling data DA2 generated based on the shape data of the three-dimensional model MD1, and generates third modeling data DA3. The modeling data generated in the second embodiment is referred to as third modeling data DA3. Specifically, first, the data generation unit 411 analyzes the shape data representing the shape of the three-dimensional model MD1, and generates second modeling data DA2 for modeling the entire three-dimensional model as shown on the left side of FIG. 12. Next, as shown on the right side of FIG. 12, the data generation unit 411 selects and extracts data of a portion corresponding to the modeling target region MA from the second modeling data DA2, thereby generating third modeling data DA3. In the process of generating the third modeling data DA3 from the second modeling data DA2, a modeling path for surrounding the cutting plane CS where the three-dimensional shape represented by the second modeling data DA2 is cut by the modeling target region MA is not generated. That is, when generating the third modeling data DA3 from the second modeling data DA2, no new modeling path is generated. In step S70 shown in FIG. 6, based on the third modeling data DA3 generated in this way, a portion corresponding to the modeling target region MA of the three-dimensional model MD1 is modeled as a three-dimensional model.

[0054] FIG. 13 is an explanatory diagram showing a method for generating a travel path TP in the second embodiment. In the process of generating the third modeling data DA3, the data generation unit 411 converts a modeling path included in data other than the portion corresponding to the modeling target region MA in the second modeling data DA2 into a travel path TP. The travel path TP is a path for moving the nozzle 61 from the discharge end position to the next discharge start position without discharging the modeling material. The data generation unit 411 converts the modeling path into the travel path TP by setting the discharge amount information of the modeling path for modeling a portion other than the portion corresponding to the modeling target region MA to zero. Note that the data generation unit 411 may configure a travel path that connects the modeling paths with the shortest distance.

[0055] In the second embodiment described above, the data of the portion corresponding to the shaping target region MA is selected from the second shaping data DA2 for shaping the entire three-dimensional shaped object MD1, thereby generating the third shaping data DA3 for shaping the shaping target portion. Therefore, the shaping target portion can be shaped by the same shaping path as when shaping the entire three-dimensional shaped object MD1. As a result, the shaping accuracy of the shaping target portion can be made close to the shaping accuracy when shaping the entire three-dimensional shaped object MD1. Also, in the second embodiment as well, similar to the first embodiment, when performing test shaping to confirm the actual shaping state of a part of the three-dimensional shaped object, the shaping of parts other than the parts that need to be confirmed is suppressed. Therefore, the amount of shaping material used during test shaping can be reduced.

[0056] Further, in the second embodiment, the third shaping data DA3 for shaping the shaping target portion can be generated by converting the shaping paths included in the data other than the portion corresponding to the shaping target region MA in the second shaping data DA2 into travel paths TP. Therefore, the third shaping data DA3 can be generated from the second shaping data DA2 by simple processing. Also, if the shaping path is converted into the travel path TP, the time required for shaping the shaping target portion can be made close to the time required for shaping the entire three-dimensional shaped object MD1. Therefore, the shaping accuracy of the shaping target portion can be made close to the shaping accuracy when shaping the entire three-dimensional shaped object.

[0057] As described above, in the second embodiment, by converting the shaping paths included in the data other than the portion corresponding to the shaping target region MA in the second shaping data DA2 into travel paths TP, the time required for shaping the shaping target portion is brought closer to the time required for shaping the entire three-dimensional shaped object MD1. On the other hand, instead of converting the shaping paths into travel paths TP, each time the shaping of each layer is completed, the nozzle 61 is made to wait at a position outside the shaping target region MA for a predetermined time, or the shaping paths are set so as to shape a columnar object called a prime pillar at a position outside the shaping target region MA, thereby the time required for shaping the shaping target portion may be brought closer to the time required for shaping the entire three-dimensional shaped object MD1. By adjusting the shaping time of each layer of the shaping target portion in this way, the temperature state of each layer during shaping can be brought closer to the temperature state when shaping the entire three-dimensional shaped object MD1. Therefore, the shaping accuracy of the shaping target portion can be brought closer to the shaping accuracy when shaping the entire three-dimensional shaped object.

[0058] In the second embodiment, as shown in FIG. 13, the shaping paths included in the data other than the portion corresponding to the shaping target region MA in the second shaping data DA2 are converted into travel paths. On the other hand, the data generation unit 411 may newly set a travel path between adjacent shaping paths at the cutting surface CS where the three-dimensional shape represented by the second shaping data DA2 is cut by the shaping target region MA. By doing so, the shaping time of the shaping target portion can be shortened.

[0059] C. Third Embodiment: The configuration of the three-dimensional shaping system 10 in the third embodiment is the same as that of the three-dimensional shaping system 10 in the first embodiment. In the first embodiment, the data generation unit 411 receives the designation of the first region AR1 from the user in step S30 of the shaping process shown in FIG. 6. On the other hand, in the third embodiment, in step S30 of FIG. 6, the data generation unit 411 analyzes the shape data representing the shape of the three-dimensional shaped object to determine the first region AR1. Since the processing contents of steps S10 to S20 and steps S40 to S70 are the same as those in the first embodiment, hereinafter, only the processing content of step S30 will be described.

[0060] FIG. 14 is a diagram showing a first region AR1 determined by the data generation unit 411. In the third embodiment, the data generation unit 411 detects, by analyzing the shape data, a region where a plurality of objects overlap in the stacking direction, and determines the detected region as the first region AR1. The range of the region automatically detected by the data generation unit 411 may be adjustable by the user within the display unit 480. FIG. 14 shows an example in which a three-dimensional model MD3 including a plurality of objects is displayed on the display unit 480, and a region where a plurality of objects overlap in the stacking direction is determined as the first region AR1. FIG. 15 shows a range in which the support structure SS is formed during the modeling of the three-dimensional model MD3 shown in FIG. 14. The data generation unit 411 determines a modeling target region MA based on the first region AR1 shown in FIG. 14, and by modeling a portion corresponding to the modeling target region MA of the three-dimensional model MD3, it is possible to confirm the peelability etc. of the support structure SS in the space sandwiched by the plurality of objects.

[0061] Note that the data generation unit 411 is not limited to a region where a plurality of objects overlap in the stacking direction, but may also determine, by analyzing the shape data representing the shape of the three-dimensional model, a region where the support structure SS is formed, a region where an overhang portion is formed, a region where the width to be formed is thinner than a predetermined width, a region where a hole having a diameter smaller than a predetermined diameter is formed, etc. as the first region AR1. Among these, which region corresponding to which condition is determined as the first region AR1 may be specified by the user via the input device 470.

[0062] FIG. 16 is a diagram showing an example in which a plurality of first regions AR1 are specified. FIG. 16 shows a state of a donut-shaped three-dimensional object MD4 viewed from above. The first region AR1 is not limited to one location, and as shown in FIG. 16, a plurality of locations may be specified for one three-dimensional object MD4. All of the plurality of first regions AR1 may be automatically identified by the data generation unit 411, or a user may specify some or all of the first regions AR1. FIG. 16 shows an example in which in a donut-shaped three-dimensional object MD4, a first region is automatically identified in a portion where a hole HL is formed and a portion where a rod-shaped protrusion PP is formed, respectively.

[0063] D. Fourth Embodiment: The configuration of the three-dimensional modeling system 10 in the fourth embodiment is the same as that of the three-dimensional modeling system 10 in the first embodiment. In the fourth embodiment, the method for determining the modeling target region in step S40 of the modeling process shown in FIG. 6 is different from that in the first embodiment. Since the processing contents of steps S10 to S30 and steps S50 to S70 are the same as those in the first embodiment, hereinafter, only the processing content of step S40 will be described.

[0064] FIG. 17 is an explanatory diagram of a method for determining a modeling target region in the fourth embodiment. In the first embodiment, the first region AR1 received in step S30 is directly determined as the modeling target region MA. In contrast, in the fourth embodiment, as shown in FIG. 17, the data generation unit 411 determines, in the X-Y plane, a second region AR2 that includes the first region AR1 and is larger than the first region AR1 as the modeling target region MA.

[0065] By thus determining the second region AR2 larger than the first region AR1 as the modeling target region MA, even when the modeling accuracy at the peripheral portion of the modeling target portion decreases, the modeling accuracy within the first region AR1 can be maintained. As a result, the modeling accuracy within the first region AR1 of the three-dimensional object MD1 can be made closer to the modeling accuracy when the entire three-dimensional object MD1 is modeled.

[0066] In the fourth embodiment, it is preferable that the width W of the region obtained by excluding the first region AR1 from the second region AR2 is larger than the line width of the shaping path and is three times or less the line width of the shaping path. If such a width W is ensured, for example, the end point or the start point of the shaping path can be accommodated within the width W instead of within the first region AR1, and when a new outer shell is formed, the outer shell can be accommodated within the width W. As a result, although the amount of the shaping material used increases as the shaping target region MA is determined based on the second region AR2 larger than the first region AR1, while minimizing the increase in the usage amount, the shaping path within the first region AR1 can be made the same as the path in the case of shaping the entire three-dimensional shaped object. Therefore, it becomes easier to approximate the shaping accuracy within the first region AR1 of the three-dimensional shaped object MD1 to the shaping accuracy in the case of shaping the entire three-dimensional shaped object MD1.

[0067] E. Fifth Embodiment: The configuration of the three-dimensional shaping system 10 in the fifth embodiment is the same as that of the three-dimensional shaping system 10 in the first embodiment. In the fifth embodiment, the processing contents of steps S30 to S50 of the shaping process shown in FIG. 6 are different from those in the first embodiment. Since the processing contents of steps S10 to S20 and steps S60 to S70 are the same as those in the first embodiment, the processing contents of steps S30 to S50 will be described below.

[0068] FIG. 18 is an explanatory diagram of a method for generating shaping data in the fifth embodiment. In the fifth embodiment, in step S30 of FIG. 6, not only the first region AR1 but also the range of the third region AR3 is accepted from the user. The third region AR3 is a region that defines the range of a plane perpendicular to the stacking direction, similar to the first region AR1, and is a region different from the first region AR1. FIG. 18 shows an example in which the first region AR1 and two third regions AR3 are specified.

[0069] In the fifth embodiment, in step S40 of FIG. 6, the data generation unit 411 determines the modeling target area MA based on the first area AR1 and the third area AR3. Specifically, the data generation unit 411 sets, as the modeling target area MA, an area including the first area AR1 and the third area AR3. In FIG. 6, the first area AR1 and the two third areas AR3 are in contact with each other, but these areas may be separated. When the first area AR1 and the third area AR3 are separated, the modeling target area MA may include an area located between the first area AR1 and the third area AR3.

[0070] In the fifth embodiment, in step S50 of FIG. 6, the data generation unit 411 applies different modeling conditions to the data of the portion corresponding to the first area AR1 among the shape data of the three-dimensional model MD1 and the data of the portion corresponding to the third area AR3 among the shape data, respectively, to generate the first modeling data DA1. FIG. 18 shows an example in which the first modeling data DA1 is generated such that the infill pattern and the infill rate are different between the first area AR1 and the third area AR3. It is preferable that the modeling conditions for the third area AR3 can be arbitrarily specified by the user. Further, when a plurality of third areas AR3 are specified, it is preferable that different modeling conditions can be specified for each of the third areas AR3. Between the first area AR1 and the third area AR3, not limited to the infill pattern and the infill rate, various modeling conditions such as the type of the support structure SS, the type of the modeling material, and the number of outer shells can be made different.

[0071] According to the fifth embodiment described above, a plurality of portions of the three-dimensional model MD1 can be modeled under different modeling conditions. Therefore, when performing a test modeling to confirm the actual modeled state of a part of the three-dimensional model MD1, the modeled state of the portion modeled under modeling conditions different from the actual modeling conditions can be confirmed.

[0072] F. Other Embodiments: (F1) In the above embodiment, the first region may be able to specify a range not only in the X and Y directions but also in the Z direction. In this case, the user may specify the range in the Z direction after specifying the ranges in the X and Y directions, or may specify the ranges in the X and Y directions after specifying the range in the Z direction.

[0073] (F2) In the above embodiment, the shape of the first region is not limited to a rectangle. For example, it may be circular, or may be a polygon other than a rectangle such as a triangle or a pentagon. Additionally, it may be a shape freely drawn by the user. Further, the first region is not limited to a columnar shape, and may be any three-dimensional region such as a conical shape, a spherical shape, or a polyhedral shape.

[0074] (F3) In the above embodiment, the shaping unit 110 plasticizes the material by means of the flat screw 40. In contrast, the shaping unit 110 may plasticize the material, for example, by rotating an in-line screw. Also, the shaping unit 110 may plasticize a filamentous material with a heater.

[0075] (F4) In the above embodiment, the material extrusion method of laminating the plasticized material was described as an example, but the present disclosure can be applied to various methods such as an inkjet method, a DMD method (Direct Metal Deposition), a binder jet method, etc.

[0076] G. Other Forms: The present disclosure is not limited to the above-described embodiments, and can be realized with various configurations without departing from the gist thereof. For example, the technical features of the embodiments corresponding to the technical features in each of the forms described below can be appropriately replaced or combined in order to solve some or all of the above-described problems, or to achieve some or all of the above-described effects. Also, if the technical feature is not described as essential in this specification, it can be appropriately deleted.

[0077] (1) According to the first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object by ejecting a modeling material from an ejection unit toward a stage to laminate layers. This manufacturing method includes a first step of displaying the three-dimensional object on a display unit based on shape data representing the three-dimensional shape of the three-dimensional object, a second step of determining a modeling target area of the three-dimensional object displayed on the display unit based on a first area defining a range of a plane perpendicular to the lamination direction of the layers, and a third step of generating first modeling data based on data of a portion corresponding to the modeling target area in the shape data, or selecting data of a portion corresponding to the modeling target area from second modeling data generated based on the shape data to generate third modeling data, and a fourth step of modeling a three-dimensional object based on the first modeling data or the third modeling data. According to such an aspect, a modeled object corresponding to the modeling target area of the three-dimensional object is modeled. Therefore, when performing test modeling to confirm the actual modeled state of a part of the three-dimensional object, modeling of parts other than the part that needs to be confirmed is suppressed.

[0078] (2) In the above aspect, the third step may include a step of generating the first modeling data by generating modeling paths for an outer shell area representing an outer shell of a portion corresponding to the modeling target area in the shape data and an infill area existing inside the outer shell area, respectively. According to such an aspect, since the infill area is surrounded by the outer shell area, the modeling target portion of the three-dimensional object can be modeled with high accuracy.

[0079] (3) In the step of generating the first modeling data in the above aspect, it may not be necessary to generate a modeling path for surrounding a cutting plane where the three-dimensional shape is cut by the modeling target area. According to such an aspect, the outer shell area of the modeling target portion can be modeled with the same modeling path as when modeling the entire three-dimensional object.

[0080] (4) In the above-described form, in the step of generating the third modeling data, the modeling paths included in the data other than the portion corresponding to the modeling target region in the second modeling data may be converted into travel paths. In such a form, the third modeling data can be generated from the second modeling data by simple processing.

[0081] (5) In the above-described form, in the second step, a second region that includes the first region and is larger than the first region may be determined as the modeling target region. According to such a form, even when the modeling accuracy at the peripheral portion of the modeling target portion decreases, the modeling accuracy within the first region can be maintained.

[0082] (6) In the above-described form, when viewed from the stacking direction, the width of the region obtained by removing the first region from the second region may be larger than the line width of the modeling path and not more than three times the line width. According to such a form, while suppressing an increase in the amount of modeling material used, it becomes easier to approximate the modeling accuracy within the first region of the three-dimensional modeled object to the modeling accuracy when the entire three-dimensional modeled object is modeled.

[0083] (7) In the above-described form, in the second step, based on a third region that is a region defining the range of a plane perpendicular to the stacking direction and is different from the first region, and the first region, the modeling target region is determined, and in the third step, different modeling conditions are applied to the data of the portion corresponding to the first region in the shape data and the data of the portion corresponding to the third region in the shape data, respectively, to generate the first modeling data. According to such a form, a plurality of portions of the three-dimensional modeled object can be modeled under different modeling conditions.

[0084] (8) In the above-described form, the second step may include a step of accepting a designation of the range of the first region within the display unit. According to such a form, the user can specify the first region within an arbitrary range.

[0085] The present disclosure can be realized in various forms, such as not limited to the method for manufacturing the three-dimensional object described above, a three-dimensional shaping system, an information processing apparatus, a computer program, and a non-transitory tangible recording medium having the computer program recorded thereon in a computer-readable manner.

Explanation of Reference Numerals

[0086] 10…Three-dimensional shaping system, 20…Material supply unit, 22…Communication path, 30…Plasticizing unit, 31…Screw case, 32…Drive motor, 40…Flat screw, 42…Groove portion, 43…Rib portion, 44…Material inlet, 46…Central portion, 47…Upper surface, 48…Lower surface, 50…Barrel, 52…Upper surface, 54…Guide groove, 56…Communication hole, 58…Barrel heater, 60…Discharge unit, 61…Nozzle, 62…Nozzle opening, 65…Flow path, 70…Discharge adjustment unit, 74…First drive unit, 75…Suction unit, 76…Second drive unit, 77…Discharge control unit, 100…Three-dimensional shaping apparatus, 110…Shaping unit, 210…Stage, 211…Shaping surface, 212…Stage heater, 230…Moving mechanism, 300…Control unit, 310…Processor, 320…Storage device, 400…Information processing apparatus, 410…CPU, 411…Data generation unit, 420…Memory, 430…Storage device, 440…Communication interface, 450…Input / output interface, 460…Bus, 470…Input device, 480…Display unit

Claims

1. A method for manufacturing a three-dimensional object by ejecting a modeling material from an ejection unit toward a stage to laminate layers, comprising: a first step of displaying the three-dimensional object on a display unit based on shape data representing the three-dimensional shape of the three-dimensional object; a second step of determining a modeling target region of the three-dimensional object displayed on the display unit based on a first region defining a range of a plane perpendicular to the lamination direction of the layers; a third step of generating first modeling data based on data of a portion of the shape data corresponding to the modeling target region, or generating third modeling data by selecting data of a portion corresponding to the modeling target region from second modeling data generated based on the shape data; a fourth step of modeling a three-dimensional object based on the first modeling data or the third modeling data; A method for manufacturing a three-dimensional object, comprising the above steps.

2. The method for manufacturing a three-dimensional object according to Claim 1, wherein: the third step includes a step of generating first modeling data by generating modeling paths for an outer shell region representing an outer shell of a portion of the shape data corresponding to the modeling target region and an infill region existing inside the outer shell region, respectively.

3. The method for manufacturing a three-dimensional object according to Claim 2, wherein: in the step of generating the first modeling data, a modeling path for surrounding a cutting plane where the three-dimensional shape is cut by the modeling target region is not generated.

4. The method for manufacturing a three-dimensional object according to Claim 1, wherein: in the step of generating the third modeling data, a modeling path included in data other than the portion corresponding to the modeling target region in the second modeling data is converted into a travel path.

5. The method for manufacturing a three-dimensional object according to Claim 1, wherein: in the second step, a second region that includes the first region and has a range larger than the first region is determined as the modeling target region.

6. The method for manufacturing a three-dimensional object according to Claim 5, wherein: when viewed from the lamination direction, the width of the region obtained by removing the first region from the second region is larger than the line width of the modeling path and is equal to or less than three times the line width.

7. The method for manufacturing a three-dimensional object according to Claim 1, wherein: In the second step, a shaping target region is determined based on a third region, which is a region defining a range of a plane perpendicular to the stacking direction and is different from the first region, and the first region. In the third step, different shaping conditions are applied to data of a portion corresponding to the first region among the shape data and data of a portion corresponding to the third region among the shape data to generate the first shaping data. A method for manufacturing a three-dimensional shaped object. **Claim 8** A method for manufacturing a three-dimensional shaped object according to claim 1, wherein the second step includes a step of receiving a designation of a range of the first region in the display unit. A method for manufacturing a three-dimensional shaped object.

Images