3D printer system, and production method of shaped object

Abstract

To provide a printer system allowing stable performance of the system when reinforcing a shaped object using a plurality of fibers.SOLUTION: A 3D printer system is provided with: a discharge part for discharging material slurry including 3D printer material and water; a position adjustment part for adjusting a position of the discharge part so as to accumulate the material slurry discharged from the discharge part; and a fiber supply part for merging a plurality of reinforcement fibers to the material slurry in the discharge part or the material slurry after discharged from the discharge part.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a 3D printer system and a method for manufacturing a modeled object. [Background technology]

[0002] Patent Document 1 discloses an additive manufacturing system for molding cementitious mixtures. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-185645 Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure provides a 3D printer system and a method for manufacturing a model that are useful for stable operation of the system when reinforcing a model with multiple fibers. [Means for solving the problem]

[0005] [1] A 3D printer system comprising: a discharge unit that discharges a material slurry containing a material for a 3D printer and water; a position adjustment unit that adjusts the position of the discharge unit so that the material slurry discharged from the discharge unit is stacked; and a fiber supply unit that merges a plurality of reinforcing fibers into the material slurry in the discharge unit or into the material slurry after it has been discharged from the discharge unit.

[0006] [2] The 3D printer system described in [1] above, wherein the discharge unit has a first nozzle that discharges the material slurry, and the fiber supply unit has a second nozzle that discharges the multiple reinforcing fibers so that they penetrate between layers of the material slurry discharged from the first nozzle and stacked in a layered state.

[0007] [3] A 3D printer system according to [1] or [2] above, wherein each of the plurality of reinforcing fibers is a metal fiber, a carbon fiber, or a synthetic fiber.

[0008] [4] The 3D printer system according to any one of [1] to [3] above, wherein the length of each of the plurality of reinforcing fibers is 3 mm to 80 mm.

[0009] [5] A 3D printer system according to any one of [1] to [4] above, further comprising: a first material supply unit that supplies a main material slurry containing a hydraulic binder and water; a second material supply unit that supplies a hardening agent slurry containing a component that hardens the hydraulic binder and water; and a mixing unit that mixes the main material slurry and the hardening agent slurry to obtain the material slurry and supplies the material slurry to the discharge unit, wherein the mixing unit has a static mixer.

[0010] [6] A method for manufacturing a shaped object, comprising: a discharge step of discharging a material slurry containing a material for a 3D printer and water from a discharge unit; a position adjustment step of adjusting the position of the discharge unit so that the material slurry discharged from the discharge unit is stacked; a fiber supply step of merging a plurality of reinforcing fibers into the material slurry in the discharge unit or into the material slurry after being discharged from the discharge unit; and a hardening step of hardening the laminate formed by stacking the material slurries to obtain a shaped object. [Effects of the Invention]

[0011] According to the present disclosure, a 3D printer system and a method for manufacturing a model are provided that are useful for stable operation of the system when reinforcing a model with multiple fibers. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic diagram illustrating an example of a 3D printer system. [Figure 2] FIG. 2 is an exploded perspective view showing an example of a mixer. [Figure 3]Figure 3(a) is a schematic diagram showing an example of a fiber supplying section, and Figure 3(b) is a schematic diagram showing an example of a fiber supplying section. [Figure 4] FIG. 4 is a photograph showing an example of the state inside the mixer when multiple fibers are joined upstream of the discharge section. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment will be described below with reference to the drawings. In the description, identical elements or elements having the same functions are given the same reference numerals, and redundant description will be omitted. Unless otherwise specified, positional relationships such as up, down, left, and right are based on the positional relationships based on the orientation of the reference numerals shown in the drawings. The dimensional ratios of each element are not limited to those shown in the drawings. When multiple materials are exemplified, one of them may be used alone, or multiple materials may be used in combination.

[0014] [3D printer system] Fig. 1 shows a schematic diagram of a 3D printer system according to one embodiment. The construction system 1 (3D printer system) shown in Fig. 1 is a system that builds a three-dimensional object by layering materials for a 3D printer based on three-dimensional data. Because the object is manufactured by the construction system 1, the construction system 1 can also be called a system for manufacturing a model.

[0015] The construction system 1 is, for example, a two-component 3D printer system that uses a base material slurry and a hardener slurry. In this case, the construction system 1 can be said to be a construction system for a laminate or a shaped object that uses a two-component hardening composition. As shown in FIG. 1, the construction system 1 may include a first material supply unit 10, a second material supply unit 20, a confluence unit 30, a flow path 32, a mixing unit 40, a discharge unit 60, and a position adjustment unit 70. In the following description, the terms "upstream" and "downstream" are used based on the direction in which the slurry containing the material for the 3D printer moves.

[0016] (First material supply section - main material slurry) The first material supply unit 10 supplies a main material slurry containing a hydraulic binder and water. The first material supply unit 10 supplies the main material slurry to a confluence unit 30 located downstream of the first material supply unit 10. The first material supply unit 10 may include a first storage unit 12 and a first liquid feed pump 14. The first storage unit 12 is a member for storing the main material slurry. The first storage unit 12 may be a transportable container, a tank truck, or a tank installed on the ground. The first liquid feed pump 14 may be any type of pump, but may also be a non-pulsating pump from the viewpoint of stabilizing the supply rate. From the viewpoint of further stabilizing the supply rate, a non-pulsating metering pump may be used as the first liquid feed pump 14.

[0017] An example of the components of the main material slurry supplied by the first material supply unit 10 will be described. The main material slurry can be prepared by blending a hydraulic binder and water. The hydraulic binder is a material containing cement and exhibiting hydraulic properties, and may also contain admixtures. Examples of cement include various Portland cements such as ordinary Portland cement, high-early-strength Portland cement, ultra-high-early-strength Portland cement, moderate-heat Portland cement, low-heat Portland cement, and sulfate-resistant Portland cement, as well as various blended cements such as blast-furnace cement and fly ash cement. Only one of these cements may be used, or multiple types may be mixed and used. Among these, from the viewpoint of improving the hardening characteristics of the hydraulic composition slurry for additive manufacturing, it is more preferable to use at least one Portland cement selected from the group consisting of ordinary Portland cement, high-early-strength Portland cement, and ultra-high-early-strength Portland cement.

[0018] The water contained in the main slurry is not particularly limited and may be, for example, tap water, distilled water, deionized water, etc. The content of water in the main slurry is preferably 15 to 60 mass %, more preferably 20 to 50 mass %, and even more preferably 25 to 45 mass %, based on the total amount of hydraulic binder.

[0019] Examples of admixtures include various admixtures such as ground granulated blast furnace slag (for example, those conforming to JISA6206:2013 "ground granulated blast furnace slag for concrete"), ground limestone, silica fume (for example, those specified in JISA6207:2016 "silica fume for concrete"), fly ash (for example, those specified in JISA6201:2015 "fly ash for concrete"), metakaolin, silica powder, expansive additives, etc. Among these, it is preferable to include ground granulated blast furnace slag and silica fume from the viewpoint of improving the pumpability of the base material slurry and the mixed slurry and extending the fluidity retention time (use life).

[0020] The ground granulated blast furnace slag preferably conforms to JISA6206:2013 "Ground granulated blast furnace slag for concrete." The Blaine specific surface area of ​​the ground granulated blast furnace slag is preferably 2500 to 10000 cm2 / g, more preferably 3000 to 9000 cm2 / g, and even more preferably 4000 to 8000 cm2 / g.

[0021] When the hydraulic binder contains an admixture, the content of the admixture relative to the total amount of the hydraulic binder is, for example, 1 to 99 mass%, preferably 10 to 90 mass%, more preferably 30 to 70 mass%. When the content of the admixture is within the above range, the main material slurry can achieve suitable pumpability and fluidity retention time.

[0022] The base slurry may contain a retarder. The retarder is not particularly limited, and examples thereof include hydroxycarboxylic acids, sugars, and inorganic retarders. The retarder preferably contains hydroxycarboxylic acids. The hydroxycarboxylic acids are a general term for hydroxycarboxylic acids and their salts. Examples of hydroxycarboxylic acids include gluconic acid, tartaric acid, citric acid, malic acid, succinic acid, and heptonic acid.

[0023] Examples of the salt of hydroxycarboxylic acid include alkali metal salts (sodium salt, potassium salt, etc.) and alkaline earth metal salts (calcium salt, magnesium salt, etc.). Of these, in terms of the setting retardation effect, availability, and cost, it is preferable to contain a sodium salt, and it is more preferable to contain sodium gluconate. The hydroxycarboxylic acid and its salt may be used alone or in combination of two or more components.

[0024] When the main slurry contains a retarder, the content of the retarder is preferably 0.05 to 1.5 mass %, more preferably 0.1 to 1.0 mass %, and even more preferably 0.2 to 0.8 mass %, relative to the total amount of hydraulic binder in the main slurry. By setting the content of the retarder within the above range, a suitable fluidity retention time (workable life) can be obtained.

[0025] The main material slurry may contain aggregate, water-reducing agent, thickener, antifoaming agent, etc. in addition to the hydraulic binder, retarder, and water.

[0026] (Second material supply section - hardener slurry) The second material supply unit 20 supplies a hardening agent slurry containing water and components that harden the hydraulic binder. The second material supply unit 20 supplies the hardening agent slurry to the confluence unit 30 located downstream of the second material supply unit 20. The second material supply unit 20 may include a second storage unit 22 and a second liquid feed pump 24. The second storage unit 22 is a member that stores the hardening agent slurry. The second storage unit 22 may be a transportable container, a tank truck, or a tank installed on the ground. The second liquid feed pump 24 may be any type of pump, but may also be a non-pulsating pump from the viewpoint of stabilizing the supply rate. From the viewpoint of further stabilizing the supply rate, a non-pulsating metering pump may be used as the second liquid feed pump 24.

[0027] An example of the components contained in the hardener slurry supplied by the second material supply unit 20 will be described. The hardener slurry contains water and a component that hardens the hydraulic binder. The hardener slurry may be prepared, for example, by adding water to a powdered hardener (premixed powder). The water contained in the hardener slurry is not particularly limited and may be, for example, tap water, distilled water, or deionized water. The content of water in the hardener slurry may be 5 to 50 mass %, 10 to 40 mass %, or 15 to 35 mass % relative to the total amount of the hardener slurry.

[0028] Components that harden hydraulic binders include accelerators and gelling agents. Accelerator-setting agents include alum, sulfates (aluminum sulfate, sodium sulfate, potassium sulfate, lithium sulfate, magnesium sulfate), carbonates (sodium carbonate, potassium carbonate, lithium carbonate), calcium thiocyanate, and calcium chloride. Alum is a double salt of a sulfate of a monovalent cation and a sulfate of a trivalent metal ion. The alum is not particularly limited, and may be, for example, potassium alum, ammonium alum, sodium alum, iron alum, chromium alum, or an anhydride thereof (calcined alum). One of these may be used alone, or two or more may be used in combination. From the standpoints of availability and cost, as well as when preparing a hardener slurry containing water, it is preferable that the accelerator contains potassium alum.

[0029] The average particle size of the alum may be 0.01 to 1.0 mm, preferably 0.02 to 0.3 mm, more preferably 0.03 to 0.2 mm, and even more preferably 0.04 to 0.1 mm. When the particle size of the alum is within the above range, aggregation is less likely to occur when the alum is mixed with the main material slurry, and mixability can be improved.

[0030] The average particle size of alum is determined from the volume-based frequency distribution measured using a laser diffraction / scattering particle size distribution analyzer. Measurements are performed under dry conditions using, for example, a laser diffraction / scattering particle size distribution analyzer, such as the "SALD-2200" manufactured by Shimadzu Corporation. The average particle size of alum is calculated as a weighted average value of the logarithmic particle size, with the volume-based frequency for that particle size being the weight, based on the relationship between the volume-based frequency and the particle size obtained in the above measurement.

[0031] The content of the quick-setting admixture in the hardener slurry is preferably 3 to 12 mass %, more preferably 4 to 10 mass %, and even more preferably 5 to 8 mass %, based on the total amount of the hardener slurry. By having the content of the quick-setting admixture in the above range, suitable rapid hardening properties and strength development can be obtained.

[0032] Examples of gelling agents include basic aluminum salts. Basic aluminum salts are basic salts containing aluminum ions and hydroxy acid ions having 2 to 6 carbon atoms. Here, the basic salt is a salt containing hydroxide ions (OH-). In other words, basic aluminum salts are salts of aluminum and hydroxy acid in which some of the anions are substituted with hydroxide ions. Basic aluminum salts can be represented by the general formula: Al(OH)3-xYb. Here, x and b are selected so that the basic aluminum salt as a whole is electrically neutral. Use of basic aluminum salts can suppress the formation of flocs, thereby particularly improving mixability.

[0033] The number of carbon atoms contained in the hydroxy acid ion contained in the basic aluminum salt is preferably 2 to 4, more preferably 2 or 3, and even more preferably 3. Examples of basic aluminum salts include basic aluminum lactate, basic aluminum hydroxyacetate, basic aluminum citrate, and basic aluminum tartrate, with basic aluminum lactate being preferred. These may be hydrates. The basic aluminum salts may be used alone or in combination of two or more.

[0034] Basic aluminum lactate is a compound represented by the general formula Al(OH)3-x(Lac.acid)x (0 < x < 3), and it is preferable that the molar ratio of Al2O3 / lactic acid is 0.3 to 2.0. Here, Lac.acid is a lactate ion. Basic aluminum lactate may be a hydrate. Examples of commercially available basic aluminum lactate include "Taxeram M160-P" (manufactured by Takaki Chemical Co., Ltd.), etc., and these can be used.

[0035] The content of the gelling agent is preferably 0.5 to 5.0% by mass, more preferably 0.8 to 4.0% by mass, and even more preferably 1.0 to 3.0% by mass with respect to the total amount of the hardening material slurry. When the hardening material slurry contains a setting accelerator (gypsum) and a gelling agent (basic aluminum salt), the content of the gelling agent may be preferably 10 to 40% by mass, more preferably 15 to 35% by mass, and even more preferably 20 to 30% by mass with respect to the total amount of the setting accelerator and the gelling agent. When the contents of the setting accelerator and the gelling agent are within this range, suitable lamination properties and quick-hardening properties can be obtained when mixed with the main material slurry, and abnormal coagulation or a decrease in strength development tendency can be suppressed.

[0036] In addition to the setting accelerator and the gelling agent, the hardening material slurry may contain silica powder, aggregate, defoaming agent, thickening agent, water reducing agent, etc.

[0037] (Confluence section) The confluence section 30 is a part where the main material slurry supplied from the first material supply section 10 and the hardening material slurry supplied from the second material supply section 20 are confluent. In the main material slurry and the hardening material slurry after confluence in the confluence section 30, the ratio of the hardening material slurry to the main material slurry may be 0.1 to 0.5 or 0.2 to 0.4 based on volume. The flow path 32 is a flow path connecting the confluence section 30 and the mixing section 40, and the main material slurry and the hardening material slurry after confluence in the confluence section 30 are introduced into the mixing section 40 through the flow path 32.

[0038] (Mixing section) The mixing section 40 is the section where the main material slurry and the hardener slurry are mixed. From the viewpoint of further improving workability, it is preferable to have an inline mixer, and from the viewpoint of simplifying the equipment and reducing weight, it is more preferable to have a static mixer. A static mixer is a mixer that does not have a driving part, and is also called a static mixer or static mixer. Because the static mixer does not have a driving part, it is lightweight and the structure of the construction system can be simplified. This makes it easy to handle at the construction site, further improving workability.

[0039] As a static mixer, a mixer having a cylinder and an element provided inside the cylinder, which mixes the components derived from the main material slurry and the hardener slurry by mixing principles such as rotation, division, inversion, and recombination, can be used.

[0040] Fig. 2 shows an example of a static mixer included in the mixing unit 40. The static mixer 40a shown in Fig. 2 includes a cylindrical body 45 and an element 41. The cylindrical body 45 is a member formed in a cylindrical shape so as to extend in one direction, and is capable of accommodating the element 41 in its internal space. Although not shown in Fig. 2, flanges having an inner diameter smaller than that of the cylindrical body 45 may be attached to both ends of the cylindrical body 45.

[0041] The element 41 is composed of a plurality of repeating units 42 connected in the flow direction of the slurry. The repeating units 42 have the same shape. The flow direction of the slurry corresponds to the direction in which the central axis CL of the cylindrical body 45 extends. The repeating unit 42 includes a plate portion 42A (42C) and a perforated portion 42B (42D).

[0042] The plate portion 42A (42C) has a main surface MP1 (MP2) perpendicular to the radial direction of the cylinder 45, and is formed so as to divide the slurry flow path into two along the direction in which the central axis CL extends. The plate portion 42A (42C) is provided so as to block the central axis CL. The gap (clearance) between the end portions E of the plate portions 42A, 42C and the inner wall of the cylinder 45 is preferably small, and the end portions E and the inner wall of the cylinder 45 may be in contact with each other.

[0043] The orientation of the main surface MP1 of the plate portion 42A and the orientation of the main surface MP2 of the plate portion 42C are shifted by 90° from each other around the central axis CL. In Fig. 2, the plate portion 42A is arranged vertically, and the plate portion 42C is arranged horizontally. In this way, the plate portions 42A and 42C whose main surfaces are oriented in different directions are provided alternately in the element 41.

[0044] The perforated portion 42B (42D) includes circulation holes 43 through which the slurry flows. The perforated portion 42B includes four claw-shaped members NB, and the circulation holes 43 of the perforated portion 42B are formed by the four claw-shaped members NB. The perforated portion 42D includes four claw-shaped members NV, and the circulation holes 43 of the perforated portion 42D are formed by the four claw-shaped members NV. The circulation holes 43 are formed closer to the central axis CL than the end E.

[0045] The base ends of two of the four claw-shaped members NV are connected to one side edge (upstream side edge) of the vertically oriented plate portion 42A so as to be aligned vertically. These two claw-shaped members NV are formed so as to move away from each other from their respective base ends toward their tips. The tip of one claw-shaped member NV is connected to a corner of one main surface (upper surface) of the horizontally oriented plate portion 42C, and the tip of the other claw-shaped member NV is connected to a corner of the other main surface (lower surface) of the plate portion 42C.

[0046] The base ends of the remaining two of the four claw-shaped members NV are connected to the other side edge (downstream side edge) of the vertically oriented plate portion 42A so as to be aligned vertically. These two claw-shaped members NV are formed so as to move away from each other from their respective base ends toward their tips. The tip of one claw-shaped member NV is connected to a corner of one main surface (upper surface) of the horizontally oriented plate portion 42C, and the tip of the other claw-shaped member NV is connected to a corner of the other main surface (lower surface) of the plate portion 42C.

[0047] The base ends of two of the four claw-shaped members NB are connected to one side edge (downstream side edge) of the horizontally placed plate portion 42C so as to be aligned horizontally. These two claw-shaped members NB are formed so as to move away from each other from their respective base ends toward their tips. The tip of one claw-shaped member NB is connected to a corner of one main surface (main surface MP1) of the plate portion 42A, and the tip of the other claw-shaped member NB is connected to a corner of the other main surface of the plate portion 42A.

[0048] The base ends of two of the four claw-shaped members NB are connected to the other side edge (upstream side edge) of the horizontally placed plate portion 42C so as to be aligned horizontally. These two claw-shaped members NB are formed so as to move away from each other from their respective base ends toward their tips. The tip of one claw-shaped member NB is connected to a corner of one main surface of the plate portion 42A, and the tip of the other claw-shaped member NB is connected to a corner of the other main surface of the plate portion 42A.

[0049] When a slurry containing a base material slurry and a hardener slurry flows into the static mixer 40a from the upstream side, the slurry flow is split into two by the plate portion 42A located on the upstream side. The two flows then flow into the perforated portion 42B adjacent to the plate portion 42A on the downstream side. The four claw-shaped members NB that make up the perforated portion 42B cause the two flows to flow into the flow holes 43 and merge, thereby becoming a single flow. The slurry flow then splits into two flows again by the plate portion 42C that is adjacent to the perforated portion 42B on the downstream side. The two flows then flow into the perforated portion 42D that is adjacent to the plate portion 42C on the downstream side. The four claw-shaped members NV that make up the perforated portion 42D cause the two flows to flow into the flow holes 43 and merge, thereby becoming a single flow.

[0050] As described above, the slurry repeatedly separates and merges in the static mixer 40a. This allows the slurry containing the main material slurry and the hardener slurry to be thoroughly mixed, resulting in a slurry with a sufficiently high mixing uniformity. Hereinafter, the slurry obtained by mixing the main material slurry and the hardener slurry in the mixing unit 40 (static mixer) will be referred to as the "material slurry." The material slurry is a slurry containing a material for a 3D printer and water. The mixing unit 40 supplies the material slurry to the discharge unit 60.

[0051] (Discharge part) Returning to FIG. 1, the discharge section 60 is a section that discharges the material slurry. The discharge section 60 is provided downstream of the mixing section 40, and the material slurry obtained by the mixing section 40 is introduced into the discharge section 60. The discharge section 60 may be connected to the downstream end of the mixing section 40. The discharge section 60 may be provided so as to be movable together with the mixing section 40. The discharge section 60 may have a nozzle 60a (first nozzle) that discharges the material slurry. The material slurry discharged from the discharge section 60 is layered as shown in FIG. 1. In FIG. 1, the laminate formed by layering the material slurries is indicated by "100", and each layer of the laminate 100 is indicated by "100a".

[0052] (Position adjustment part) The position adjustment unit 70 is a part (device) that adjusts the position of the discharge unit 60 so that the material slurry discharged from the discharge unit 60 is laminated. The discharge unit 60 discharges the material slurry while the position of the discharge unit 60 is adjusted by the position adjustment unit 70, thereby forming the laminate 100. When the mixing unit 40 is provided so as to be movable together with the discharge unit 60, the position adjustment unit 70 moves the mixing unit 40 together with the discharge unit 60. The position adjustment unit 70 may be, for example, a robot arm or a gantry crane.

[0053] By hardening the laminate 100, a shaped object including the hardened body can be obtained. The hardened body may be a cement hardened body. The position of the discharge unit 60 that discharges the material slurry is adjusted by the position adjustment unit 70, so the construction system 1 can obtain shaped objects (laminated body 100) having various shapes. The shaped objects constructed (manufactured) by the construction system 1 are not particularly limited, and specific examples include buildings and structures. The construction system 1 may construct shaped objects such as secondary concrete products, buried formwork, buildings or benches to be installed in parks, etc.

[0054] (Fiber Supply Department) The construction system 1 has a fiber supply unit (see Fig. 3(a) and Fig. 3(b)). The fiber supply unit of the construction system 1 is a part that merges multiple reinforcing fibers into the material slurry in the discharge unit 60 or into the material slurry after being discharged from the discharge unit 60. Hereinafter, the reinforcing fibers that merge into the material slurry will be referred to as "reinforcing fibers f."

[0055] In order to improve the strength of the object obtained by the construction system 1, the construction system 1 uses a fiber supply unit to merge multiple reinforcing fibers f into the material slurry before hardening. Each of the multiple reinforcing fibers f is, for example, a high-tensile fiber. Each of the multiple reinforcing fibers f may be a metal fiber (for example, a steel fiber), a carbon fiber, or a synthetic fiber (for example, an aramid fiber or a vinylon fiber). Each of the multiple reinforcing fibers f may be a synthetic fiber such as an aramid fiber or a vinylon fiber that complies with JISA6208:2018 (Synthetic short fibers for concrete and mortar). The multiple reinforcing fibers f may include two or more types of fibers.

[0056] The length (fiber length) of each of the multiple reinforcing fibers f is shorter than the length along the discharge path of each layer 100a constituting the laminate 100. The length along the discharge path of each layer 100a is defined by the length of the movement trajectory of the center of the discharge port of the discharge unit 60 when forming one layer 100a. The fiber supply unit of the construction system 1 supplies the multiple reinforcing fibers f so that at least some of the layers 100a of the laminate 100 (for example, each of all the layers 100a) contain two or more reinforcing fibers f. In other words, focusing on any one layer 100a of the laminate 100, two or more discontinuous reinforcing fibers f are contained. The fiber supply unit of the construction system 1 supplies each of the multiple reinforcing fibers f in a single state (single yarn state) rather than as a twisted yarn.

[0057] From the viewpoint of improving the strength of the shaped object, the fiber length of each of the plurality of reinforcing fibers (f) may be 3 mm or more, 3.5 mm or more, or 4 mm or more. From the viewpoint of simplifying the fiber supply unit, the fiber length of each of the plurality of reinforcing fibers (f) may be 80 mm or less, 50 mm or less, 20 mm or less, 12 mm or less, or 8 mm or less. For example, the fiber length of each of the plurality of reinforcing fibers (f) is 3 mm to 80 mm, 3 mm to 50 mm, 3 mm to 20 mm, or 4 mm to 8 mm. Each of the plurality of reinforcing fibers (f) may be a short fiber (for example, a synthetic short fiber conforming to JISA6208:2018).

[0058] The diameter (fiber diameter) of each of the multiple reinforcing fibers f may be 100 μm or more, 150 μm or more, or 180 μm or more from the viewpoint of improving the strength of the shaped object. The fiber diameter of each of the multiple reinforcing fibers f may be 400 μm or less, 350 μm or less, or 300 μm or less from the viewpoint of simplifying the fiber supply unit. For example, the fiber diameter of each of the multiple reinforcing fibers f is 100 μm to 400 μm, or 180 μm to 300 μm.

[0059] When the value obtained by dividing the fiber length by the fiber diameter is defined as the aspect ratio, the aspect ratio (fiber length / fiber diameter) of each of the multiple reinforcing fibers f may be 10 to 100, 15 to 90, or 20 to 80. The ratio of the multiple reinforcing fibers f supplied to the material slurry may be 0.1% to 0.5%, or 0.2% to 0.4% by volume.

[0060] As shown in FIG. 3(a), the construction system 1 may have a fiber supply unit 80. The fiber supply unit 80 is configured to merge a plurality of reinforcing fibers f into the material slurry after it has been discharged from the discharge unit 60. The fiber supply unit 80 supplies a plurality of reinforcing fibers f to the material slurry (an intermediate product of the laminate 100) that has been discharged from the discharge unit 60 and is not yet hardened and is in the process of being layered. The fiber supply unit 80 has a nozzle 80a (second nozzle). The nozzle 80a discharges a plurality of reinforcing fibers f. The nozzle 80a is configured to discharge a plurality of reinforcing fibers f so as to penetrate between the layers of the material slurry that has been discharged from the nozzle 60a of the discharge unit 60 and is in a layered state.

[0061] The nozzle 80a is capable of ejecting a plurality of reinforcing fibers f so that two or more reinforcing fibers f penetrate at least between the uppermost layer 100a of an intermediate product (intermediate product of the laminate 100) in a state in which the material slurry is stacked and another layer 100a adjacent to that layer 100a. When focusing on one reinforcing fiber f after being ejected from the nozzle 80a, the reinforcing fiber f is embedded in two adjacent layers 100a or three or more consecutive layers 100a.

[0062] The nozzle 80a may be attached to the nozzle 60a that discharges the material slurry. In this case, the nozzle 80a also moves as the discharge unit 60 (nozzle 60a) is driven by the position adjustment unit 70. This makes it easy to merge the multiple reinforcing fibers f with the material slurry being discharged from the nozzle 60a and layered as it is layered. The fiber supply unit 80 may discharge the multiple reinforcing fibers f from the nozzle 80a by any means, but for example, may use air to push the multiple reinforcing fibers f out of the discharge opening of the nozzle 80a.

[0063] The construction system 1 may have a fiber supply unit 90, as shown in FIG. 3(b), instead of the fiber supply unit 80. The fiber supply unit 90 is configured to merge a plurality of reinforcing fibers f into the material slurry in the discharge unit 60. The fiber supply unit 90 is connected to the nozzle 60a of the discharge unit 60, and merges a plurality of reinforcing fibers f into the material slurry contained in the nozzle 60a. The fiber supply unit 90 may feed a plurality of reinforcing fibers f into the material slurry in the nozzle 60a by any means.

[0064] When the fiber supply unit 90 is provided, the nozzle 60a discharges material slurry containing multiple reinforcing fibers f. The fiber supply unit 90 may supply multiple reinforcing fibers f into the nozzle 60a so that each layer 100a contains two or more reinforcing fibers f. When focusing on one reinforcing fiber f (contained in the intermediate product of the laminate 100) after being discharged from the nozzle 60a, the reinforcing fiber f is embedded in only one layer 100a, unlike when the fiber supply unit 80 is provided. When the fiber supply unit 90 is provided, the construction system 1 may add a curing accelerator to the material slurry in the discharge unit 60 (nozzle 60a) in addition to the reinforcing fibers f.

[0065] [Manufacturing method for molded objects] A method for manufacturing a shaped object may be performed by a construction system 1 provided with a fiber supply unit 80 or a construction system 1 provided with a fiber supply unit 90. This method for manufacturing a shaped object includes at least a discharging step, a position adjusting step, a fiber supplying step, and a curing step. The discharging step is a step of discharging a material slurry containing a material for the 3D printer and water from the discharging unit 60. The position adjusting step is a step of adjusting the position of the discharging unit 60 so that the material slurry discharged from the discharging unit 60 is layered.

[0066] The fiber supplying step is a step of merging a plurality of reinforcing fibers f into the material slurry in the discharge unit 60 or into the material slurry after being discharged from the discharge unit 60. In the fiber supplying step, for example, the fiber supplying unit 80 supplies a plurality of reinforcing fibers f to the material slurry that has been discharged from the discharge unit 60 and has not yet hardened. In the fiber supplying step, the fiber supplying unit 90 may supply a plurality of reinforcing fibers f to the material slurry in the discharge unit 60. The hardening step is a step of hardening the layered body 100 formed by stacking the material slurries to obtain a shaped object.

[0067] The method for manufacturing a shaped object may include a first material supplying step, a second material supplying step, and a mixing step. The first material supplying step is a step of supplying a main material slurry containing a hydraulic binder and water from the first material supplying unit 10 to a downstream member. The second material supplying step is a step of supplying a hardening material slurry containing a component for hardening the hydraulic binder and water from the second material supplying unit 20 to a downstream member. The mixing step is a step of mixing the main material slurry and the hardening material slurry using a static mixer in the mixing unit 40 to obtain a material slurry, and supplying the material slurry to the discharge unit 60.

[0068] [Example of issues when reinforcing fibers are joined] FIG. 4 shows a photograph illustrating a problem that occurred when multiple reinforcing fibers (f) were merged in a construction system 1 that does not include a fiber supply unit 80 or a fiber supply unit 90. Specifically, the inventors attempted to construct a shaped object by adding multiple reinforcing fibers (f) to the first storage unit 12 of the first material supply unit 10, which is different from the fiber supply unit 80 or the fiber supply unit 90, and then pumping the main material slurry containing the multiple reinforcing fibers (f) using the first liquid feed pump 14. As the reinforcing fibers (f), vinylon fibers with a fiber diameter of 200 μm, a fiber length of 6 mm, and an aspect ratio of 30 were used, and the multiple reinforcing fibers (f) were added to the material slurry at a volume ratio of 0.3%. As a result of this attempt, a problem occurred in which fibers clogged the element 41 in the static mixer of the mixing unit 40, as indicated by "A" in the photograph of FIG. 4. From the results of this trial, it can be seen that by merging multiple reinforcing fibers f with the material slurry downstream of the mixing section 40, the problem of fiber clogging in the element 41 caused by the merging of the reinforcing fibers f does not occur.

[0069] [Variations] Although one embodiment has been described above, the contents of the present disclosure are not necessarily limited to the above-described embodiment, and can be modified as appropriate within the scope of the gist thereof.

[0070] The construction system 1 may be configured in any manner as long as it includes a discharge unit that discharges a material slurry capable of obtaining a shaped object, a position adjustment unit that adjusts the position of the discharge unit, and a fiber supply unit that merges multiple reinforcing fibers into the material slurry within the discharge unit or after it has been discharged from the discharge unit.The construction system 1 may also be a system (one-component 3D printer system) that can layer a material slurry capable of obtaining a shaped object without mixing a main material slurry and a hardener slurry.

[0071] Summary of this disclosure The 3D printer system (1) described above includes a discharge unit (60) that discharges a material slurry containing a material for the 3D printer and water, a position adjustment unit (70) that adjusts the position of the discharge unit (60) so that the material slurry discharged from the discharge unit (60) is stacked, and fiber supply units (80, 90) that merge a plurality of reinforcing fibers (f) into the material slurry in the discharge unit (60) or into the material slurry after being discharged from the discharge unit (60).

[0072] Merging multiple reinforcing fibers (f) into the material slurry before hardening improves the strength of the object produced by the 3D printer system. If such multiple reinforcing fibers (f) were to merge with the material slurry or the slurry used to obtain the material slurry (hereinafter referred to as “material slurry, etc.”) upstream of the discharge section (60), the multiple reinforcing fibers (f) could impede the flow of the material slurry, etc., in the components that deliver the material slurry, etc., to the discharge section (60), or could cause problems such as wear or damage to the components that deliver the material slurry, etc. In contrast, in the 3D printer system (1), the multiple reinforcing fibers (f) merge with the material slurry at the discharge section (60) or after being discharged from the discharge section (60), thereby avoiding such problems. Therefore, this is useful for stable system operation when reinforcing an object with multiple fibers.

[0073] In the 3D printer system (1) described above, the discharge unit (60) may have a first nozzle (60a) that discharges the material slurry. The fiber supply unit (80) may have a second nozzle (80a) that discharges a plurality of reinforcing fibers (f) so as to penetrate between the layers of the material slurry discharged from the first nozzle (60a) and stacked. In this case, the layers (100a) of the material slurry are connected to each other via the plurality of reinforcing fibers (f), which is useful for improving the strength of the model.

[0074] In the 3D printer system (1) described above, each of the multiple reinforcing fibers may be a metal fiber, a carbon fiber, or a synthetic fiber. In this case, the fiber itself has a certain degree of strength, which is useful for improving the strength of the model.

[0075] In the 3D printer system (1) described above, the length of each of the plurality of reinforcing fibers (f) may be 3 mm to 80 mm. In this case, it is useful to simultaneously improve the strength of the model and simplify the fiber supply units (80, 90).

[0076] The 3D printer system (1) described above may further include a first material supply unit (10) that supplies a base material slurry containing a hydraulic binder and water, a second material supply unit (20) that supplies a hardening agent slurry containing a component that hardens the hydraulic binder and water, and a mixer (40) that mixes the base material slurry with the hardening agent slurry to obtain a material slurry and supplies the material slurry to the discharge unit (60). The mixer (40) may include a static mixer. As described above, if multiple reinforcing fibers (f) are mixed with the material slurry, etc., upstream of the discharge unit (60) (more specifically, upstream of the discharge unit (60) and the mixer (40)), a problem may occur in which the fibers clog an element of the static mixer of the mixer (40). In contrast, in the 3D printer system (1), the reinforcing fibers (f) join the material slurry downstream of the mixing section (40) having a static mixer, which prevents the element of the static mixer in the mixing section (40) from becoming clogged with fibers.

[0077] The method for manufacturing a 3D printer described above includes a discharge step of discharging a material slurry containing a material for a 3D printer and water from a discharge unit (60), a position adjustment step of adjusting the position of the discharge unit (60) so that the material slurry discharged from the discharge unit (60) is layered, a fiber supply step of adding a plurality of reinforcing fibers (f) to the material slurry in the discharge unit (60) or to the material slurry after being discharged from the discharge unit (60), and a curing step of curing the laminate (100) formed by layering the material slurry to obtain a 3D printer. In this manufacturing method, the plurality of reinforcing fibers (f) are combined with the material slurry in the discharge unit (60) or after being discharged from the discharge unit (60). Therefore, similar to the 3D printer system (1) described above, this method is useful for stable system operation when reinforcing a 3D printer with a plurality of fibers. [Explanation of symbols]

[0078] 1...construction system (3D printer system), 10...first material supply section, 20...second material supply section, 40...mixing section, 60...discharge section, 60a...nozzle, 70...position adjustment section, 80, 90...fiber supply section, 80a...nozzle, f...reinforcing fiber, 100...laminated body, 100a...layer.

Claims

1. A discharge unit that discharges a material slurry containing a material for a 3D printer and water; a position adjusting unit that adjusts the position of the discharge unit so that the material slurry discharged from the discharge unit is layered; a fiber supply unit that merges a plurality of reinforcing fibers into the material slurry in the discharge unit or the material slurry after being discharged from the discharge unit; A 3D printer system comprising:

2. the discharge unit has a first nozzle that discharges the material slurry, The fiber supply unit has a second nozzle that discharges the plurality of reinforcing fibers from the first nozzle so as to penetrate between layers in the material slurry in a stacked state. The 3D printer system of claim 1 .

3. Each of the plurality of reinforcing fibers is a metal fiber, a carbon fiber, or a synthetic fiber. The 3D printer system according to claim 1 or 2.

4. The length of each of the plurality of reinforcing fibers is 3 mm to 80 mm. The 3D printer system according to claim 1 or 2.

5. a first material supply unit that supplies a main material slurry containing a hydraulic binder and water; a second material supply unit that supplies a hardening material slurry containing a component that hardens the hydraulic binder and water; a mixing unit that mixes the main material slurry and the hardener slurry to obtain the material slurry and supplies the material slurry to the discharge unit; Further provided with The mixing unit has a static mixer. The 3D printer system according to claim 1 or 2.

6. A discharge step of discharging a material slurry containing a material for a 3D printer and water from a discharge unit; a position adjusting step of adjusting the position of the discharge part so that the material slurry discharged from the discharge part is layered; a fiber supplying step of merging a plurality of reinforcing fibers into the material slurry in the discharge section or into the material slurry after being discharged from the discharge section; a curing step of curing a laminate formed by laminating the material slurries to obtain a shaped object; A method for manufacturing a shaped object, comprising:

Images