Additive molding device

Abstract

Smooth out the rising edges of the fiber material. [Solution] The additive molding apparatus 1 includes a molding table 2 including a molding support surface 2a for supporting a molded object 8, a molding head 3 including a nozzle 312 for discharging a molding fiber material 9, positioned on the molding support surface 2a of the molding table 2 and movable along the molding support surface 2a of the molding table 2, and a fiber leveling mechanism 34 provided so as to sandwich the nozzle 312 and including a cylinder lower end surface 341a for pressing the molding fiber material 9 against the molding table 2. The fiber leveling mechanism 34 switches between a molding mode T34A in which the distance from the molding table 2 to the cylinder lower end surface 341a is longer than the distance from the molding table 2 to the nozzle 312, and a leveling mode T34B in which the distance from the molding table 2 to the cylinder lower end surface 341a is shorter than the distance from the molding table 2 to the nozzle 312, and the cylinder lower end surface 341a presses the molding fiber material 9 toward the molding table 2.

Description

Technical Field

[0001] The present invention relates to an additive manufacturing apparatus.

Background Art

[0002] There is known an additive manufacturing apparatus that obtains a desired three-dimensional object by laminating string-like fiber materials. Patent Document 1 discloses a technique related to a 3D printer using a fibrous body. In the apparatus of Patent Document 1, when discharging from a nozzle, the composite filament melted by heating is pressed in the thickness direction to open the reinforcing fiber bundle.

[0003] After adding the shaped fiber material to a desired region, the shaped fiber material is cut. By this cutting, a portion that has not been added to the object and rises from the surface of the object occurs. Since such a rising portion hinders the next addition operation, it is pressed toward the surface of the object. For example, Patent Document 2 discloses an operation of leveling the shaped fiber material after cutting the shaped fiber material. The technique disclosed in this Patent Document 2 cuts the filament by pressing a pipe having a predetermined curvature shape against the fiber-reinforced filament. Then, by moving the nozzle head a predetermined distance in a predetermined direction, the filament is leveled to the end.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] There are two ways of cutting the shaping fiber material: cutting the portion of the shaping fiber material that is not being extruded from the nozzle, and cutting the portion of the shaping fiber material that is being extruded from the nozzle. When cutting the portion of the shaping fiber material that is not being extruded from the nozzle, the length of the shaping fiber material from the portion attached to the object to the cut portion tends to be longer. On the other hand, when cutting the portion of the shaping fiber material that is being extruded from the nozzle, the shaping fiber material can be cut near the portion attached to the object, making it possible to shorten the aforementioned rising portion of the shaping fiber material. However, even a short rising portion can interfere with the next shaping operation, so it is necessary to smooth out the rising portion.

[0006] Therefore, the present invention aims to provide an additive molding apparatus capable of leveling the rising portion of the fibrous material when cutting a portion of the fibrous material being extruded from a nozzle. [Means for solving the problem]

[0007] An additive manufacturing apparatus according to one embodiment of the present invention comprises a build table including a support surface for supporting a build object made of laminated fibrous material, a build head including a nozzle for discharging fibrous material toward the build table, positioned on the support surface of the build table and movable along the support surface of the build table, and a fiber leveling mechanism including a fiber leveling surface provided to sandwich the nozzle and for pressing the fibrous material toward the build table, wherein the fiber leveling mechanism can switch between a build mode in which the distance from the build table to the fiber leveling surface is longer than the distance from the build table to the nozzle, and a leveling mode in which the distance from the build table to the fiber leveling surface is shorter than the distance from the build table to the nozzle, and the fiber leveling surface presses the fibrous material toward the build table.

[0008] According to this device, the edges of the fibrous material layered by the build head are pressed toward the build table by the fiber leveling surface of the fiber leveling mechanism, which is shaped to be level. As a result, the parts of the fibrous material that rise from the build table can be leveled to a shape that does not interfere with the next build operation.

[0009] The above additive manufacturing apparatus may further include a controller that provides a control signal to the fiber leveling mechanism for switching between the printing mode and the leveling mode. With this configuration, the printing mode and the leveling mode can be switched automatically.

[0010] The above additive manufacturing apparatus may further include a fiber cutting mechanism for cutting the fibrous material extending from the support surface of the build table to the nozzle of the build head. This configuration allows the fibrous material to be cut.

[0011] The above additive manufacturing apparatus may further include a material supply mechanism that winds and holds the fibrous material and supplies it to the build head, and a fiber holding mechanism that switches between a configuration in which it grips the fibrous material extending from the material supply mechanism to the build head and a configuration in which it does not grip the fibrous material extending from the material supply mechanism to the build head. With this configuration, when cutting the fibrous material, it is possible to prevent unintended unwinding of the fibrous material from the bobbin around which the fibrous material is wound.

[0012] The controller of the additive manufacturing apparatus described above may output a control signal to switch from the manufacturing mode to the leveling mode, a control signal to move the fiber leveling surface along the support surface of the build table when in the leveling mode, and a control signal to switch from the leveling mode to the manufacturing mode. This control makes it possible to level out any raised parts of the fibrous material in the direction of movement of the fiber leveling surface.

[0013] The controller of the additive manufacturing apparatus described above may output a control signal for cutting the fibrous material extending from the support surface of the build table to the nozzle of the build head by the fiber cutting mechanism, a control signal for switching the fiber leveling mechanism from a build mode to a leveling mode, a control signal for moving the fiber leveling surface along the support surface of the build table when in leveling mode, and a control signal for switching the fiber leveling mechanism from a leveling mode to a build mode. This control allows for the execution of cutting the fibrous material and leveling the raised portion of the fibrous material created by the cutting.

[0014] The controller of the additive manufacturing apparatus described above may output a control signal for gripping the fibrous material to be manufactured by the fiber holding mechanism, a control signal for cutting the fibrous material that extends from the support surface of the build table to the nozzle of the build head and is gripped by the fiber holding mechanism by the fiber cutting mechanism, a control signal for switching the fiber leveling mechanism from the manufacturing form to the leveling form, a control signal for moving the fiber leveling surface along the support surface of the build table when in the leveling form, and a control signal for switching the fiber leveling mechanism from the leveling form to the manufacturing form. This control allows for the execution of gripping the fibrous material to be manufactured, cutting the fibrous material, and leveling the raised portion of the fibrous material created by the cutting.

[0015] In the additive molding apparatus described above, the nozzle tip surface is provided with an outlet for discharging the molding fiber material, and the fiber leveling surface may surround the outlet when viewed from the axial direction of the outlet. With this configuration, regardless of the direction of nozzle movement, the areas where the molding fiber material has risen can be leveled.

[0016] In the additive manufacturing apparatus described above, the shape of the fiber leveling surface may be circular. This configuration also allows for leveling of areas where the fabricated fiber material has risen, regardless of the direction of nozzle movement.

[0017] In the additive molding apparatus described above, the axis of the fiber leveling surface may overlap with the axis of the nozzle. This configuration also allows for leveling of areas where the molded fiber material has risen.

[0018] In the above-described additive shaping apparatus, the fiber leveling mechanism may include a leveling cylinder including a fiber leveling surface, and a leveling mechanism actuator that reciprocates the leveling cylinder along the axial direction of the leveling cylinder. According to this configuration, the cylinder for leveling the raised portion of the shaped fiber material can be disposed at a position that does not interfere with the operation of laminating the shaped fiber material.

[0019] In the above-described additive shaping apparatus, the shaping head may include a heater that heats the leveling cylinder, and the leveling cylinder may press while heating the shaped fiber material formed of a thermoplastic resin.

Advantages of the Invention

[0020] According to the present invention, it is possible to provide an additive shaping apparatus capable of leveling the raised portion of the fiber material when cutting the portion of the shaped fiber material discharged from the nozzle.

Brief Description of the Drawings

[0021] [Figure 1] FIG. 1 is a diagram showing a schematic configuration of an additive shaping apparatus according to an embodiment. [Figure 2] FIG. 2(a) is a perspective view showing a fiber cutting mechanism in a standby state. FIG. 2(b) is a perspective view showing the fiber cutting mechanism in a cutting state. [Figure 3] [[ID=2M]]FIG. 3(a) is a cross-sectional view showing a fiber leveling mechanism in a shaping state. FIG. 3(b) is a cross-sectional view showing the fiber leveling mechanism in a leveling state. [Figure 4] FIG. 4 is a flowchart showing the operation of the additive shaping apparatus of FIG. 1. [Figure 5] FIG. 5(a) is a diagram showing the operation of the shaping head moving to the lamination start position. FIG. 5(b) is a diagram showing the operation of executing the shaping operation and the operation of reaching the lamination end position. [Figure 6]Fig. 6(a) is a diagram showing the operation in which the shaping head moves to the head cutting position. Fig. 6(b) is a diagram showing the operation in which the fiber holding mechanism sandwiches the shaped fiber material. [Figure 7] Fig. 7(a) is a diagram showing the operation in which the fiber cutting mechanism moves to the head cutting position. Fig. 7(b) is a diagram showing the operation in which the fiber cutting mechanism cuts the shaped fiber material. [Figure 8] Fig. 8(a) is a diagram showing the operation in which the fiber cutting mechanism moves to the standby position. Fig. 8(b) is a diagram showing the operation in which the leveling cylinder descends. [Figure 9] Fig. 9(a) is a diagram showing the operation in which the leveling cylinder moves horizontally. Fig. 9(b) is a diagram showing the operation in which the leveling cylinder ascends.

Embodiments for Carrying out the Invention

[0022] Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same reference numerals are assigned to the same elements, and redundant descriptions are omitted.

[0023] Figure 1 shows the configuration of an additive manufacturing apparatus 1, which is an embodiment of the apparatus. The additive manufacturing apparatus 1 deposits the fibrous material 9 onto a build table 2 located below the build head 3 by extruding the fibrous material 9 from the build head 3. As a result, a three-dimensional object can be fabricated. The additive manufacturing apparatus 1 is an additive manufacturing (AM) apparatus using the so-called fused deposition modeling (FDM) method. In other words, the additive manufacturing apparatus 1 deposits or adheres the fibrous material 9 onto the build table 2 by extruding heated fibrous material 9 from the build head 3. As the fibrous material 9, for example, a material including fiber-reinforced plastic (FRP) is used. Specifically, the fibrous material 9 includes fiber-reinforced plastic and resin. In this case, the fibrous material 9 is positioned with the direction of the fibers oriented in the direction of movement of the build head 3. Examples of fiber-reinforced plastics include glass fibers or carbon fibers. Fiber-reinforced plastics may use discontinuous or continuous fibers.

[0024] The additive manufacturing apparatus 1 comprises a build table 2, a build head 3, a head actuator 4, and a controller 5. The build table 2 supports the object 8. The build table 2 has an object support surface 2a. The build head 3 extrudes the molten fiber material 9 toward the build table 2. The build head 3 is positioned on the build table 2.

[0025] The head actuator 4 moves the build head 3 relative to the build table 2. More specifically, the head actuator 4 lowers the build head 3 so that it is closer to the build object support surface 2a. The head actuator 4 then raises the build head 3 so that it is further away from the build object support surface 2a. Furthermore, the head actuator 4 moves the build head 3 along the build object support surface 2a. The movement of the build head 3 along the build object support surface 2a may be a parallel movement that maintains the distance from the build head 3 to the build table 2. The controller 5 controls the build head 3 and the head actuator 4. For example, the controller 5 performs the aforementioned relative movement of the build head 3 with respect to the build table 2 by giving the head actuator 4 a control signal C4. The operation of the build head 3 by the controller 5 will be described later.

[0026] The 3D printer head includes a fiber dispensing mechanism 31, a fiber holding mechanism 32, a fiber cutting mechanism 33, and a fiber leveling mechanism 34. These mechanisms are fixed to the head frame 35 and together constitute the 3D printer head 3. Therefore, these mechanisms can be moved as a single unit by the head actuator 4.

[0027] The fiber dispensing mechanism 31 dispenses the fibrous material 9 toward the build table 2. The fiber dispensing mechanism 31 includes a bobbin 311, a nozzle 312, and a nozzle heater 313. A guide mechanism for guiding the string-like fibrous material 9 may be provided in the path from the bobbin 311 to the nozzle 312 as needed.

[0028] The shaping fiber material 9 is wound around the bobbin 311. The bobbin 311 is positioned above the head frame 35. The nozzle 312 presses the shaping fiber material 9 against the object 8 while heating it with heat received from the nozzle heater 313. The nozzle 312 is positioned below the head frame 35. The tip of the nozzle 312 includes a nozzle lower end surface 312a that presses the shaping fiber material 9 against the object while applying heat to it. A nozzle discharge port 312H (see Figure 3(a)) is provided on this nozzle lower end surface 312a. The shape of the nozzle discharge port 312H when viewed in plan from its axis is, for example, circular.

[0029] The fiber holding mechanism 32 grips the shaping fiber material 9 extending between the bobbin 311 and the nozzle 312 when cutting the shaping fiber material 9. When the shaping fiber material 9 is cut, tension may act on the shaping fiber material 9 due to the impact of the cut. This tension may cause unintended unwinding of the shaping fiber material 9 from the bobbin 311. If this occurs, the encoder on the bobbin 311 may not function properly when starting the next shaping operation, resulting in a state that is judged as abnormal. Therefore, when cutting the shaping fiber material 9, the fiber holding mechanism 32 grips the shaping fiber material 9 extending between the bobbin 311 and the nozzle 312. As a result, the tension caused by the impact of the cut is contained at the part gripped by the fiber holding mechanism 32 and does not reach the shaping fiber material 9 wound around the bobbin 311. Thus, unintended unwinding of the shaping fiber material 9 from the bobbin 311 can be prevented.

[0030] The fiber holding mechanism 32 is positioned between the bobbin 311 and the nozzle 312. The fiber holding mechanism 32 includes a backing plate 321, a holding plate 322, and a holding actuator 323. The backing plate 321 is a member fixed to the head frame 35. The backing plate 321 may be in contact with the shaping fiber material 9 being fed from the bobbin 311 to the nozzle 312. The holding plate 322 switches between a position away from the backing plate 321 and a position in contact with the backing plate 321. The movement of the holding plate 322 is based on the holding actuator 323, which receives a control signal C32 from the controller 5.

[0031] When the presser plate 322 is away from the backing plate 321, the shaping fiber material 9 can move from the bobbin 311 to the nozzle 312. In other words, during the shaping operation, the presser plate 322 is away from the backing plate 321. When the presser plate 322 is in contact with the backing plate 321, the shaping fiber material 9 cannot move from the bobbin 311 to the nozzle 312. In other words, during the cutting operation described later, the presser plate 322 is in contact with the backing plate 321.

[0032] The fiber cutting mechanism 33 cuts the fibrous material 9 extending between the build table 2 and the nozzle 312. The fiber cutting mechanism 33 moves between a standby position T33A (see Figure 2(a)) where it is positioned during a build operation and a head cutting position T33B (see Figure 2(b)) where it is positioned during a cutting operation. The fiber cutting mechanism 33 includes a cutting module 33M and a cutting actuator 33A. The cutting module 33M moves from the standby position T33A to the head cutting position T33B and back from the head cutting position T33B to the standby position T33A by the cutting actuator 33A, which receives a control signal C33 from the controller 5. The cutting module 33M has the function of gripping the fibrous material 9 and the function of cutting the gripped fibrous material 9. These operations are performed according to the control signal C33 given to the fiber cutting mechanism 33 from the controller 5. The cutting module 33M consists of components fixed to the cutting mechanism frame 338 and components that are movably mounted relative to the cutting mechanism frame 338.

[0033] As shown in Figure 2(a), the cutting module 33M, as an element for cutting the shaping fiber material, includes a motor 334, a vibration unit 335, and a clipper unit 336. The clipper unit 336 has an upper blade 3361 and a lower blade 3362, each having multiple small blades arranged in a row. The lower blade 3362 is fixed to the cutting mechanism frame 338. The upper blade 3361 reciprocates relative to the fixed lower blade 3362 in the direction of the arrangement of the small blades. As a result, the object sandwiched between the upper blade 3361 and the lower blade 3362 is cut in the direction from the upper blade 3361 to the lower blade 3362. With such a clipper unit 336, the blades that cut the shaping fiber material 9 are not always the same, and the shaping fiber material 9 is cut by different blades each time. Therefore, wear on the upper blade 3361 and the lower blade 3362 can be suppressed. Furthermore, the clipper unit 336 can reduce the height dimension in which the upper blade 3361 and lower blade 3362 are aligned. As a result, the length of the fiber-raised portion 91 created by cutting can be shortened.

[0034] When the shaping fiber material 9 is cut by the clipper unit 336, reliable cutting can be achieved by maintaining the position of the shaping fiber material 9. Therefore, the cutting module 33M is equipped with a function to grip the shaping fiber material 9. As elements for gripping the shaping fiber material 9, the cutting module 33M has a fiber gripping plate 331, an air chuck 332, and a chuck guide 333. The fiber gripping plate 331 moves relative to the cutting mechanism frame 338. Specifically, the fiber gripping plate 331 can move towards the cutting mechanism frame 338 and move away from the cutting mechanism frame 338. Therefore, the fiber cutting mechanism can switch between a configuration in which a gap is formed between the fiber gripping plate 331 and the cutting mechanism frame 338 (see Figure 2(a)) and a configuration in which the fiber gripping plate 331 is abutting against the cutting mechanism frame 338 (see Figure 2(b)). These switching operations are performed by a chuck guide 333 and an air chuck 332 fixed to the cutting mechanism frame 338. The chuck guide 333 and the air chuck 332 are so-called linear actuators that enable reciprocating movement along the axis. The fiber gripping plate 331 is a rectangular plate member in plan view. The longitudinal end face of the fiber gripping plate 331 is in contact with the end face of the fiber gripping plate 331 provided on the back surface of the cutting mechanism frame 338. The shaping fiber material 9 is sandwiched between these end faces.

[0035] The fiber leveling mechanism 34 leveles the raised portion of the shaping fiber material 9 that is created by cutting. In the following description, the raised portion of the shaping fiber material 9 will be referred to as the "fiber raised portion 91" (see Figure 6(a), etc.). Furthermore, in the description of this embodiment, "leveling" refers to the action of pressing the fiber raised portion 91 toward the shaping object 8. In other words, "leveling" means deforming the fiber raised portion 91 so that it does not interfere with the next shaping operation.

[0036] As a result of the "leveling" operation, the fiber rise portion 91 deforms from a shape that rises from the molded object 8 to a state in contact with the molded object 8. In this state of contact with the molded object 8, it is not necessary for the entire fiber rise portion 91 to be in contact with the molded object 8. At least the tip of the fiber rise portion 91 must be in contact with the molded object 8. Furthermore, the state of contact with the molded object 8 also includes the state in which the fiber rise portion 91 is joined to the molded object 8. The joining of the fiber rise portion 91 to the molded object 8 may be such that the entire fiber rise portion 91 is joined to the molded object 8, or it may be such that the tip of the fiber rise portion 91 is joined to the molded object 8.

[0037] As shown in Figure 3(a), the fiber leveling mechanism 34 includes a leveling cylinder 341, a leveling mechanism frame 342, and a leveling mechanism actuator 343.

[0038] The leveling cylinder 341 is a component that presses the fiber rise portion 91 toward the molded object support surface 2a. The leveling cylinder 341 has a cylindrical shape. A nozzle 312 is located inside the leveling cylinder 341. Therefore, the axis of the leveling cylinder 341 overlaps with the axis of the nozzle 312. The leveling cylinder 341 has a lower end surface 341a and an upper end surface 341b. The lower end surface 341a is a pressing surface that presses the fiber rise portion 91 toward the molded object support surface 2a. A cylinder opening 341H is provided on the lower end surface 341a. The lower end of the nozzle 312 can protrude from this cylinder opening 341H. The upper end surface 341b is a heat receiving surface that contacts the nozzle heater 313.

[0039] The leveling cylinder 341 is capable of reciprocating relative to the nozzle 312 along its axis. This reciprocating movement allows the leveling cylinder 341 and the nozzle 312 to take on two different forms. In other words, the fiber leveling mechanism 34 switches between the shaping form T34A (see Figure 3(a)) and the leveling form T34B (see Figure 3(b)) depending on the position of the leveling cylinder 341.

[0040] The first form is the molding form T34A shown in Figure 3(a). In molding form T34A, the lower end of the nozzle 312 protrudes from the cylinder opening 341H of the leveling cylinder 341. With respect to the molded object support surface 2a, in molding form T34A, the distance from the molded object support surface 2a to the lower end surface of the cylinder 341a is greater than the distance from the molded object support surface 2a to the lower end surface of the nozzle 312a. In this molding form T34A, the nozzle 312 can discharge the molding fiber material 9 from the nozzle discharge port 312H and deposit the molding fiber material 9 onto the molded object 8.

[0041] The second form is the leveling form T34B shown in Figure 3(b). In leveling form T34B, the lower end of the nozzle 312 does not protrude from the cylinder opening 341H of the leveling cylinder 341. In other words, in leveling form T34B, the lower end of the nozzle 312 is located inside the leveling cylinder 341. With respect to the molded object support surface 2a, in leveling form T34B, the distance from the molded object support surface 2a to the lower end surface 341a of the cylinder is smaller than the distance from the molded object support surface 2a to the lower end surface 312a of the nozzle. In this leveling form, the lower end surface 341a of the cylinder can come into contact with the fiber rise portion 91. Therefore, the leveling operation described later can be performed.

[0042] <Operation of Additive Molding Device 1> The operation of the additive molding apparatus 1 will be explained in detail below, with reference to the flowchart (Figure 4) and process diagrams (Figures 5 to 9).

[0043] First, the object 8 is fabricated (S1). Specifically, the build head 3 moves to the layering start position P1 (S11: see Figure 5(a)). This operation is performed by the controller 5 giving a control signal C4 to the head actuator 4. The head actuator 4 moves the build head 3 so that the tip of the nozzle 312 is at the layering start position P1.

[0044] Next, the printing operation is performed (S12: see Figure 5(b)). This operation is performed when the controller 5 gives a control signal C4 to the head actuator 4. Upon receiving the control signal C4, the head actuator 4 moves the printing head 3 horizontally from the start position P1 to the end position P2. At this time, the printing fiber material 9 is extruded, the extruded printing fiber material 9 is heated, and the printing fiber material 9 is pressed.

[0045] Then, the stacking ends (S13: see Figure 5(b)).

[0046] Next, the shaping fiber material 9 is cut (S2). Specifically, first, the printing head 3 moves to the head cutting position (S21: see Figure 6(a)). The head cutting position T33B is a predetermined distance from the stacking end position P2 along the direction from the stacking start position P1 to the stacking end position P2. When viewed from above, if the distance from the stacking end position P2 to the head cutting position T33B is short, the stacking end position P2 may overlap with the internal area of ​​the leveling cylinder 341 when viewed from above. Also, when viewed from above, the stacking end position P2 may overlap with the lower end surface 341a of the leveling cylinder 341. In such cases, the entire fiber rising portion 91 from the stacking end position P2 to the tip can be pressed towards the shaping support surface 2a.

[0047] On the other hand, if the distance from the end of the layering process P2 to the head cutting position T33B is large when viewed from above, the end of the layering process P2 may be located outside the leveling cylinder 341 when viewed from above. In such cases, there will be a portion of the fiber rise portion 91 that is not pressed toward the object support surface 2a. Specifically, the portion of the fiber rise portion 91 from the end of the layering process P2 to the outer peripheral surface 341s of the leveling cylinder 341 will not be pressed toward the object support surface 2a. However, even in such cases, the portion of the fiber rise portion 91 from the lower end surface 341a of the cylinder to the tip can be pressed toward the object support surface 2a. As a result, the fiber rise portion 91 as a whole can be shaped in a way that does not interfere with the next printing operation.

[0048] Furthermore, the head cutting position T33B is located a predetermined distance above the object support surface 2a of the build table 2. Therefore, a gap is formed between the tip surface of the nozzle 312 and the object support surface 2a. As will be described later, the fiber cutting mechanism 33, which will be described later, is inserted into this gap. Furthermore, as the build process moves from the end of the build process position P2 to the head cutting position T33B, the build fiber material 9 continues to be ejected from the nozzle 312. As a result, a portion is formed that extends from the end of the build process position P2 to the nozzle discharge port 312H at the head cutting position T33B. Since the nozzle discharge port 312H is spaced apart from the object support surface 2a, this portion rises from the object support surface 2a.

[0049] Next, the fiber holding mechanism 32 grips the shaping fiber material 9 (S22: see Figure 6(b)). This operation is performed when the controller 5 gives a control signal C32 to the fiber holding mechanism 32. Upon receiving the control signal C32, the fiber holding mechanism 32 presses the holding plate 322 toward the backing plate 321 by driving the holding actuator 323. As a result, a portion of the shaping fiber material 9 is sandwiched between the backing plate 321 and the holding plate 322. In this state, even if the shaping fiber material 9 located downstream of the fiber holding mechanism 32 (towards the nozzle 312) is pulled, the shaping fiber material 9 located upstream of the fiber holding mechanism 32 (towards the bobbin 311) will not be fed out.

[0050] Next, the fiber cutting mechanism 33 moves to the cutting position (S23: see Figure 7(a)). This operation is performed by the controller 5 giving a control signal C33 to the cutting actuator 33A. More specifically, the fiber cutting mechanism 33 descends (S231: see Figure 7(a)). As mentioned above, when the fiber cutting mechanism 33 has finished descending, it is positioned between the molded object support surface 2a and the nozzle lower end surface 312a when viewed from the horizontal direction. This movement is a linear movement by the cutting actuator 33A.

[0051] Next, the fiber cutting mechanism 33 moves horizontally (S232: see Figure 7(a)). As a result of this movement, the fiber cutting mechanism 33 is positioned so that the shaped fiber material 9 is in the gap between the fiber gripping plate 331 and the clipper unit 336. This movement may be a linear movement along the shaped object support surface 2a, or a rotational movement along the shaped object support surface 2a.

[0052] When the horizontal movement is complete, the gap between the fiber gripping plate 331 and the clipper unit 336 is located inside the leveling cylinder 341 when viewed from above. More specifically, the tips of the upper blade 3361 and lower blade 3362 of the clipper unit 336 are located inside the leveling cylinder 341 when viewed from above. As a result, the tips of the fiber rise portion 91 formed by cutting are located inside the leveling cylinder 341 when viewed from above.

[0053] Next, the fiber cutting mechanism 33 cuts the shaping fiber material 9 (S24: see Figure 7(b)). This operation is performed when the controller 5 gives a control signal C33 to the cutting module 33M. More specifically, the fiber gripping plate 331 grips the shaping fiber material 9 (S241: see Figure 2(b)). Upon receiving the control signal C33, the cutting module 33M first moves the fiber gripping plate 331 toward the cutting mechanism frame 338 using the air chuck 332. As a result, the shaping fiber material 9 is sandwiched between the fiber gripping plate 331 and another fiber gripping plate provided on the back surface of the cutting mechanism frame 338. In this state, the shaping fiber material 9 cannot move.

[0054] Next, the motor 334 is driven (S242: see Figure 7(b)). Upon receiving the control signal C33, the cutting module 33M starts rotating the motor 334. This rotation is transmitted via the gearbox 337 to the eccentric camshaft 3351 of the vibration unit 335. Then, in response to the rotation of the eccentric camshaft 3351, a small reciprocating movement occurs of the upper blade 3361 of the clipper unit 336. As a result, the shaping fiber material 9 is cut by the upper blade 3361 of the clipper unit 336.

[0055] Next, the motor 334 is stopped (S243: see Figure 7(b)). Upon receiving the control signal C33, the disconnection module 33M stops the rotation of the motor 334. The stopping of the rotation of the motor 334 may be performed on the condition that a predetermined time has elapsed since the start of the rotation of the motor 334.

[0056] Then, the fiber gripping plate 331 releases the molded fiber material 9 (S244). Upon receiving the control signal C33, the cutting module 33M separates the fiber gripping plate 331 from the cutting mechanism frame 338 using the air chuck 332.

[0057] Next, the fiber cutting mechanism 33 moves to the standby position (S25: see Figure 8(a)). This operation is performed by the controller 5 giving a control signal C33 to the cutting actuator 33A. More specifically, the cutting actuator 33A, having received the control signal C33, moves the fiber cutting mechanism 33 horizontally (S251: see Figure 8(a)). This movement is the reverse of the horizontal movement in step S232 described above. Next, the cutting actuator 33A, having received the control signal C33, moves the fiber cutting mechanism 33 upward (S252: see Figure 8(a)). This movement is also the reverse of the movement in step S231 described above.

[0058] Next, the fiber rise portion 91 is leveled (S3). This operation is performed by the controller 5 providing a control signal C34 to the fiber leveling mechanism 34 and the head actuator 4.

[0059] Specifically, the leveling mechanism actuator 343, which receives the control signal C34, lowers the leveling cylinder 341 (S31: see Figure 8(b)). As a result of the lowering, the fiber rise portion 91 is sandwiched between the molded object support surface 2a and the lower end surface 341a of the leveling cylinder 341. When welding the fiber rise portion 91, the leveling cylinder 341 is lowered so that a pressing force is generated from the leveling cylinder 341 to the molded table 2.

[0060] Next, the leveling cylinder 341 moves horizontally due to the head actuator 4 receiving the control signal C34 (S32: see Figure 9(a)). This movement is along the direction in which the fiber rise portion 91 extends. This movement continues until the lower end surface 341a of the leveling cylinder 341 passes the tip 91s of the fiber rise portion 91. This movement ensures that at least the tip 91s of the fiber rise portion 91 is pressed toward the molded object 8. Furthermore, the leveling cylinder 341 is in contact with the nozzle heater 313 until just before it begins to descend, and is therefore at a high temperature. As a result, in this step S32, the fiber rise portion 91 can be pressed while being heated. According to step S32, when the molded fiber material 9 is a thermoplastic resin, the molded fiber material 9 can be deformed while being heated.

[0061] Then, the leveling mechanism actuator 343, having received the control signal C34, raises the leveling cylinder 341 (S33: see Figure 9(b)). This movement continues until the upper end surface 341b of the leveling cylinder 341 comes into contact with the nozzle heater 313.

[0062] After step S3, the process returns to step S1 and is executed in order. By repeating steps S1, S2, and S3 while changing the layering start position P1 each time, a fabricated object 8 with the desired shape can be obtained.

[0063] <Effects and Effects> The additive molding apparatus 1 comprises a molding table 2 including a molded object support surface 2a for supporting a molded object 8 formed by stacking molding fiber material 9, a molding head 3 including a nozzle 312 for discharging the molding fiber material 9 toward the molding table 2, positioned on the molded object support surface 2a of the molding table 2 and movable along the molded object support surface 2a of the molding table 2, and a fiber leveling mechanism 34 including a cylinder lower end surface 341a provided to sandwich the nozzle 312 and for pressing the molding fiber material 9 against the molding table 2. The fiber leveling mechanism 34 switches between two modes: a printing mode T34A in which the distance from the build table 2 to the lower end surface 341a of the cylinder is longer than the distance from the build table 2 to the nozzle 312, and a leveling mode T34B in which the distance from the build table 2 to the lower end surface 341a of the cylinder is shorter than the distance from the build table 2 to the nozzle 312, and the lower end surface 341a of the cylinder presses the fibrous material 9 toward the build table 2.

[0064] According to this device, the edges of the fibrous material 9, which is layered by the build head 3, are pressed toward the build table 2 by the lower cylinder surface 341a of the fiber leveling mechanism 34, which has a leveling shape T34B. As a result, the portion of the fibrous material 9 that rises from the build table 2 can be leveled to a shape that does not interfere with the next build operation.

[0065] The additive molding apparatus 1 further includes a controller 5 that provides a control signal to the fiber leveling mechanism 34 for switching between the molding form T34A and the leveling form T34B. With this configuration, the molding form T34A and the leveling form T34B can be switched automatically.

[0066] The additive manufacturing apparatus 1 further includes a fiber cutting mechanism 33 for cutting the fibrous material 9 that extends from the object support surface 2a of the build table 2 to the nozzle 312 of the build head 3. With this configuration, the fibrous material 9 can be cut.

[0067] The additive molding apparatus 1 further includes a bobbin 311 that winds and holds the molding fiber material 9 and supplies the molding fiber material 9 to the molding head 3, and a fiber holding mechanism 32 that switches between a configuration in which the molding fiber material 9 extending from the bobbin 311 to the molding head 3 is gripped and a configuration in which the molding fiber material 9 extending from the bobbin 311 to the molding head 3 is not gripped. With this configuration, when cutting the molding fiber material 9, it is possible to prevent unintended unwinding of the molding fiber material 9 from the bobbin 311 in which the molding fiber material 9 is wound.

[0068] The controller 5 outputs a control signal to switch from the printing mode T34A to the leveling mode T34B, a control signal to move the lower end surface 341a of the cylinder along the object support surface 2a of the build table 2 when in the leveling mode T34B, and a control signal to switch from the leveling mode T34B to the printing mode T34A. This control allows the raised portions of the printing fiber material 9 that are present in the direction of movement of the lower end surface 341a of the cylinder to be leveled.

[0069] The controller 5 outputs a control signal to cut the fibrous material 9 extending from the object support surface 2a of the build table 2 to the nozzle 312 of the build head 3 using the fiber cutting mechanism 33; a control signal to switch the fiber leveling mechanism 34 from build mode T34A to leveling mode T34B; a control signal to move the lower end surface 341a of the cylinder along the object support surface 2a of the build table 2 when in leveling mode T34B; and a control signal to switch the fiber leveling mechanism 34 from leveling mode T34B to build mode T34A. This control allows the controller to perform the operation of cutting the fibrous material 9 and the operation of leveling the raised portion of the fibrous material 9 caused by the cutting.

[0070] The controller 5 outputs a control signal for gripping the fibrous material 9 with the fiber holding mechanism 32, a control signal for cutting the fibrous material 9 that extends from the object support surface 2a of the build table 2 to the nozzle 312 of the build head 3 and is gripped by the fiber holding mechanism 32 with the fiber cutting mechanism 33, a control signal for switching the fiber leveling mechanism 34 from build mode T34A to leveling mode T34B, a control signal for moving the lower end surface 341a of the cylinder along the object support surface 2a of the build table 2 when in leveling mode T34B, and a control signal for switching the fiber leveling mechanism 34 from leveling mode T34B to build mode T34A. This control allows the controller to perform the operation of gripping the fibrous material 9, the operation of cutting the fibrous material 9, and the operation of leveling the raised portion of the fibrous material 9 caused by the cutting.

[0071] The tip surface of the nozzle 312 is provided with a nozzle discharge port 312H for discharging the molding fiber material 9, and the lower end surface 341a of the cylinder surrounds the nozzle discharge port 312H when viewed from the axial direction of the nozzle discharge port 312H. With this configuration, regardless of the direction of movement of the nozzle 312, the areas where the molding fiber material 9 has risen can be leveled.

[0072] The shape of the lower end surface 341a of the cylinder is circular. This configuration also allows the areas where the molding fiber material 9 has risen to be leveled, regardless of the direction of movement of the nozzle 312.

[0073] The axis of the lower end surface 341a of the cylinder overlaps with the axis of the nozzle 312. This configuration also allows for leveling the areas where the molding fiber material 9 has risen.

[0074] The fiber leveling mechanism 34 includes a leveling cylinder 341 including a lower end surface 341a of the cylinder, and a leveling mechanism actuator 343 that reciprocates the leveling cylinder 341 along the axial direction of the leveling cylinder 341. With this configuration, the leveling cylinder 341 for leveling the raised portions of the molded fiber material 9 can be positioned in a location that does not interfere with the operation of stacking the molded fiber material 9.

[0075] <Variation> The present invention can be implemented in various forms, including the embodiments described above, by making various changes and improvements based on the knowledge of those skilled in the art. Furthermore, it is possible to construct modified versions by utilizing the technical matters described in the embodiments described above. The configurations of the embodiments may also be used in appropriate combinations.

[0076] <Note> This disclosure includes the following components:

[0077] This disclosure includes [1] a build table including a support surface for supporting a molded object made of laminated fibrous material, A build head includes a nozzle for discharging the shaping fiber material toward the build table, and is positioned on the support surface of the build table and movable along the support surface of the build table, The device includes a fiber leveling mechanism that is provided so as to sandwich the nozzle and includes a fiber leveling surface for pressing the shaping fiber material onto the shaping table, The aforementioned fiber leveling mechanism is, A molding configuration in which the distance from the molding table to the fiber leveling surface is longer than the distance from the molding table to the nozzle, The additive manufacturing apparatus switches between a leveling mode in which the distance from the build table to the fiber leveling surface is shorter than the distance from the build table to the nozzle, and the fiber leveling surface presses the fibrous material toward the build table.

[0078] This disclosure is [2] "the additive molding apparatus according to [1] above, further comprising a controller that provides a control signal to the fiber leveling mechanism for switching between the molding mode and the leveling mode."

[0079] This disclosure is [3] "the additive molding apparatus according to [2] above, further comprising a fiber cutting mechanism for cutting the molding fiber material extending from the support surface of the molding table to the nozzle of the molding head."

[0080] This disclosure includes [4] a material supply mechanism that winds and holds the molding fiber material and supplies the molding fiber material to the molding head, A configuration for gripping the molding fiber material extending from the material supply mechanism to the molding head, The additive molding apparatus according to [3] above, further comprising a fiber holding mechanism that switches between a configuration in which the molding fiber material extending from the material supply mechanism to the molding head is not gripped and a configuration in which it is switched between.

[0081] This disclosure includes [5] "The controller is, A control signal for switching from the molding form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus described in [2] above outputs a control signal for switching from the leveling form to the molding form.

[0082] This disclosure includes [6] "The controller, A control signal for cutting the shaping fiber material extending from the support surface of the molding table to the nozzle of the molding head by the fiber cutting mechanism, A control signal for switching the fiber leveling mechanism from the shaping form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus described in [3] above outputs a control signal for switching the fiber leveling mechanism from the leveling form to the molding form.

[0083] This disclosure includes [7] "The controller, A control signal for gripping the shaping fiber material by the fiber holding mechanism, A control signal for cutting the fibrous material extending from the support surface of the build table to the nozzle of the build head and being held by the fiber holding mechanism, is provided by the fiber cutting mechanism. A control signal for switching the fiber leveling mechanism from the shaping form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus described in [4] above outputs a control signal for switching the fiber leveling mechanism from the leveling form to the molding form.

[0084] This disclosure includes [8] "The nozzle tip surface of the nozzle is provided with an outlet for discharging the molding fiber material, The fiber leveling surface is an additive molding apparatus as described in any one of the above items [1] to [7], which surrounds the discharge port when viewed from the axial direction of the discharge port.

[0085] This disclosure is [9] "an additive molding apparatus according to any one of the above [1] to [8], wherein the shape of the fiber leveling surface is circular."

[0086] This disclosure relates to

[10] "an additive molding apparatus according to any one of the above [1] to [9], wherein the axis of the fiber leveling surface overlaps with the axis of the nozzle."

[0087] This disclosure is

[11] "an additive molding apparatus according to any one of [1] to

[10] above, comprising: a leveling cylinder including the fiber leveling surface; and a leveling mechanism actuator for reciprocating the leveling cylinder along the axial direction of the leveling cylinder."

[0088] This disclosure is

[12] “The additive molding apparatus according to

[11] , wherein the molding head has a heater for heating the leveling cylinder, and the leveling cylinder presses the molding fiber material, which is made of a thermoplastic resin, while heating it.” [Explanation of Symbols]

[0089] 1. Additive molding device 2. Build Table 3. Modeling head 5 Controllers 8 Sculptures 9. Shaping Fiber Materials 32 Fiber Retaining Mechanism 33 Fiber cutting mechanism 34. Fiber leveling mechanism 312 Nozzles 313 Nozzle Heater (Heater) 341 Leveling Cylinder 343 Leveling mechanism actuator C4, C32, C33, C34 control signals T34A Forming T34B leveling form

Claims

1. A build table including a support surface for supporting a molded object made of layered shaping fiber material, A build head includes a nozzle for discharging the shaping fiber material toward the build table, and is positioned on the support surface of the build table and movable along the support surface of the build table, The device includes a fiber leveling mechanism that is provided so as to sandwich the nozzle and includes a fiber leveling surface for pressing the shaping fiber material onto the shaping table, The aforementioned fiber leveling mechanism is, A molding configuration in which the distance from the molding table to the fiber leveling surface is longer than the distance from the molding table to the nozzle, Additive molding apparatus that switches between a leveling mode in which the distance from the molding table to the fiber leveling surface is shorter than the distance from the molding table to the nozzle, and the fiber leveling surface presses the molding fiber material toward the molding table.

2. The additive molding apparatus according to claim 1, further comprising a controller that provides a control signal to the fiber leveling mechanism for switching between the molding mode and the leveling mode.

3. The additive molding apparatus according to claim 2, further comprising a fiber cutting mechanism for cutting the molding fiber material extending from the support surface of the molding table to the nozzle of the molding head.

4. A material supply mechanism that winds and holds the molding fiber material and supplies the molding fiber material to the molding head, A configuration for gripping the molding fiber material extending from the material supply mechanism to the molding head, The additive molding apparatus according to claim 3, further comprising a fiber holding mechanism that switches between a configuration in which the molding fiber material extending from the material supply mechanism to the molding head is not gripped and a configuration in which it is not gripped.

5. The aforementioned controller, A control signal for switching from the molding form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus according to claim 2, which outputs a control signal for switching from the leveling form to the molding form.

6. The aforementioned controller, A control signal for cutting the shaping fiber material extending from the support surface of the molding table to the nozzle of the molding head by the fiber cutting mechanism, A control signal for switching the fiber leveling mechanism from the shaping form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus according to claim 3, which outputs a control signal for switching the fiber leveling mechanism from the leveling form to the molding form.

7. The aforementioned controller, A control signal for gripping the shaping fiber material by the fiber holding mechanism, A control signal for cutting the fibrous material extending from the support surface of the build table to the nozzle of the build head and being held by the fiber holding mechanism, is provided by the fiber cutting mechanism. A control signal for switching the fiber leveling mechanism from the shaping form to the leveling form, When the leveling configuration is as described above, a control signal is provided to move the fiber leveling surface along the support surface of the molding table, The additive molding apparatus according to claim 4, which outputs a control signal for switching the fiber leveling mechanism from the leveling form to the molding form.

8. The nozzle tip surface of the nozzle is provided with an outlet for discharging the molding fiber material. The additive molding apparatus according to claim 1, wherein the fiber leveling surface surrounds the discharge port when viewed from the axial direction of the discharge port.

9. The additive molding apparatus according to claim 1, wherein the shape of the fiber leveling surface is circular.

10. The additive molding apparatus according to any one of claims 1 to 9, wherein the axis of the fiber leveling surface overlaps with the axis of the nozzle.

11. The additive molding apparatus according to claim 1, wherein the fiber leveling mechanism comprises a leveling cylinder including the fiber leveling surface, and a leveling mechanism actuator that reciprocates the leveling cylinder along the axial direction of the leveling cylinder.

12. The molding head has a heater for heating the leveling cylinder, The additive molding apparatus according to claim 11, wherein the leveling cylinder presses the molding fiber material, which is made of thermoplastic resin, while heating it.

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