Method of manufacturing three-dimensional modeled object

Abstract

To provide a method of manufacturing a three-dimensional modeled object capable of forming a high quality modeled object.SOLUTION: A method of manufacturing a three-dimensional modeled object has the steps of: discharging a sacrificial layer material onto a stage 200 to form one or a plurality of sacrificial layers 600; discharging a modeled object material onto the sacrificial layers 600 to form a modeled object 700; and separating between the modeled object 700 and the sacrificial layers 600. The sacrificial layer material and the modeled object material are different materials. The step of forming the sacrificial layers 600 forms the sacrificial layers 600 that include recesses 620 into which a part of the modeled object 700 enters at least in a portion that comes into contact with the modeled object 700.SELECTED DRAWING: Figure 3

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a method for manufacturing a molded object using a three-dimensional modeling apparatus, in which a sacrificial layer is formed on a stage and the molded object is molded on the sacrificial layer. The sacrificial layer needs to have good adhesion to the molded object in order to mold the object on the sacrificial layer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-35401 Summary of the Invention [Problem to be solved by the invention]

[0004] However, while the method described in Patent Document 1 ensures adhesion between the sacrificial layer and the molded object, it reduces the ability to separate the sacrificial layer from the molded object after modeling. In other words, it is necessary to ensure both adhesion between the sacrificial layer and the molded object and separability between the sacrificial layer and the molded object. [Means for solving the problem]

[0005] A method for manufacturing a three-dimensional object includes the steps of: discharging a first material onto a stage to form one or more sacrificial layers; discharging a second material onto the sacrificial layers to form a three-dimensional object; and separating the object from the sacrificial layer, wherein the first material and the second material are different materials. The step of forming the sacrificial layer forms the sacrificial layer, at least in the portion in contact with the object, to include a recess into which a portion of the object can fit. [Brief explanation of the drawings]

[0006] [Figure 1]FIG. 1 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus. [Figure 2A] FIG. 2 is a perspective view showing the configuration of a flat screw. [Figure 2B] FIG. [Figure 3] FIG. [Figure 4A] FIG. 4 is a side view showing the configuration of a sacrificial layer and a modeled object. [Figure 4B] FIG. 4B is an enlarged side view of part A of the sacrificial layer and the shaped object shown in FIG. 4A. [Figure 5] 10 is a flowchart showing a method for manufacturing a three-dimensional object. [Figure 6A] 1A to 1C are plan views illustrating a method for manufacturing a three-dimensional object. [Figure 6B] 1A to 1C are side views illustrating a method for manufacturing a three-dimensional object. [Figure 7A] 1A to 1C are plan views illustrating a method for manufacturing a three-dimensional object. [Figure 7B] 1A to 1C are side views illustrating a method for manufacturing a three-dimensional object. [Figure 8A] 1A to 1C are plan views illustrating a method for manufacturing a three-dimensional object. [Figure 8B] 1A to 1C are side views illustrating a method for manufacturing a three-dimensional object. [Figure 9] 10A and 10B are plan views showing comparative grid densities of sacrificial layers; [Figure 10] 1 is a chart comparing and evaluating the conditions for forming the sacrificial layer. DETAILED DESCRIPTION OF THE INVENTION

[0007] The configuration of the 3D printing apparatus 1000 and a method for manufacturing a 3D object will be described below with reference to the drawings. In the following drawings, three mutually perpendicular axes will be referred to as the X-axis, Y-axis, and Z-axis. The direction along the X-axis will be referred to as the "X-direction," the direction along the Y-axis as the "Y-direction," and the direction along the Z-axis as the "Z-direction." The direction of the arrow is the + direction, and the direction opposite to the + direction is referred to as the - direction. Note that viewing from the +Z direction or the -Z direction is also referred to as planar view or planar.

[0008] First, the configuration of a three-dimensional modeling apparatus 1000 will be described with reference to FIG.

[0009] 1, the three-dimensional printing apparatus 1000 is an apparatus that forms a three-dimensional object 700 by a material extrusion method. The three-dimensional printing apparatus 1000 includes a printing unit 100 that generates and dispenses a printing material, a printing stage 200 that serves as a base for the object 700, a movement mechanism 300 that controls the dispensing position of the printing material, an information processing device 400, and a control unit 500 that controls each part of the three-dimensional printing apparatus 1000.

[0010] Under the control of the control unit 500, the modeling unit 100 discharges a modeling material, which is a plasticized solid material, toward the stage 200. The modeling unit 100 includes a material supply unit 110, which is a supply source of raw materials before they are converted into the modeling material, a plasticization unit 120, which converts the raw materials into the modeling material, and a discharge unit 130, which discharges the modeling material.

[0011] The material supply unit 110 supplies the raw material MR to the plasticization unit 120. The material supply unit 110 is configured, for example, by a hopper that stores the raw material MR. The material supply unit 110 is connected to the plasticization unit 120 via a communication passage 111. The raw material MR is input into the material supply unit 110 in the form of pellets, powder, or the like.

[0012] The plasticizing unit 120 plasticizes the raw material MR supplied from the material supply unit 110 to generate a paste-like modeling material that exhibits fluidity, and guides the material to the discharge unit 130. In this embodiment, "plasticizing" is a concept that includes melting, and refers to changing a material from a solid to a fluid state.

[0013] Specifically, for materials that undergo glass transition, plasticization means raising the temperature of the material above the glass transition point. For materials that do not undergo glass transition, plasticization means raising the temperature of the material above the melting point. The modeling material can be a material containing a crystalline resin or an amorphous resin. In this embodiment, the modeling material contains a crystalline resin. Therefore, resins such as polyethylene, polypropylene, POM, and PEEK are used as the raw material MR.

[0014] The plasticizing section 120 includes a screw case 121, a drive motor 122, a flat screw 140, and a barrel 150. The flat screw 140 is also called a rotor or a scroll. The barrel 150 is also called a screw facing portion.

[0015] The flat screw 140 is housed in a screw case 121. An upper surface 140a of the flat screw 140 is connected to a drive motor 122. The flat screw 140 rotates in the screw case 121 by a rotational driving force generated by the drive motor 122. The drive motor 122 is driven under the control of the control unit 500. Note that the flat screw 140 may be driven by the drive motor 122 via a reducer.

[0016] A lower surface 140b of the flat screw 140 faces an upper surface 150a of the barrel 150. A space is formed between the groove 142 on the lower surface 140b of the flat screw 140 and the upper surface 150a of the barrel 150. Raw material MR is supplied from the material supply unit 110 through a material inlet 144 (see FIG. 2A) into this space.

[0017] A barrel heater 158 is embedded in the barrel 150 to heat the raw material MR supplied into the groove 142 of the rotating flat screw 140. A communication hole 156 is provided in the center of the barrel 150.

[0018] The discharge unit 130 includes a nozzle 131 that discharges the modeling material, a flow path 133 for the modeling material provided between the flat screw 140 and the nozzle opening 132, and a discharge control unit 160 that controls the discharge of the modeling material.

[0019] The nozzle 131 is connected to the communication hole 156 of the barrel 150 through a flow path 133. The nozzle 131 discharges the modeling material generated in the plasticizing section 120 from a nozzle opening 132 at the tip thereof toward the stage 200.

[0020] The discharge control unit 160 includes a discharge adjustment unit 161 that opens and closes the flow path 133, and a suction unit 162 that sucks in the modeling material and temporarily stores it. The discharge adjustment unit 161 is provided inside the flow path 133, and changes the opening degree of the flow path 133 by rotating inside the flow path 133.

[0021] In this embodiment, the discharge adjustment unit 161 is configured by a butterfly valve. The discharge adjustment unit 161 is driven by a first drive unit 171 under the control of the control unit 500. The first drive unit 171 is configured by, for example, a stepping motor. The control unit 500 can adjust the flow rate of the modeling material flowing from the plasticizing unit 120 to the nozzle 131, i.e., the discharge amount of the modeling material discharged from the nozzle 131, by controlling the rotation angle of the butterfly valve using the first drive unit 171. The discharge adjustment unit 161 can adjust the discharge amount of the modeling material and can also control the on / off of the outflow of the modeling material.

[0022] The suction unit 162 is connected between the discharge adjustment unit 161 and the nozzle opening 132 in the flow path 133. When the discharge of the modeling material from the nozzle 131 stops, the suction unit 162 temporarily sucks the modeling material in the flow path 133, thereby suppressing the tailing phenomenon in which the modeling material hangs down like a string from the nozzle opening 132.

[0023] In this embodiment, the suction unit 162 is configured with a plunger. The suction unit 162 is driven by a second drive unit 172 under the control of the control unit 500. The second drive unit 172 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 200 is disposed at a position facing the nozzle opening 132 of the nozzle 131. The stage 200 is disposed so as to be parallel to the X and Y directions, i.e., the horizontal direction. The stage 200 has a modeling surface 200a on which the model 700 is to be modeled.

[0025] For example, a sacrificial layer 600 for forming a model 700 is formed on the stage 200. On the sacrificial layer 600, the model 700 is formed.

[0026] The movement mechanism 300 changes the relative position between the stage 200 and the nozzle 131 under the control of the control unit 500. In this embodiment, the position of the nozzle 131 is fixed, and the movement mechanism 300 moves the stage 200. The movement mechanism 300 is configured by a three-axis positioner that moves the stage 200 in three axial directions, that is, the X, Y, and Z directions, using the driving forces of three motors.

[0027] The control unit 500 is a control device that controls the overall operation of the 3D printing apparatus 1000. The control unit 500 is configured by a computer that includes one or more processors 510, a storage device 520 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 control unit 500 and the information processing device 400 are connected so that they can communicate with each other.

[0028] The processor 510 executes the program stored in the storage device 520, thereby controlling the modeling unit 100 and the movement mechanism 300 in accordance with the modeling data acquired from the information processing device 400, and forms the modeled object 700 on the stage 200. Note that the control unit 500 may be realized by a combination of circuits instead of being configured by a computer.

[0029] Next, the configuration of the flat screw 140 will be described with reference to FIG. 2A.

[0030] The flat screw 140 shown in Fig. 2A is shown with the upper surface 140a and the lower surface 140b shown in Fig. 1 positioned vertically inversely. The flat screw 140 has a generally cylindrical shape with a length in the axial direction, which is the direction along its central axis, that is shorter than the length in the direction perpendicular to the axial direction. The flat screw 140 is positioned so that the rotation axis RX, which is the center of rotation of the flat screw 140, is parallel to the Z direction.

[0031] A spiral groove 142 is formed on the lower surface 140b of the flat screw 140, which is the surface that intersects with the rotation axis RX. The communication passage 111 of the material supply section 110 communicates with the groove 142 from the side surface of the flat screw 140. In this embodiment, three grooves 142 are formed, separated by convex portions 143. The number of grooves 142 is not limited to three, and may be one, or two or more. The groove 142 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.

[0032] Next, the configuration of barrel 150 will be described with reference to FIG. 2B.

[0033] 2B, a plurality of guide grooves 154 are formed on the upper surface 150a of the barrel 150, and are connected to the communication holes 156 and extend spirally from the communication holes 156 toward the outer periphery. Note that one end of the guide grooves 154 does not have to be connected to the communication holes 156. Also, the guide grooves 154 can be omitted.

[0034] The raw material MR supplied into the groove 142 of the flat screw 140 is plasticized in the groove 142, flows along the groove 142 due to the rotation of the flat screw 140, and is led to the center 146 of the flat screw 140 as a modeling material. The paste-like modeling material that has flowed into the center 146 and has fluidity is supplied to the discharge part 130 via a communication hole 156 provided in the center of the barrel 150.

[0035] It is not necessary for all types of substances constituting the modeling material to be plasticized, as long as at least some of the types of substances constituting the modeling material are plasticized, thereby converting the modeling material into a fluid state as a whole.

[0036] Next, the configurations of the sacrificial layer 600 and the model 700 will be described with reference to FIGS. 3, 4A, and 4B.

[0037] 3, 4A, and 4B, a sacrificial layer 600 is formed on the stage 200. A model 700 is formed on the sacrificial layer 600. In other words, the sacrificial layer 600 is used to form the model 700. The sacrificial layer 600 is a layer that is separated from the model 700 after the model 700 is formed.

[0038] The stage 200 is made of, for example, stainless steel. A plurality of grooves 210 are formed on the modeling surface 200a of the stage 200. The grooves 210 are provided to increase the adhesion with the model 700, specifically, the adhesion with the sacrificial layer 600 used to form the model 700.

[0039] As described above, the sacrificial layer 600 is formed to form the shaped object 700. The sacrificial layer 600 is formed to have recesses 620 at least in the portion that contacts the shaped object 700. Specifically, the sacrificial layer 600 has a sacrificial layer material 610 as a first material formed in a lattice pattern. The recesses 620 are the gaps between the sacrificial layer materials 610 formed in a lattice pattern. The sacrificial layer 600 is formed by stacking one or more sacrificial layer materials 610.

[0040] In this way, since the lattice-shaped sacrificial layer 600 is formed on the stage 200, it is possible to make a portion of the model 700 fit into the lattice-shaped recesses 620, thereby ensuring adhesion between the model 700 and the sacrificial layer 600. This makes it possible to improve the quality of the model 700. Furthermore, since the lattice-shaped sacrificial layer 600 is formed on the stage 200 having the grooves 210, when the model 700 is formed on the sacrificial layer 600, it is possible to prevent the model 700 from fitting into the grooves 210 of the stage 200, thereby preventing excessive adhesion. Therefore, after the model 700 is formed, the sacrificial layer 600 and the model 700 can be separated.

[0041] The sacrificial layer material 610, which is the first material that will become the sacrificial layer 600, and the modeling material 710, which is the second material that will become the model 700, are different materials. The sacrificial layer material 610 is, for example, a resin such as POM (Poly Oxy Methylene). The modeling material 710 is, for example, PP (Poly Propylene) or talc.

[0042] In this way, by using different materials for the sacrificial layer material 610 and the modeling object material 710, the different materials are brought into contact with each other, and therefore, after forming the modeling object 700, the modeling object 700 and the sacrificial layer 600 can be easily separated. In other words, it is possible to ensure adhesion between the modeling object 700 and the sacrificial layer 600 during modeling, while also ensuring separability between the modeling object 700 and the sacrificial layer 600 after modeling.

[0043] Furthermore, it is preferable that the sacrificial layer material 610 has higher sliding properties than the modeling object material 710. In this way, since a material with high sliding properties is used for the sacrificial layer material 610, it becomes possible to use a material suitable for the purpose for modeling the modeling object material 710 without worrying about sliding properties, and the range of materials that can be used for the modeling object 700 can be expanded.

[0044] 4B , the distance between the sacrificial layer materials 610 of the sacrificial layer 600, i.e., the lattice spacing W2, is greater than at least the width between the shaping material 710 of the shaping object 700 that contacts the sacrificial layer 600, i.e., the line width W1. Specifically, the lattice spacing W2 of the sacrificial layer 600 is 1.86 times or more the line width W1 of the shaping object 700.

[0045] In this way, since the lattice spacing W2 of the sacrificial layer 600 is larger than the line width W1 of the model 700, it is possible to ensure adhesion between the sacrificial layer 600 and the model 700, as well as separability.

[0046] The depth of the lattice of the sacrificial layer 600, i.e., the depth H2 of the sacrificial layer 600 composed of a plurality of sacrificial layer materials 610, is greater than the thickness of at least one layer of the model 700 in contact with the sacrificial layer 600, i.e., the thickness H1 of the model material 710. Specifically, the depth H2 of the sacrificial layer 600 is 2.5 times or more the thickness H1 of at least one layer of the model material 710 in contact with the sacrificial layer 600.

[0047] In this way, since the lattice depth H2 of the sacrificial layer 600 is deeper than the thickness H1 of one layer of the object material 710, it is possible to ensure the separation between the sacrificial layer 600 and the object 700 while maintaining adhesion between the sacrificial layer 600 and the object 700.

[0048] Next, a method for manufacturing the shaped object 700 will be described with reference to FIGS. 5 to 8B.

[0049] 5, in step S11, a sacrificial layer 600 is formed. Before forming the sacrificial layer 600, it is preferable to fill the grooves 210 provided in the stage 200 with a sacrificial layer material 610 and flatten the surface.

[0050] In this way, the sacrificial layer 600 is formed on the stage 200 with the grooves 210 filled in, so that excessive adhesion between the sacrificial layer 600 and the stage 200 can be suppressed, and the sacrificial layer 600 can be easily peeled off from the stage 200.

[0051] 6A and 6B, a sacrificial layer material 610 made of POM is discharged onto the flattened stage 200 to form a lattice-shaped sacrificial layer 600. The sacrificial layer 600 is a lattice-shaped sacrificial layer 600 including the recesses 620 described above.

[0052] The lattice-shaped sacrificial layer 600 is preferably formed with lines at different angles within the same layer. A similar sacrificial layer material 610 is laminated on top of this. In this way, the lattice-shaped sacrificial layer 600 is formed with lines at different angles within the same layer, so it is possible to prevent steps from occurring in the height direction at the intersections of the sacrificial layer material 610, and it is possible to maintain a balance between adhesion and separability.

[0053] In step S12, a model 700 is formed. Specifically, as shown in Figures 7A and 7B, a model material 710 made of PP talc is dispensed onto the sacrificial layer 600 to form the model 700.

[0054] In step S13, the sacrificial layer 600 and the modeled object 700 are separated. Specifically, as shown in FIGS. 8A and 8B , after the modeled object 700 has been formed, the sacrificial layer 600 and the modeled object 700 are separated. As described above, the modeled object 700 is formed on the lattice-shaped sacrificial layer 600. Furthermore, because the material of the sacrificial layer 600 and the material of the modeled object 700 are different, the sacrificial layer 600 and the modeled object 700 can be easily separated. In other words, it is possible to ensure adhesion between the modeled object 700 and the sacrificial layer 600 during modeling, while also ensuring separability between the modeled object 700 and the sacrificial layer 600 after modeling.

[0055] Next, with reference to FIGS. 9 and 10, an evaluation of the sacrificial layer 600 when the conditions for forming the sacrificial layer 600 are changed will be described.

[0056] 9 shows an image of the sacrificial layer 600 when the grid density is set to 80%, 60%, 50%, and 40%. Note that the grid density refers to the density when a pattern having a surface area of ​​40% and another pattern having the same surface area of ​​40% are overlapped orthogonally in the case of a grid density of 80%, for example.

[0057] The chart shown in Fig. 10 compares the comparative example and the example when the conditions for forming the sacrificial layer 600 are changed. Evaluation A indicates that both modeling and reuse of the sacrificial layer 600 are possible. Evaluation B indicates that modeling is possible but the sacrificial layer 600 cannot be reused. Evaluation C indicates that modeling is not possible.

[0058] Note that "being able to be molded" means that the sacrificial layer 600 and the molded object 700 do not peel off during molding. Furthermore, "the sacrificial layer 600 is reusable" means that the molded object 700 and the sacrificial layer 600 are easily removable, and no part of the molded object 700 remains on the sacrificial layer 600.

[0059] 10, in the comparative example, when the grid density was 80% and when no grid was used, the result was evaluated as C, and modeling was not possible. When the grid density was 80%, the result was evaluated as C because part of the model 700 did not fit into the grid.

[0060] When the grid density was set to 70% and 60%, the result was rated as B, and the sacrificial layer 600 could not be reused. Even when the grid density was set to 40%, if the anchor depth, i.e., the depth to which part of the model 700 penetrated the grid, was 1 mm, the result was rated as B.

[0061] Next, in the examples, when the grid density was set to 50% and 40%, the evaluation was determined to be A, and the object could be molded and the sacrificial layer 600 could be reused. Note that when the grid density was 40%, the anchor depth, i.e., the depth to which part of the molded object 700 penetrates the grid, is preferably 0.5 mm or 0.6 mm.

[0062] As described above, by forming the sacrificial layer 600 under conditions judged to be evaluation A, the shape of the model 700 is not damaged and the sacrificial layer 600 can be reused, thereby reducing time and costs during the next modeling.

[0063] Furthermore, by forming the sacrificial layer 600 under conditions judged to be evaluation B, although the sacrificial layer 600 cannot be reused, it is possible to form objects that previously could not be formed because they peeled off during formation.

[0064] As described above, the manufacturing method of the model 700 of this embodiment includes the steps of ejecting a sacrificial layer material 610 onto the stage 200 to form one or more sacrificial layers 600, ejecting a model material 710 onto the sacrificial layer 600 to form the model 700, and separating the model 700 from the sacrificial layer 600, wherein the sacrificial layer material 610 and the model material 710 are different materials, and the step of forming the sacrificial layer 600 forms the sacrificial layer 600, at least in the portion in contact with the model 700, including a recess 620 into which a portion of the model 700 can be inserted.

[0065] According to this method, the sacrificial layer material 610 is used for the sacrificial layer 600, and the modeling material 710 is used for the modeled object 700, bringing different materials into contact with each other. This makes it possible to easily separate the modeled object 700 from the sacrificial layer 600 after formation of the modeled object 700, allowing the sacrificial layer 600 to be reused repeatedly. Furthermore, the sacrificial layer 600 is formed to include a recess 620 into which a portion of the modeled object 700 fits, thereby improving adhesion between the sacrificial layer 600 and the modeled object 700. In other words, it is possible to ensure adhesion between the modeled object 700 and the sacrificial layer 600 during modeling, while also ensuring separability between the modeled object 700 and the sacrificial layer 600 after modeling.

[0066] In the method for manufacturing the model 700 of this embodiment, the step of forming the sacrificial layer 600 preferably involves forming the sacrificial layer 600 in a lattice shape on the stage 200. According to this method, the sacrificial layer 600 in a lattice shape is formed on the stage 200, and therefore, when the model 700 is formed on the sacrificial layer 600, excessive adhesion can be prevented.

[0067] Furthermore, in the method for manufacturing the modeled object 700 of this embodiment, it is preferable that the lattice spacing W2 of the sacrificial layer 600 is larger than at least the line width W1 of the modeled object 700 that is in contact with the sacrificial layer 600. According to this method, the lattice spacing W2 of the sacrificial layer 600 is larger than the line width W1 of the modeled object 700, and therefore it is possible to ensure adhesion between the sacrificial layer 600 and the modeled object 700, as well as separability.

[0068] Furthermore, in the method for manufacturing the model 700 of this embodiment, the lattice spacing W2 is preferably at least 1.86 times the line width W1 of the model 700. According to this method, the lattice spacing W2 is larger by the above multiple, so that it is possible to ensure adhesion between the sacrificial layer 600 and the model 700, as well as separability.

[0069] Furthermore, in the method for manufacturing the molded object 700 of this embodiment, it is preferable that the sacrificial layer 600 has higher sliding properties than the molded object 700. According to this method, a material with high sliding properties is used for the sacrificial layer 600, and therefore the molded object 700 can be manufactured using a material suitable for the purpose without having to worry about sliding properties, thereby widening the range of materials that can be used to manufacture the molded object 700.

[0070] Furthermore, in the method for manufacturing the model 700 of this embodiment, the stage 200 is provided with grooves 210, and before forming the sacrificial layer 600, the method includes a step of discharging a sacrificial layer material 610 into the grooves 210 of the stage 200 to fill the grooves 210 with the sacrificial layer material 610, and the step of forming the sacrificial layer 600 preferably includes forming the sacrificial layer 600 on the stage 200 whose grooves 210 are filled with the sacrificial layer material 610. According to this method, the sacrificial layer 600 is formed on the stage 200 whose grooves 210 are filled, which makes it possible to prevent excessive adhesion between the sacrificial layer 600 and the stage 200, and enables the sacrificial layer 600 and the model 700 to be peeled off from the stage 200.

[0071] Furthermore, in the method for manufacturing the molded object 700 of this embodiment, it is preferable to stack lattice-shaped layers formed with lines at different angles within the same layer in the step of forming the lattice-shaped sacrificial layer 600. According to this method, the lattice-shaped sacrificial layer 600 is formed with lines at different angles within the same layer, which makes it possible to prevent steps from occurring in the height direction and maintain a balance between adhesion and separability.

[0072] Modifications of the above-described embodiment will now be described.

[0073] As described above, the stage 200 is not limited to having the grooves 210 provided thereon, and a stage 200 that does not have the grooves 210 provided thereon in advance may be used.

[0074] As described above, the method of forming the model 700 is not limited to discharging the model material 710 onto the sacrificial layer 600. The sacrificial layer 600 and the model 700 do not need to be in direct contact with each other, and a raft that constitutes part of the model 700 may be formed between the sacrificial layer 600 and the model 700. The raft is a base that prevents the bottom surface of the model 700 from becoming rough, and is a layer that is ultimately separated from the completed product.

[0075] The raft molding conditions are, for example, as follows: Line width: 0.5 mm; Line height: 0.2 mm; Material: PP talc; Total number of layers: 8; Thickness: 1.6 mm. Also, for the first layer, the head injection conditions are the same to bury the anchor, but the scanning speed is 30% of the scanning speed for the second layer and beyond. The scanning speed for the second layer and beyond is 50 mm / s. [Explanation of symbols]

[0076] 100...shaping section, 110...material supply section, 111...communicating passage, 120...plasticizing section, 121...screw case, 122...drive motor, 130...discharge section, 131...nozzle, 132...nozzle opening, 133...flow path, 140...flat screw, 140a...upper surface, 140b...lower surface, 142...groove section, 143...convex section, 144...material inlet, 146...center section, 150...barrel, 150a...upper surface, 154...guide groove, 156...communicating hole, 158...barrel heater , 160...discharge control unit, 161...discharge adjustment unit, 162...suction unit, 171...first drive unit, 172...second drive unit, 200...stage, 200a...printing surface, 210...groove, 300...movement mechanism, 400...information processing device, 500...control unit, 510...processor, 520...storage device, 600...sacrificial layer, 610...sacrificial layer material as first material, 700...modeled object as three-dimensional model, 710...modeled object material as second material, 1000...three-dimensional modeling device.

Claims

1. dispensing a first material onto a stage to form one or more sacrificial layers; discharging a second material onto the sacrificial layer to form a shaped object; separating the object from the sacrificial layer; and the first material and the second material are different materials, In the step of forming the sacrificial layer, the sacrificial layer is formed to include a recess into which a portion of the object fits, at least in a portion that contacts the object.

2. The method for manufacturing a three-dimensional object according to claim 1, In the step of forming the sacrificial layer, the sacrificial layer is formed in a grid shape on the stage.

3. The method for manufacturing a three-dimensional object according to claim 2, a lattice spacing of the sacrificial layer that is larger than at least a line width of the object that is in contact with the sacrificial layer;

4. The method for manufacturing a three-dimensional object according to claim 3, a lattice spacing that is 1.86 times or more the line width of the object;

5. The method for manufacturing a three-dimensional object according to claim 1, The method for manufacturing a three-dimensional object, wherein the sacrificial layer has higher sliding properties than the object.

6. The method for manufacturing a three-dimensional object according to claim 1, The stage is provided with a groove, a step of discharging the first material into the groove of the stage to fill the groove with the first material before forming the sacrificial layer; In the step of forming the sacrificial layer, the sacrificial layer is formed on the stage in which the grooves are filled with the first material.

7. The method for manufacturing a three-dimensional object according to claim 2, The method for manufacturing a three-dimensional object includes stacking the lattice-shaped layers formed with lines at different angles within the same layer in the step of forming the lattice-shaped sacrificial layer.

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