Method for producing three-dimensional shaped article and information processing apparatus

Abstract

To provide a technique capable of suppressing a void part from remaining in a three-dimensional shaped article.SOLUTION: A method for producing a three-dimensional shaped article includes: a first step of specifying a missing region of the three-dimensional shaped article on the basis of first data having path data representing a path along which a discharge unit moves relative to a stage while discharging a shaping material and having discharge amount data representing a discharge amount of the shaping material in the path; a second step of receiving designation of an overlap allowable amount which is an allowable amount of overlap between partial shaped articles corresponding to paths adjacent to each other in the same layer; a third step of generating shaping data from the first data such that a partial shaped article that fills the missing region is generated in a case where it is determined that the missing region can be filled by overlapping the partial shaped articles within a range of the designated overlap allowable amount; and a fourth step of shaping the three-dimensional shaped article by controlling relative movement of the discharge unit with respect to the stage based on the shaping data.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a three-dimensional object and an information processing device. [Background technology]

[0002] Regarding a method for manufacturing a three-dimensional object, for example, Patent Document 1 describes a method in which a nozzle that extrudes a modeling material is moved along a build path for constructing each layer of the three-dimensional object. The build path includes a peripheral path, a bulk cluster path, and a residual path. The peripheral path is a path that forms a boundary between the three-dimensional object and the outside, and the bulk cluster path is a path that fills the area surrounded by the peripheral path. The technology described in Patent Document 1 reduces the void ratio by filling the void areas that cannot be filled by the peripheral path and the bulk cluster path with the residual path. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2009-525207 Summary of the Invention [Problem to be solved by the invention]

[0004] When filling a void region with a remaining path, depending on the shape of the void region, the additional remaining path may not be generated properly, leaving a void portion, which may result in a loss of part of the three-dimensional object. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object by stacking layers of a modeling material discharged from a discharging unit toward a stage. The method includes: a first step of identifying a missing region of the three-dimensional object based on first data, the first data having path data representing a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data representing an amount of the modeling material discharged along the path; a second step of accepting a designation of an allowable overlap amount, which is an allowable amount of overlap between partial objects corresponding to adjacent paths in the same layer; a third step of generating modeling data from the first data when it is determined that the missing region can be filled by overlapping the partial objects within the specified allowable overlap amount, so as to generate partial objects that fill the missing region; and a fourth step of controlling the movement of the discharging unit relative to the stage based on the designation data.

[0006] According to a second aspect of the present disclosure, there is provided an information processing apparatus that generates modeling data for forming a three-dimensional object by stacking layers by discharging a modeling material from a discharging unit toward a stage. The information processing apparatus includes: an acquisition unit that acquires first data having path data representing a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data representing an amount of the modeling material dispensed along the path; an identification unit that identifies a missing region of the three-dimensional object based on the first data; a reception unit that receives a specification of an allowable overlap amount, which is an allowable amount of overlap between adjacent partial objects corresponding to the path in the same layer; and a data generation unit that generates modeling data from the first data when it is determined that the missing region can be filled by overlapping the partial objects within the specified allowable overlap amount. [Brief explanation of the drawings]

[0007] [Figure 1]FIG. 1 is an explanatory diagram illustrating a schematic configuration of a three-dimensional printing system. [Figure 2] FIG. 2 is a perspective view showing a schematic configuration of a screw. [Figure 3] FIG. 2 is a schematic plan view of the barrel. [Figure 4] FIG. 2 is an explanatory diagram schematically illustrating how the three-dimensional printing apparatus prints a model. [Figure 5] FIG. 1 is an explanatory diagram illustrating a schematic configuration of an information processing device. [Figure 6] 10 is a flowchart of a modeling process executed in the three-dimensional modeling system. [Figure 7] FIG. 3 is a diagram showing an example of a missing area in the first embodiment. [Figure 8] FIG. 10 is a diagram showing a state in which a new partial object that fills in a missing region has been generated. [Figure 9] FIG. 11 is a diagram showing shape data of a layer for which modeling data is to be generated in the second embodiment. [Figure 10] FIG. 10 is a diagram visualizing the shaping data when a missing region occurs in the second portion. [Figure 11] FIG. 10 is a diagram illustrating visualization of shaping data when an overlap tolerance is set for the outer boundary region. [Figure 12] FIG. 10 is a diagram visualizing the shaping data when a missing area occurs in the infill area in the second portion. [Figure 13] FIG. 10 is a diagram visualizing the shaping data when an overlap tolerance is set for the infill area of ​​the second portion. [Figure 14] FIG. 10 is a diagram visualizing shaping data in a case where a missing area occurs between an outer region and an infill region. [Figure 15] FIG. 10 is a visualization of the printing data when the overlap tolerance is set to 10%. [Figure 16] FIG. 10 is a diagram visualizing the printing data when the overlap tolerance is set to 50%. [Figure 17] FIG. 10 is an explanatory diagram showing how a defective area is expanded. [Figure 18]13 is a flowchart of a formation process executed in the fifth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] A. First embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing system 10 according to a first embodiment. Arrows indicating mutually orthogonal X, Y, and Z directions are shown in FIG. 1. The X and Y directions are parallel to a horizontal plane, and the Z direction is a vertically upward direction. The arrows indicating the X, Y, and Z directions are also shown in other figures as appropriate so that the illustrated directions correspond to those in FIG. 1. In the following description, when specifying the direction, positive and negative signs are used in combination to indicate the direction indicated by the arrow in each figure, with "+" indicating the direction indicated by the arrow and "-" indicating the opposite direction. Hereinafter, the +Z direction will also be referred to as "up" and the -Z direction as "down."

[0009] The three-dimensional printing system 10 includes a three-dimensional printing device 100 and an information processing device 400. The three-dimensional printing device 100 of this embodiment is a device that prints a model by a material extrusion method. The three-dimensional printing device 100 includes a control unit 300 for controlling each unit of the three-dimensional printing device 100. The control unit 300 and the information processing device 400 are connected to each other so that they can communicate with each other.

[0010] The three-dimensional modeling apparatus 100 includes a modeling unit 110 that generates and dispenses a modeling material, a modeling stage 210 that serves as a base for the model, and a movement mechanism 230 that controls the dispense position of the modeling material.

[0011] Under the control of the control unit 300, the modeling unit 110 ejects a modeling material, which is a plasticized solid material, onto the stage 210. The modeling unit 110 includes a material supply unit 20, which is a supply source of raw materials before they are converted into the modeling material, a plasticization unit 30, which converts the raw materials into the modeling material, and a discharge unit 60, which discharges the modeling material.

[0012] The material supply unit 20 supplies the raw material MR to the plasticizing unit 30. The material supply unit 20 is configured, for example, by a hopper that stores the raw material MR. The material supply unit 20 is connected to the plasticizing unit 30 via a communication passage 22. The raw material MR is fed into the material supply unit 20 in the form of powder or pellets. As the raw material MR, for example, a thermoplastic resin such as acrylonitrile-butadiene-styrene resin (ABS), polypropylene resin (PP), polyethylene resin (PE), or polyacetal resin (POM) is used.

[0013] The plasticizing unit 30 plasticizes the raw material MR supplied from the material supply unit 20 to generate a paste-like modeling material that exhibits fluidity, and then guides the material to the discharge unit 60. In this embodiment, "plasticization" is a concept that includes melting, and refers to changing a material from a solid to a fluid state. Specifically, for materials that undergo glass transition, plasticization refers to raising the temperature of the material above the glass transition point. For materials that do not undergo glass transition, plasticization refers to raising the temperature of the material above the melting point.

[0014] The plasticizing section 30 includes a screw case 31, a drive motor 32, a screw 40, and a barrel 50. The screw 40 is also called a rotor, a scroll, or a flat screw. The barrel 50 is also called a screw facing portion.

[0015] The screw 40 is housed in a screw case 31. An upper surface 47 of the screw 40 is connected to the drive motor 32, and the screw 40 rotates in the screw case 31 by the rotational driving force generated by the drive motor 32. The drive motor 32 is driven under the control of the control unit 300. Note that the screw 40 may be driven by the drive motor 32 via a reducer.

[0016] 2 is a perspective view showing a schematic configuration of the lower surface 48 side of the screw 40. To facilitate understanding of the technology, the screw 40 shown in FIG. 2 is shown with the positional relationship between the upper surface 47 and the lower surface 48 shown in FIG. 1 reversed in the vertical direction. The screw 40 has a roughly cylindrical shape in which the length in the axial direction, which is the direction along its central axis, is shorter than the length in the direction perpendicular to the axial direction. The screw 40 is positioned so that the rotation axis RX, which is the center of rotation of the screw 40, is parallel to the Z direction.

[0017] A spiral groove 42 is formed on a lower surface 48 of the screw 40, which is a surface that intersects with the rotation axis RX. The communication passage 22 of the material supply section 20 described above communicates with the groove 42 from the side surface of the screw 40. In this embodiment, three grooves 42 are formed, separated by ridges 43. The number of grooves 42 is not limited to three, and may be one, or two or more. The groove 42 is not limited to a spiral shape, and may be a spiral or involute curve shape, or may have a shape that extends in an arc from the center to the outer periphery.

[0018] 1, the lower surface 48 of the screw 40 faces the upper surface 52 of the barrel 50, and a space is formed between the groove 42 of the lower surface 48 of the screw 40 and the upper surface 52 of the barrel 50. Raw material MR is supplied to this space between the screw 40 and the barrel 50 from the material supply section 20 through a material inlet 44 shown in FIG.

[0019] A barrel heater 58 is embedded in the barrel 50 to heat the raw material MR supplied into the groove 42 of the rotating screw 40. A communication hole 56 is provided in the center of the barrel 50.

[0020] 3 is a schematic plan view showing the top surface 52 of the barrel 50. A plurality of guide grooves 54 are formed on the top surface 52 of the barrel 50, and are connected to the communicating holes 56 and extend spirally from the communicating holes 56 toward the outer periphery. Note that one end of the guide grooves 54 does not have to be connected to the communicating holes 56. Also, the guide grooves 54 can be omitted.

[0021] The raw material MR supplied into the groove 42 of the screw 40 is plasticized in the groove 42, flows along the groove 42 due to the rotation of the screw 40, and is led to the center 46 of the screw 40 as a modeling material. The paste-like modeling material that has flowed into the center 46 and exhibits fluidity is supplied to the discharge section 60 through a communication hole 56 provided in the center of the barrel 50. Note that it is not necessary for all types of substances constituting the modeling material to be plasticized. It is sufficient for the modeling material to be converted into a fluid state as a whole by plasticizing at least some of the types of substances constituting the modeling material.

[0022] The discharge unit 60 in FIG. 1 includes a nozzle 61 that discharges the modeling material, a flow path 65 for the modeling material provided between the screw 40 and the nozzle opening 62, and a discharge control unit 77 that controls the discharge of the modeling material.

[0023] The nozzle 61 is connected to the communication hole 56 of the barrel 50 through a flow path 65. The nozzle 61 discharges the modeling material produced in the plasticizing section 30 from a nozzle opening 62 at the tip thereof toward the stage 210.

[0024] The discharge control unit 77 includes a discharge adjustment unit 70 that opens and closes the flow path 65, and a suction unit 75 that sucks in the modeling material and temporarily stores it.

[0025] 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 this embodiment, the discharge adjustment unit 70 is configured 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 configured 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, i.e., the discharge amount of the modeling material discharged from the nozzle 61, by using the first drive unit 74 to control the rotation angle of the discharge adjustment unit 70. The discharge adjustment unit 70 can adjust the discharge amount of the modeling material and can also control the on / off of the outflow of the modeling material.

[0026] The suction unit 75 is connected between the discharge adjustment unit 70 and the nozzle opening 62 in the flow path 65. 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 tailing phenomenon in which the modeling material hangs like a string from the nozzle opening 62. In this embodiment, the suction unit 75 is configured with 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 configured with, for example, a stepping motor or a rack-and-pinion mechanism that converts the rotational force of the stepping motor into translational motion of the plunger.

[0027] The stage 210 is disposed 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 disposed so as to be parallel to the X and Y directions, i.e., the horizontal direction. The stage 210 is provided with a stage heater 212 for preventing the modeling material discharged onto the stage 210 from cooling suddenly. The stage heater 212 is controlled by the control unit 300.

[0028] The movement mechanism 230 changes the relative position between the stage 210 and the nozzle 61 under the control of the control unit 300. In this embodiment, the position of the nozzle 61 is fixed, and the movement mechanism 230 moves the stage 210. The movement mechanism 230 is configured by a three-axis positioner that moves the stage 210 in three axial directions, that is, the X, Y, and Z directions, using the driving forces of three motors. In this specification, unless otherwise specified, movement of the nozzle 61 means moving the nozzle 61 and the discharge unit 60 relative to the stage 210.

[0029] In other embodiments, instead of a configuration in which the moving mechanism 230 moves the stage 210, a configuration in which the moving mechanism 230 moves the nozzle 61 relative to the stage 210 while the position of the stage 210 is fixed may be employed. Alternatively, 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 employed. Even with these configurations, the relative positional relationship between the nozzle 61 and the stage 210 can be changed.

[0030] 1 shows only one modeling unit 110, the 3D modeling device 100 may include multiple modeling units 110. By including multiple modeling units 110, different types of modeling materials can be discharged from each modeling unit 110. Therefore, for example, the main body of the modeled object and the support structure that supports the modeled object can be modeled using different types of modeling materials.

[0031] The control unit 300 is a control device that controls the overall operation of the 3D printing apparatus 100. The control unit 300 is configured by a computer that includes one or more processors 310, a storage device 320 including a main storage device and an auxiliary storage device, and an input / output interface that inputs and outputs signals to and from the outside. The processor 310 executes a program stored in the storage device 320 to control the printing unit 110 and the movement mechanism 230 in accordance with printing data acquired from the information processing device 400, and prints a printed object on the stage 210. Note that the control unit 300 may be realized by a combination of circuits instead of being configured by a computer.

[0032] 4 is an explanatory diagram that schematically shows how the three-dimensional printing apparatus 100 prints a model. In the three-dimensional printing apparatus 100, as described above, the raw material MR in a solid state is plasticized to produce the modeling material MM. The control unit 300 discharges the modeling material MM from the nozzle 61 while changing the position of the nozzle 61 relative to the stage 210 in a direction along the modeling surface 211 of the stage 210, while maintaining the distance between the nozzle 61 and the modeling surface 211 of the stage 210. The modeling material MM discharged from the nozzle 61 is continuously deposited in the direction of movement of the nozzle 61.

[0033] The control unit 300 repeatedly moves the nozzle 61 to form layers ML. After forming one layer ML, the control unit 300 moves the position of the nozzle 61 relative to the stage 210 in the Z direction, which is the stacking direction of the layers ML. Then, a model is formed by stacking additional layers ML on the layers ML that have been formed so far.

[0034] The control unit 300 may temporarily suspend the discharge of the modeling material from the nozzle 61, for example, when the nozzle 61 moves in the Z direction after completing one layer ML or when each layer has multiple independent modeling regions. 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 from the nozzle 61. After changing the position of the nozzle 61, the control unit 300 opens the flow path 65 with the discharge adjustment unit 70 while discharging the modeling material from the suction unit 75, thereby restarting the deposition of the modeling material MM from the new position of the nozzle 61.

[0035] 5 is an explanatory diagram showing a schematic configuration of an information processing device 400. The information processing device 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 via a bus 460. An input device 470 such as a keyboard or a mouse, and a display unit 480 such as a liquid crystal display are connected to the input / output interface 450. The information processing device 400 is connected to the control unit 300 of the three-dimensional printing apparatus 100 via the communication interface 440.

[0036] The CPU 410 executes the programs stored in the storage device 430 to function as an acquisition unit 411, an identification unit 412, a reception unit 413, and a data generation unit 414.

[0037] The acquiring unit 411 acquires first data. The first data includes path data representing paths along which the discharging unit 60 moves relative to the stage 210 while discharging the modeling material, and also includes discharge amount data representing the amount of modeling material discharged along each path. The paths are also called paths.

[0038] The identifying unit 412 identifies a missing region of the three-dimensional object based on the first data. The missing region will be described later.

[0039] The receiving unit 413 receives a specification of the allowable overlap amount, which is the allowable amount of overlap between partial objects corresponding to adjacent paths in the same layer. Adjacent paths refer to paths that are parallel or approximately parallel and lined up next to each other. A partial object corresponding to a path is an object that is formed by depositing the modeling material on the stage 210 by discharging the modeling material from the discharging unit 60 along the path, and is an object that constitutes part of the three-dimensional object. While a path does not have a width, a partial object does. The width of a partial object is called the line width.

[0040] When the data generation unit 414 determines that the missing area can be filled by overlapping the partial objects within the specified overlap allowance, it generates modeling data from the first data so that a partial object that fills the missing area is generated. The partial object that fills the missing area may be a partial object that is added independently of an existing partial object, or may be a partial object that is added by extending an existing partial object. The modeling data may also be called second data.

[0041] 6 is a flowchart of the 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 S60 shown in FIG. 6 are executed by the information processing device 400, and the processes of steps S70 to S80 are executed by the three-dimensional modeling device 100.

[0042] In step S10, the acquisition unit 411 of the information processing device 400 acquires first data from the storage device 430. As described above, the first data includes path data that represents paths along which the discharging unit 60 moves relative to the stage 210 while discharging the modeling material, and also includes discharge amount data that represents the amount of modeling material discharged along each path. The first data includes path data and discharge amount data for each layer ML of the three-dimensional object. The path data includes multiple linear paths. The discharge amount data is individually associated with each path. By discharging the modeling material along each path toward the stage 210 in an amount determined by the discharge amount data, a linear partial object that becomes part of the three-dimensional object is formed on the stage 210. The discharge amount data corresponding to each path is set so that the line width of the partial object formed on the stage 210 is a predetermined width.

[0043] Prior to executing step S10, the CPU 410 of the information processing device 400 may acquire shape data representing the three-dimensional shape of the three-dimensional object from another computer, a recording medium, or the storage device 430, generate first data from the shape data, and store the first data in the storage device 430. The shape data is data representing the shape of the three-dimensional object created using three-dimensional CAD software, three-dimensional CG software, or the like. As the shape data, for example, data in STL format, AMF format, or the like is used.

[0044] In step S20, the identification unit 412 identifies a missing region of the three-dimensional object based on the first data acquired in step S10. Step S20 corresponds to the first step in this disclosure.

[0045] FIG. 7 is a diagram showing an example of a missing region in the first embodiment. FIG. 7 shows an outer region A1 and an infill region A2 that constitute a layer L1 of a three-dimensional object. The outer region A1 is a region that forms the outline of the three-dimensional object, and the infill region A2 is a region located inside the outer region A1. In FIG. 7, two partial objects are formed in the outer region A1 by two circular passes, and seven partial objects are formed in the infill region A2 by seven circular passes. A circular pass is a continuous path that makes one loop. A path that makes one loop is a path whose start point and end point are continuous. In FIG. 7 and subsequent figures, the partial objects are hatched.

[0046] In the layer L1, a rectangular void has occurred in the center of the infill region A2. To fill this void with a partial object formed by a circular pass, the void needs to be twice the line width of the partial object. Therefore, if the width of the void is less than twice the line width of the partial object, the void will not be filled with the partial object and will become a missing area MA. In the first embodiment, the identifying unit 412 analyzes the first data, detects voids that will not be filled with a partial object formed by a circular pass, and identifies the voids as missing areas MA.

[0047] In step S30 of FIG. 6 , the receiving unit 413 receives a specification of an overlap tolerance, which is the allowable amount of overlap between partial objects corresponding to adjacent paths within the same layer. Step S30 corresponds to the second step in this disclosure. In the first embodiment, in step S30, an overlap tolerance is specified for partial objects corresponding to adjacent paths within a circular path. The receiving unit 413 receives the specification of the overlap tolerance from the user, for example, via the input device 470. The user specifies the overlap tolerance, for example, using a numerical value or a percentage. When the line width of a partial object corresponding to a path is 1 mm, the overlap tolerance can be specified in the range of 0 mm to 1 mm, or 0% to 100%. When the overlap tolerance is 0%, adjacent partial objects do not overlap. When the overlap tolerance is 100%, adjacent partial objects completely overlap. In other words, the larger the overlap tolerance, the greater the overlap between partial objects, making it possible to fill a narrow missing area MA. However, as the overlap tolerance increases, the proportion of partial objects that overlap in the vertical direction also increases, which may result in a decrease in the modeling accuracy of the 3D object. Therefore, it is preferable to set an upper limit to the overlap tolerance. The upper limit may be, for example, 50%.

[0048] In step S40, the data generation unit 414 determines whether the missing area MA can be filled by overlapping the partial objects within the allowable overlap amount received in step S30. In the first embodiment, the data generation unit 414 generates a new circular path that satisfies the specified allowable overlap amount, and fills the missing area MA with a new partial object formed by that circular path. Therefore, for example, if the line width of the partial object is 1 mm and the width of the missing area MA is 1.5 mm, it is determined that the missing area MA can be filled with a new partial object that goes around the entire area if a value of 0.5 mm or more or 50% or more is specified as the allowable overlap amount.

[0049] If the data generation unit 414 determines in step S40 that the missing area MA can be filled, then in step S50, the data generation unit 414 generates modeling data from the first data so as to generate a new partial model that fills the missing area MA. Step S50 corresponds to the third step in this disclosure.

[0050] Fig. 8 is a diagram showing a state in which a new partial object that fills the missing area MA has been generated. Fig. 8 shows an example in which the missing area MA shown in Fig. 7 has been filled with a partial object that is formed by a new circular path CP. The data generation unit 414 generates a new circular path for forming a circle of partial objects that includes overlapping portions within the allowable overlap amount, and adds path data and discharge amount data that represent the circular path to the first data, thereby generating the formation data.

[0051] If the data generation unit 414 determines in step S40 that the missing area MA cannot be filled, the data generation unit 414 generates modeling data from the first data without adding new path data and discharge amount data to the first data in step S60. Specifically, the first data is left unchanged and used as the modeling data.

[0052] If the data generation unit 414 determines in step S40 that the missing area MA cannot be filled, the CPU 410 of the information processing device 400 may display a warning to the effect that the missing area MA cannot be filled on the display unit 480. Furthermore, if the data generation unit 414 determines in step S40 that the missing area MA cannot be filled, the CPU 410 may return the process to step S30 and accept a new specification of the allowable overlap amount from the user.

[0053] In step S70 of FIG. 6, the control unit 300 of the three-dimensional modeling apparatus 100 acquires, from the information processing apparatus 400, the modeling data generated in step S50 or step S60.

[0054] In step S80, the control unit 300 controls the discharging unit 60 and the moving mechanism 230 in accordance with the modeling data acquired from the information processing device 400, and forms a three-dimensional object on the modeling surface 211 of the stage 210. Step S80 corresponds to the fourth step in this disclosure.

[0055] According to the 3D printing system 10 of the first embodiment described above, by accepting a user specification of the allowable overlap amount between partial objects, a new partial object is generated that includes overlapping portions within the specified allowable overlap amount, and the missing area MA can be filled with the new partial object. This makes it possible to prevent voids from remaining in the 3D object. As a result, the printing accuracy of the 3D object can be improved.

[0056] Furthermore, in the first embodiment, an allowable overlap amount is specified for partial objects corresponding to adjacent paths within a circular path that makes a full circuit along a continuous route, which makes it easier to fill in missing areas MA that occur within the circular path.

[0057] B. Second embodiment: The configuration of the three-dimensional printing system 10 in the second embodiment is the same as that of the three-dimensional printing system 10 in the first embodiment. In the second embodiment, the processing contents of steps S20 to S60 of the printing process shown in Fig. 6 are different from those in the first embodiment. The processing contents of the other steps are the same as those in the first embodiment, so detailed explanations will be omitted.

[0058] In the second embodiment, in step S20 of the forming process shown in FIG. 6, the identification unit 412 identifies missing areas MA individually for the outer area A1 and the infill area A2 that constitute the layer based on the first data acquired in step S10.

[0059] In step S30, the receiving unit 413 receives a specification of an allowable overlap amount for partial objects corresponding to adjacent paths in the outer region A1, and also receives a specification of another allowable overlap amount for partial objects corresponding to adjacent paths in the infill region A2. In other words, the receiving unit 413 receives a specification of an allowable overlap amount separately for the outer region A1 and the infill region A2.

[0060] In step S40, the data generation unit 414 determines whether it is possible to fill the missing area MA identified in each of the outer area A1 and the infill area A2 by arranging partial objects so that they overlap within the individually specified overlap allowance range. If the data generation unit 414 determines that it is possible to fill the missing area MA, it generates modeling data from the first data in step S50 so that the missing area MA is filled. If it determines that it is not possible to fill the missing area MA, it generates modeling data from the first data in step S60 without filling the missing area MA. If the determination results differ between the outer area A1 and the infill area A2, the data generation unit 414 generates modeling data from the first data so that the missing area MA is filled in the area where it is determined that it is possible to fill the missing area MA.

[0061] 9 is a diagram showing shape data of a layer L2 for which modeling data is to be generated in the second embodiment. The layer L2 has a rectangular first portion P1 and three second portions P2 protruding from the first portion P1.

[0062] Fig. 10 is a visualization of the printing data when a missing area MA occurs in the second portion P2. Because the width of the second portion P2 is narrow, if overlapping of partial objects is not permitted in the outer region A1, there is a possibility that a partial object will not be formed in the outer region A1 within the second portion P2, and a partial object will be formed only in the outer region A1 of the first portion P1, as shown in Fig. 10. In this case, the outer region A1 within the second portion P2 becomes a missing area MA.

[0063] 11 is a diagram visualizing the modeling data when an overlap tolerance is set for the outer region A1. In the second embodiment, in step S30 of the modeling process, the overlap tolerance is set separately for the outer region A1 and the infill region A2. Therefore, by setting the overlap tolerance for the outer region A1, the data generation unit 414 can generate path data and discharge amount data for the narrow second portion P2 so that adjacent partial modeling objects are arranged so that they partially overlap, as shown in FIG. 11. This makes it possible to prevent a missing region MA from occurring in the outer region A1.

[0064] Fig. 12 is a visualization of the printing data when a missing area MA occurs in the infill area A2 within the second part P2. In the example shown in Fig. 12, the line width of the partial object that forms the outer area A1 is narrower than the line width of the partial object shown in Figs. 10 and 11. Because the width of the second part P2 is narrow, if overlapping of partial objects is not permitted in the infill area A2 within the second part P2, as shown in Fig. 12, a partial object may not be formed in the infill area A2 of the second part P2, resulting in a missing area MA in the infill area A2.

[0065] 13 is a diagram visualizing the shaping data when an overlap tolerance is set for the infill area A2 of the second portion P2. In the second embodiment, in step S30 of the shaping process, the overlap tolerance is set separately for the outer area A1 and the infill area A2. Therefore, by setting the overlap tolerance for the infill area A2, as shown in FIG. 13, the data generation unit 414 can generate path data and discharge amount data for the infill area A2 in the narrow second portion P2 so that adjacent partial shaping objects are arranged to partially overlap each other. This makes it possible to prevent a missing area MA from occurring in the infill area A2.

[0066] In the second embodiment described above, the allowable overlap amount can be individually specified for the partial objects corresponding to adjacent paths in the outer region A1 and the partial objects corresponding to adjacent paths in the infill region A2, making it possible to specify an appropriate allowable overlap amount depending on the region in which the missing region MA occurs.

[0067] In the second embodiment, the receiving unit 413 receives the designation of the allowable overlap amount separately for the outer area A1 and the infill area A2. Alternatively, the receiving unit 413 may receive the designation of the allowable overlap amount for only one of the outer area A1 and the infill area A2.

[0068] C. Third embodiment: The configuration of the three-dimensional printing system 10 in the third embodiment is the same as that of the three-dimensional printing system 10 in the first embodiment. In the third embodiment, the processing of steps S20 to S40 of the printing process shown in Fig. 6 is different from that in the first embodiment. The processing contents of the other steps are the same as those in the first embodiment, so detailed explanations will be omitted.

[0069] In the third embodiment, in step S20 of the forming process shown in FIG. 6, the identification unit 412 identifies a missing area MA that exists between the outer area A1 and the infill area A2 that constitute the layer based on the first data acquired in step S10.

[0070] In step S30, the receiving unit 413 receives a specification of the allowable overlap amount between two adjacent partial objects that correspond to paths in the outer region A1 and the infill region A2. In other words, the receiving unit 413 receives a specification of the allowable overlap amount between adjacent partial objects that straddle the outer region A1 and the infill region A2.

[0071] In step S40, the data generation unit 414 determines whether the missing area MA identified in step S20 can be filled by overlapping adjacent partial objects that straddle the outer area A1 and the infill area A2 within the allowable overlap range specified in step S30. If the data generation unit 414 determines that the missing area MA can be filled, then in step S50, the data generation unit 414 generates modeling data from the first data so as to fill the missing area MA. Specifically, the data generation unit 414 generates path data and discharge rate data for forming the partial object in the infill area A2 within the outer area A1, allowing the partial object in the outer area A1 and the partial object in the infill area A2 to overlap within the allowable overlap range, and records the data in the modeling data. If the data generation unit 414 determines that the missing area MA cannot be filled, then in step S60, the data generation unit 414 generates modeling data from the first data without filling the missing area MA.

[0072] Fig. 14 is a visualization of modeling data in which a missing area MA occurs between the outer area A1 and infill area A2 that constitute the layer L3. The layer L3 shown in Fig. 14 includes a rectangular third portion P3 and three fourth portions P4 that protrude from the third portion P3. In the example shown in Fig. 14, the outer area A1 is formed in the third portion P3 and the fourth portion P4 by partial objects corresponding to two circular passes. A partial object is arranged in part of the infill area A2 of the third portion P3, but no partial object is formed in the infill area A2 of the fourth portion P4, resulting in a missing area MA.

[0073] Fig. 15 is a visualization of the modeling data when the overlap tolerance is set to 10%. When the overlap tolerance between adjacent partial objects in infill region A2 and outer region A1 is set to 10%, new partial objects or partial objects that are extensions of existing partial objects are placed in the missing region MA shown in Fig. 14, so that almost the entire infill region A2 of the third portion P3 and the fourth portion P4 is filled with partial objects.

[0074] 16 is a diagram visualizing the modeling data when the overlap tolerance is set to 50%. When the overlap tolerance between adjacent partial objects in infill area A2 and outer area A1 is set to 50%, the partial objects are arranged over the entire infill area A2 of the third portion P3 and the fourth portion P4, more than when the overlap tolerance is set to 10%. However, when the overlap tolerance is increased, partial objects may overlap in the stacking direction, which may reduce modeling accuracy. Therefore, it is preferable to set the overlap tolerance in the range of 1% to 50%.

[0075] According to the third embodiment described above, an allowable overlap amount is specified for the adjacent partial objects in the outer region A1 and the infill region A2, which makes it easier to fill in the missing region MA that occurs between the outer region A1 and the infill region A2.

[0076] D. Fourth embodiment: The configuration of the three-dimensional printing system 10 in the fourth embodiment is the same as that of the three-dimensional printing system 10 in the first embodiment. In the fourth embodiment, the processing of steps S30 to S50 of the printing process shown in Fig. 6 is different from that in the first embodiment. The processing contents of the other steps are the same as those in the first embodiment, so detailed explanations will be omitted.

[0077] 6, the identifying unit 412 identifies a missing area MA based on the first data acquired in step S10. In the fourth embodiment, similar to the first embodiment, the identifying unit 412 analyzes the first data to detect a void that is not filled by the partial object formed by the circular pass, and identifies the void as a missing area MA.

[0078] In step S30, the receiving unit 413 receives a specification of the allowable overlap amount between partial objects corresponding to adjacent paths around the missing area MA.

[0079] In step S40, the data generation unit 414 expands the missing area MA identified in step S20 by overlapping the partial objects that correspond to adjacent paths around the missing area MA within the allowable overlap amount specified in step S30, and determines whether it is possible to fill the expanded missing area MA with a new partial object. If the data generation unit 414 determines that the missing area MA can be filled, in step S50, it generates modeling data from the first data so that a partial object that fills the missing area MA is generated. If it determines that the missing area MA cannot be filled, in step S60, it generates modeling data from the first data without filling the missing area MA.

[0080] 17 is an explanatory diagram showing how the missing region MA in layer L4 is expanded. The data generation unit 414 expands the area of ​​the missing region MA by modifying the first data so that the multiple partial objects surrounding the missing region MA gradually overlap each other within the allowable overlap amount. Then, the data generation unit 414 generates path data and discharge amount data for placing a new partial object in the expanded missing region MA, and adds these data to the first data to generate the modeling data. The new partial object is, for example, a partial object that is represented by a circular path.

[0081] According to the fourth embodiment described above, the defective area MA can be expanded by gradually overlapping the partial objects around the defective area MA, making it easier to fill the inside of the defective area MA.

[0082] In the fourth embodiment, in step S30 of the modeling process, not only is it possible to accept specification of the allowable overlap amount between partial objects corresponding to paths that are adjacent to each other around the missing area MA, but it is also possible to accept specification of the allowable overlap amount for partial objects corresponding to paths that are adjacent to each other within the circular path, as in the first embodiment. In this way, even if the missing area MA does not expand sufficiently, the partial objects placed within the missing area MA can be made to overlap with each other, thereby increasing the possibility that the missing area MA can be filled.

[0083] E. Fifth embodiment: 18 is a flowchart of the modeling process executed in the fifth embodiment. The configuration of the three-dimensional modeling system 10 in the fifth embodiment is the same as that of the three-dimensional modeling system 10 in the first embodiment.

[0084] In the fifth embodiment, the processing of step S25 is added to the flowchart of the formation processing shown in FIG. 6. In the fifth embodiment, the processing contents other than step S25 are the same as those of the second embodiment. In the fifth embodiment, when a missing area MA is identified in the outer area A1 in step S20, the identification unit 412 displays a warning on the display unit 480. The warning may be displayed, for example, by displaying a pop-up window containing a warning message on the display unit 480, or when the formation data is visualized and displayed on the display unit 480, the area corresponding to the missing area MA may be displayed in a flashing display or a conspicuous color.

[0085] According to the fifth embodiment described above, it is possible to notify the user that a missing area MA has occurred in the outer boundary area A1, which has a significant impact on the appearance of the three-dimensional structure.

[0086] The user may be able to arbitrarily specify the location of the defective area MA that is the target of the warning. For example, a warning may be displayed when a defective area MA is identified in a user-specified area among (1) the innermost area of ​​the circular path, (2) the outer area A1, or (3) the area between the outer area A1 and the infill area A2. Furthermore, the user may be able to specify the area of ​​the defective area MA that is the target of the warning. In this way, if the user can specify the location of the defective area MA that is the target of the warning and the area of ​​the defective area MA, the occurrence of the defective area MA can be warned based on different criteria for each user.

[0087] F. Other Embodiments: (F1) In each of the above embodiments, a layer is composed of an outer region A1 and an infill region A2. Of the outer region A1 and the infill region A2, the outer region A1 may be composed of more subdivided regions. Specifically, the outer region A1 may have an outermost region, which is the outermost region, and an inner region inside it. In this case, the allowable overlap amount may be specified separately for the outermost region and the inner region. By doing so, even if missing regions MA occur in each of the outermost region and the inner region that make up the outer region A1, it is possible to increase the possibility of filling these missing regions MA according to the individual allowable overlap amounts.

[0088] (F2) In the above embodiment, the molding unit 110 plasticizes the material using a flat screw. However, the molding unit 110 may also plasticize the material by, for example, rotating an in-line screw. Alternatively, the molding unit 110 may plasticize the filament-shaped material using a heater.

[0089] G. Other forms: The present disclosure is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit thereof. For example, the technical features of the embodiments corresponding to the technical features in each aspect described below can be appropriately replaced or combined to solve some or all of the above-described problems or achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0090] (1) According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object by stacking layers of a modeling material discharged from a discharging unit toward a stage. The method includes: a first step of identifying a missing region of the three-dimensional object based on first data, the first data having path data representing a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data representing an amount of the modeling material discharged along the path; a second step of accepting a designation of an allowable overlap amount, which is an allowable amount of overlap between partial objects corresponding to adjacent paths in the same layer; a third step of generating modeling data from the first data when it is determined that the missing region can be filled by overlapping the partial objects within the specified allowable overlap amount, so as to generate partial objects that fill the missing region; and a fourth step of controlling the movement of the discharging unit relative to the stage based on the designation data. According to this embodiment, it is possible to prevent voids from remaining in the three-dimensional object, which would otherwise cause damage to part of the three-dimensional object.

[0091] (2) In the above-described embodiment, in the second step, the allowable overlap amount may be specified for partial objects corresponding to adjacent paths within a circular path that makes a full circuit by a continuous path. According to this embodiment, it becomes easier to fill in missing areas within the circular path.

[0092] (3) In the above embodiment, the layer may have an outer region that forms the outline of the three-dimensional object and an infill region located inside the outer region, and in the second step, the allowable overlap amount may be individually specified for partial objects that correspond to adjacent paths in the outer region and for partial objects that correspond to adjacent paths in the infill region. This embodiment makes it easier to fill in missing areas between the outer region and the infill region.

[0093] (4) In the above embodiment, the layer may have an outer region that forms the outline of the three-dimensional object and an infill region located inside the outer region, and in the second step, the allowable overlap amount may be specified for a partial object that corresponds to a path in the outer region and a partial object that corresponds to a path in the infill region, which are adjacent to each other. With this embodiment, an appropriate allowable overlap amount can be specified depending on the region where a missing region occurs.

[0094] (5) In the above-described embodiment, the second step may specify the allowable overlap amount between the partial objects corresponding to adjacent paths around the missing area, and the third step may generate the modeling data from the first data so that the partial objects corresponding to adjacent paths around the missing area overlap within the allowable overlap amount to widen the missing area specified in the first step and generate partial objects that fill the widened missing area. According to this embodiment, widening the missing area makes it easier to fill the missing area.

[0095] (6) In the above embodiment, the layer may have an outer region that forms the outline of the three-dimensional object, the outer region having an outermost region and an inner region inside the outermost region, and in the second step, the allowable overlap amount may be individually specified for the outermost region and the inner region.

[0096] (7) In the above aspect, the layer may have an outer region that forms the outline of the three-dimensional object, and when the missing region is identified in the outer region, the step of displaying on a display unit a message indicating that the missing region has been identified in the outer region may be included. According to this aspect, it is possible to notify a user that a missing region has occurred in the outer region, which has a significant impact on the appearance of the three-dimensional object.

[0097] (8) According to a second aspect of the present disclosure, there is provided an information processing device that generates modeling data for forming a three-dimensional object by stacking layers by discharging a modeling material from a discharging unit toward a stage. The information processing device includes: an acquisition unit that acquires first data having path data that represents a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data that represents an amount of the modeling material dispensed along the path; an identification unit that identifies a missing region of the three-dimensional object based on the first data; a reception unit that receives a designation of an allowable overlap amount, which is an allowable amount of overlap between adjacent partial objects corresponding to the paths in the same layer; and a data generation unit that generates the modeling data from the first data when it is determined that the missing region can be filled with a new partial object including an overlapping portion within the specified allowable overlap amount.

[0098] The present disclosure can be realized in various forms, including not only the above-described methods for manufacturing three-dimensional objects and information processing devices, but also computer programs and non-transitory tangible recording media on which computer programs are recorded in a computer-readable manner. [Explanation of symbols]

[0099] 10...3D modeling system, 20...material supply section, 22...communicating passage, 30...plasticizing section, 31...screw case, 32...drive motor, 40...screw, 42...groove section, 43...ridge section, 44...material inlet, 46...center section, 47...upper surface, 48...lower surface, 50...barrel, 52...upper surface, 54...guide groove, 56...communicating hole, 58...barrel heater, 60...discharge section, 61...nozzle, 62...nozzle opening, 65...flow path, 70...discharge adjustment section, 74...first drive section, 75...suction section, 76...second drive section, 77...discharge control section Control unit, 100... three-dimensional printing apparatus, 110... printing unit, 210... stage, 211... printing surface, 212... stage heater, 230... movement mechanism, 300... control unit, 310... processor, 320... storage device, 400... information processing device, 410... CPU, 411... acquisition unit, 412... identification unit, 413... reception unit, 414... 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 stacking layers of a modeling material discharged from a discharge unit toward a stage, the method comprising: a first step of identifying a missing region of the three-dimensional object based on first data having path data that represents a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data that represents a discharge amount of the modeling material on the path; a second step of receiving a designation of an allowable overlap amount, which is an allowable amount of overlap between partial objects corresponding to adjacent paths in the same layer; a third step of generating modeling data from the first data so that a partial object that fills the missing area is generated when it is determined that the missing area can be filled by overlapping the partial objects within the specified range of the overlap allowance; a fourth step of controlling the relative movement of the discharge unit with respect to the stage based on the modeling data to model the three-dimensional object; A method for manufacturing a three-dimensional object having the above structure.

2. The method for manufacturing a three-dimensional object according to claim 1, In the second step, the allowable overlap amount is specified for partial objects corresponding to adjacent paths within a circular path that makes a full circuit by a continuous path.

3. The method for manufacturing a three-dimensional object according to claim 1, the layer has an outer region that forms an outline of the three-dimensional object and an infill region that is located inside the outer region, a method for manufacturing a three-dimensional object, wherein in the second step, the allowable overlap amount is individually specified for partial objects corresponding to paths adjacent to each other within the outer region and partial objects corresponding to paths adjacent to each other within the infill region.

4. The method for manufacturing a three-dimensional object according to claim 1, the layer has an outer region that forms an outline of the three-dimensional object and an infill region that is located inside the outer region, a method for manufacturing a three-dimensional object, wherein in the second step, the allowable overlap amount is specified for a partial object corresponding to a path within the outer region and a partial object corresponding to a path within the infill region, the partial object being adjacent to each other.

5. The method for manufacturing a three-dimensional object according to claim 1, in the second step, the allowable overlap amount between the partial objects corresponding to the paths adjacent to each other around the missing region is specified, in the third step, the modeling data is generated from the first data so that partial models corresponding to adjacent paths around the missing area are overlapped within the allowable overlap amount to expand the missing area identified in the first step, and a partial model that fills the expanded missing area is generated.

6. The method for manufacturing a three-dimensional object according to claim 1, the layer has an outer region that forms an outline of the three-dimensional object; the outer region has an outermost region and an inner region inside the outermost region, In the second step, the allowable overlap amount is individually specified for the outermost peripheral region and the inner peripheral region.

7. The method for manufacturing a three-dimensional object according to claim 1, the layer has an outer region that forms an outline of the three-dimensional object; When the missing area is identified in the outer boundary area, a display indicating that the missing area has been identified in the outer boundary area is displayed on a display unit.

8. An information processing device that generates modeling data for forming a three-dimensional object by stacking layers of a modeling material discharged from a discharge unit toward a stage, an acquiring unit that acquires first data having path data that represents a path along which the discharging unit moves relative to the stage while discharging the modeling material, and having discharge amount data that represents a discharge amount of the modeling material on the path; an identifying unit that identifies a missing region of the three-dimensional object based on the first data; a receiving unit that receives a designation of an allowable overlap amount, which is an allowable amount of overlap between partial objects corresponding to the paths adjacent to each other in the same layer; a data generation unit that generates the modeling data from the first data so that a partial model that fills the missing area is generated when it is determined that the missing area can be filled by overlapping the partial models within the specified range of the overlap allowance; An information processing device comprising:

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