Additive manufacturing apparatus, additive manufacturing control device, and additive manufacturing program

Abstract

It suppresses the occurrence of molding defects. [Solution] The additive manufacturing apparatus 1 includes a build table 2 which includes a support surface 2a that supports an intermediate product 8 made of stacked string-shaped fibrous material 9, a build head 3 which allows and prohibits the discharge of the fibrous material 9 toward the build table 2 and is movable relative to the support surface 2a of the build table 2, and a controller 5 which controls the operation of the build head 3. The controller 5 performs an discharge operation (S2) which discharges the fibrous material 9 from the tip of the build nozzle 312 of the build head 3, and an approach operation (S4) which, after the discharge operation, moves the build nozzle 312 in the in-plane direction X along the support surface 2a while moving the build nozzle 312 in the out-of-plane direction Z toward the target surface 8a of the intermediate product 8.

Description

Technical Field

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[0001] The present invention relates to an additive manufacturing apparatus, an additive manufacturing control apparatus, and an additive manufacturing program.

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. The apparatus of Patent Document 1 focuses on the orientation direction of continuous fibers and the discharge direction of continuous fibers during manufacturing, and makes it difficult to separate the continuous fibers from the molding material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the lamination operation of the string-like fiber material on the object, a welded portion where the fiber material is welded to the object is formed, and the fiber material is sequentially discharged starting from this point. If this welded portion peels off from the object, the relative positional relationship between the fiber material and the object cannot be maintained, resulting in molding defects.

[0005] The present invention provides an additive manufacturing apparatus, an additive manufacturing control apparatus, and an additive manufacturing program capable of suppressing the occurrence of molding defects.

Means for Solving the Problems

[0006] An additive manufacturing apparatus, according to one embodiment of the present invention, comprises a build table including a support surface for supporting a molded object made of stacked string-like fibrous material, a build head that permits and prohibits the ejection of fibrous material toward the build table and is movable relative to the support surface of the build table, and a controller that controls the operation of the build head. The controller performs an ejection operation in which the fibrous material is ejected from the tip of the build nozzle of the build head, and an approach operation in which, after the ejection operation, the build nozzle is moved in an in-plane direction along the support surface while the build nozzle is moved out-of-plane toward the surface to be built of the molded object.

[0007] This additive manufacturing apparatus performs an approach operation after the extrusion operation. During the approach operation, the printing nozzle is moved in the in-plane direction along the support surface while simultaneously moving out-of-plane toward the surface to be printed. With this movement of the printing nozzle, the tip of the printing fiber material is positioned on the opposite side of the direction of movement of the printing nozzle. The tip of the printing fiber material positioned in this location does not obstruct the printing operation by the printing nozzle. Therefore, it is possible to reliably form a starting point for bonding new printing fiber material to the surface to be printed, thereby suppressing the occurrence of printing defects.

[0008] The controller of the additive manufacturing apparatus described above may perform a restraining operation that prohibits the extrusion of the fibrous material after the extrusion operation but before the approach operation. This operation prevents the fibrous material from being pushed back into the inside of the printing nozzle while the approach operation is being performed.

[0009] The controller of the additive manufacturing apparatus described above may perform a positioning operation before the extrusion operation, positioning it at an approach start position where the height from the tip of the printing nozzle to the surface to be printed is greater than the length of the fibrous material to be extruded during the extrusion operation. Such an operation allows for the extrusion of a desired length of fibrous material.

[0010] The controller of the additive manufacturing apparatus described above performs the following actions after the approach motion: a release motion which allows the extrusion of the fibrous material to be printed; a bonding motion which, after the release motion, presses the printing nozzle against the surface to be printed along the out-of-plane direction, thereby bonding the fibrous material sandwiched between the tip of the printing nozzle and the surface to be printed; and a separation motion which, after the bonding motion, moves the printing nozzle away from the surface to be printed along the out-of-plane direction. As a result of the separation motion, the position where the printing nozzle is positioned may be set to be closer to the surface to be printed than the approach start position. Even with such an action, the tip portion of the fibrous material is positioned on the opposite side of the direction of movement of the printing nozzle.

[0011] The controller of the additive manufacturing apparatus described above may set the in-plane movement speed to be greater than or equal to the out-of-plane movement speed during the approach operation. Even with such operation, the leading edge of the fabricated fiber material is positioned on the opposite side of the direction of movement of the fabrication nozzle.

[0012] The controller of the additive manufacturing apparatus described above may have its in-plane movement speed equal to its out-of-plane movement speed during the approach operation. Even with such operation, the leading edge of the fabricated fiber material is positioned on the opposite side of the direction of movement of the fabrication nozzle.

[0013] In the additive manufacturing apparatus described above, the approach operation includes a pre-contact approach operation from a state where the tip of the fibrous material does not contact the surface to be manufactured to a state where the tip of the fibrous material contacts the surface to be manufactured, and a post-contact approach operation from the state where the tip of the fibrous material contacts the surface to be manufactured to bring the printing nozzle even closer to the surface to be manufactured. The controller may move the printing nozzle such that the relationship between the in-plane movement speed and the out-of-plane movement speed during the post-contact approach operation is the same as the relationship between the in-plane movement speed and the out-of-plane movement speed during the pre-contact approach operation. Even with such an operation, the tip portion of the fibrous material is positioned on the side opposite to the direction of travel of the printing nozzle.

[0014] Another embodiment of the present invention is an additive manufacturing control device for additive manufacturing using an apparatus comprising: a build table including a support surface for supporting a molded object made of stacked string-like shaping fiber material; and a build head that permits and prohibits the dispensing of shaping fiber material toward the build table and is movable relative to the support surface of the build table. The additive molding control device includes an ejection unit that ejects molding fiber material from the tip of the molding nozzle of the molding head, and an approach unit that, after the ejection operation, moves the molding nozzle in an in-plane direction along the support surface while moving it in an out-of-plane direction toward the molding target surface of the molded object.

[0015] Another embodiment of the present invention is an additive manufacturing program for additive manufacturing performed using an apparatus comprising: a build table including a support surface for supporting a molded object made of stacked string-like shaping fiber material; and a build head that permits and prohibits the dispensing of shaping fiber material toward the build table and is movable relative to the support surface of the build table. The additive manufacturing program causes the computer to function as an extrusion unit that extrudes the fibrous material from the tip of the printing nozzle of the build head, and as an approach unit that, after the extrusion operation, moves the printing nozzle in an in-plane direction along the support surface while moving it out-of-plane toward the surface to be built of the object.

[0016] The above-described additive manufacturing control device and additive manufacturing program also make it possible to reliably form the starting point for bonding new fibrous material to the surface to be manufactured, thereby suppressing the occurrence of manufacturing defects. [Effects of the Invention]

[0017] According to the present invention, an additive manufacturing apparatus, an additive manufacturing control device, and an additive manufacturing program capable of suppressing the occurrence of manufacturing defects are provided. [Brief explanation of the drawing]

[0018] [Figure 1] Figure 1 shows a schematic configuration of an additive manufacturing apparatus according to an embodiment. [Figure 2] FIG. 2 is a schematic diagram showing an example of the physical configuration of the controller shown in FIG. 1. [Figure 3] FIG. 3 is a flowchart showing the modeling method executed by the additional modeling device shown in FIG. 1. [Figure 4] FIG. 4(a) is a diagram schematically showing one step of the flowchart shown in FIG. 3. FIG. 4(b) is a diagram schematically showing one step of the flowchart shown in FIG. 3. [Figure 5] FIG. 5(a) is a diagram schematically showing one step of the flowchart shown in FIG. 3. FIG. 5(b) is a diagram schematically showing one step of the flowchart shown in FIG. 3. [Figure 6] FIG. 6(a) is a diagram schematically showing one step of the flowchart shown in FIG. 3. FIG. 6(b) is a diagram schematically showing one step of the flowchart shown in FIG. 3. [Figure 7] FIG. 7(a) is a diagram schematically showing one step of the flowchart shown in FIG. 3. FIG. 7(b) is a diagram schematically showing one step of the flowchart shown in FIG. 3. [Figure 8] FIG. 8(a) is a diagram schematically showing one step of the flowchart shown in FIG. 3. FIG. 8(b) is a diagram schematically showing one step of the flowchart shown in FIG. 3. [Figure 9] FIG. 9 is a diagram schematically showing one step of the flowchart shown in FIG. 3.

MODE FOR CARRYING OUT THE INVENTION

[0019] 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.

[0020] <Additional Modeling Device> 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 attaches the fibrous material 9 to the intermediate object 8 being formed on the build table 2 by extruding the fibrous material 9 from the build head 3. As the fibrous material 9, for example, a material including fiber-reinforced plastics (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.

[0021] 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 intermediate object 8 to be built. The build table 2 has a support surface 2a. The build head 3 extrudes the fibrous material 9 toward the build table 2. The build head 3 is positioned on the build table 2.

[0022] The 3D printing head includes a fiber dispensing mechanism 31, a fiber feeding and pressing mechanism 32, and a fiber cutting mechanism 33. These mechanisms are fixed to the head frame 35 and together constitute the 3D printing head 3. Therefore, these mechanisms can be moved as a single unit by the head actuator 4.

[0023] 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 build 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 build nozzle 312 as needed.

[0024] The shaping fiber material 9 is wound around the bobbin 311. The bobbin 311 is positioned above the head frame 35. The shaping nozzle 312 presses the shaping fiber material 9 against the shaping intermediate object 8 while heating it with heat received from the nozzle heater 313. The shaping nozzle 312 is positioned below the head frame 35. The tip of the shaping nozzle 312 includes a nozzle tip 312a that presses the shaping fiber material 9 against the object while applying heat to it. A nozzle discharge port is provided at this nozzle tip 312a. The shape of the nozzle discharge port when viewed in plan from the nozzle axis 312T is, for example, circular.

[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 support surface 2a. This type of movement is referred to as "downward movement along the out-of-plane direction Z". The head actuator 4 then raises the build head 3 so that it is further away from the support surface 2a. This type of movement is referred to as "upward movement along the out-of-plane direction Z". Furthermore, the head actuator 4 moves the build head 3 along the support surface 2a. This type of movement is referred to as "movement along the in-plane direction X".

[0026] The controller 5 controls the build head 3 and the head actuator 4. For example, the controller 5 performs the relative movement of the build head 3 with respect to the build table 2 by giving a control signal C4 to the head actuator 4. The controller 5 has as functional components an actuator control unit 51, an ejection control unit 52, and a cutting mechanism control unit 53. The actuator control unit 51 outputs a control signal C4 to be given to the head actuator 4. The ejection control unit 52 outputs a control signal C32 to be given to the fiber feeding and pressing mechanism 32. The cutting mechanism control unit 53 outputs a control signal C33 to be given to the fiber cutting mechanism 33.

[0027] As shown in Figure 2, the controller 5 physically includes a processor 501 which is a CPU (Central Processing Unit), a recording medium which is a RAM (Random Access Memory) 502 and a ROM (Read Only Memory) 503, a communication module 504, and input / output devices 505, etc., each of which is electrically connected internally. The input / output devices 505 include a keyboard, mouse, display device, touch panel display device, speaker, etc. The computer elements shown in Figure 2 may be provided on a server in the cloud, or they may be provided separately on multiple networked computers. Each of the functional units of the controller 5 described above is realized by loading the additive manufacturing program 50P of the embodiment onto the hardware such as the processor 501 and RAM 502, thereby operating the communication module 504 and input / output devices 505, etc., under the control of the processor 501, and reading data from ROM 503, and reading and writing data to RAM 502. In other words, the additive molding program 50P, when loaded into the hardware, causes the computer 50 to operate as the actuator control unit 51, the ejection control unit 52, and the cutting mechanism control unit 53. The controller 5 may also be equipped with other types of recording media such as an HDD (Hard Disk Drive) or an SSD (Solid State Drive).

[0028] <Operation of the additive molding device> Next, the operation of the additive manufacturing apparatus 1 will be explained with reference to the flowchart shown in Figure 3. This operation is performed by the controller 5 controlling the components of the additive manufacturing apparatus 1. The operation of the additive manufacturing apparatus 1 can also be considered as an additive manufacturing method. In the following explanation, it is assumed that the surface to be manufactured 8a is parallel to the support surface 2a. Therefore, terms such as "up," "down," and "horizontal" can be defined with respect to the support surface 2a or with respect to the surface to be manufactured 8a. However, in the manufacturing operation, the surface to be manufactured 8a may be tilted with respect to the support surface 2a. In such cases, terms such as "up," "down," and "horizontal" should strictly be defined with respect to the surface to be manufactured 8a, not the support surface 2a.

[0029] First, the controller 5 positions the build nozzle 312 at the approach start position P1 (S1: see Figure 4(a)). Step S1 is the positioning operation. The approach start position P1 is set to a position a predetermined distance away from the build surface 8a of the intermediate object 8. The approach height H1 from the approach start position P1 to the build surface 8a is greater than the extrusion length L2 of the build fiber material 9 to be extruded from the tip of the build nozzle 312 in the later step S2.

[0030] Next, the controller 5 extrudes the fibrous material 9 from the molding nozzle 312 (S2: see Figure 4(b)). Step S2 is the extrusion operation. The controller 5 operates the fiber feeding and pressing mechanism 32 to extrude the fibrous material 9 from the nozzle tip 312a of the molding nozzle 312 for a predetermined length. The length of the extruded fibrous material 9 may be 3 millimeters or more. The length of the extruded fibrous material 9 may be 6 millimeters or less. The length of the extruded fibrous material 9 may be 5.5 millimeters as an example. In other words, the length of the extruded fibrous material 9 may be selected from a range of approximately 3 to 6 millimeters. In the following description, we will assume that the length of the extruded fibrous material 9 is 5.5 millimeters as an example. The length of the extruded fibrous material 9 may be defined as the extrusion length L2 from the material tip 9a of the fibrous material 9 to the nozzle tip 312a of the molding nozzle 312. The extrusion length L2 is shorter than the approach height H1 mentioned above. Therefore, the leading edge 9a of the extruded molding fiber material 9 is separated from the molding surface 8a by a predetermined height H1a.

[0031] For example, the controller 5 may extrude the molding fiber material 9 for a predetermined length, or it may appropriately change the extrusion length according to the shape of the molding intermediate 8. For example, instead of the extrusion length L2, the controller 5 may use the height H1a from the molding surface 8a to the material tip 9a of the molding fiber material 9 as a control parameter.

[0032] Next, the controller 5 restrains the molding fiber material 9 (S3: Figure 5(a)). Step S3 is the restraining operation. The controller 5 sends a control signal to the fiber feeding and pressing mechanism 32, which switches the fiber feeding and pressing mechanism 32 to a state in which the molding fiber material 9 is restrained. As a result of this operation, even if force is applied to the molding fiber material 9, the molding fiber material 9 will not be pulled out of the molding nozzle 312, nor will the molding fiber material 9 be pushed back into the molding nozzle 312.

[0033] Next, the controller 5 moves the build nozzle 312 from the approach start position P1 to the layering start position P4 (S4: see Figures 5(a), 5(b), 6(a), and 6(b)). Step S4 is the approach operation. The controller 5 moves the build nozzle 312 along the approach trajectory T4 connecting the approach start position P1 to the layering start position P4. The approach trajectory T4 is a straight line that forms a predetermined angle with respect to the build surface 8a. The angle of the approach trajectory T4 with respect to the build surface 8a may be 30 degrees or more. Alternatively, the angle of the approach trajectory T4 with respect to the build surface 8a may be 60 degrees or less. In other words, the angle of the approach trajectory T4 with respect to the build surface 8a may be selected from the range of 30 to 60 degrees. For example, the angle of the approach trajectory T4 with respect to the build surface 8a may be 45 degrees or more. In the following description, we assume that the angle of the approach trajectory T4 with respect to the build surface 8a is 45 degrees. Furthermore, the controller 5 moves the build nozzle 312 (specifically the nozzle tip 312a) along the approach trajectory T4 while maintaining the nozzle axis 312T of the build nozzle 312 perpendicular to the build surface 8a. This step S4 includes four phases S4a, S4b, S4c, and S4d.

[0034] First, the first phase S4a (see Figure 5(a)) is the period when the tip of the fibrous material 9 is away from the surface 8a to be printed. The first phase S4a is the period during which the pre-contact approach operation is performed. In the first phase S4a, the fibrous material 9 is not subjected to any external force that would cause deformation, and therefore maintains its extruded state. For example, in the first phase S4a, the fibrous material 9 extends in a direction along the nozzle axis 312T of the printing nozzle 312.

[0035] When the build nozzle 312 moves along the approach trajectory T4 shown in Figure 5(a), the velocity of the build nozzle 312 can be decomposed into an in-plane velocity along the in-plane direction X and an out-of-plane velocity along the out-of-plane direction Z. When the approach trajectory T4 is at a 45-degree angle to the build surface 8a, the in-plane velocity is the same as the out-of-plane velocity.

[0036] The second phase S4b (see Figure 5(b)) is the moment when the tip of the shaping fiber material 9 comes into contact with the surface 8a to be fabricated. Once the material tip 9a touches the surface 8a to be fabricated, this material tip 9a can subsequently become the starting point of an external force that causes deformation of the shaping fiber material 9.

[0037] The third phase S4c (see Figure 6(a)) is the period after the tip of the molding fiber material 9 has contacted the surface to be molded 8a, during which it continues to move. The third phase S4c is the period during which the post-contact approach movement is performed. For example, if the rigidity of the molding fiber material 9 is relatively low, it may deform by bending with the material tip 9a and the nozzle tip 312a as fulcrums. Also, if the rigidity of the molding fiber material 9 is relatively high, it may deform by bending at the nozzle tip 312a. In this third phase S4c, the controller 5 moves the molding nozzle 312 so that the in-plane velocity and the out-of-plane velocity are the same. The molding fiber material 9, which is subjected to external forces accompanied by such deformation, may also be subjected to a force that pushes it back into the molding nozzle 312. However, in step S4, which includes this third phase S4c, the molding fiber material 9 is constrained by the fiber feeding and holding mechanism 32. Therefore, the molding fiber material 9, which is subjected to external force, will not be pushed back into the molding nozzle 312.

[0038] As shown in Figure 6(b), by moving along this approach trajectory T4, the extruded molding fiber material 9 can be positioned upstream of the layering start position P4. In other words, the extruded molding fiber material 9 can be positioned on the opposite side of the direction of travel of the molding nozzle 312. With this arrangement of the molding fiber material 9, the molding fiber material 9 will not obstruct the dotting process in step S6, which will be described later. Therefore, the dotting point that serves as the starting point for layering can be reliably formed.

[0039] In the first phase S4a, the second phase S4b, and the third phase S4c, the relationship between the in-plane velocity and the out-of-plane velocity is not limited to being equal to each other. For example, the in-plane velocity may be set to be faster than the out-of-plane velocity. In this case, the approach trajectory T4 to the surface 8a of the object to be printed will be less than 45 degrees.

[0040] Furthermore, in the second phase S4b and the third phase S4c, if the in-plane velocity is slower than the out-of-plane velocity, the approach trajectory T4 to the surface 8a to be printed becomes greater than 45 degrees. When this angle becomes large, unintended deflection or distortion occurs in the printed fiber material 9. For example, the extruded printed fiber material 9 may be positioned on the side of the direction of travel of the printing nozzle 312.

[0041] In the second phase S4b and the third phase S4c, care must be taken when setting the approach trajectory T4 due to the constraint on the material tip 9a and the external forces resulting from the movement of the molding nozzle 312. On the other hand, in the first phase S4a, since no external forces that cause deformation act on the molding fiber material 9, there is a high degree of freedom in setting a portion of the approach trajectory T4 corresponding to the first phase S4a.

[0042] After going through the three phases S4a, S4b, and S4c described above, the process proceeds to the fourth phase S4d (see Figure 6(b)). The fourth phase S4d occurs when the nozzle tip 312a of the printing nozzle 312 is located at the layering start position P4. When the nozzle tip 312a is located at the layering start position P4, a new layer of fibrous material 9 is sandwiched between the nozzle tip 312a and the surface to be printed 8a. In the fourth phase S4d, the nozzle tip 312a has not yet pressed the layer of fibrous material 9 against the surface to be printed 8a.

[0043] Next, the controller 5 releases the constraint on the molding fiber material 9 (S5). Step S5 is the release operation. The controller 5 switches the fiber feeding and pressing mechanism 32 to a state where the constraint on the molding fiber material 9 is released by sending a control signal to the fiber feeding and pressing mechanism 32. As a result of this operation, if a force is applied to the molding fiber material 9, the molding fiber material 9 becomes capable of being pulled out from the molding nozzle 312.

[0044] Next, the controller 5 moves the printing nozzle 312 from the layering start position P4 to the dot-pressing position P6 (S6: see Figure 7(a)). Step S6 is both a part of the printing operation and a bonding operation. This step S6 integrates the resin of the new printing fiber material 9 with the resin of the already layered printing fiber material 9 exposed on the printing surface 8a. This integration of resin bonds the new printing fiber material 9 to the already layered printing fiber material 9 exposed on the printing surface 8a. Specifically, as shown in Figure 7(a), the controller 5 moves the printing nozzle 312 from the layering start position P4 to the dot-pressing position P6. This dot-pressing position P6 is set slightly below the layering start position P4. In this step S6, it is necessary to slightly compress the new printing fiber material 9. Therefore, the height from the printing surface 8a to the dot-pressing position P6 may be set to be smaller than the thickness of the printing fiber material 9. Furthermore, in step S6, the crushed area of ​​the shaping fiber material 9 is heated simultaneously with the crushing of the shaping fiber material 9. This heating slightly melts the resin of the new shaping fiber material 9 and the resin of the already layered shaping fiber material 9 exposed on the surface 8a to be printed. This heating may be performed by a nozzle heater 313 provided on the printing nozzle 312. In other words, the nozzle tip 312a of the printing nozzle 312 has the function of crushing the shaping fiber material 9 and the function of heating the shaping fiber material 9.

[0045] In the above explanation, the constraints on the shaping fiber material 9 were released before moving from the lamination start position P4 to the spot-pressing position P6. Conversely, the constraints on the shaping fiber material 9 may be released after moving from the lamination start position P4 to the spot-pressing position P6. Alternatively, the movement from the lamination start position P4 to the spot-pressing position P6 and the release of the constraints on the shaping fiber material 9 may be performed in parallel.

[0046] Next, the controller 5 moves the build nozzle 312 from the tack-pressing position P6 to the cooling standby position P7 (S7: see Figure 7(b)). The cooling standby position P7 may be defined as the cooling height H7, which is the length along the out-of-plane direction Z from the welding point 9S. The cooling height H7 is lower than the approach height H1 mentioned above. The cooling height H7 may also correspond to the in-plane distance D7 from the layering start position P4 to the re-layering position P10 described later. In other words, the controller 5 raises the build nozzle 312. In this movement, the controller 5 raises the build nozzle 312 only in the out-of-plane direction. That is, the controller 5 does not move the build nozzle 312 in the in-plane direction with respect to the build surface 8a.

[0047] When step S8 is performed, the constraints on the shaping fiber material 9 are released. Since the shaping fiber material 9 is still at a temperature higher than room temperature, it is loosely welded to the shaping intermediate object 8 at the welding point 9S. When the shaping nozzle 312 is raised, the shaping fiber material 9 remains stationary and does not move as the shaping nozzle 312 rises. When the shaping nozzle 312 is raised, the frictional force acting between the shaping nozzle 312 and the shaping fiber material 9 is extremely small, so even though the shaping fiber material 9 is loosely welded to the shaping intermediate object 8, it does not move as the shaping nozzle 312 rises. As a result, the shaping fiber material 9 is ejected from the shaping nozzle 312 as the shaping nozzle 312 rises.

[0048] Next, the controller 5 causes the printing nozzle 312 to wait in the cooling standby position P7 for a predetermined time (S8: see Figure 7(b)). The waiting time can be set in advance. After this waiting time has elapsed, the welded area is welded to the intermediate object 8 with the desired strength. In this state, it is possible to resist the tensile force that acts on the welded area 9S during step S12, which will be described later. In other words, even if a tensile force acts on the welded area 9S in accordance with the movement of the printing nozzle 312, the welded area 9S will not detach from the surface 8a being printed.

[0049] Next, the controller 5 restrains the molding fiber material 9 (S9: see Figure 8(a)). The specific details are the same as in step S3 described above, so a detailed explanation will not be repeated.

[0050] Next, the controller 5 moves the printing nozzle 312 from the cooling standby position P7 to the re-layering position P10 (S10: see Figure 8(a)). For example, if the length of the printing fiber material 9 extruded from the printing nozzle 312 when it is moved to the cooling standby position P7 corresponds to the in-plane distance D7 from the layering start position P4 to the re-layering position P10, then moving the printing nozzle 312 from the cooling standby position P7 to the re-layering position P10 allows the printing fiber material 9 to be layered without slack between the layering start position P4 and the re-layering position P10.

[0051] Next, the controller 5 releases the constraints on the molding fiber material 9 (S11: see Figure 8(b)). The specific details are the same as in step S5 described above, so a detailed explanation will not be repeated.

[0052] Next, the controller 5 moves the printing nozzle 312 from the re-layering position P10 to the layering completion position P12 (S12: see Figure 8(b)). In this step S12, the printing fiber material 9 is layered between the re-layering position P10 and the layering completion position P12. In this step S12, the controller 5 moves the printing nozzle 312 along the shape of the surface to be printed 8a. Moving along the shape of the surface to be printed 8a means, for example, moving while maintaining a constant distance from the surface to be printed 8a to the nozzle tip 312a. In this step S12 as well, the printing nozzle 312 may heat the new printing fiber material 9 and press it against the already layered printing fiber material 9 exposed on the surface to be printed 8a.

[0053] Next, the controller 5 moves the printing nozzle 312 from the layer completion position P12 to the cutting position (S13: see Figure 9). Step S13 is part of the printing operation. This creates a predetermined gap between the printing surface 8a and the printing nozzle 312. Then, the controller 5 restrains the printing fiber material 9 (S14: see Figure 9).

[0054] Next, the controller 5 cuts the fibrous material 9 (S15: see Figure 9). First, the controller 5 moves the printing nozzle 312 slightly upward in the out-of-plane direction Z. The controller 5 sends a control signal to the fiber cutting mechanism 33, which moves the fiber cutting mechanism 33 into this gap, and the fiber cutting mechanism 33 cuts the fibrous material 9.

[0055] The controller 5 can obtain a molded intermediate object 8 having the desired shape by repeating the above steps S1 to S15.

[0056] <Effects and Effects> The additive manufacturing apparatus 1 includes a build table 2 which includes a support surface 2a for supporting an intermediate product 8 made of stacked string-like fibrous material 9, a build head 3 which allows and prohibits the ejection of the fibrous material 9 toward the build table 2 and is movable relative to the support surface 2a of the build table 2, and a controller 5 which controls the operation of the build head 3. The controller 5 performs an ejection operation (S2) which ejects the fibrous material 9 from the tip of the build nozzle 312 of the build head 3, and an approach operation (S4) which, after the ejection operation, moves the build nozzle 312 in the in-plane direction X along the support surface 2a while moving the build nozzle 312 in the out-of-plane direction Z toward the target surface 8a of the intermediate product 8.

[0057] The controller 5 includes an ejection control unit 52 that ejects the molding fiber material 9 from the tip of the molding nozzle 312 of the molding head 3, and an actuator control unit 51 that, after the ejection operation (S2), moves the molding nozzle 312 in the in-plane direction X along the support surface 2a, while moving it in the out-of-plane direction Z toward the molding target surface 8a of the molding intermediate object 8.

[0058] The additive manufacturing program 50P causes the computer 50 to function as an ejection control unit 52 that ejects the fibrous material 9 from the tip of the molding nozzle 312 of the molding head 3, and as an actuator control unit 51 that, after the ejection operation (S2), moves the molding nozzle 312 in the in-plane direction X along the support surface 2a, while moving it in the out-of-plane direction Z toward the surface 8a of the intermediate object 8 to be molded.

[0059] This additive manufacturing apparatus 1 performs an approach operation (S4) after the extrusion operation (S2). In the approach operation (S4), the manufacturing nozzle 312 is moved in the in-plane direction X along the support surface 2a, while simultaneously moving in the out-of-plane direction Z toward the manufacturing target surface 8a of the intermediate object 8. With this movement of the manufacturing nozzle 312, the tip portion of the manufacturing fiber material 9 is positioned on the opposite side of the direction of travel of the manufacturing nozzle 312. The tip portion of the manufacturing fiber material 9 positioned in this location does not obstruct the manufacturing operation (S6, S13) by the manufacturing nozzle 312. Therefore, it is possible to reliably form a starting point for joining new manufacturing fiber material 9 to the manufacturing target surface 8a, thereby suppressing the occurrence of manufacturing defects.

[0060] The controller 5 performs a restraining operation (S3) after the ejection operation (S2) and before the approach operation (S4) to prohibit the ejection of the molding fiber material 9. This operation prevents the molding fiber material 9 from being pushed back into the molding nozzle 312 while the approach operation (S4) is being performed.

[0061] Before the extrusion operation (S2), the controller 5 performs a positioning operation (S1) to position the build nozzle 312 at an approach start position P1 where the height from the tip of the build nozzle 312 to the build surface 8a is greater than the length of the build fiber material 9 to be extruded in the extrusion operation (S2). This operation allows the build fiber material 9 to be extruded to the desired length.

[0062] After the approach operation (S4), the controller 5 performs a release operation (S5) that allows the extrusion of the fibrous material 9, a bonding operation (S6) that presses the printing nozzle 312 against the surface 8a along the out-of-plane direction Z after the release operation (S5) to bond the fibrous material 9 sandwiched between the tip of the printing nozzle 312 and the surface 8a to the surface 8a, and a separation operation (S7) that moves the printing nozzle 312 away from the surface 8a along the out-of-plane direction Z after the bonding operation (S6). As a result of the separation operation (S7), the cooling standby position P7 where the printing nozzle 312 is positioned is set to be closer to the surface 8a than the approach start position P1. Even with this operation, the tip portion of the fibrous material 9 is positioned on the opposite side of the direction of travel of the printing nozzle 312.

[0063] In the approach operation (S4), the controller 5 sets the movement speed in the in-plane direction X to be greater than or equal to the movement speed in the out-of-plane direction Z. Even with this operation, the leading edge of the molding fiber material 9 is positioned on the opposite side of the direction of travel of the molding nozzle 312.

[0064] The controller 5 sets the movement speed in the in-plane direction X to be equal to the movement speed in the out-of-plane direction Z during the approach operation (S4). Even with this operation, the leading edge of the molding fiber material 9 is positioned on the opposite side of the direction of travel of the molding nozzle 312.

[0065] The controller 5 moves the printing nozzle 312 such that the relationship between the movement speed in the in-plane direction X and the movement speed in the out-of-plane direction Z during the post-contact approach operation (S4c) is the same as the relationship between the movement speed in the in-plane direction X and the movement speed in the out-of-plane direction Z during the pre-contact approach operation (S4a). Even with this operation, the leading edge of the printing fiber material 9 is positioned on the side opposite to the direction of travel of the printing nozzle 312.

[0066] Although several embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above. The present invention may be modified or applied to other claims without changing the gist of each claim.

[0067] <Additional Note> This disclosure includes the following components:

[0068] This disclosure includes [1] a build table including a support surface for supporting a molded object made of stacked string-like shaping fiber material, A build head that permits and prohibits the dispensing of the build fiber material toward the build table and is movable relative to the support surface of the build table, The system includes a controller that controls the operation of the molding head, The aforementioned controller, The ejection operation involves ejecting the fibrous material from the tip of the molding nozzle of the molding head, The additive manufacturing apparatus performs an approach operation in which, after the aforementioned ejection operation, the molding nozzle is moved in an in-plane direction along the support surface while the molding nozzle is moved in an out-of-plane direction toward the surface to be molded of the molded object.

[0069] This disclosure is [2] “The additive molding apparatus according to [1] above, wherein the controller performs a restraining operation that prohibits the dispensing of the molding fiber material after the dispensing operation and before the approach operation.”

[0070] This disclosure is [3] “The additive manufacturing apparatus according to [1] or [2] above, wherein the controller performs a positioning operation before the ejection operation, positioning the controller at an approach start position where the height from the tip of the molding nozzle to the surface to be molded is greater than the length of the molding fiber material to be ejected in the ejection operation.”

[0071] This disclosure includes [4] "the controller provides a release operation that allows the extrusion of the shaping fiber material after the approach operation, After the release operation, the molding nozzle is pressed against the surface to be molded along the out-of-plane direction, thereby joining the molding fiber material sandwiched between the tip of the molding nozzle and the surface to be molded to the surface to be molded. After the bonding operation, a separation operation is performed to move the molding nozzle away from the surface to be molded along the out-of-plane direction. As a result of the separation operation, the position where the molding nozzle is positioned is closer to the surface to be molded than the approach start position, in the additive molding apparatus described in [3] above.

[0072] This disclosure is [5] "an additive molding apparatus according to any one of the above [1] to [4], wherein the controller, in the approach operation, sets the speed of movement in the in-plane direction to be equal to or greater than the speed of movement in the out-of-plane direction."

[0073] This disclosure relates to [6] "an additive manufacturing apparatus according to any one of [1] to [5] above, wherein the controller makes the in-plane movement speed equal to the out-of-plane movement speed in the approach operation."

[0074] This disclosure includes [7] "The approach operation is, A pre-contact approach operation from a state in which the tip of the shaping fiber material does not contact the surface to be shaped to a state in which the tip of the shaping fiber material contacts the surface to be shaped, This includes a post-contact approach operation in which the molding nozzle is brought closer to the molding surface from a state in which the tip of the molding fiber material is in contact with the molding surface, The controller moves the molding nozzle such that the relationship between the moving speed in the in-plane direction and the moving speed in the out-of-plane direction during the post-contact approach operation is the same as the relationship between the moving speed in the in-plane direction and the moving speed in the out-of-plane direction during the pre-contact approach operation, as described in any one of the above [1] to [6].

[0075] This disclosure includes [8] a build table including a support surface for supporting a molded object made of stacked string-like shaping fiber material, An additive manufacturing control device for additive manufacturing performed using an apparatus comprising: a molding head that permits and prohibits the dispensing of the molding fiber material toward the molding table and is movable relative to the support surface of the molding table, The molding head includes an ejection unit that ejects the molding fiber material from the tip of the molding nozzle, An additive molding control device comprising: an approach operation unit that, after the aforementioned ejection operation, moves the molding nozzle in an in-plane direction along the support surface while simultaneously moving it in an out-of-plane direction toward the molding target surface of the molded object.

[0076] This disclosure includes [9] a build table including a support surface for supporting a molded object made of stacked string-like shaping fiber material, An additive manufacturing program for additive manufacturing performed using an apparatus comprising: a build head that permits and prohibits the dispensing of the build fiber material toward the build table and is movable relative to the support surface of the build table, Computers, An ejection unit that ejects the molding fiber material from the tip of the molding nozzle of the molding head, and An additive manufacturing program that, after the aforementioned ejection operation, causes the molding nozzle to function as an approach unit, moving it in an in-plane direction along the support surface while simultaneously moving it out-of-plane toward the surface to be molded of the molded object. [Explanation of symbols]

[0077] 1. Additive molding device 2. Build Table 2a Support surface 3. Modeling head 4 Head Actuators 5 Controllers 8 Modeling intermediates (modeled objects) 8a Surface to be molded 9. Shaping Fiber Materials 9a Material tip 9S welding points 31 Fiber Dispensing Mechanism 32. Pressing mechanism 33 Fiber cutting mechanism 35 Headframe 50 Computers 50P Additive Manufacturing Program 51 Actuator control unit (approach motion unit) 52 Discharge control unit (discharge operation unit) 53 Cutting mechanism control unit 311 Bobbin 312 Printing Nozzle 312a Nozzle tip 312T Nozzle Axis 313 Nozzle Heater C4 control signal C32 control signal C33 Control Signal D7 In-plane distance P1 Approach starting position P4 Lamination start position P6 Spot pressing position P7 Cooling standby position P10 Re-lamination position P12 End of stacking position S12 Step T4 Approach Trajectory X in-plane direction Z out-of-plane direction

Claims

1. A build table including a support surface for supporting a molded object made by layering string-like shaping fiber material, A build head that permits and prohibits the dispensing of the build fiber material toward the build table and is movable relative to the support surface of the build table, The system includes a controller that controls the operation of the molding head, The aforementioned controller, The ejection operation involves ejecting the fibrous material from the tip of the molding nozzle of the molding head, Additive molding apparatus that, after the discharge operation, performs an approach operation in which the molding nozzle is moved in an in-plane direction along the support surface while the molding nozzle is moved in an out-of-plane direction toward the surface to be molded of the molded object.

2. The additive molding apparatus according to claim 1, wherein the controller performs a restraining operation that prohibits the dispensing of the molding fiber material after the dispensing operation and before the approach operation.

3. The additive manufacturing apparatus according to claim 1, wherein the controller performs a positioning operation before the ejection operation, positioning itself at an approach start position where the height from the tip of the molding nozzle to the surface to be molded is greater than the length of the molding fiber material to be ejected in the ejection operation.

4. The controller, after the approach operation, performs a release operation that allows the extrusion of the shaping fiber material, After the release operation, the molding nozzle is pressed against the surface to be molded along the out-of-plane direction, thereby joining the molding fiber material sandwiched between the tip of the molding nozzle and the surface to be molded to the surface to be molded. After the bonding operation, a separation operation is performed to move the molding nozzle away from the surface to be molded along the out-of-plane direction. As a result of the separation operation, the position where the molding nozzle is positioned is closer to the surface to be molded than the approach start position, according to claim 3, an additive molding apparatus.

5. The additive molding apparatus according to claim 1, wherein the controller, in the approach operation, sets the movement speed in the in-plane direction to be greater than or equal to the movement speed in the out-of-plane direction.

6. The additive molding apparatus according to claim 1, wherein the controller makes the movement speed in the in-plane direction equal to the movement speed in the out-of-plane direction during the approach operation.

7. The aforementioned approach operates as follows: A pre-contact approach operation from a state in which the tip of the shaping fiber material does not contact the surface to be shaped to a state in which the tip of the shaping fiber material contacts the surface to be shaped, This includes a post-contact approach operation in which the molding nozzle is brought closer to the molding surface from a state in which the tip of the molding fiber material is in contact with the molding surface, The additive manufacturing apparatus according to claim 1, wherein the controller moves the molding nozzle such that the relationship between the moving speed in the in-plane direction and the moving speed in the out-of-plane direction during the post-contact approach operation is the same as the relationship between the moving speed in the in-plane direction and the moving speed in the out-of-plane direction during the pre-contact approach operation.

8. A build table including a support surface for supporting a molded object made by layering string-like shaping fiber material, An additive manufacturing control device for additive manufacturing performed using an apparatus comprising: a molding head that permits and prohibits the dispensing of the molding fiber material toward the molding table and is movable relative to the support surface of the molding table, The molding head includes an ejection unit that ejects the molding fiber material from the tip of the molding nozzle, Additive molding control device having an approach operation unit that moves the molding nozzle in an in-plane direction along the support surface while moving it out-of-plane toward the molding surface of the molded object after the ejection operation.

9. A build table including a support surface for supporting a molded object made by layering string-like shaping fiber material, An additive manufacturing program for additive manufacturing performed using an apparatus comprising: a build head that permits and prohibits the dispensing of the build fiber material toward the build table and is movable relative to the support surface of the build table, Computers, An ejection unit that ejects the molding fiber material from the tip of the molding nozzle of the molding head, and An additive manufacturing program that, after the aforementioned ejection operation, functions as an approach operation unit that moves the molding nozzle in an in-plane direction along the support surface while simultaneously moving it out-of-plane toward the surface to be molded of the molded object.

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