Method for producing three-dimensional molding

Abstract

To provide a technique capable of improving quality of a three-dimensional molding molded by laminating layers.SOLUTION: A method for producing a three-dimensional molding includes at least one of the following steps: a first laminating step in which the n-th layer is laminated, a temperature measurement step in which the temperature distribution of the n-th layer is measured, and a temperature prediction step in which the temperature distribution of the n-th layer is predicted; a data generation step in which the molding data for the (n+1)-th layer is generated or modified based on the temperature distribution of the n-th layer; and a second laminating step in which the (n+1)-th layer is laminated based on the generated or modified molding data for the (n+1)-th layer. The n-th layer includes a first region and a second region, the first region being a region with a lower temperature than the second region. In the data generation step, the molding data for the (n+1)-th layer is generated or modified so that the molding material is laminated over the first region before laminating over the second region.SELECTED DRAWING: Figure 6

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a technology for creating a three-dimensional object by extruding molten thermoplastic material onto a base from an extrusion nozzle that scans according to preset shape data, and then layering more molten material on top of the hardened material on the base. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-192710 Summary of the Invention [Problem to be solved by the invention]

[0004] There is a demand for technology that can improve the quality of three-dimensional objects that are created by stacking layers. [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 including: discharging a modeling material from a discharge unit provided in a three-dimensional printing device to laminate a plurality of layers in accordance with modeling data for forming the three-dimensional object layer by layer, the modeling data being generated based on shape data representing the shape of the three-dimensional object; the method including at least one of a first lamination step of discharging the modeling material from the discharge unit to laminate an n-th layer, where n is an integer equal to or greater than 1; a temperature measurement step of measuring a temperature distribution of the n-th layer; and a temperature prediction step of predicting a temperature distribution of the n-th layer; The method comprises a data generation process for generating or modifying the modeling data for the (n+1)th layer based on the temperature distribution of the nth layer, and a second stacking process for ejecting the modeling material from the ejection unit to stack the (n+1)th layer based on the generated or modified modeling data for the (n+1)th layer, wherein the nth layer has a first region and a second region, the first region being a region with a lower temperature than the second region, and in the data generation process, the modeling data for the (n+1)th layer is generated or modified so that the modeling material is stacked above the first region before being stacked above the second region. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing system according to a first embodiment. [Figure 2] FIG. 2 is a perspective view showing a schematic configuration of a screw. [Figure 3] Schematic plan view of the barrel. [Figure 4] FIG. 2 is an explanatory diagram schematically illustrating how the three-dimensional printing apparatus prints a three-dimensional object. [Figure 5] FIG. 1 is an explanatory diagram showing a schematic configuration of an information processing apparatus. [Figure 6] 10 is a flowchart of a forming process. [Figure 7] FIG. 10 is a diagram showing an example of a nozzle movement path included in the modeling data of the (n+1)th layer generated in step S40. [Figure 8] FIG. 10 is a diagram showing another example of the nozzle movement path included in the modeling data of the (n+1)th layer generated in step S40. [Figure 9] FIG. 10 is a diagram showing an example of a nozzle movement path included in the modeling data of the (n+1)th layer corrected in step S90. [Figure 10] FIG. 10 is a diagram showing another example of the nozzle movement path included in the modeling data of the (n+1)th layer corrected in step S90. [Figure 11] FIG. 11 is a diagram showing an example of a nozzle movement path included in the modeling data of the (n+1)th layer generated in step S40 of the modeling processing according to the second embodiment. [Figure 12] FIG. 11 is a diagram showing an example of a nozzle movement path included in the modeling data of the (n+1)th layer corrected in step S90 of the modeling processing in the second embodiment. [Figure 13] 10 is a flowchart of a formation process according to a third embodiment. [Figure 14] FIG. 10 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer generated in step S41. [Figure 15] FIG. 10 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer corrected in step S91. [Figure 16] 10 is a flowchart of a formation process according to a fourth embodiment. [Figure 17] 13 is a flowchart of a formation process according to a fifth embodiment. [Figure 18] 13 is a flowchart of a formation process according to a sixth embodiment. [Figure 19] 13 is a flowchart of a formation process according to the seventh embodiment. [Figure 20] 13 is a flowchart of a formation process according to the eighth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0007] A. First embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing system 10 according to a first embodiment. FIG. 1 shows arrows representing mutually orthogonal X, Y, and Z directions. The X and Y directions are parallel to a horizontal plane. The Z direction is parallel to the vertical direction. The X, Y, and Z directions in FIG. 1 and the X, Y, and Z directions in other figures indicate the same directions. When specifying a direction, positive and negative signs are used in combination to indicate the direction indicated by the arrow, with "+" indicating the positive direction and "-" indicating the negative direction opposite to the direction indicated by the arrow.

[0008] The three-dimensional printing system 10 includes a three-dimensional printing device 100 and an information processing device 400. The three-dimensional printing device 100 of this embodiment is a device that prints a three-dimensional object by a material extrusion method. The three-dimensional printing device 100 includes a control unit 300 for controlling each unit of the three-dimensional printing device 100. The control unit 300 and the information processing device 400 are connected to each other so that they can communicate with each other.

[0009] The three-dimensional modeling device 100 comprises a modeling unit 110 that generates and dispenses modeling material, a modeling stage 210 that serves as the base for the three-dimensional object, a moving mechanism 230 that controls the dispense position of the modeling material, and a temperature measurement unit 250 that measures the temperature distribution of the modeling material dispensed onto the stage 210.

[0010] 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 being 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.

[0011] The material supply unit 20 supplies raw material MR to the plasticization unit 30 for generating the modeling material. The material supply unit 20 is configured, for example, by a hopper. The material supply unit 20 stores raw material MR in pellet or powder form. As the raw material MR, for example, a thermoplastic resin such as polypropylene resin (PP), polyethylene resin (PE), or polyacetal resin (POM) is used. A communication passage 22 connecting the material supply unit 20 and the plasticization unit 30 is provided below the material supply unit 20. The material supply unit 20 supplies the raw material MR to the plasticization unit 30 via the communication passage 22.

[0012] The plasticizing unit 30 plasticizes at least a portion of the raw material MR supplied from the material supply unit 20 to generate a fluid, paste-like modeling material, which is then introduced to the discharge unit 60. Here, "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. The plasticizing unit 30 includes a screw 40, a screw case 31, a drive motor 32, and a barrel 50.

[0013] The screw 40 is housed in a screw case 31. The upper surface side of the screw 40 is connected to a drive motor 32. The screw 40 rotates in the screw case 31 by the rotational driving force generated by the drive motor 32. The axial direction of the rotation axis RX of the screw 40 is along the Z direction. The rotation speed of the screw 40 is controlled by the control unit 300 controlling the rotation speed of the drive motor 32. The screw 40 may be driven by the drive motor 32 via a reducer. The screw 40 is also called a rotor or a flat screw.

[0014] The barrel 50 is installed on the -Z direction side of the screw 40. An opposing surface 52, which is the upper surface of the barrel 50, faces the groove forming surface 48, which is the lower surface of the screw 40. A communication hole 56, which communicates with the flow path 65 of the discharge section 60, is formed in the center of the barrel 50. A plasticizing heater 58 is provided inside the barrel 50. The temperature of the plasticizing heater 58 is controlled by the control section 300.

[0015] FIG. 2 is a perspective view showing a schematic configuration of the screw 40. The screw 40 has a generally cylindrical shape whose length along the rotation axis RX is shorter than its length perpendicular to the rotation axis RX. A spiral groove 42 is formed on the groove-forming surface 48, centered on a central portion 46. The groove 42 communicates with a material inlet 44 formed on the side surface of the screw 40. Material supplied from the material supply unit 20 is supplied to the groove 42 through the material inlet 44. The grooves 42 are formed by being separated by ridge portions 43. While FIG. 2 shows an example in which three grooves 42 are formed, the number of grooves 42 may be one or more. Note that the groove 42 is not limited to a spiral shape, and may be a spiral shape or an involute curve shape, or may have a shape extending in an arc from the central portion 46 to the outer periphery.

[0016] 3 is a schematic plan view of the barrel 50. A plurality of guide grooves 54 are formed around the communicating hole 56 in the opposing surface 52. One end of each guide groove 54 is connected to the communicating hole 56, and extends in a spiral shape from the communicating hole 56 toward the outer periphery of the opposing surface 52. Note that one end of the guide groove 54 does not have to be connected to the communicating hole 56. Furthermore, the barrel 50 does not necessarily have to have any guide grooves 54 formed therein.

[0017] The material supplied to the grooves 42 of the screw 40 is plasticized within the grooves 42 by the rotation of the screw 40 and the heat of the plasticizing heater 58, and flows along the grooves 42, and is guided to the center section 46 of the screw 40 as a modeling material. The pasty modeling material that has flowed into the center section 46 and exhibits fluidity is supplied to the discharge section 60 via the communication holes 56. Note that not all types of substances that make up the modeling material need to be plasticized in the plasticizing section 30. It is sufficient that the modeling material is converted into a fluid state as a whole by plasticizing at least some of the types of substances that make up the modeling material.

[0018] The discharge unit 60 shown in Figure 1 includes a nozzle 61 that discharges the modeling material, a flow path 65 for the modeling material provided between the screw 40 and the nozzle opening 62, and a discharge control unit 77 that controls the discharge of the modeling material.

[0019] 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.

[0020] 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.

[0021] 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 as a butterfly 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 as, for example, a stepping motor. The control unit 300 can adjust the flow rate of the modeling material flowing from the plasticizing unit 30 to the nozzle 61, i.e., the discharge amount of the modeling material discharged from the nozzle 61, by using the first drive unit 74 to control the rotation angle of the butterfly valve. 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.

[0022] 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.

[0023] The stage 210 is disposed at a position facing the nozzle opening 62 of the nozzle 61. The three-dimensional modeling device 100 forms a three-dimensional object by discharging a modeling material from the nozzle 61 onto a modeling surface 211, which is the upper surface of the stage 210, and stacking layers. The stage 210 is equipped with a stage heater 212 to prevent the modeling material discharged onto the stage 210 from cooling suddenly. The temperature of the stage heater 212 is controlled by the control unit 300.

[0024] The movement mechanism 230 changes the relative position of the nozzle 61 and the stage 210. In this embodiment, the movement mechanism 230 moves the stage 210 relative to the nozzle 61, which is fixed in position. The change in the relative position of the nozzle 61 with respect to the stage 210 is also simply referred to as movement of the nozzle 61. 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. Each motor of the movement mechanism 230 is driven under the control of the control unit 300.

[0025] 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.

[0026] The temperature measurement unit 250 measures the temperature distribution of the layers stacked on the build surface 211 of the stage 210. The temperature measurement unit 250 is, for example, a thermo camera or a thermopile. The temperature measurement unit 250 is fixed to the barrel case 59 that houses the barrel 50. Note that the temperature measurement unit 250 does not have to be fixed to the barrel case 59 as long as it is provided in a position where it can measure the temperature distribution of the layers stacked on the build surface 211.

[0027] The control unit 300 is a control device that controls the overall operation of the 3D printing apparatus 100. The control unit 300 is configured by a computer that includes one or more processors 310, a storage device 320 including a main storage device and an auxiliary storage device, and an input / output interface that inputs and outputs signals to and from the outside. The processor 310 executes a program stored in the storage device 320 to control the printing unit 110 and the movement mechanism 230 in accordance with printing data acquired from the information processing device 400, and prints a 3D object on the stage 210. Note that the control unit 300 may be realized by a combination of circuits instead of being configured by a computer.

[0028] 4 is an explanatory diagram that schematically shows how the three-dimensional printing apparatus 100 prints a three-dimensional object. In the three-dimensional printing apparatus 100, as described above, the raw material MR in a solid state is plasticized to produce the printing material MM. The control unit 300 discharges the printing material MM from the nozzle 61 while changing the position of the nozzle 61 relative to the stage 210 in a direction along the printing surface 211 of the stage 210, while maintaining the distance between the nozzle 61 and the printing surface 211 of the stage 210. The printing 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 layers ML. After forming one layer ML, the control unit 300 moves the position of the nozzle 61 relative to the stage 210 in the Z direction. Then, a three-dimensional object is formed by stacking additional layers ML on the 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 one layer ML or when each layer has multiple independent modeling regions. In this case, the discharge adjustment unit 70 closes the flow path 65 to stop the discharge of the modeling material MM from the nozzle opening 62, and the suction unit 75 temporarily sucks the modeling material from the nozzle 61. After changing the position of the nozzle 61, the control unit 300 opens the flow path 65 with the discharge adjustment unit 70 while discharging the modeling material from the suction unit 75, thereby restarting the deposition of the modeling material MM from the new position of the nozzle 61.

[0031] 5 is an explanatory diagram showing a schematic configuration of an information processing device 400. The information processing device 400 is configured as a computer in which a CPU 410, a memory 420, a storage device 430, a communication interface 440, and an input / output interface 450 are interconnected via a bus 460. An input device 470 such as a keyboard or a mouse, and a display device 480 such as a liquid crystal display are connected to the input / output interface 450. The information processing device 400 is connected to the control unit 300 of the three-dimensional printing apparatus 100 via the communication interface 440.

[0032] The CPU 410 executes a program stored in the storage device 430, thereby functioning as a temperature prediction unit 411 and a data generation unit 412. The temperature prediction unit 411 predicts the temperature distribution of layers stacked on the printing surface 211 of the stage 210. The data generation unit 412 generates printing data, which is data for printing a three-dimensional object layer by layer.

[0033] 6 is a flowchart of the modeling process executed by the information processing device 400 and the three-dimensional modeling device 100. The modeling process is executed to realize a method for manufacturing a three-dimensional object. The processes from step S10 to step S40 are executed by the information processing device 400, and the processes from step S50 to step S110 are executed by the three-dimensional modeling device 100.

[0034] In step S10, the data generation unit 412 of the information processing device 400 acquires shape data representing the three-dimensional shape of the three-dimensional object from another computer, a recording medium, or the storage device 430. The shape data is data representing the shape of the three-dimensional object created using three-dimensional CAD software, three-dimensional CG software, or the like. As the shape data, data in STL format, AMF format, or the like can be used, for example.

[0035] In step S20, the data generation unit 412 generates slice data. The slice data refers to data representing the shape of the three-dimensional object sliced ​​into multiple layers. More specifically, the data generation unit 412 generates the slice data by slicing the shape of the three-dimensional object represented in the shape data into multiple layers along the XY plane.

[0036] In step S30, the temperature prediction unit 411 predicts the temperature distribution of the layers stacked on the build surface 211 of the stage 210. Specifically, the temperature prediction unit 411 predicts the temperature distribution of each layer by simulating how the layers are stacked on the build surface 211. When n is an integer greater than or equal to 1, the temperature prediction unit 411 predicts the temperature distribution of the nth layer, i.e., the temperature distribution of the uppermost layer, when the nth layer is stacked. In this specification, the nth layer is also simply referred to as the nth layer. Here, the first layer is the bottom layer. For example, the temperature prediction unit 411 simulates how the nth layer stacked above the n-1th layer cools over time, thereby predicting the temperature distribution of the nth layer at a predetermined time after the nth layer was stacked. In this simulation, an initial temperature is set for each layer from the first layer to the nth layer at the time the layer was stacked. The temperature prediction unit 411 predicts the temperature distribution for all layers that make up the three-dimensional object.

[0037] The nth layer has a first region and a second region. The first region is a region with a lower temperature than the second region. Specifically, the first region is a region with a lower temperature than a reference temperature, and the second region is a region with a higher temperature than the reference temperature. The reference temperature is, for example, the average or median temperature of the nth layer. The reference temperature may be a temperature determined in advance by the user. The temperature prediction unit 411 predicts the temperature distribution of the nth layer to predict the positions of the first and second regions of the nth layer. Step S30 is also referred to as a temperature prediction step.

[0038] In step S40, the data generation unit 412 generates modeling data based on the slice data and modeling conditions. Here, the modeling conditions include the line width, the modeling pattern, the filling rate of the three-dimensional object, etc. The modeling data includes path data, discharge amount information associated with the path data, and the movement speed of the nozzle 61. The path data is data representing a movement path along which the nozzle 61 moves while discharging the modeling material, using multiple partial paths. The partial paths are linear paths and are represented, for example, using the start and end points of the partial paths. The discharge amount information is information representing the amount of modeling material discharged along each partial path. The movement speed of the nozzle 61 is the movement speed of the nozzle 61 in a direction along the XY plane when depositing the modeling material on the stage 210. The movement speed of the nozzle 61 is also referred to as the movement speed of the discharge unit 60. The modeling data is represented, for example, by G-code. The data generation unit 412 generates modeling data for modeling the (n+1)th layer based on the prediction result of the temperature distribution of the nth layer in step S30. Hereinafter, the modeling data for modeling the nth layer will also be simply referred to as “modeling data of the nth layer.”

[0039] FIG. 7 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data for the (n+1)th layer generated in step S40. FIG. 7 shows the positions of the first region RG1 and the second region RG2 of the nth layer predicted in step S30. FIG. 7 also shows the movement path of the nozzle 61 when stacking the (n+1)th layer with arrows. The numbers at the start points of each movement path indicate the order in which the modeling material is ejected from the nozzle 61 when stacking the (n+1)th layer. As shown in FIG. 7, the data generation unit 412 generates the path data for the (n+1)th layer so that the modeling material is stacked above the first region RG1 of the nth layer before being stacked above the second region RG2 of the nth layer. The data generation unit 412 also sets the movement speed of the nozzle 61 when stacking the (n+1)th layer. Specifically, the data generation unit 412 sets a first speed, which is the movement speed of the nozzle 61 when depositing the modeling material above the first region RG1 of the nth layer, and a second speed, which is the movement speed of the nozzle 61 when depositing the modeling material above the second region RG2 of the nth layer. The data generation unit 412 sets the first speed to be faster than the second speed. In step S40, the data generation unit 412 generates modeling data for all layers that constitute the three-dimensional model. Step S40 is also referred to as a first data generation process.

[0040] FIG. 8 is a diagram showing another example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer generated in step S40. In the example shown in FIG. 8, the nth layer has multiple first regions. As shown in FIG. 8, when the nth layer has two first regions RG3 and RG4 and a second region RG5, the data generation unit 412 generates the modeling data of the (n+1)th layer such that the modeling material is first stacked above the first regions RG3 and RG4, and then stacked above the second region RG5. Note that when the nth layer has three or more first regions, the data generation unit 412 generates the modeling data of the (n+1)th layer such that the modeling material is first stacked above all of the first regions, and then stacked above the second region.

[0041] In step S50 of FIG. 6, the control unit 300 of the three-dimensional modeling apparatus 100 acquires the modeling data generated in step S40 from the information processing apparatus 400.

[0042] In step S60, the control unit 300 stacks the first layer in accordance with the modeling data of the first layer included in the modeling data acquired in step S50.

[0043] After step S60 is executed, the control unit 300 repeatedly executes steps S70 to S100 as one cycle, thereby stacking layers from the second layer to the top layer of the three-dimensionally shaped object. The control unit 300 stacks one layer in one cycle. Hereinafter, the cycle of measuring the temperature distribution of the nth layer of the three-dimensionally shaped object and stacking the (n+1)th layer of the three-dimensionally shaped object will also be referred to as the nth cycle. That is, in the nth cycle, the temperature of the nth layer is measured and the (n+1)th layer is stacked. When step S70 is executed for the first time, the first cycle is started. In the first cycle, the temperature distribution of the first layer is measured and the second layer is stacked.

[0044] In step S70, the temperature measurement unit 250 measures the temperature distribution of the nth layer. The temperature measurement unit 250 measures the temperature distribution of the uppermost layer at the time step S70 is executed. For example, in step S70 in the first cycle, the temperature of the first layer is measured, and in step S70 in the second cycle, the temperature of the second layer is measured. The data measured by the temperature measurement unit 250 is transmitted to the control unit 300. Step S70 is also referred to as a temperature measurement step.

[0045] In step S80, control unit 300 acquires the data transmitted from temperature measurement unit 250. Control unit 300 identifies the actual positions of the first region and the second region on the nth layer using the temperature distribution data of the nth layer measured by temperature measurement unit 250. The temperature distribution data of the nth layer measured by temperature measurement unit 250 is stored in storage device 320 included in control unit 300. The temperature distribution data of each layer measured by temperature measurement unit 250 is preferably used to improve the accuracy of a simulation that predicts the temperature distribution of each layer.

[0046] In step S90, the control unit 300 corrects the modeling data for the (n+1)th layer based on the measurement results of the temperature distribution of the nth layer. Specifically, if the positions of the first and second regions of the nth layer identified in step S80 differ from the positions of the first and second regions of the nth layer predicted in step S30, the control unit 300 corrects the modeling data for the (n+1)th layer generated in step S40. The control unit 300 corrects the path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer identified in step S80 before it is deposited above the second region of the nth layer identified in step S80. Note that if the positions of the first and second regions of the nth layer identified in step S80 are the same as the positions of the first and second regions of the nth layer predicted in step S30, step S90 is not executed. Step S90 is also referred to as a second data generation process. Steps S40 and S90 are collectively referred to as a data generation process.

[0047] 9 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer corrected in step S90. FIG. 9 shows the positions of the first region RG11 and the second region RG12 of the nth layer identified in step S80. FIG. 9 also shows, with arrows, the movement path of the nozzle 61 corrected in step S90 when stacking the (n+1)th layer. The numbers shown at the start points of each movement path indicate the order in which the modeling material is ejected from the nozzle 61 when stacking the (n+1)th layer.

[0048] FIG. 10 is a diagram showing another example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer corrected in step S90. In the example shown in FIG. 10, the nth layer has multiple first regions. As shown in FIG. 10, when the nth layer has two first regions RG13 and RG14 and a second region RG15, the control unit 300 corrects the modeling data of the (n+1)th layer so that the modeling material is first stacked above the first region RG13 and the first region RG14, and then the modeling material is stacked above the second region RG15. Note that when the nth layer has three or more first regions, the control unit 300 corrects the modeling data of the (n+1)th layer so that the modeling material is first stacked above all of the first regions, and then the modeling material is stacked above the second region.

[0049] In step S100 of FIG. 6, the control unit 300 models the (n+1)th layer in accordance with the modeling data for the (n+1)th layer corrected in step S90.

[0050] In step S110, the control unit 300 determines whether or not the stacking of all layers constituting the three-dimensional object has been completed. If the stacking of all layers has not been completed, the control unit 300 returns the process to step S70 and starts the next cycle. If the stacking of all layers has been completed, the control unit 300 ends the modeling process.

[0051] As described above, the (n+1)th layer is laminated in step S100 of the nth cycle, and the (n+2)th layer is laminated in step S100 of the (n+1)th cycle. That is, the nth layer is laminated in step S100 of the (n-1)th cycle, and the (n+1)th layer is laminated in step S100 of the nth cycle. In this specification, step S100 of the (n-1)th cycle is also referred to as the first lamination step, and step S100 of the nth cycle is also referred to as the second lamination step. Note that when step S70 is performed for the first time, step S60 is referred to as the first lamination step, and step S100 of the first cycle is referred to as the second lamination step.

[0052] According to the first embodiment described above, the method for manufacturing a three-dimensional structure includes a first lamination step of laminating an nth layer; at least one of a temperature prediction step of predicting a temperature distribution in the nth layer and a temperature measurement step of measuring a temperature distribution in the nth layer; a data generation step of generating or modifying modeling data for the n+1th layer based on the temperature distribution in the nth layer; and a second lamination step of laminating the n+1th layer based on the modeling data for the n+1th layer. In the data generation step, the modeling data for the n+1th layer is generated or modified so that the modeling material is deposited above the first region of the nth layer before being deposited above the second region of the nth layer. Here, the first region is a region with a lower temperature than the second region. The adhesion strength between the nth layer and the n+1th layer depends on the temperature of the nth layer when the n+1th layer is laminated. Here, the adhesion strength is the strength in the lamination direction. In this embodiment, the lamination direction is the Z direction. Therefore, compared to stacking the (n+1)th layer without considering the temperature distribution of the nth layer, the method for manufacturing a three-dimensional object according to the first embodiment can make the temperature of each part of the nth layer more uniform when the modeling material constituting the (n+1)th layer is stacked on top of the nth layer. Therefore, the adhesion strength between the nth layer and the (n+1)th layer can be made uniform regardless of their positions on the XY plane. As a result, the quality of the three-dimensional object produced by stacking layers can be improved.

[0053] Furthermore, in this embodiment, when the nth layer has a plurality of first regions, in the data generating process, the modeling data for the (n+1)th layer is generated or corrected so that the modeling material is stacked above the plurality of first regions, and then the modeling material is stacked above the second region. Therefore, even when the nth layer has a plurality of first regions, the adhesion strength between the nth layer and the (n+1)th layer can be made uniform regardless of their positions on the XY plane.

[0054] In the present embodiment, in the data generating process, the data generating unit 412 sets a first speed, which is the movement speed of the nozzle 61 when depositing the modeling material above the first region of the nth layer, and a second speed, which is the movement speed of the nozzle 61 when depositing the modeling material above the second region of the nth layer. The first speed is faster than the second speed. Therefore, a decrease in the temperature of the first region can be suppressed until the modeling material is deposited above the entire first region of the nth layer. Furthermore, time can be gained for the temperature of the second region to decrease until the modeling material is deposited above the entire second region of the nth layer.

[0055] In this embodiment, the method for manufacturing a three-dimensional object includes a temperature prediction step and a temperature measurement step, and the data generation step includes a first data generation step and a second data generation step. In the first data generation step, modeling data for the (n+1)th layer is generated based on the predicted temperature distribution of the (n)th layer in the temperature prediction step. In the second data generation step, the modeling data for the (n+1)th layer generated in the first data generation step is corrected based on the measured temperature distribution of the (n+1)th layer in the temperature measurement step. Therefore, if the temperature distribution of the (n)th layer predicted in the temperature prediction step differs from the temperature distribution of the (n+1)th layer measured in the temperature measurement step, the modeling data for the (n+1)th layer can be corrected based on the temperature distribution of the (n+1)th layer measured in the temperature measurement step, thereby making the adhesion strength between the (n+1)th layer and the (n+1)th layer uniform regardless of their positions on the XY plane. Furthermore, if the measured temperature distribution of each layer differs from the predicted temperature distribution, the quality of the three-dimensional object can be further improved by modifying the shape of the three-dimensional object or by modifying the modeling data to simultaneously form a thermal protection wall around a portion where the temperature is likely to drop.

[0056] B. Second embodiment: In the second embodiment, the content of the modeling data generated or corrected in the modeling process is different from that in the first embodiment. The configuration of each part of the three-dimensional modeling system 10 in the second embodiment is the same as that in the first embodiment.

[0057] FIG. 11 is a diagram illustrating an example of a movement path of the nozzle 61 included in the modeling data of the (n+1)th layer generated in step S40 of the modeling process in the second embodiment. In the example illustrated in FIG. 11, the nth layer has a plurality of first regions and a second region adjacent to the plurality of first regions. As illustrated in FIG. 11, when the nth layer has two first regions RG21 and RG22 and a second region RG23 adjacent to the first region RG21 and the first region RG22, the data generation unit 412 generates the (n+1)th modeling data so that the modeling material is stacked above the first regions RG21 and RG22 without stopping the dispensing of the modeling material while allowing the modeling material to be stacked above the second region RG23. Specifically, the data generation unit 412 generates path data for the (n+1)th layer to stack the modeling material as follows. First, the modeling material is deposited above one first region RG21, and then the nozzle 61 is moved above another first region RG22 while depositing the modeling material above a portion of the second region RG23, and the modeling material is deposited above the first region RG22. Then, the modeling material is deposited above the remaining portion of the second region RG23. Note that if the n-th layer has three or more first regions, the data generation unit 412 generates the (n+1)-th modeling data so that the modeling material is deposited above all of the first regions without stopping the dispensing of the modeling material, while allowing the modeling material to be deposited above the second regions.

[0058] FIG. 12 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data of the (n+1)th layer corrected in step S90 of the modeling process in the second embodiment. In the example shown in FIG. 12, the nth layer has a plurality of first regions and a second region adjacent to the plurality of first regions. As shown in FIG. 12, when the nth layer has two first regions RG31 and RG32 and a second region RG33 adjacent to the first region RG31 and the first region RG32, the control unit 300 corrects the modeling data of the (n+1)th layer so that the modeling material is stacked above the first regions RG31 and RG32 without stopping the dispensing of the modeling material, while allowing the modeling material to be stacked above the second region RG33. Specifically, the control unit 300 corrects the path data of the (n+1)th layer so that the modeling material is stacked as follows. First, the nozzle 61 is moved above one first region RG31, and then the nozzle 61 is moved above the other first region RG32 while depositing the modeling material above a portion of the second region RG33, and the modeling material is deposited above the first region RG32. Then, the nozzle 61 is moved above the remaining portion of the second region RG33. If the n-th layer has three or more first regions, the control unit 300 modifies the (n+1)-th modeling data so that the modeling material is deposited above all of the first regions without stopping the ejection of the modeling material, while allowing the modeling material to be deposited above the second regions.

[0059] According to the second embodiment described above, when stacking the (n+1)th layer, the number of times that the discharge of the modeling material from the nozzle 61 is temporarily stopped can be reduced.

[0060] C. Third embodiment: In the third embodiment, the content of the modeling process is different from that in the first embodiment. The configuration of each part of the three-dimensional modeling system 10 in the third embodiment is the same as that in the first embodiment.

[0061] 13 is a flowchart of the formation processing in the third embodiment. Note that the same reference numerals are assigned to parts in which the same processing as in the formation processing in the first embodiment is executed, and the description thereof will be omitted.

[0062] In step S31, the temperature prediction unit 411 predicts the change over time in the temperature distribution of the layers stacked on the build surface 211 of the stage 210. Specifically, the temperature prediction unit 411 predicts the change over time in the temperature distribution of each layer by simulating the process of stacking layers on the build surface 211. The change over time in the temperature distribution of a layer refers to the rate of decrease in the temperature of that layer per unit time after the stacking of that layer is completed. Specifically, the change over time in the temperature distribution of a layer refers to the rate of decrease in the temperature of that layer per unit time from the time the stacking of that layer is completed until a predetermined time has elapsed. The temperature prediction unit 411 predicts the change over time in the temperature distribution of the nth layer, i.e., the temperature distribution of the uppermost layer, when layers up to the nth layer have been stacked. For example, the temperature prediction unit 411 simulates the cooling over time of the nth layer stacked above the (n-1)th layer, thereby predicting the rate of decrease in temperature per unit time for each portion of the nth layer from the time the nth layer is stacked until a predetermined time has elapsed. In this simulation, an initial temperature is set for each layer from the first layer to the nth layer at the time when the layer is stacked. The temperature prediction unit 411 predicts the change in temperature distribution over time for all layers constituting the three-dimensional object.

[0063] The first or second region of the nth layer has a third region and a fourth region. The third region is a region where the temperature drops faster than the fourth region. In other words, the third region is a region where the temperature drops at a higher rate per unit time than the fourth region. The temperature prediction unit 411 predicts the time change in the temperature distribution of the nth layer, thereby predicting the positions of the first, second, third, and fourth regions of the nth layer.

[0064] In step S41, the data generation unit 412 generates modeling data for modeling the (n+1)th layer, based on the time change in the temperature distribution of the nth layer predicted in step S31.

[0065] FIG. 14 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data for the (n+1)th layer generated in step S41. FIG. 14 shows the positions of the first region RG1, the second region RG2, the third region RG51, and the fourth region RG52 of the nth layer predicted in step S31. In the example shown in FIG. 14, the first region RG1 has the third region RG51 and the fourth region RG52. FIG. 14 also shows the movement path of the nozzle 61 when stacking the (n+1)th layer with arrows. As shown in FIG. 14, the data generation unit 412 generates the path data for the (n+1)th layer so that the modeling material is stacked above the first region RG1 of the nth layer before being stacked above the second region RG2 of the nth layer, and so that the modeling material is stacked above the third region RG51 before being stacked above the fourth region RG52. That is, the data generation unit 412 generates the path data for the (n+1)th layer so that the modeling material is stacked in the following order: above the third region RG51 of the first region RG1, above the fourth region RG52 of the first region RG1, and above the second region RG2. Note that, in a case where the second region RG2 has the third region RG51 and the fourth region RG52, the data generation unit 412 generates the modeling data for the (n+1)th layer so that the modeling material is stacked in the following order: above the first region RG1, above the third region RG51 of the second region RG2, and above the fourth region RG52 of the second region RG2.

[0066] 13, the temperature measurement unit 250 measures the change over time in the temperature distribution of the nth layer. That is, the temperature measurement unit 250 measures the change over time in the temperature distribution of the uppermost layer at the time step S71 is executed. The data measured by the temperature measurement unit 250 is transmitted to the control unit 300.

[0067] In step S81, control unit 300 acquires data transmitted from temperature measurement unit 250. Control unit 300 identifies the actual positions of the first, second, third, and fourth regions on the nth layer using data on the change in temperature distribution over time on the nth layer measured by temperature measurement unit 250. The data on the change in temperature distribution over time on the nth layer measured by temperature measurement unit 250 is stored in storage device 320 included in the control device.

[0068] In step S91, the control unit 300 corrects the modeling data for the (n+1)th layer based on the measurement results of the time change in the temperature distribution of the nth layer. Specifically, the control unit 300 corrects the modeling data for the (n+1)th layer generated in step S41 when the positions of the first, second, third, and fourth regions of the nth layer identified in step S81 differ from the positions of the first, second, third, and fourth regions of the nth layer predicted in step S31. The control unit 300 corrects the path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer identified in step S81 before it is deposited above the second region of the nth layer identified in step S81. The control unit 300 also corrects the path data for the (n+1)th layer so that the modeling material is deposited above the third region of the nth layer identified in step S81 before it is deposited above the fourth region of the nth layer identified in step S81. Note that if the positions of the first, second, third, and fourth regions of the nth layer identified in step S81 are the same as the positions of the first, second, third, and fourth regions of the nth layer predicted in step S31, step S91 is not executed.

[0069] FIG. 15 is a diagram showing an example of the movement path of the nozzle 61 included in the modeling data for the (n+1)th layer corrected in step S91. FIG. 15 shows the positions of the first region RG11, the second region RG12, the third region RG61, and the fourth region RG62 of the nth layer identified in step S81. In the example shown in FIG. 15, the first region RG1 has the third region RG61 and the fourth region RG62. FIG. 15 also shows, with arrows, the movement path of the nozzle 61 when stacking the (n+1)th layer corrected in step S91. As shown in FIG. 15, the control unit 300 corrects the path data for the (n+1)th layer so that the modeling material is stacked in the following order: above the third region RG61 of the first region RG11, above the fourth region RG62 of the first region RG11, and above the second region RG12. In addition, when the second region RG12 has a third region RG61 and a fourth region RG62, the control unit 300 modifies the modeling data of the n+1th layer so that the modeling material is stacked in the following order: above the first region RG11, above the third region RG61 that the second region RG12 has, and above the fourth region RG62 that the second region RG12 has.

[0070] According to the third embodiment described above, in the data generation process of the method for manufacturing a three-dimensional object, modeling data for the (n+1)th layer is generated or modified based on the time change in the temperature distribution of the nth layer so that the modeling material is deposited above the third region before the fourth region. Here, the third region is a region where the temperature drops more quickly than the fourth region. This makes it possible to make the temperature of each part of the nth layer more uniform when the modeling material constituting the (n+1)th layer is deposited above the nth layer. This makes it possible to make the adhesion strength between the nth layer and the (n+1)th layer uniform regardless of their positions on the XY plane.

[0071] D. Fourth embodiment: In the fourth embodiment, the content of the modeling process is different from that in the first embodiment. The configuration of each part of the three-dimensional modeling system 10 in the fourth embodiment is the same as that in the first embodiment.

[0072] 16 is a flowchart of the formation processing in the fourth embodiment. Note that the same reference numerals are assigned to parts in which the same processing as in the formation processing in the first embodiment is executed, and the description thereof will be omitted.

[0073] In the fourth embodiment, step S30 is not executed. That is, the temperature prediction unit 411 does not predict the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210.

[0074] In step S42, the data generation unit 412 generates modeling data for the first layer.

[0075] In step S92, the control unit 300 generates modeling data for the (n+1)th layer based on the measurement results of the temperature distribution of the nth layer. Specifically, the control unit 300 generates path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer identified in step S80 before being deposited above the second region of the nth layer identified in step S80.

[0076] In step S102, the control unit 300 models the (n+1)th layer in accordance with the modeling data for the (n+1)th layer generated in step S92.

[0077] According to the fourth embodiment described above, modeling data for the (n+1)th layer is generated based on the measurement results of the temperature distribution of the nth layer. Therefore, compared to stacking the (n+1)th layer without considering the temperature distribution of the nth layer, the temperature of each part of the nth layer can be made more uniform when the modeling material constituting the (n+1)th layer is stacked above the nth layer. Therefore, the adhesion strength between the nth layer and the (n+1)th layer can be made uniform regardless of their positions on the XY plane.

[0078] E. Fifth embodiment: In the fifth embodiment, the content of the modeling process is different from that in the third embodiment. The configuration of each part of the three-dimensional modeling system 10 in the fifth embodiment is the same as that in the third embodiment.

[0079] 17 is a flowchart of the formation processing in the fifth embodiment. Note that the same reference numerals are assigned to parts in which the same processing as in the formation processing in the first and third embodiments is executed, and the description thereof will be omitted.

[0080] In the fifth embodiment, step S31 is not executed. That is, the temperature prediction unit 411 does not predict the change over time in the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210.

[0081] In step S43, the data generation unit 412 generates modeling data for the first layer.

[0082] In step S93, the control unit 300 generates modeling data for the (n+1)th layer based on the measurement results of the change in temperature distribution over time of the nth layer. Specifically, the control unit 300 generates the path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer identified in step S81 before being deposited above the second region of the nth layer identified in step S81. The control unit 300 also generates the path data for the (n+1)th layer so that the modeling material is deposited above the third region of the nth layer identified in step S81 before being deposited above the fourth region of the nth layer identified in step S81.

[0083] In step S103, the control unit 300 models the (n+1)th layer in accordance with the modeling data for the (n+1)th layer generated in step S93.

[0084] According to the fifth embodiment described above, modeling data for the (n+1)th layer is generated based on the measurement results of the change in temperature distribution over time for the nth layer. Therefore, the temperature of each part of the nth layer can be made more uniform when the modeling material constituting the (n+1)th layer is stacked on top of the nth layer. Therefore, the adhesion strength between the nth layer and the (n+1)th layer can be made uniform regardless of their positions on the XY plane.

[0085] F. Sixth embodiment: In the sixth embodiment, the content of the modeling process is different from that in the fifth embodiment. The configuration of each part of the three-dimensional modeling system 10 in the sixth embodiment is the same as that in the fifth embodiment.

[0086] 18 is a flowchart of the formation process in the sixth embodiment. Note that the same reference numerals are used to denote parts in which the same processes as those in the formation processes in the first, third, and fifth embodiments are executed, and the description thereof will be omitted. The following describes the case where the first region has a third region and a fourth region.

[0087] In step S11, the processes of steps S10 to S60 of the fifth embodiment shown in Fig. 17 are executed. Specifically, in step S11, the processes of steps S10, S20, S43, S50, and S60 shown in Fig. 17 are executed in the order described above. After step S11 is executed, steps S71 and S81 shown in Fig. 17 are executed in order.

[0088] In step S201, the control unit 300 generates modeling data for the (n+1)th layer, which corresponds to a portion located above the third region of the nth layer.

[0089] In step S202, the control unit 300 stacks a portion of the (n+1)th layer located above the third region of the nth layer in accordance with the modeling data generated in step S201.

[0090] In step S203, the control unit 300 generates modeling data for the (n+1)th layer, which corresponds to a portion located above the fourth region of the nth layer.

[0091] In step S204, the temperature measurement unit 250 measures the change over time in the temperature distribution in the fourth region of the nth layer.

[0092] In step S205, the control unit 300 determines whether the temperature of the fourth region of the nth layer has fallen below a predetermined temperature. The predetermined temperature is preferably equal to or lower than the upper limit of the temperature at which the shape of the nth layer can be maintained when the nth+1th layer is stacked, and equal to or higher than the temperature at which the interlayer adhesion between the nth layer and the nth+1th layer is maximized. If the temperature of the fourth region of the nth layer has fallen below the predetermined temperature, the control unit 300 returns the process to step S204.

[0093] In step S206, the control unit 300 stacks a portion of the (n+1)th layer located above the fourth region of the nth layer in accordance with the modeling data generated in step S203.

[0094] In step S207, the control unit 300 generates modeling data for the (n+1)th layer, which corresponds to a portion located above the second region of the nth layer.

[0095] In step S208, the control unit 300 stacks a portion of the (n+1)th layer located above the second region of the nth layer in accordance with the modeling data generated in step S207.

[0096] According to the sixth embodiment described above, when the temperature of the fourth region of the nth layer falls below a predetermined temperature, the portion of the (n+1)th layer located above the fourth region of the nth layer is laminated. Therefore, when the (n+1)th layer is laminated above the fourth region of the nth layer, deformation of the shape of the three-dimensional object can be suppressed. Furthermore, interlayer adhesion between the nth layer and the (n+1)th layer can be improved.

[0097] G. Seventh embodiment: In the seventh embodiment, the content of the modeling process is different from that in the first embodiment. The configuration of each part of the three-dimensional modeling system 10 in the seventh embodiment is the same as that in the first embodiment.

[0098] 19 is a flowchart of the formation processing according to the seventh embodiment. Note that the same reference numerals are assigned to parts in which the same processing as in the formation processing according to the first embodiment is executed, and the description thereof will be omitted.

[0099] In step S14, the data generation unit 412 acquires modeling data from another computer, a recording medium, or the storage device 430. The modeling data acquired by the data generation unit 412 in step S14 is modeling data for all layers that constitute the three-dimensional object.

[0100] In step S30, the temperature prediction unit 411 predicts the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210.

[0101] In step S44, the data generation unit 412 modifies the modeling data for the (n+1)th layer based on the prediction result of the temperature distribution of the nth layer in step S30. Specifically, the data generation unit 412 modifies the path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer predicted in step S30 before being deposited above the second region of the nth layer predicted in step S30. The data generation unit 412 modifies the path data for all layers constituting the three-dimensional object. After step S44 is executed, steps S50 and S60 are executed in order. In the seventh embodiment, steps S70, S80, and S90 are not executed. That is, the temperature measurement unit 250 does not measure the temperature distribution of the nth layer. Furthermore, the control unit 300 does not modify the modeling data for the (n+1)th layer based on the measurement result of the temperature distribution of the nth layer.

[0102] In step S104, the control unit 300 models the (n+1)th layer in accordance with the modeling data corrected in step S44.

[0103] According to the seventh embodiment described above, the modeling data for the (n+1)th layer is corrected based on the predicted temperature distribution of the (n+1)th layer. Therefore, compared to stacking the (n+1)th layer without considering the temperature distribution of the (n+1)th layer, the temperature of each part of the (n+1)th layer can be made more uniform when the modeling material constituting the (n+1)th layer is stacked above the (n+1)th layer. Therefore, the adhesion strength between the (n+1)th layer and the (n+1)th layer can be made uniform regardless of their positions on the XY plane.

[0104] H. Eighth embodiment: In the eighth embodiment, the content of the modeling process is different from that in the third embodiment. The configuration of each part of the three-dimensional modeling system 10 in the eighth embodiment is the same as that in the third embodiment.

[0105] 20 is a flowchart of the formation processing in the eighth embodiment. Note that the same reference numerals are assigned to parts in which the same processing as in the formation processing in the first and third embodiments is executed, and the description thereof will be omitted.

[0106] In step S15, the data generation unit 412 acquires modeling data from another computer, a recording medium, or the storage device 430.

[0107] In step S31, the temperature prediction unit 411 predicts the change over time in the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210.

[0108] In step S45, the data generation unit 412 corrects the modeling data for the (n+1)th layer based on the prediction result of the time change in the temperature distribution of the nth layer in step S31. Specifically, the data generation unit 412 corrects the path data for the (n+1)th layer so that the modeling material is deposited above the first region of the nth layer predicted in step S31 earlier than above the second region of the nth layer predicted in step S31, and so that the modeling material is deposited above the third region of the nth layer predicted in step S31 earlier than above the fourth region of the nth layer predicted in step S31. The data generation unit 412 corrects the path data for all layers constituting the three-dimensional model. After step S45 is executed, steps S50 and S60 are executed in sequence. In the eighth embodiment, steps S71, S81, and S91 are not executed. That is, the temperature measurement unit 250 does not measure the time change in the temperature distribution of the nth layer. Furthermore, the control unit 300 does not modify the modeling data of the (n+1)th layer based on the measurement results of the change over time in the temperature distribution of the nth layer.

[0109] In step S105, the control unit 300 models the (n+1)th layer in accordance with the modeling data corrected in step S45.

[0110] According to the eighth embodiment described above, the modeling data for the (n+1)th layer is corrected based on the predicted time change in the temperature distribution of the nth layer. Therefore, the temperature of each part of the nth layer can be made more uniform when the modeling material constituting the (n+1)th layer is stacked on top of the nth layer. Therefore, the adhesion strength between the nth layer and the (n+1)th layer can be made uniform regardless of the position on the XY plane.

[0111] I. Other Embodiments: (I-1) In the first and second embodiments, in step S30 of the modeling process, the temperature prediction unit 411 predicts the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210. Furthermore, in step S40, the data generation unit 412 generates modeling data for modeling the (n+1)th layer based on the prediction result of the temperature distribution of the nth layer in step S30. In contrast, step S30 does not have to be executed. In this case, in step S40, the data generation unit 412 generates modeling data based on the slice data and modeling conditions.

[0112] (I-2) In the third embodiment, in step S31 of the modeling process, the temperature prediction unit 411 predicts a change over time in the temperature distribution of the layers stacked on the modeling surface 211 of the stage 210. Furthermore, in step S41, the data generation unit 412 generates modeling data for modeling the (n+1)th layer, based on the change over time in the temperature distribution of the nth layer predicted in step S31. In contrast, step S31 does not have to be executed. In this case, in step S41, the data generation unit 412 generates modeling data based on slice data and modeling conditions.

[0113] (I-3) In the first and second embodiments, in step S70 of the modeling process, the temperature measurement unit 250 measures the temperature distribution of the nth layer. Furthermore, in step S80, the control unit 300 identifies the actual positions of the first region and the second region in the nth layer using the temperature distribution data of the nth layer. Furthermore, in step S90, the control unit 300 corrects the modeling data of the (n+1)th layer based on the measurement results of the temperature distribution of the nth layer. In contrast, steps S70, S80, and S90 of the modeling process may not be executed. In this case, in step S100, the control unit 300 stacks the (n+1)th layer in accordance with the modeling data generated in step S40.

[0114] (I-4) In the third embodiment, in step S71 of the modeling process, the temperature measurement unit 250 measures the change in temperature distribution over time of the nth layer. Furthermore, in step S81, the control unit 300 identifies the actual positions of the first, second, third, and fourth regions in the nth layer using the data of the change in temperature distribution over time of the nth layer measured by the temperature measurement unit 250. Furthermore, in step S91, the control unit 300 corrects the modeling data of the (n+1)th layer based on the measurement results of the change in temperature distribution over time of the nth layer. In contrast, steps S71, S81, and S91 of the modeling process may not be executed. In this case, in step S100, the control unit 300 stacks the (n+1)th layer in accordance with the modeling data generated in step S41.

[0115] (I-5) In the above embodiment, the data generator 412 sets the first speed and the second speed in the first data generating step. Alternatively, the controller 300 may set the first speed and the second speed in the second data generating step.

[0116] (I-6) In the above embodiment, the data generating unit 412 sets the first speed and the second speed in the data generating process. In contrast, the first speed and the second speed do not need to be set in the modeling process.

[0117] (I-7) In the above embodiment, the 3D printing system 10 includes the information processing device 400. In contrast, the 3D printing system 10 does not necessarily include the information processing device 400. In this case, the steps of the printing process executed by the information processing device 400 in the above embodiment are executed by the control unit 300.

[0118] J. Other forms: The present disclosure is not limited to the above-described embodiments and can be realized in various forms without departing from the spirit thereof. For example, the present disclosure can also be realized in the following forms. The technical features in the above embodiments corresponding to the technical features in each form described below can be appropriately replaced or combined to solve some or all of the problems of the present disclosure or to achieve some or all of the effects of the present disclosure. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0119] (1) According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object, the method comprising: discharging a modeling material from a discharge unit provided in a three-dimensional printing device to laminate a plurality of layers in accordance with modeling data for forming the three-dimensional object layer by layer, the modeling data being generated based on shape data representing the shape of the three-dimensional object; and the method includes at least one of a first lamination step of discharging the modeling material from the discharge unit to laminate an n-th layer, where n is an integer equal to or greater than 1; a temperature measurement step of measuring a temperature distribution of the n-th layer; and a temperature prediction step of predicting a temperature distribution of the n-th layer. The method comprises a data generation process for generating or modifying the modeling data for the (n+1)th layer based on the temperature distribution of the nth layer, and a second stacking process for ejecting the modeling material from the ejection unit to stack the (n+1)th layer based on the generated or modified modeling data for the (n+1)th layer, wherein the nth layer has a first region and a second region, the first region being a region with a lower temperature than the second region, and in the data generation process, the modeling data for the (n+1)th layer is generated or modified so that the modeling material is stacked above the first region before being stacked above the second region. According to this embodiment, the temperature of each portion of the nth layer can be made more uniform when the modeling material constituting the n+1th layer is stacked on top of the nth layer, compared to when the nth layer is stacked without considering the temperature distribution of the nth layer, thereby improving the quality of the three-dimensional object produced by stacking the layers.

[0120] (2) In the above embodiment, the nth layer has a plurality of the first regions and a second region adjacent to the plurality of first regions, and in the data generation process, the modeling data of the n+1th layer may be generated or modified so that the modeling material is stacked above the plurality of first regions without stopping the ejection of the modeling material, while allowing the modeling material to be stacked above the second regions. According to this aspect, when the (n+1)th layer is stacked, the number of times that the discharge of the modeling material from the discharge part is temporarily stopped can be reduced.

[0121] (3) In the above embodiment, the nth layer may have a plurality of the first regions, and in the data generation process, the modeling data for the n+1th layer may be generated or modified so that the modeling material is stacked above the plurality of first regions, and then the modeling material is stacked above the second region. According to this configuration, when the nth layer has multiple first regions, the temperature of each part of the nth layer can be made more uniform when the building material constituting the n+1th layer is stacked on top of the nth layer.

[0122] (4) In the above embodiment, the temperature measurement process may measure the change in temperature distribution of the nth layer over time, the temperature prediction process may predict the change in temperature distribution of the nth layer over time, the first region or the second region may have a third region and a fourth region, and the third region may be a region where the temperature drops faster than the fourth region, and the data generation process may generate or modify the modeling data of the (n+1)th layer based on the change in temperature distribution of the nth layer over time so that the modeling material is stacked above the third region before being stacked above the fourth region. According to this embodiment, when the modeling material constituting the (n+1)th layer is stacked on top of the nth layer, the temperature of each portion of the nth layer can be made more uniform.

[0123] (5) In the above embodiment, in the data generation process, a first speed is set, which is the movement speed of the discharge unit when stacking the modeling material above the first region, and a second speed is set, which is the movement speed of the discharge unit when stacking the modeling material above the second region, and the first speed may be faster than the second speed. According to this embodiment, a decrease in the temperature of the first region can be suppressed until the modeling material is deposited over the entire first region of the n-th layer, and time can be gained for the temperature of the second region to decrease until the modeling material is deposited over the entire second region of the n-th layer.

[0124] (6) In the above-described embodiment, the method may include the temperature measurement process and the temperature prediction process, and the data generation process may include a first data generation process for generating the modeling data for the (n+1)th layer based on the prediction result of the temperature distribution of the nth layer in the temperature prediction process, and a second data generation process for modifying the modeling data for the (n+1)th layer generated in the first data generation process based on the measurement result of the temperature distribution of the nth layer in the temperature measurement process. According to this embodiment, even if the temperature distribution of the nth layer predicted in the temperature prediction process differs from the temperature distribution of the nth layer measured in the temperature measurement process, the temperature of each part of the nth layer can be made more uniform when the building material constituting the n+1th layer is stacked on top of the nth layer. [Explanation of symbols]

[0125] 10...three-dimensional modeling system, 20...material supply unit, 22...communicating passage, 30...plasticizing unit, 31...screw case, 32...drive motor, 40...screw, 42...groove, 43...ridge portion, 44...material inlet, 46...center portion, 48...groove forming surface, 50...barrel, 52...opposing surface, 54...guide groove, 56...communicating hole, 58...plasticizing heater, 59...barrel case, 60...discharge unit, 61...nozzle, 62...nozzle opening, 65...flow path, 70...discharge adjustment unit, 74...first drive unit, 75...suction unit, 76...second drive unit, 77...discharge control unit, 100...three-dimensional modeling device, 110...modeling unit, 210...stage, 211...modeling surface, 212...stage heater, 230...movement mechanism, 250... Temperature measurement unit, 300...control unit, 310...processor, 320...storage device, 400...information processing device, 410...CPU, 411...temperature prediction unit, 412...data generation unit, 420...memory, 430...storage device, 440...communication interface, 450...input / output interface, 460...bus, 470...input device, 480...display device, ML...layer, MM...molding material, MR...raw material, RG1, RG11, RG13, RG14, RG21, RG22, RG3, RG31, RG32, RG4...first region, RG12, RG15, RG2, RG23, RG33, RG5...second region, RG51, RG61...third region, RG52, RG62...fourth region, RX...rotation axis

Claims

1. A method for manufacturing a three-dimensional object, comprising: discharging a modeling material from a discharging unit provided in a three-dimensional modeling device to stack a plurality of layers in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data representing a shape of the three-dimensional object; When n is an arbitrary integer of 1 or more, a first lamination step of discharging the modeling material from the discharge portion to laminate an n-th layer; At least one of a temperature measuring step of measuring a temperature distribution in the n-th layer and a temperature predicting step of predicting a temperature distribution in the n-th layer; a data generating step of generating or correcting the modeling data for the (n+1)th layer based on the temperature distribution of the nth layer; a second lamination process of discharging the modeling material from the discharging unit based on the generated or corrected modeling data of the (n+1)th layer to laminate the (n+1)th layer, the nth layer has a first region and a second region; the first region is a region having a lower temperature than the second region, In the data generating step, the modeling data of the (n+1)th layer is generated or corrected so that the modeling material is stacked above the first region before being stacked above the second region. A method for manufacturing three-dimensional objects.

2. The method for manufacturing a three-dimensional object according to claim 1, the n-th layer has a plurality of the first regions and the second region in contact with the plurality of first regions, In the data generating step, the modeling data of the (n+1)th layer is generated or corrected so that the modeling material is stacked above the plurality of first regions without stopping the dispensing of the modeling material, while allowing the modeling material to be stacked above the second region. A method for manufacturing three-dimensional objects.

3. The method for manufacturing a three-dimensional object according to claim 1, the n-th layer has a plurality of the first regions, In the data generating step, the modeling data of the (n+1)th layer is generated or corrected so that the modeling material is stacked above the second region after the modeling material is stacked above the plurality of first regions. A method for manufacturing three-dimensional objects.

4. The method for manufacturing a three-dimensional object according to claim 1, In the temperature measuring step, a change in temperature distribution over time of the n-th layer is measured; In the temperature prediction step, a time change in the temperature distribution of the n-th layer is predicted; the first region or the second region has a third region and a fourth region, the third region is a region where the temperature decreases more rapidly than the fourth region, In the data generating step, the modeling data of the (n+1)th layer is generated or corrected based on a time change in the temperature distribution of the nth layer so that the modeling material is stacked above the third region prior to being stacked above the fourth region. A method for manufacturing three-dimensional objects.

5. The method for manufacturing a three-dimensional object according to claim 1, In the data generating step, a first speed is set as a moving speed of the discharge unit when depositing the modeling material above the first region, and a second speed is set as a moving speed of the discharge unit when depositing the modeling material above the second region, The first speed is faster than the second speed. A method for manufacturing three-dimensional objects.

6. The method for manufacturing a three-dimensional object according to claim 1, the temperature measuring step and the temperature predicting step, The data generating step includes: a first data generating step of generating the modeling data of the (n+1)th layer based on a result of predicting the temperature distribution of the nth layer in the temperature predicting step; a second data generating step of correcting the modeling data of the (n+1)th layer generated in the first data generating step, based on a measurement result of the temperature distribution of the nth layer in the temperature measuring step, A method for manufacturing three-dimensional objects.

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