Manufacturing methods for three-dimensional objects

Abstract

This provides a technology for filling void areas more easily. [Solution] The method for manufacturing a three-dimensional object comprises: a first step of acquiring shape data representing the three-dimensional shape of the three-dimensional object; a second step of generating first printing path data including first path information according to first conditions based on the shape data; a third step of determining whether or not there are gap areas in the first printing path data; a fourth step of generating second printing path data including second path information representing a movement path that fills the gap areas, according to second conditions different from the first conditions, if there are gap areas; and a fifth step of printing the three-dimensional object according to the first printing path data if there are no gap areas, and according to the first printing path data and the second printing path data if there are gap areas. In the third step, the presence or absence of gap areas is determined based on the difference between the length of the inner circling path and the length of the outer circling path.

Description

Technical Field

[0004]

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

Background Art

[0002] ] Regarding a method for manufacturing a three-dimensional object, Patent Document 1 discloses a technique for generating a remaining path that fills a void region in a build path for constructing a layer of a three-dimensional object. In the technique of Patent Document 1, an intermediate path for calculating the dimensions of the void region is generated in the void region, the dimensions of the void region are determined based on the generated intermediate path, and a remaining path is generated based on the determined dimensions.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] ] In the technique of Patent Document 1, for example, when the shape of the void region is relatively complex, the processing load for generating the intermediate path and determining the dimensions of the void region increases. Therefore, a technique for more simply filling the void region is desired.

Means for Solving the Problems

[0005] According to one embodiment of the present disclosure, a method for manufacturing a three-dimensional object is provided. This manufacturing method comprises: a first step of acquiring shape data representing the three-dimensional shape of the three-dimensional object; a second step of generating first molding path data, which includes first path information representing the movement path of the extrusion unit, based on the acquired shape data, according to a first condition relating to the movement path; a third step of determining whether or not there is a gap region in the first molding path data; a fourth step of generating second molding path data, which includes second path information representing the movement path that fills the gap region, according to a second condition different from the first condition, if there is a gap region; and a fifth step of manufacturing the three-dimensional object by extruding molding material from the extrusion unit toward the stage to build layers, according to the first molding path data if there is no gap region, and according to the first molding path data and the second molding path data if there is a gap region. The first path information includes information representing an inner path which is a circular movement path, and information representing an outer path which is a circular movement path located outside the inner path. In the third step, the presence or absence of the gap region is determined based on the difference between the length of the inner path and the length of the outer path. [Brief explanation of the drawing]

[0006] [Figure 1] An explanatory diagram showing the schematic configuration of the three-dimensional molding system in the first embodiment. [Figure 2] A perspective view showing the schematic configuration of the lower side of a flat screw. [Figure 3] A schematic plan view showing the top side of the barrel. [Figure 4] A schematic diagram illustrating how a 3D printing machine creates an object. [Figure 5] An explanatory diagram showing the general configuration of an information processing device. [Figure 6] Flowchart of the molding process in the first embodiment. [Figure 7] A diagram illustrating an example of the first build path data. [Figure 8] Figure 1 illustrates an example of the third step in the first embodiment. [Figure 9] Figure 2 illustrates an example of the third step in the first embodiment. [Figure 10] A diagram illustrating an example of second molding path data in the first embodiment. [Figure 11] A diagram illustrating an example of second molding path data in the second embodiment. [Figure 12] A diagram illustrating an example of second molding path data in the third embodiment. [Figure 13] Flowchart of the molding process in the fourth embodiment. [Figure 14] Flowchart of the molding process in the fifth embodiment. [Figure 15] A diagram illustrating an example of second molding path data in the fifth embodiment. [Modes for carrying out the invention]

[0007] A. First Embodiment: Figure 1 is an explanatory diagram showing the schematic configuration of the three-dimensional molding system 10 in the first embodiment. Figure 1 shows arrows indicating the mutually orthogonal X, Y, and Z directions. The X and Y directions are parallel to the horizontal plane, and the Z direction is along the vertically upward direction. In other figures, arrows indicating the X, Y, and Z directions are shown as appropriate, so that the directions shown correspond to those in Figure 1. In the following description, when specifying the direction, the direction indicated by the arrow in each figure will be denoted as "+" and the opposite direction as "-", and positive and negative signs will be used in the direction notation. Hereafter, the +Z direction will also be referred to as "up" and the -Z direction as "down".

[0008] The three-dimensional molding system 10 comprises a three-dimensional molding apparatus 100 and an information processing device 400. The three-dimensional molding apparatus 100 in this embodiment is a device that molds objects by a material extrusion method. The three-dimensional molding apparatus 100 is equipped with a control unit 300 for controlling each part of the three-dimensional molding apparatus 100. The control unit 300 and the information processing device 400 are connected to each other so as to be able to communicate with each other.

[0009] The three-dimensional shaping device 100 includes a shaping unit 110 that generates and discharges a shaping material, a shaping stage 210 that serves as a base for the shaped object, and a moving mechanism 230 that controls the discharge position of the shaping material.

[0010] Under the control of the control unit 300, the shaping unit 110 discharges the shaping material obtained by plasticizing the solid-state material onto the stage 210. The shaping unit 110 includes a material supply unit 20 that is a supply source of the raw material before being converted into the shaping material, a plasticizing unit 30 that converts the raw material into the shaping material, and a discharge unit 60 that discharges the shaping material.

[0011] The material supply unit 20 supplies the raw material MR to the plasticizing unit 30. The material supply unit 20 is constituted by, for example, a hopper that houses the raw material MR. The material supply unit 20 is connected to the plasticizing unit 30 via a communication path 22. The raw material MR is input into the material supply unit 20 in the form of powder or pellets. As the raw material MR, for example, thermoplastic resins such as acrylonitrile-butadiene-styrene resin (ABS), polypropylene resin (PP), polyethylene resin (PE), and polyacetal resin (POM) are used.

[0012] The plasticizing unit 30 plasticizes the raw material MR supplied from the material supply unit 20 to generate a paste-like shaping material that exhibits fluidity, and guides it to the discharge unit 60. In the present embodiment, "plasticization" is a concept that includes melting, and is to change from a solid state to a state having fluidity. Specifically, in the case of a material in which glass transition occurs, plasticization is to raise the temperature of the material above the glass transition point. In the case of a material in which glass transition does not occur, plasticization is to raise the temperature of the material above the melting point.

[0013] The plasticizing unit 30 has a screw case 31, a drive motor 32, a flat screw 40, and a barrel 50. The flat screw 40 is also called a rotor or a scroll. The barrel 50 is also called a screw facing portion.

[0014] The flat screw 40 is housed inside the screw case 31. The upper surface 47 of the flat screw 40 is connected to the drive motor 32, and the flat screw 40 rotates inside the screw case 31 by the rotational driving force generated by the drive motor 32. The drive motor 32 drives under the control of the control unit 300. Note that the flat screw 40 may be driven by the drive motor 32 via a speed reducer.

[0015] FIG. 2 is a perspective view showing a schematic configuration on the lower surface 48 side of the flat screw 40. The flat screw 40 shown in FIG. 2 is shown with the positional relationship between the upper surface 47 and the lower surface 48 shown in FIG. 1 reversed in the vertical direction for ease of understanding of the technology. The flat screw 40 has a substantially cylindrical shape in which the length in the axial direction, which is the direction along its central axis, is smaller than the length in the direction perpendicular to the axial direction. The flat screw 40 is arranged such that the rotation axis RX, which is its center of rotation, is parallel to the Z direction.

[0016] On the lower surface 48 of the flat screw 40, which is a surface intersecting the rotation axis RX, a spiral groove portion 42 is formed. The communication passage 22 of the above-described material supply unit 20 communicates with the groove portion 42 from the side surface of the flat screw 40. In the present embodiment, the groove portion 42 is formed in three portions separated by ridge portions 43. Note that the number of the groove portions 42 is not limited to three, and may be one or two or more. The groove portion 42 is not limited to a spiral shape, and may be a helical shape or an involute curve shape, or may be a shape extending in an arc from the central portion 46 toward the outer periphery.

[0017] As shown in FIG. 1, the lower surface 48 of the flat screw 40 faces the upper surface 52 of the barrel 50, and a space is formed between the groove portion of the lower surface 48 of the flat screw 40 and the upper surface 52 of the barrel 50. Raw material MR is supplied from the material supply unit 20 to this space between the flat screw 40 and the barrel 50 through the material inlet 44 shown in FIG. 2.

[0018] The barrel 50 has a barrel heater 58 embedded in it for heating the raw material MR supplied into the groove 42 of the rotating flat screw 40. A communication hole 56 is provided in the center of the barrel 50.

[0019] Figure 3 is a schematic plan view showing the upper surface 52 of the barrel 50. Multiple guide grooves 54 are formed on the upper surface 52 of the barrel 50, connected to the communication hole 56 and extending in a spiral shape from the communication hole 56 toward the outer circumference. One end of the guide groove 54 does not necessarily have to be connected to the communication hole 56. Also, the guide grooves 54 can be omitted.

[0020] The raw material MR supplied into the groove 42 of the flat screw 40 is plasticized within the groove 42 and flows along the groove 42 as the flat screw 40 rotates, and is guided to the central part 46 of the flat screw 40 as molding material. The paste-like molding material that has flowed into the central part 46 and exhibits fluidity is supplied to the discharge part 60 through a communication hole 56 provided in the center of the barrel 50. It should be noted that not all types of substances constituting the molding material need to be plasticized. The molding material only needs to be converted into a fluid state as a whole by plasticizing at least some of the types of substances constituting the molding material.

[0021] The discharge unit 60 in Figure 1 comprises a nozzle 61 for discharging the molding material, a flow path 65 for the molding material provided between the flat screw 40 and the nozzle opening 62, and a discharge control unit 77 for controlling the discharging of the molding material.

[0022] The nozzle 61 is connected to the communication hole 56 of the barrel 50 through the flow path 65. The nozzle 61 extrudes the molding material generated in the plasticizing section 30 from the nozzle opening 62 at its tip toward the stage 210.

[0023] 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 up the molding material and temporarily stores it.

[0024] The discharge adjustment unit 70 is located within the flow path 65 and changes the opening of the flow path 65 by rotating within the flow path 65. In this embodiment, the discharge adjustment unit 70 is configured as a valve. The discharge adjustment unit 70 is driven by a first drive unit 74 under the control of a 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 molding material flowing from the plasticizer 30 to the nozzle 61, that is, the amount of molding material discharged from the nozzle 61, by controlling the rotation angle of the discharge adjustment unit 70 using the first drive unit 74. The discharge adjustment unit 70 can adjust the amount of molding material discharged and can also control the on / off switching of the molding material outflow.

[0025] The suction unit 75 is connected in the flow path 65 between the discharge adjustment unit 70 and the nozzle opening 62. The suction unit 75 suppresses the trailing phenomenon, where the material dangles from the nozzle opening 62 in a string-like manner, by temporarily sucking the material in the flow path 65 when the discharge of the material from the nozzle 61 stops. In this embodiment, the suction unit 75 is composed of 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 composed of, for example, a stepping motor or a rack and pinion mechanism that converts the rotational force of the stepping motor into the translational motion of the plunger.

[0026] The stage 210 is positioned opposite the nozzle opening 62 of the nozzle 61. In the first embodiment, the build surface 211 of the stage 210 opposite the nozzle opening 62 of the nozzle 61 is positioned parallel to the X,Y direction, i.e., the horizontal direction. The stage 210 is equipped with a stage heater 212 to suppress the rapid cooling of the build material extruded onto the stage 210. The stage heater 212 is controlled by the control unit 300.

[0027] The moving mechanism 230 changes the relative position between the stage 210 and the nozzle 61 under the control of the control unit 300. In this embodiment, the position of the nozzle 61 is fixed, and the moving mechanism 230 moves the stage 210. The moving mechanism 230 is composed of a three-axis positioner that moves the stage 210 in three axes in the X, Y, and Z directions using the driving force of three motors. In this specification, unless otherwise specified, movement of the nozzle 61 means moving the nozzle 61 or discharge unit 60 relative to the stage 210.

[0028] In other embodiments, instead of moving the stage 210 with the moving mechanism 230, a configuration may be adopted in which the stage 210 remains in a fixed position and the moving mechanism 230 moves the nozzle 61 relative to the stage 210. Alternatively, a configuration may be adopted in which the moving mechanism 230 moves the stage 210 in the Z direction and the nozzle 61 in the X and Y directions, or in which the moving mechanism 230 moves the stage 210 in the X and Y directions and the nozzle 61 in the Z direction. Even with these configurations, the relative positional relationship between the nozzle 61 and the stage 210 can be changed.

[0029] Although Figure 1 shows only one molding unit 110, the three-dimensional molding apparatus 100 may have multiple molding units 110. By having multiple molding units 110, different types of molding materials can be extruded from each molding unit 110. Therefore, for example, the main body of the molded object and the support structure that supports the molded object can be molded using different types of molding materials.

[0030] The control unit 300 is a control device that controls the operation of the entire three-dimensional molding apparatus 100. The control unit 300 is composed of a computer that includes one or more processors 310, a storage device 320 consisting of a main memory and an auxiliary storage device, and an input / output interface for inputting and outputting signals to and from the outside. The processor 310 executes a program stored in the storage device 320, and in accordance with the molding data acquired from the information processing device 400, controls the molding unit 110 and the moving mechanism 230 to create a molded object on the stage 210. Note that the control unit 300 may be implemented by a combination of circuits instead of being composed of a computer.

[0031] Figure 4 is a schematic diagram illustrating how the three-dimensional molding apparatus 100 fabricates an object. As described above, in the three-dimensional molding apparatus 100, the solid raw material MR is plasticized to produce the molding material MM. The control unit 300 maintains the distance between the molding surface 211 of the stage 210 and the nozzle 61, and while changing the position of the nozzle 61 relative to the stage 210 in a direction along the molding surface 211 of the stage 210, it ejects the molding material MM from the nozzle 61. The molding material MM ejected from the nozzle 61 is continuously deposited in the direction of movement of the nozzle 61.

[0032] 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, which is the layering direction of the layers ML. Then, the object is fabricated by further layering ML on top of the layers ML that have been formed so far.

[0033] The control unit 300 may, for example, temporarily suspend the ejection of the molding material from the nozzle 61 when the nozzle 61 moves in the Z direction after completing one layer ML, or when there are multiple independent molding regions in each layer. In this case, the ejection adjustment unit 70 closes the flow path 65 to stop the ejection of the molding material MM from the nozzle opening 62, and the suction unit 75 temporarily sucks up the molding material inside the nozzle 61. After changing the position of the nozzle 61, the control unit 300 restarts the deposition of the molding material MM from the changed position of the nozzle 61 by opening the flow path 65 with the ejection adjustment unit 70 while discharging the molding material inside the suction unit 75.

[0034] Figure 5 is an explanatory diagram showing the schematic configuration of the information processing device 400. The information processing device 400 is configured as a computer in which a CPU 410, memory 420, storage device 430, communication interface 440, and input / output interface 450 are interconnected by a bus 460. An input device 470, such as a keyboard or mouse, and a display unit 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 molding device 100 via the communication interface 440.

[0035] The CPU 410 functions as a data generation unit 411 by executing a program stored in the storage device 430. The data generation unit 411 generates molding data used by the three-dimensional molding apparatus 100 to fabricate three-dimensional objects. The molding data includes path information representing the movement path of the nozzle 61 and discharge amount information representing the amount of molding material discharged in each movement path, for each layer obtained by slicing the shape of the model into multiple layers. In this embodiment, the path information includes information representing the line width. The line width means the width of the molding material discharged along the movement path. Here, "width of the molding material" means the width in the direction perpendicular to the layering direction and the extension direction of the movement path. The line width is also represented as the width centered on the trajectory of the movement path.

[0036] Figure 6 is a flowchart of the molding process performed in the three-dimensional molding system 10. The molding process is a process for realizing the manufacturing method of a three-dimensional object as described in this disclosure. The processes from steps S10 to S40 shown in Figure 6 are performed in the information processing device 400, and the processes from steps S50 and S60 are performed in the three-dimensional molding apparatus 100.

[0037] In step S10, the data generation unit 411 of the information processing device 400 acquires shape data representing the three-dimensional shape of a three-dimensional object from another computer, recording medium, or storage device 430. The shape data is data representing the shape of a three-dimensional object created using three-dimensional CAD software, three-dimensional CG software, etc. As shape data, for example, data in STL format or AMF format is used. Step S10 is also called the first process.

[0038] In step S20, the data generation unit 411 generates first build path data based on the shape data acquired in step S10. More specifically, in step S20, the data generation unit 411 generates first build path data by analyzing the shape data acquired in step S10 using slicer software. Step S20 is also referred to as the second step.

[0039] In step S20, the data generation unit 411 generates first molding path data according to a first condition. The first condition is a type of path condition. The path condition is a condition relating to the movement path. In this embodiment, the path condition includes a path pattern condition and a line width condition. The path pattern condition defines at least the type of path pattern. The path pattern is the pattern of the movement path. In this embodiment, the path pattern condition also includes an angle condition that defines the arrangement angle of the path pattern. The line width condition is a condition that defines the line width of the movement path. In this embodiment, the path pattern in the first condition is a circular pattern. More specifically, the path pattern in the first condition is a circular pattern that circles along the X and Y directions. That is, the movement path generated according to the first condition includes a movement path along the X direction and a movement path along the Y direction.

[0040] Figure 7 illustrates an example of the first build path data. In Figure 7, the first build path data SD1 is shown as an example of the first build path data. The first build path data SD1 is based on the first shape data KD1, which represents the shape of the three-dimensional object OB.

[0041] As shown in Figure 7, the first build path data SD1 includes first path information PD1 as path information. The first path information PD1 includes inner path information representing the inner path IP and outer path information representing the outer path OP. The inner path IP is a circular movement path located inside the outer path OP. The outer path OP is a circular movement path located outside the inner path IP. More specifically, the outer path OP circles around the inner path IP. The line width of the inner path IP is also called the first line width W1. The line width of the outer path OP is also called the second line width W2. In this embodiment, the first line width W1 and the second line width W2 are the same width. The first path information PD1 includes information representing the first line width W1 and information representing the second line width W2. The first line width W1 and the second line width W2 in the first path information PD1 are realized based on the line width conditions in the first condition.

[0042] In this embodiment, the outer pass OP and the inner pass IP each correspond to the outer shell pass. The outer shell pass is a pass for creating the outer shell region, which represents the outer shell of the three-dimensional object OB. The outer shell pass is configured as one or more circular passes. In this embodiment, the outer shell pass is configured as two circular passes, with the innermost circular pass corresponding to the inner pass IP and the outermost circular pass corresponding to the outer pass OP. In other embodiments, the outer pass OP and the inner pass IP may each be infill passes. The infill pass is a pass for creating the infill region of the three-dimensional object OB. The infill region is the region located inside the outer shell region when viewed in the stacking direction. Alternatively, for example, the inner pass IP may be the infill pass and the outer pass OP may be the outer shell pass.

[0043] In the example in Figure 7, the first build path data SD1 includes a gap region GA. The gap region GA is the region corresponding to the gap between the inner path IP and the outer path OP. The gap region GA corresponds to the region where the inner path IP cannot be generated according to the first condition. For example, in the example in Figure 7, the dimension Dy1 in the Y direction of the gap region GA is less than twice the first line width W1, so the inner path IP is not generated in the gap region GA. This is because, in this embodiment, in order to generate the inner path, which is a circular path along the X and Y directions, according to the path pattern condition and angle condition included in the first condition, a region having a width of at least twice the first line width W1 in the X and Y directions is required.

[0044] In step S30 of Figure 6, the data generation unit 411 determines whether or not there is a gap region in the first molding path data SD1. In step S30, the data generation unit 411 determines whether or not there is a gap region based on the difference between the inner and outer paths. The difference between the inner and outer paths is the difference between the length of the inner path IP and the length of the outer path OP. In this embodiment, the difference between the inner and outer paths represents the difference between the inner circumference length of the outer path OP and the outer circumference length of the inner path IP. More specifically, in step S30, the data generation unit 411 determines that there is a gap region GA if the inner circumference length of the outer path OP is greater than the outer circumference length of the inner path IP. Step S30 is also called the third step.

[0045] Figure 8 is the first diagram illustrating an example of the third step in this embodiment. Figure 8 shows the trajectory TJ1 of the inner path IP and the trajectory TJ2 of the outer path OP. As shown in Figure 8, in this embodiment, the data generation unit 411 calculates the inner circumference length of the outer path OP as the length of trajectory TJ2b, which is obtained by shrinking trajectory TJ2 inward by a width W2b, which corresponds to half of the second line width W2. The data generation unit 411 also calculates the outer circumference length of the inner path IP as the length of trajectory TJ1b, which is obtained by expanding trajectory TJ1 outward by a width W1b, which corresponds to half of the first line width W1. In the example in Figure 8, since the length of trajectory TJ2b is greater than the length of trajectory TJ1b, that is, since the inner circumference length of the outer path OP is greater than the outer circumference length of the inner path IP, it is determined that there is a gap region GA.

[0046] Figure 9 is a second diagram illustrating an example of the third step in this embodiment. Figure 9 shows an inner path trajectory TJ3 different from the example in Figure 8, and an outer path trajectory TJ4 different from the example in Figure 8. Figure 9 shows trajectory TJ4b, which is obtained by shrinking trajectory TJ4 inward by a width W2b, which corresponds to half of the second line width W2. The data generation unit 411 also shows trajectory TJ3b, which is obtained by expanding trajectory TJ3 outward by a width W1b, which corresponds to half of the first line width W1. In the example in Figure 9, since the length of trajectory TJ4b and the length of trajectory TJ3b are the same, that is, since the inner circumference length of the outer path OP and the outer circumference length of the inner path IP are the same, it is determined that there is no gap region.

[0047] If there is a gap area in step S30 of Figure 6, in step S40, the data generation unit 411 generates second build path data according to the second condition. The second condition is a different path condition from the first condition. When step S40 is executed, build data including the first build path data and the second build path data is generated. Step S40 is also called the fourth step.

[0048] Figure 10 illustrates an example of second build path data. Figure 10 shows second build path data SD2 as an example of second build path data. Second build path data SD2 includes second path information PD2, which represents the filling path FP. The filling path FP is the movement path that fills the gap region GA.

[0049] In this embodiment, the path pattern condition in the second condition is different from the path pattern condition in the first condition. More specifically, the path pattern represented by the path condition in the second condition is a non-circular linear pattern. Such a non-circular linear pattern is also called a "rectolina pattern". A rectolina pattern is composed of a single linear path extending in the main direction, or a bellows-shaped path that reciprocates in the main direction. A bellows-shaped path is composed of multiple main paths extending in the main direction and one or more secondary paths. Each main path is arranged so as to be aligned in an orthogonal direction perpendicular to the main direction. In this embodiment, the main direction is the X direction. Also, in this embodiment, the orthogonal direction is the Y direction. A secondary path is a moving path that intersects with a main path, connecting one end of adjacent main paths in the orthogonal direction by the shortest possible distance. Furthermore, as a result of the path pattern in the second condition being a rectolina pattern, the path pattern of the filling path FP represented by the second path information PD2 is a rectolina pattern.

[0050] Furthermore, in this embodiment, the angle of the path pattern in the second condition is predetermined regardless of the shape of the gap area. That is, the angle condition in the second condition represents the arrangement angle independent of the shape of the gap area. Here, shape includes size. More specifically, in this embodiment, the angle condition in the second condition represents the arrangement angle that realizes the main path extending in the main direction. That is, in this embodiment, the main direction is predetermined in the X direction regardless of the shape of the gap area by the second condition.

[0051] As shown in Figure 6, if there is no gap area in step S30, step S40 is not executed. In this case, the generated print data includes the first print path data but does not include the second print data.

[0052] In step S50 of Figure 6, the control unit 300 of the three-dimensional molding apparatus 100 acquires the molding data generated in step S30 or step S40 from the information processing device 400. In step S60, the control unit 300 controls the ejection unit 60 and the moving mechanism 230 according to the molding data acquired in step S50, and molds a three-dimensional object on the molding surface 211 of the stage 210. That is, the control unit 300 molds the three-dimensional object according to the first molding path data if there are no gaps, and according to the first molding path data and the second molding path data if there are gaps. Step S60 is also called the fifth step.

[0053] In the method for manufacturing a three-dimensional object according to this embodiment described above, the presence or absence of a gap region is determined based on the difference between the length of the inner path and the length of the outer path. If a gap region exists, second printing path data, which includes second path information representing a filling path to fill the gap region, is generated according to a second condition different from the first condition. Therefore, the presence or absence of a gap region can be determined by a simple process of comparing the length of the inner path and the length of the outer path, and if a gap region exists, the gap region can be filled by a simple process of generating second printing path data according to a second condition different from the first condition. Furthermore, by filling the gap region in this way, the printing accuracy and strength of the three-dimensional object OB can be improved.

[0054] Furthermore, in this embodiment, the difference between the inner and outer paths represents the difference between the inner circumference of the outer path and the outer circumference of the inner path. Therefore, the presence or absence of a gap region can be determined with greater accuracy by a simple process of comparing the inner circumference of the outer path with the outer circumference of the inner path.

[0055] Furthermore, in this embodiment, the inner circumference of the outer path is calculated as the length of the trajectory obtained by shrinking the outer path's trajectory inward by a width equivalent to half the first line width. The outer circumference of the inner path is calculated as the length of the trajectory obtained by expanding the inner path's trajectory outward by a width equivalent to half the second line width. In the third step, if the inner circumference of the outer path is greater than the outer circumference of the inner path, it is determined that there is a gap region. Therefore, the inner circumference of the outer path and the outer circumference of the inner path can be calculated more easily regardless of the shape of the three-dimensional object, and the inner circumference of the outer path and the outer circumference of the inner path can be compared more easily.

[0056] Furthermore, in this embodiment, the path pattern in the second condition is different from the path pattern in the first condition. Therefore, if there is a gap, the gap can be filled by a simple process of generating the second build data with a different path pattern than the first build path data. In particular, in this embodiment, the path pattern in the second condition is a rectolina pattern. Since a rectolina pattern is a relatively simple path pattern, this allows for even simpler processing to fill the gap. Moreover, in this embodiment, the angle of the path pattern in the second condition is predetermined regardless of the shape of the gap, so the gap can be filled by an even simpler process.

[0057] B. Second Embodiment: Figure 11 illustrates an example of second build path data in the second embodiment. Figure 11 shows second build path data SD2b as an example of second build path data. Second build path data SD2b includes second path information PD2b representing the filling path FPb. In this embodiment, unlike the first embodiment, the movement path represented by the path pattern in the second condition includes a path Pt1 along the first edge SG1 of the gap region GA and a path Pt2 along the second edge SG2 of the gap region GA. The three-dimensional molding apparatus 100 and information processing apparatus 400 in this embodiment are the same as in the first embodiment, except that they are not specifically described.

[0058] In this embodiment, the path pattern condition in the second condition represents a rectrinia pattern that includes a movement path along edge SG1 and a movement path along edge SG2. Edges SG1 and SG2 may be any edges that demarcate the gap region GA, as long as they extend in different directions. In this embodiment, edge SG1 and path Pt1 are aligned in the Y direction. Edge SG2 and path Pt2 are aligned in the X direction. In this embodiment, the angle condition in the second condition is defined as an angle condition that can generate a filling path FPb with a longer overall length. As a result, the gap region GA is filled with a bellows-like movement path that moves back and forth in the Y direction (the main direction) while advancing in the X direction.

[0059] According to the method for manufacturing a three-dimensional object in the second embodiment described above, the movement path represented by the path pattern in the second condition includes a path Pt1 along the first edge SG1 of the gap region GA and a path Pt2 along the second edge SG2. As a result, the filling path FPb can be generated according to the shape of the gap region GA, thereby increasing the possibility of the gap region GA being filled to a higher density.

[0060] C. Third Embodiment: Figure 12 illustrates an example of second build path data in the third embodiment. Figure 12 shows second build path data SD2c as an example of second build path data. Second build path data SD2c includes second path information PD2c representing the filling path FPc. In this embodiment, unlike the first embodiment, the line width of the filling path FPc in the second condition is smaller than the line width of the inner path IP in the first condition. The three-dimensional molding apparatus 100 and information processing apparatus 400 in this embodiment are the same as in the first embodiment, except that they are not specifically described.

[0061] In this embodiment, the path pattern in the second condition is a circular pattern similar to the path pattern in the first condition. Also, the line width W3 is less than or equal to half the width of dimension Dy1. As a result, a filling path FP of the circular pattern is generated in the gap region GA.

[0062] In the manufacturing method for three-dimensional objects according to the third embodiment described above, the line width in the second condition is smaller than the line width of the inner path in the first condition. In this way, if there is a gap area, the gap area can be filled by a simple process of generating second build path data with a smaller line width than the first build path data.

[0063] D. Fourth Embodiment: Figure 13 is a flowchart of the molding process in the fourth embodiment. As shown in Figure 13, unlike the first embodiment, the molding process in this embodiment includes a display process in step S31. The three-dimensional molding apparatus 100 and the information processing apparatus 400 in this embodiment are the same as in the third embodiment, except that they are not specifically described.

[0064] If there is a gap area in step S30, in step S31, the data generation unit 411 performs a display process. The display process is to display a reference value for line width on the display unit 480, corresponding to the magnitude of the difference between the internal and external paths. More specifically, the reference value for line width is set as the preferred line width value for the movement path to fill the gap area. The magnitude of the difference between the internal and external paths correlates with the size of the gap area. More specifically, the larger the difference between the internal and external paths, the larger the gap area tends to be. Therefore, by setting the reference value for line width according to the magnitude of the difference between the internal and external paths, the reference value for line width can be set more appropriately.

[0065] In step S32, the data generation unit 411 receives the line width setting from the user and determines the received line width as the line width for the second condition. In step S32, the user sets the line width by inputting it, for example, via the input device 470. In step S32, the user can set the line width for the second condition by taking into account, for example, the reference value of the line width displayed in step S31. In this embodiment, the second condition is determined when step S32 is executed in this way and the line width for the second condition is determined. In this embodiment, the conditions other than the line width condition for the second condition are the same as the second condition in the third embodiment.

[0066] In step S40b, the data generation unit 411 generates second molding path data according to the second condition determined in step S32.

[0067] In step S41, the data generation unit 411 displays the generation result of the second molding path data generated in step S40b on the display unit 480. In step S41, for example, each movement path as shown in Figure 12 is displayed as an image on the display unit 480. The user can, for example, check whether the generation result is appropriate by taking into account the reference value of the line width generated in step S31 and the generation result displayed in step S41.

[0068] In step S42, the data generation unit 411 determines whether or not to regenerate the second build path data. In step S42, the data generation unit 411 determines to regenerate the second build path data, for example, when a predetermined input is made by the user via the input device 470. If it is determined in step S42 to regenerate the second build path data, the data generation unit 411 returns to step S32. In step S32 again, the user can set a second condition for regenerating the second build path data, for example, by taking into account the reference value of the line width generated in step S31 and the generation result displayed in step S41. If it is determined in step S42 not to regenerate the second build path data, build data including the first build path data and the second build path data at that point is generated. In step S60, a three-dimensional object is built according to this build data.

[0069] The method for manufacturing a three-dimensional object according to the fourth embodiment described above includes a step of displaying a reference value for line width corresponding to the magnitude of the difference between the inner and outer paths on the display unit 480. Therefore, the reference value for line width corresponding to the size of the gap area can be easily confirmed by the user.

[0070] E. Fifth Embodiment: Figure 14 is a flowchart of the molding process in the fifth embodiment. In this embodiment, unlike the first embodiment, the data generation unit 411 performs a line width determination process prior to the fourth step. The line width determination process determines the line width in the second condition by adjusting the line width of the movement path so that the gap region GA can be filled within a line width range predetermined by the user. The three-dimensional molding apparatus 100 and the information processing apparatus 400 in this embodiment are the same as in the first embodiment unless otherwise described.

[0071] In step S33, the data generation unit 411 accepts the user's setting of the line width range. In step S33, the user sets the line width range by inputting a numerical value for setting the line width range, for example, via the input device 470. Note that step S33 may be executed at any time before the line width determination process.

[0072] In steps S34 and S35, the data generation unit 411 performs line width determination processing. First, in step S34, the data generation unit 411 determines a provisional line width based on the line width setting range received in step S33, thereby determining a provisional path condition. The provisional path condition is a path condition different from the first condition. In this embodiment, the conditions other than the line width condition in the provisional path condition are the same as the second condition in the third embodiment. The provisional line width may be determined randomly from, for example, a range of line widths set by the user. Alternatively, the provisional line width may be determined by specifying a line width according to a certain magnification or a certain numerical width from, for example, a range of line widths set by the user.

[0073] In step S35, the data generation unit 411 verifies whether the gap area can be filled according to the provisional path conditions determined in step S34. More specifically, in step S35, the data generation unit 411 generates provisional build path data according to the provisional path conditions and verifies whether the gap area can be filled by determining whether the provisional build path data includes a filling path.

[0074] If it is determined in step S35 that the filling area cannot be filled, the data generation unit 411 returns to step S34. In step S34 again, the previously selected line width may be excluded from the selection of provisional line widths. If it is determined in step S35 that the filling area can be filled, in step S40c, the data generation unit 411 determines the provisional path conditions determined in step S34 as second conditions and obtains second build path data by generating second build path data according to the determined second conditions. In other embodiments, the determination of provisional path conditions in step S34 and the verification using provisional build data in step S35 are performed until the line width in the second condition is determined. In other embodiments, in step S40c, the data generation unit 411 may, for example, obtain the provisional build path data generated in step S35 as second build path data.

[0075] Figure 15 illustrates an example of second build path data in the fifth embodiment. Figure 15 shows second build path data SD2e as an example of second build path data. Second build path data SD2e includes second path information PD2e representing the filling path FPe. In the example in Figure 15, the line width W4 of the filling path FPe is greater than the first line width W1 and less than or equal to the dimension Dy1. The line width W4 corresponds to the line width determined by the line width determination process described above. Thus, in this embodiment, the line width W4 of the filling path may be greater than the first line width W1. Such a line width W4 can be determined in step S33 by setting a range of line widths that includes line widths greater than the first line width W1. In the example in Figure 15, the gap region GA can be filled more densely compared to the case where the line width of the filling path is the first line width W1.

[0076] The method for manufacturing a three-dimensional object according to the fifth embodiment described above includes a step prior to the fourth step in which the line width is adjusted within a range of line widths predetermined by the user so as to be able to fill the gap area, thereby determining the line width in the second condition. Therefore, the gap area can be filled while adjusting the line width of the filling path within a range desired by the user.

[0077] F. Other embodiments: (F-1) In each of the above embodiments, the inner-outer path difference represents the difference between the inner circumference of the outer path and the outer circumference of the inner path, but is not limited to this. For example, the inner-outer path difference may be represented as the difference between the length of the trajectory of the outer path and the length of the trajectory of the inner path.

[0078] (F-2) In each of the above embodiments, a gap is determined to exist when the inner circumference of the outer path is greater than the outer circumference of the inner path, but this is not limited to this. For example, a gap may be determined to exist when the difference between the inner circumference of the outer path and the outer circumference of the inner path is outside a predetermined reference range.

[0079] (F-3) In each of the above embodiments, the inner circumference of the outer path is calculated as the length of the trajectory TJ2b, and the outer circumference of the inner path is calculated as the length of the trajectory TJ1b, but they may be calculated by other methods.

[0080] (F-4) In each of the above embodiments, the pattern condition in the second condition may represent a path pattern different from the rectrinia pattern and the circulating pattern. More specifically, the pattern condition in the second condition may be, for example, a non-circulating curved pattern or a non-circulating path pattern that combines one or more straight lines and one or more curves.

[0081] (F-5) In the first embodiment described above, the angle of the path pattern in the second condition is predetermined regardless of the shape of the gap area, but is not limited to this. For example, the angle of the path pattern in the second condition may be determined according to the shape of the gap area. In this case, the angle of the path pattern in the second condition may be determined according to the direction of the edges that demarcate the gap area, as in the second embodiment. Alternatively, for example, the gap area may be approximated by a bounding box, and the angle of the path pattern in the second condition may be determined so that a movement path is formed along the longitudinal direction of the bounding box. Alternatively, for example, the angle of the path pattern in the second condition may be determined so that a movement path is formed along the longitudinal direction of the three-dimensional object to be fabricated.

[0082] G. Other forms: This disclosure is not limited to the embodiments described above, and can be implemented in various forms without departing from its spirit. For example, this disclosure can also be implemented in the following forms. The technical features in the embodiments described below that correspond to the technical features in each of the forms described below can be replaced or combined as appropriate in order to solve some or all of the problems of this disclosure, or to achieve some or all of the effects of this disclosure. Furthermore, if such technical features are not described as essential in this specification, they can be deleted as appropriate.

[0083] (1) According to one embodiment of the present disclosure, a method for manufacturing a three-dimensional object is provided, which manufactures a three-dimensional object by extruding a molding material from an extrusion unit toward a stage and stacking layers. This manufacturing method comprises: a first step of acquiring shape data representing the three-dimensional shape of the three-dimensional object; a second step of generating first molding path data, which includes first path information representing the movement path of the extrusion unit, based on the acquired shape data, in accordance with first conditions relating to the movement path; a third step of determining whether or not there is a gap region in the first molding path data; a fourth step of generating second molding path data, which includes second path information representing the movement path that fills the gap region, in accordance with second conditions different from the first conditions, if there is a gap region; and a fifth step of molding the three-dimensional object according to the first molding path data if there is no gap region, and according to the first molding path data and the second molding path data if there is a gap region. The first path information includes information representing an inner path which is a circular movement path, and information representing an outer path which is a circular movement path located outside the inner path, and in the third step, the presence or absence of the gap region is determined based on the difference between the length of the inner path and the length of the outer path. With this configuration, the presence or absence of a gap can be determined by a simple process of comparing the length of the inner path with the length of the outer path, and if a gap exists, the gap can be filled by a simple process of generating second build path data with a second condition different from the first condition.

[0084] (2) In the above embodiment, the first path information includes information representing a first line width, which is the line width of the inner path, and information representing a second line width, which is the line width of the outer path, and the difference may represent the difference between the inner circumference length of the outer path and the outer circumference length of the inner path. According to this embodiment, the presence or absence of a gap region can be determined with greater accuracy by a simple process of comparing the inner circumference length of the outer path and the outer circumference length of the inner path.

[0085] (3) In the above embodiment, the inner circumference is calculated as the length of the trajectory obtained by reducing the trajectory of the outer path inward by a width equivalent to half the second line width, and the outer circumference is calculated as the length of the trajectory obtained by expanding the trajectory of the inner path outward by a width equivalent to half the first line width, and in the third step, if the inner circumference is greater than the outer circumference, it may be determined that there is a gap region. According to this embodiment, the inner circumference of the outer path and the outer circumference of the inner path can be calculated more easily regardless of the shape of the three-dimensional object, and the inner circumference of the outer path and the outer circumference of the inner path can be compared more easily.

[0086] (4) In the above embodiment, the path pattern of the movement path in the second condition may be different from the path pattern in the first condition. According to this embodiment, when there is a gap area, the gap area can be filled by a simple process of generating second build path data with a different path pattern from the first build path data.

[0087] (5) In the above embodiment, the path pattern in the second condition may be a non-circular straight line pattern. This embodiment allows for filling of gap areas with a simpler process.

[0088] (6) In the above embodiment, the angle of the path pattern in the second condition may be predetermined regardless of the shape of the gap region. According to this embodiment, the gap region can be filled by an even simpler process.

[0089] (7) In the above embodiment, the movement path represented by the path pattern in the second condition may include a path along the first edge of the gap region and a path along the second edge of the gap region. According to this embodiment, since a path for filling the gap region can be generated according to the shape of the gap region, the possibility of filling the gap region to a higher density can be increased.

[0090] (8) In the above embodiment, the line width of the movement path in the second condition may be smaller than the line width of the inner path in the first condition. According to this embodiment, the gap area can be filled by a simple process of generating the second build path data with a line width smaller than that of the first build path data.

[0091] (9) The above embodiment may further include a step of displaying a reference value for line width corresponding to the magnitude of the difference on the display unit. This embodiment allows the user to easily confirm the reference value for line width corresponding to the size of the gap area.

[0092] (10) In the above embodiment, the system may further include a step of determining the line width of the movement path in the second condition by adjusting the line width of the movement path so that the gap area can be filled within a range predetermined by the user, prior to the fourth step. In this embodiment, the gap area can be filled while adjusting the line width of the movement path for filling the gap area within a range desired by the user.

[0093] This disclosure is not limited to the method for manufacturing three-dimensional objects as described above, but can be implemented in various forms, including three-dimensional printing systems, information processing devices, computer programs, and non-temporary tangible recording media on which computer programs are recorded in a computer-readable manner. [Explanation of Symbols]

[0094] 10...3D modeling system, 20...Material supply unit, 22...Communication passage, 30...Plasticizing unit, 31...Screw case, 32...Drive motor, 40...Flat screw, 42...Groove section, 43...Protruding section, 44...Material inlet, 46...Center section, 47...Top surface, 48...Bottom surface, 50...Barrel, 52...Top surface, 54...Guide groove, 56...Communication hole, 58...Barrel heater, 60...Discharge section, 61...Nozzle, 62...Nozzle opening, 65...Flow path, 70...Discharge adjustment unit, 74...First drive unit, 75...Suction unit, 7 6…Second drive unit, 77…Ejection control unit, 100…Three-dimensional molding device, 110…Mounting unit, 210…Stage, 211…Mounting surface, 212…Stage heater, 230…Moving mechanism, 300…Control unit, 310…Processor, 320…Storage device, 400…Information processing device, 410…CPU, 411…Data generation unit, 420…Memory, 430…Storage device, 440…Communication interface, 450…Input / output interface, 460…Bus, 470…Input device, 480…Display unit

Claims

1. A method for manufacturing a three-dimensional object, A first step is to acquire shape data representing the three-dimensional shape of the aforementioned three-dimensional object, A second step of generating first molding path data, which includes first path information representing the movement path of the ejection unit, based on the acquired shape data, in accordance with first conditions relating to the movement path, A third step of determining whether or not there is a gap region in the first molding path data, If the gap region exists, a fourth step is to generate second molding path data, which includes second path information representing the movement path that fills the gap region, according to a second condition different from the first condition. The process includes a fifth step of forming the three-dimensional object by extruding the molding material from the extrusion unit toward the stage to build up layers, according to the first molding path data if there is no gap area, and according to the first molding path data and the second molding path data if there is a gap area, thereby building up layers. The first path information includes information representing an inner path which is a circular movement path, and information representing an outer path which is a circular movement path located outside the inner path. A method for manufacturing a three-dimensional object, wherein in the third step, the presence or absence of the gap region is determined based on the difference between the length of the inner path and the length of the outer path.

2. A method for manufacturing a three-dimensional object according to claim 1, The first path information includes information representing a first line width, which is the line width of the inner path, and information representing a second line width, which is the line width of the outer path. A method for manufacturing a three-dimensional object, wherein the difference represents the difference between the inner circumference length of the outer path and the outer circumference length of the inner path.

3. A method for manufacturing a three-dimensional object according to claim 2, The inner circumference length is calculated as the length of the trajectory obtained by reducing the trajectory of the outer path inward by a width equivalent to half the second line width. The outer circumference length is calculated as the length of the trajectory obtained by expanding the trajectory of the inner path outward by a width equivalent to half the first line width. A method for manufacturing a three-dimensional object, wherein in the third step, it is determined that there is a gap region if the inner circumference is greater than the outer circumference.

4. A method for manufacturing a three-dimensional object according to claim 1, A method for manufacturing a three-dimensional object, wherein the path pattern of the movement path in the second condition is different from the path pattern in the first condition.

5. A method for manufacturing a three-dimensional object according to claim 4, A method for manufacturing a three-dimensional object, wherein the path pattern in the second condition is a non-circular linear pattern.

6. A method for manufacturing a three-dimensional object according to claim 5, A method for manufacturing a three-dimensional object, wherein the angle of the path pattern in the second condition is predetermined regardless of the shape of the gap region.

7. A method for manufacturing a three-dimensional object according to claim 5, A method for manufacturing a three-dimensional object, wherein the movement path represented by the path pattern in the second condition includes a path along the first edge of the gap region and a path along the second edge of the gap region.

8. A method for manufacturing a three-dimensional object according to claim 1, A method for manufacturing a three-dimensional object, wherein the line width of the movement path in the second condition is smaller than the line width of the inner path in the first condition.

9. A method for manufacturing a three-dimensional object according to claim 8, further, A method for manufacturing a three-dimensional object, comprising the step of displaying a reference value for line width corresponding to the magnitude of the aforementioned difference on a display unit.

10. A method for manufacturing a three-dimensional object according to any one of claims 1 to 9, further, A method for manufacturing a three-dimensional object, comprising the step of determining the line width of the movement path under the second condition by adjusting the line width of the movement path so that it can fill the gap area within a range predetermined by the user, prior to the fourth step.

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