Method for producing three-dimensional shaped article

Abstract

To provide a technique capable of suppressing warpage of a three-dimensional shaped article.SOLUTION: Provided is a method for producing a three-dimensional shaped article, including: a first step of discharging a first shaping material to shape a peeling layer on a stage; a second step of discharging a second shaping material to laminate a shaping layer on the peeling layer to shape a main body portion of the three-dimensional shaped object; and a third step of discharging a third shaping material to shape a brim layer on the peeling layer; wherein the peeling layer and the brim layer are layers separated from the main body portion shaped in the second step, and a corner portion of the brim layer and an outline of the main body portion are in contact with each other over a plurality of shaping layers.SELECTED DRAWING: Figure 5

Description

[Technical Field]

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

[0002] Patent Document 1 discloses that, in order to prevent warping during the formation of a three-dimensional object, a circular brim is formed so as to contact the outer periphery of the layer to be formed so as to be in contact with the area where warping is predicted to occur. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-72943 Summary of the Invention [Problem to be solved by the invention]

[0004] If the area of ​​the brim is increased in accordance with the shape of the three-dimensional object, the brim itself may deform, making it impossible to sufficiently suppress warping 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, the method comprising: a first step of dispensing a first modeling material to form a release layer on a stage; a second step of dispensing a second modeling material to stack modeling layers on the release layer to form a main body portion of the three-dimensional object; and a third step of dispensing a third modeling material to form a brim layer on the release layer, wherein the release layer and the brim layer are layers separated from the main body portion formed in the second step, and corners of the brim layer and the main body portion are in contact across multiple modeling layers. [Brief explanation of the drawings]

[0006] [Figure 1]FIG. 1 is an explanatory diagram illustrating a schematic configuration of a three-dimensional modeling apparatus. [Figure 2] FIG. 2 is a perspective view showing a schematic configuration of a flat screw. [Figure 3] FIG. 2 is a schematic plan view of the barrel. [Figure 4] 1A to 1C are explanatory diagrams schematically illustrating the basic operation of the three-dimensional modeling apparatus. [Figure 5] 10 is a flowchart of a three-dimensional modeling process. [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. 10 is a perspective view showing a state during the production of a three-dimensional object. [Figure 9] FIG. 10 is a diagram showing the evaluation results of the amount of warpage of the main body portion. [Figure 10] FIG. 1 is a perspective view showing the configuration of Sample 2. [Figure 11] FIG. 1 is a perspective view showing the configuration of Sample 3. [Figure 12] FIG. 10 is a perspective view showing the configuration of Sample 4. [Figure 13] FIG. 1 is a perspective view showing the configuration of Sample 5. [Figure 14] FIG. 1 is a perspective view showing the configuration of Sample 6. DETAILED DESCRIPTION OF THE INVENTION

[0007] A. First embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing apparatus 100 according to a first embodiment. FIG. 1 shows arrows indicating mutually orthogonal X, Y, and Z directions. 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."

[0008] The three-dimensional modeling apparatus 100 of this embodiment is an apparatus that forms a three-dimensional object by a material extrusion method. 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 three-dimensional object, a movement mechanism 230 that controls the dispense position of the modeling material, and a control unit 300 that controls each part of the three-dimensional modeling apparatus 100. While FIG. 1 shows one modeling unit 110, in this embodiment, the three-dimensional modeling apparatus 100 is provided with multiple modeling units 110 that generate and dispense different modeling materials. Each modeling unit 110 has the same configuration.

[0009] 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.

[0010] 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 pellets, powder, or the like. As the raw material MR, for example, a resin material such as ABS (acrylonitrile butadiene styrene), PEEK (polyether ether ketone), or PP (polypropylene) is used. The raw material MR may also contain inorganic materials such as metals and ceramics.

[0011] 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.

[0012] The plasticizing section 30 includes 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 facing portion.

[0013] FIG. 2 is a perspective view showing a schematic configuration of the lower surface 48 side of the flat screw 40. To facilitate understanding of the technology, the flat 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. 2 reversed in the vertical direction. FIG. 3 is a schematic plan view showing the upper surface 52 side of the barrel 50. The flat 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 flat screw 40 is positioned so that the rotation axis RX, which is its rotation center, is parallel to the Z direction.

[0014] As shown in Fig. 1, the flat screw 40 is housed in a screw case 31. An upper surface 47 of the flat screw 40 is connected to a drive motor 32, and the flat 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. The flat screw 40 may be driven by the drive motor 32 via a reducer.

[0015] As shown in Fig. 2, a spiral groove 42 is formed on the lower surface 48 of the flat screw 40, which is the surface that intersects with the rotation axis RX. The communication passage 22 of the material supply unit 20 described above communicates with the groove 42 from the side surface of the flat 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, but may also be a spiral or involute curve shape, or may have a shape that extends in an arc from the center to the outer periphery.

[0016] 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 42 of the lower surface 48 of the flat screw 40 and the upper surface 52 of the barrel 50. Raw material MR is supplied to this space between the flat screw 40 and the barrel 50 from the material supply section 20 through the material inlet 44 shown in FIG.

[0017] As shown in Fig. 1, a barrel heater 58 is embedded in the barrel 50 to heat the raw material MR supplied into the groove 42 of the rotating flat screw 40. A communication hole 56 is provided in the center of the barrel 50. As shown in Fig. 3, a plurality of guide grooves 54 are formed in the top surface 52 of the barrel 50, connected to the communication hole 56 and extending spirally from the communication hole 56 toward the outer periphery. Note that one end of the guide groove 54 does not have to be connected to the communication hole 56. Furthermore, the guide groove 54 may be omitted.

[0018] The raw material MR supplied into the groove 42 of the flat screw 40 is plasticized in the groove 42, flows along the groove 42 due to the rotation of the flat screw 40, and is guided to the central portion 46 of the flat screw 40 as a modeling material. The pasty modeling material that has flowed into the central portion 46 and exhibits fluidity is supplied to the discharge portion 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.

[0019] 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 flat screw 40 and the nozzle opening 62, and a discharge control unit 77 that controls the discharge of the modeling material.

[0020] 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.

[0021] 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.

[0022] 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 controlling the rotation angle of the valve using the first drive unit 74. 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.

[0023] 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.

[0024] 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 may be provided with a stage heater to prevent the modeling material discharged onto the stage 210 from cooling rapidly.

[0025] 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.

[0026] 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.

[0027] The control unit 300 is configured by a computer including one or more processors 310, a storage unit 320 including a main storage unit and an auxiliary storage unit, and an input / output interface for inputting and outputting signals to and from the outside. The processor 310 executes a program stored in the storage unit 320 to control the modeling unit 110 and the movement mechanism 230 in accordance with the modeling data stored in the storage unit 320, thereby forming a three-dimensional object on the stage 210. The modeling data for forming the three-dimensional object includes, for each layer obtained by slicing the shape of the three-dimensional object, path information indicating the movement path of the nozzle 61 and discharge amount information indicating the amount of modeling material dispensed on each movement path. The movement path of the nozzle 61 refers to the path along which the nozzle 61 moves relative to the modeling surface 211 of the stage 210 while discharging the modeling material. Note that the control unit 300 may be realized by a combination of circuits instead of being configured by a computer.

[0028] 4 is an explanatory diagram schematically illustrating the basic operation of the three-dimensional modeling apparatus 100. As described above, in the three-dimensional modeling apparatus 100, 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.

[0029] The control unit 300 repeatedly moves the nozzle 61 to form the modeling layers ML. After forming one modeling 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 modeling layers ML. Then, a three-dimensional object is formed by stacking additional modeling layers ML on the modeling layers ML that have been formed so far.

[0030] 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 the formation of one modeling layer ML, or when each modeling 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.

[0031] FIG. 5 is a flowchart of the three-dimensional printing process executed by the control unit 300. The three-dimensional printing process shown in FIG. 5 implements a method for manufacturing a three-dimensionally shaped object. FIG. 6 is a perspective view of a main body 80 of a three-dimensionally shaped object formed by the three-dimensional printing process. FIG. 7 is a side view of the main body 80. FIGS. 6 and 7 show an example of a main body 80 of a three-dimensionally shaped object, which is hollow and open at the top. The main body 80 has a rectangular bottom surface 81 and a cylindrical wall portion 82 connected to the outer periphery of the bottom surface 81 and extending upward. The outermost portion of the main body 80 in the horizontal direction is hereinafter referred to as the outer shell. The outer shell of the main body 80 has multiple corners. In this disclosure, the term "corner" refers to a portion that protrudes outward and is not limited to a sharp corner but also includes curved corners such as rounded corners. For example, in the case of a cylindrical shape, the entire side surface of the cylinder corresponds to the corner.

[0032] In step S10 of Fig. 5, the control unit 300 controls the modeling unit 110, which dispenses the first modeling material, and the movement mechanism 230 to model a release layer on the modeling surface 211 of the stage 210. The release layer is a layer that enables the main body 80 and a brim layer 86, which will be described later, to be easily peeled off from the stage 210. The release layer is also called a "raft." The first modeling material is, for example, PP.

[0033] FIG. 8 is a perspective view showing a state during the production of the three-dimensional object MD. FIG. 8 shows a state in which a release layer 83 has been formed below the main body portion 80. The area of ​​the release layer 83 is larger than the area of ​​the bottom surface 81 of the main body portion 80. The number of layers constituting the release layer 83 is, for example, 1 to 10 layers and can be specified arbitrarily by the user. The release layer 83 is used as a temporary stage. Data for forming the release layer 83 may be included in the forming data, or may be generated by the control unit 300 by analyzing the forming data for forming the main body portion 80.

[0034] In step S20 shown in FIG. 5, the control unit 300 controls the modeling unit 110, which dispenses the second modeling material, and the movement mechanism 230 to model the bottom layer of the main body portion 80 on the peel-off layer 83 in accordance with the modeling data. As shown in FIG. 8, the bottom layer of the main body portion 80 is a layer that forms the bottom surface 81 of the main body portion 80. The second modeling material is, for example, ABS. In this embodiment, the second modeling material is a material different from the first modeling material. In other words, the peel-off layer 83 and the main body portion 80 are modeled using different modeling materials.

[0035] 5 , the control unit 300 controls the modeling unit 110, which dispenses the third modeling material, and the moving mechanism 230 to model the bottom layer of the brim layer 86 on the release layer 83. The brim layer 86 is a layer that prevents the main body unit 80 from peeling off from the release layer 83.

[0036] As shown in FIG. 8 , the control unit 300 shapes the bottom layer of the brim layer 86 on the release layer 83. The control unit 300 shapes the bottom layer of the brim layer 86 so that it is adjacent to and in contact with the outer shell of the bottom layer of the main body portion 80. "Adjacent to and in contact with" means that the bottom layer of the main body portion 80 and the bottom layer of the brim layer 86 are adjacent to and in contact with each other. The brim layer 86 is not formed below the main body portion 80. When viewed from the +Z direction, the outer edge of the brim layer 86 is located between the outer periphery of the bottom layer of the main body portion 80 and the outer periphery of the release layer 83. The brim layer 86 has a plate-shaped portion 84 and a support structure portion 85. The bottom layer of the brim layer 86 forms the plate-shaped portion 84. The number of layers that make up the plate-shaped portion 84 can be, for example, 1 to 10, and can be freely specified by the user. In this embodiment, the support structure portion 85 has a rectangular prism shape. The data for forming the brim layer 86 may be included in the forming data, or may be generated by the control unit 300 by analyzing the forming data for forming the main body portion 80.

[0037] In this embodiment, the third modeling material used to model the brim layer 86 is the same as the second modeling material used to model the main body portion 80. Therefore, the modeling unit 110 that dispenses the third modeling material is the same as the modeling unit 110 that dispenses the second modeling material. Note that the order of steps S20 and S30 described above may be reversed. In other words, the bottom layer of the brim layer 86 may be modeled before the bottom layer of the main body portion 80 is modeled.

[0038] In step S40 of FIG. 5 , the control unit 300 controls the molding unit 110 and the movement mechanism 230 to mold the remaining layers of the main body portion 80, i.e., the layers other than the bottom layer of the main body portion 80, and the remaining layers of the brim layer 86, i.e., the layers other than the bottom layer of the brim layer 86. In step S40, the control unit 300 molds the brim layer 86 so that it contacts the main body portion 80 across multiple molding layers ML. The control unit 300 also molds the brim layer 86 so that corners of the side surfaces of the support structure 85 contact corners of the outer periphery of the main body portion 80. In other words, the control unit 300 molds the brim layer 86 so that the support structure 85 and the main body portion 80 are in line contact. In the first embodiment, the control unit 300 molds support structures 85 that are separate from each other at positions corresponding to multiple corners of the outer periphery of the main body portion 80. Furthermore, the control unit 300 forms the support structure 85 with a height corresponding to the height of the corner of the main body 80. Specifically, in this embodiment, the support structure 85 is formed with a height equal to the height of the corner of the main body 80. In this disclosure, "a height corresponding to the height of the corner of the main body 80" refers to a height within a range of ±10% of the height of the corner of the main body 80.

[0039] In step S50 of FIG. 5, the peel layer 83 and the brim layer 86 are separated from the main body 80 formed in steps S20 and S40. The separation step in step S50 is performed manually or by using a cutting device. The main body 80 of the three-dimensional object is manufactured through the series of steps described above. Note that step S10 described above is also referred to as the "first step." Steps S20 and S40 are also referred to as the "second step." Steps S30 and S40 are also referred to as the "third step."

[0040] According to the first embodiment described above, the main body 80 of the three-dimensional object MD and the corners of the brim layer 86, more specifically, the corners of the support structure 85, contact each other across multiple modeling layers ML, thereby effectively preventing warping of the main body 80. In particular, in this embodiment, the support structures 85 that are separated from each other are formed at positions corresponding to multiple corners of the outer periphery of the main body 80, thereby more effectively preventing warping of the main body 80.

[0041] Furthermore, in this embodiment, the support structure 85 has a rectangular prism shape, and the corners of the side surfaces of the support structure 85 come into contact with the corners of the outer periphery of the main body 80. This reduces the contact area between the main body 80 and the brim layer 86. As a result, the brim layer 86 can be easily peeled off from the main body 80 while minimizing the effect of the brim layer 86 on the appearance of the main body 80.

[0042] Furthermore, in this embodiment, the height of the support structure 85 corresponds to the height of the corners of the main body 80, which effectively prevents warping of the main body 80. The height of the support structure 85 is preferably 5% or more of the height of the corners of the main body 80, and more preferably the same as the height of the corners of the main body 80.

[0043] Furthermore, in this embodiment, even if there is a risk that the main body portion 80 will peel off from the peel-off layer 83 during modeling due to a difference in shrinkage rate between the main body portion 80 and the release layer 83, because the main body portion 80 and the brim layer 86 are modeled from the same modeling material, the contact area of ​​the main body portion 80 with the release layer 83 is substantially increased, thereby improving the adhesion of the main body portion 80 to the release layer 83. Furthermore, because the main body portion 80 and the brim layer 86 are modeled from the same modeling material, it is possible to prevent the main body portion 80 from separating from the brim layer 86 during modeling and to prevent distortion at the boundary between the brim layer 86 and the main body portion 80 due to differences in materials.

[0044] FIG. 9 shows the evaluation results for the amount of warpage of the main body portion 80. Figure 9 shows the results of measuring the amount of warpage of the bottom surface 81 of the main body portion 80 for each of the molded object samples of various shapes. The shape of the main body portion 80 of each sample, except for Samples 4 and 6, was the same as the main body portion 80 shown in FIG. 6 , with dimensions of 50 mm in the X direction, 50 mm in the Y direction, and 20 mm in the Z direction. PP talc was used as the material for each sample. The amount of warpage of the bottom surface 81 of each sample was calculated by measuring the difference in height between the most upwardly protruding part and the most downwardly recessed part of the bottom surface 81. In the evaluation results shown in FIG. 9, "A" indicates the highest evaluation and "D" indicates the lowest evaluation.

[0045] Sample 1 is a sample formed by molding a brim layer 86 including a rectangular pillar-shaped support structure 85, similar to the three-dimensional object MD shown in Fig. 8. The height of the support structure 85 is 20 mm, the same as the height of the object. The amount of warpage of Sample 1 was 85 µm, the smallest amount of warpage.

[0046] 10 is a perspective view showing the shape of a three-dimensional object MD2 of Sample 2. Sample 2 is a sample formed by forming a brim layer 86 including a cylindrical support structure 85. The height of the support structure 85 is 20 mm, the same as the height of the object. The amount of warping of Sample 2 was 116 μm, which was greater than that of Sample 1.

[0047] 11 is a perspective view showing the shape of a three-dimensionally shaped object MD3 of Sample 3. Sample 3 is a sample formed by molding a brim layer 86 including a rectangular pillar-shaped support structure 85. The height of the support structure 85 is 1 mm, which is 5% of the height of the main body 80. The amount of warpage of Sample 3 was 176 μm, which was larger than the amounts of warpage of Samples 1 and 2.

[0048] FIG. 12 is a perspective view showing the shape of a three-dimensionally shaped object MD4 of Sample 4. Sample 4 is a sample in which multiple grooves 87 are formed on the inner surface of a hollow main body portion 80 along the Z direction, which is the stacking direction of the shaping layers ML. The brim layer 86 of Sample 4 does not include a support structure 85. The amount of warpage of Sample 4 was 194 μm, which was approximately the same as that of Sample 3. Note that the shape of the main body portion 80 in Sample 4 corresponds to a shape in which the main body portion and the brim layer are shaped so that the corners of the multiple support structures contact the planar inner surface of the main body portion. Therefore, even if a brim layer 86 including support structures that contact the inner surface of the main body portion 80 is shaped, it is believed that a warpage suppression effect similar to that of Sample 4 can be achieved. Note that while Sample 4 does not include support structures 85, support structures 85 that contact the outer corners of the main body portion 80 may be shaped, as in Samples 1 to 3.

[0049] 13 is a perspective view showing the shape of the three-dimensional object MD5 of Sample 5. Sample 5 has a shape obtained by omitting the support structure 85 from the three-dimensional object MD shown in FIG. 8. The amount of warpage of Sample 5 was 254 μm, which was the largest among Samples 1 to 6.

[0050] FIG. 14 is a perspective view showing the shape of a three-dimensionally molded object MD6 of Sample 6. Sample 6 is a sample in which a brim layer 86 without a support structure 85 is molded. In Sample 6, the shape of the main body portion 80 itself was modified, and rounded corners with a radius of 10 mm (i.e., 10R) were formed at the corners. The control unit 300 formed rounded corners at the corners of the main body portion 80 by modifying the molding data used to mold the main body portion 80. In this way, even by changing the shape of the main body portion 80 itself, the amount of warpage was equivalent to that of Samples 3 and 4.

[0051] According to the evaluation results of each sample described above, it was confirmed that warping of the main body portion 80 of the three-dimensional object can be suppressed by forming a brim layer 86 including a support structure portion 85 whose corners contact the main body portion 80.

[0052] B. Other Embodiments: (B1) In the above embodiment, the support structure 85 included in the brim layer 86 contacts the corners of the outer periphery of the main body 80. However, the support structure 85 may contact any part of the outer periphery of the main body 80.

[0053] (B2) In the above embodiment, the support structure 85 may contact any position on the inner surface of the main body 80. Furthermore, if the main body 80 has a corner that protrudes inward, the support structure 85 may be formed on the inside of the main body 80 so as to contact the corner.

[0054] (B3) In the above embodiment, a plurality of support structures 85 separated from one another are formed at positions corresponding to all corners of the main body 80. In contrast to this, the support structures 85 may be formed to correspond to some of the corners of the main body 80, rather than all of the corners.

[0055] (B4) In the above embodiment, the support structure 85 has a shape that extends along the vertical direction. However, if the main body 80 has a curved portion on its side, the support structure 85 may have a portion that curves along the shape of the side of the main body 80.

[0056] (B5) In the above embodiment, the first modeling material and the second modeling material are different materials, and the second modeling material and the third modeling material are the same material. However, for example, the first modeling material, the second modeling material, and the third modeling material may each be the same material. In this case, the three-dimensional modeling device 100 may be provided with only one modeling unit 110. Furthermore, the first modeling material, the second modeling material, and the third modeling material may each be different modeling materials. In this case, the three-dimensional modeling device 100 is provided with at least three modeling units 110.

[0057] (B6) In the above embodiment, the molding unit 110 plasticizes the material using the flat screw 40. However, the molding unit 110 may also plasticize the material by, for example, rotating an in-line screw. Alternatively, the molding unit 110 may also plasticize the filament-shaped material using a heater.

[0058] C. 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.

[0059] (1) According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object, the method comprising: a first step of dispensing a first modeling material to form a release layer on a stage; a second step of dispensing a second modeling material to stack modeling layers on the release layer to form a main body portion of the three-dimensional object; and a third step of dispensing a third modeling material to form a brim layer on the release layer, wherein the release layer and the brim layer are layers separated from the main body portion formed in the second step, and corners of the brim layer and the main body portion are in contact across multiple modeling layers. According to this configuration, the main body portion and the brim layer are formed on the peel-off layer so that the corners of the brim layer and the main body portion are in contact across multiple forming layers, thereby making it possible to easily peel off the three-dimensional object from the stage while suppressing warping in the main body portion.

[0060] (2) In the above embodiment, the brim layer may have a plurality of support structures that are separated from one another and positioned corresponding to a plurality of corners of the outer contour of the main body. With this embodiment, warping of the main body can be effectively suppressed.

[0061] (3) In the above embodiment, the support structure may have a rectangular prism or a cylindrical shape.

[0062] (4) In the above embodiment, corners of the side surfaces of the support structure may contact corners of the outer periphery of the main body portion. In this embodiment, the contact area between the main body portion and the brim layer is small, so that the brim layer can be easily peeled off from the main body portion while suppressing the influence of the brim layer on the appearance of the main body portion.

[0063] (5) In the above embodiment, the height of the support structure may be 5% or more of the height of the corner of the main body.

[0064] (6) In the above embodiment, the height of the support structure may correspond to the height of the corners of the main body.

[0065] (7) In the above embodiment, the main body portion may have a hollow shape, and the main body portion may have a groove on an inner surface thereof that is aligned with the stacking direction of the modeling layers.

[0066] The present disclosure is not limited to the above-described method for manufacturing a three-dimensional object, but can be realized in various forms, such as a three-dimensional printing system, a three-dimensional printing device, a computer program, and a non-transitory tangible recording medium on which a computer program is recorded in a computer-readable manner. [Explanation of symbols]

[0067] 20...Material supply section, 22...Communicating passage, 30...Plasticizing section, 31...Screw case, 32...Drive motor, 40...Flat screw, 42...Groove section, 43...Convex ridge section, 44...Material inlet, 46...Central 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, 7 0...discharge adjustment unit, 74...first drive unit, 75...suction unit, 76...second drive unit, 77...discharge control unit, 80...main body unit, 81...bottom surface, 82...wall unit, 83...peeling layer, 84...plate-shaped unit, 85...support structure unit, 86...brim layer, 87...groove, 100...three-dimensional printing device, 110...printing unit, 210...stage, 211...printing surface, 230...movement mechanism, 300...control unit, 310...processor, 320...memory unit

Claims

1. a first step of discharging a first modeling material to model a release layer on a stage; a second step of discharging a second modeling material to stack a modeling layer on the release layer to form a main body portion of a three-dimensional object; a third step of discharging a third modeling material to form a brim layer on the release layer; Equipped with the release layer and the brim layer are layers that are separated from the main body portion shaped by the second step, The corners of the brim layer and the main body portion are in contact with each other across multiple modeling layers. A method for manufacturing three-dimensional objects.

2. The method for manufacturing a three-dimensional object according to claim 1, the brim layer has a plurality of support structures separated from one another at positions corresponding to a plurality of corners of the outer periphery of the main body.

3. The method for manufacturing a three-dimensional object according to claim 2, A method for manufacturing a three-dimensional object, wherein the support structure has a rectangular prism or a cylindrical shape.

4. The method for manufacturing a three-dimensional object according to claim 3, A method for manufacturing a three-dimensional object, wherein corners of the side surfaces of the support structure contact corners of the outer casing of the main body.

5. The method for manufacturing a three-dimensional object according to claim 2, A method for manufacturing a three-dimensional object, wherein the height of the support structure portion is 5% or more of the height of the corner portion of the main body portion.

6. The method for manufacturing a three-dimensional object according to claim 2, A method for manufacturing a three-dimensional object, wherein the height of the support structure portion corresponds to the height of the corner portion of the main body portion.

7. The method for manufacturing a three-dimensional object according to claim 1, The main body portion has a hollow shape, The main body portion has a groove on an inner surface thereof that is aligned with a stacking direction of the modeling layers.

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