Molded objects, methods for designing molded objects, and methods for manufacturing molded objects

Abstract

To provide a molded object that allows for greater freedom in design. [Solution] A 3D-printed object W is manufactured by a 3D printer and has a 3D-printed section W1 having a shape defined based on a regular curve.

Description

Technical Field

[0001] The present invention relates to a three-dimensional object, a method for designing an object, and a method for manufacturing an object.

Background Art

[0002] In recent years, as an object manufacturing apparatus for manufacturing a three-dimensional object, for example, a 3D printer using a fused deposition modeling method is widely known (see, for example, Patent Document 1).

[0003] In the case of an object manufactured using a 3D printer, although the degree of freedom in design is higher than before and it can cope with a more complex shape, the more complex the shape, the more support is required to support the necessary parts of the model during shaping, and it is often difficult to remove the support that becomes unnecessary after shaping.

[0004] Also, when manufacturing an object using a conventional 3D printer, a lattice structure such as a lattice structure has been used (see, for example, Patent Document 2). The lattice structure is a structure in which lattices branched in a dendritic shape are arranged periodically, and since the inside of the object can be made into a cavity, weight reduction can be easily achieved. However, since each element (side) of this lattice structure has a linear structure, it lacks flexibility (elasticity), and when forming a curved surface (curve), it was necessary to combine a plurality of unit cells. In addition, since the lattice structure is configured to connect the ends of the branched lattices to each other, the connection direction (angle) is limited.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] Therefore, one of the objectives of the present invention is to provide a molded object, a molded object design method, and a molded object manufacturing method that can further improve the degree of freedom in molding. [Means for solving the problem]

[0007] An embodiment of the present invention is a molded object manufactured by a molded object manufacturing apparatus, having a molded part with a shape defined based on a regular curve.

[0008] In the above-described molded object, the molded part may have a loop shape defined based on a regular curve.

[0009] The above-mentioned molded object may be a solid shape having an outer edge shape defined based on a regular curve.

[0010] In the above-mentioned molded object, multiple molded parts may be connected to each other.

[0011] In the above-described molded object, the multiple molded parts may be identical in shape or mirror-image symmetrical in shape to one another.

[0012] In the above-described object, the multiple molded parts may have different sizes and shapes from one another.

[0013] In the above-described molded object, the cross-sectional shape of the molded portion may have side edges that extend along the molded table of the molded object manufacturing apparatus.

[0014] In the above-mentioned molded object, the cross-sectional shape of the molded part may be a Reuleaux polygon.

[0015] In the above-described molded object, the cross-sectional shape of the molded part may be the intersection of two circles.

[0016] The above-mentioned molded object may form at least a part of a porous structure.

[0017] The above-mentioned molded object may form at least a part of the mesh.

[0018] The above-shaped object may have an outer surface portion forming at least a part of the filter medium.

[0019] The above-shaped object may form a connecting portion that connects between a plurality of structural portions.

[0020] Moreover, the shaped object design method of the present invention forms the shaped data of the shaped portion by setting a thickness on a surface obtained by connecting adjacent positive leaf curves with a line.

[0021] The above-shaped object design method may form the shaped data of the shaped portion by sweeping a predetermined cross-sectional shape along a positive leaf curve.

[0022] The above-shaped object design method may form the shaped data of the shaped portion by connecting cross-sectional shapes at different positions along a positive leaf curve.

[0023] The above-shaped object design method may form the shaped data of the shaped portion by setting a thickness on a surface surrounded by a positive leaf curve.

[0024] Moreover, the shaped object manufacturing method of the present invention manufactures a shaped object by a shaped object manufacturing apparatus based on the shaped data formed by the above-shaped object design method.

Effects of the Invention

[0025] According to an embodiment of the present invention, it is possible to further improve the degree of freedom in shaping.

Brief Description of the Drawings

[0026] [Figure 1] It is a front view schematically showing a 3D printer of a thermal melting lamination method, which is a shaped object manufacturing apparatus according to an embodiment of the present invention. [Figure 2] It is an explanatory view showing an example of a positive leaf curve for constituting a shaped object or a shaped portion manufactured using the above 3D printer. [Figure 3]The first design method for the fabrication data of the same fabricated object is shown in perspective view in the order of (a) and (b). [Figure 4] The second design method for the molding data of the same molded object is shown in perspective view in the order of (a) and (b). [Figure 5] The diagram shows an object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view from one direction, and (e) is a perspective view from another direction. [Figure 6] The following diagram shows other objects manufactured using the same 3D printer: (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view from one direction, and (e) is a perspective view from another direction. [Figure 7] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, and (c) is a side view from the +Y axis. [Figure 8] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 9] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 10] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 11] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 12]The following figure shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view, and (e) is a front view showing an example of its cross-sectional shape. [Figure 13] Figure 10 is a photograph showing an example of the manufacturing process of a molded object. [Figure 14] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view from one direction, and (e) is a perspective view from another direction. [Figure 15] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 16] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 17] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 18] Figure 16 is a perspective view showing an example of the application of the molded object. [Figure 19] (a) is a perspective view showing an example of a folio curve, and (b) is a perspective view showing a molded object formed by connecting multiple molded parts manufactured based on the folio curve in (a). [Figure 20] The figure shows an example of the printing data for the same printed object, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 21]The following figure shows other examples of the printing data for the same printed object, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 22] The following figure shows yet another example of the printing data for the same printed object, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 23] The following figure shows yet another example of the printing data for the same printed object, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 24] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 25] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 26] (a) is a perspective view showing the mesh of the fabricated object shown in Figure 24, and (b) is a perspective view showing an example of (a) in use. [Figure 27] Figure 25 is a perspective view showing other examples of uses for the molded object. [Figure 28] Figure 25 shows photographs illustrating examples of the manufacturing process of the molded object; (a) shows the normal state, and (b) shows the state under which tensile force is applied. [Figure 29] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 30] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 31] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 32] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 33] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 34] Figure 32 is a photograph showing an example of the manufacturing process of the molded object. [Figure 35] Figure 32 is an explanatory diagram showing application examples of the printed object, where (a) shows an example where the printed object is inserted and placed inside, and (b) shows an example where the printed object is attached to the outside. [Figure 36] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view from one direction, and (e) is a perspective view from another direction. [Figure 37] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view from one direction, and (e) is a perspective view from another direction. [Figure 38] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 39]The following figure shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, (c) is a side view from the +Y axis, (d) is an oblique view, and (e) is a front view showing an example of its cross-sectional shape. [Figure 40] This is a schematic diagram illustrating an example where the same molded object is used as a connecting part between structural components. [Figure 41] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis, (b) is a side view from the +X axis, and (c) is a side view from the +Y axis. [Figure 42] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, and (c) a perspective view. [Figure 43] This is an explanatory diagram showing a third design method for the modeling data of the same molded object. [Figure 44] Figure 43 shows the manufactured object based on the design data, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 45] This diagram illustrates the fourth design method for the modeling data of the same molded object, in the order of (a) to (f). [Figure 46] Figure 45 shows the manufactured object based on the design data, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 47] The following diagram shows yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is an oblique view, and (e) is a plan view from the -Z axis direction. [Figure 48]The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 49] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a side view from the +Y axis, and (d) a perspective view. [Figure 50] The following diagrams show other objects manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) a side view from the +X axis, (c) a perspective view from one direction, (d) a perspective view from another direction, and (e) a photograph from the -Z axis. [Figure 51] Figure 50 is a perspective view showing application examples of the molded objects, where (a) shows an example using a single molded object, and (b) shows an example using a pair of molded objects. [Figure 52] (a) through (c) are explanatory diagrams showing other examples of the fourth design method for the modeling data of the same molded object. [Figure 53] The following figure shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis and (b) being a plan view from the +X axis. [Figure 54] The following figure shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis and (b) being a plan view from the +X axis. [Figure 55] Figure 54 is an explanatory diagram showing an example of the application of the molded object. [Figure 56] The following figure shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis and (b) being a plan view from the +X axis. [Figure 57] The following diagram shows yet another object manufactured using the same 3D printer, with (a) being a plan view from the +Z axis, (b) being a plan view from the +X axis, and (c) being a perspective view. [Figure 58] Figure 30 is a photograph showing an example of the manufacturing process of the molded object. [Figure 59] The image shows the main body of a foam generating device as an example of an application of a 3D-printed object, with (a) being a perspective view and (b) being a cross-sectional view. [Figure 60] (a) is a photograph showing an example of foam generated by the foam generating means shown in Figure 59, and (b) is a photograph showing an example of foam from a comparative example. [Modes for carrying out the invention]

[0027] One embodiment of the present invention will be described with reference to the drawings.

[0028] In Figure 1, 1 is a fused deposition modeling (FDM) 3D printer, which is a device for manufacturing molded objects. This FDM 3D printer (hereinafter sometimes simply referred to as "3D printer 1") is a molding machine that sequentially builds up layers of resin, a molding material that has been melted by heat, one layer at a time, based on 3D modeling data, to produce a three-dimensional object W.

[0029] The resin used as the molding material in 3D printer 1 is, for example, a thermoplastic resin, such as general-purpose plastics, engineering plastics, super engineering plastics, reinforced resins, recycled plastics, biomass plastics, and biodegradable plastics. More specifically, examples include PVC, POM, PBAT, AAS, PS, PLA, PBS, PE, plant fiber-reinforced PLA, plant fiber-reinforced PBS, ABS, glass fiber-reinforced ABS, carbon fiber-reinforced ABS, PP, glass fiber-reinforced PP, basalt fiber-reinforced PLA, basalt fiber-reinforced ABS, basalt fiber-reinforced PP, basalt fiber-reinforced PC, basalt fiber-reinforced PE, basalt fiber-reinforced PVC, carbon fiber-reinforced PP, PC, glass fiber-reinforced PC, PC·ABS, ASA, TPE, TPU, cellulose acetate, PA, PETG, etc. The molding material can be in any shape, such as pellets or filaments. Furthermore, the 3D printer 1 is, for example, a single-nozzle head type, and only one type of resin is required for printing; a support resin (such as a water-soluble resin) is not necessary. Also, the printing material is not limited to resin; it may also be metal, ceramic, silicone, etc. Moreover, these printing materials may have one or more properties among flexibility, antibacterial properties, chemical resistance, heat resistance, stain resistance, and weather resistance, or these properties may be added using desired additives.

[0030] The 3D printer 1 comprises, for example, a box-shaped main body 3 having a build chamber 2 inside, a build head 4 that can move in the X-axis direction (horizontal direction, left to right) and the Z-axis direction (vertical direction, height) within the build chamber 2, and a build table 5 that can move in the Y-axis direction (horizontal direction, front to back) within the build chamber 2.

[0031] Furthermore, since the build head 4 is movable in the X and Z axes and the build table 5 is movable in the Y axis, the build head 4 moves in three dimensions relative to the build table 5 (as will be described later, the 3D printer 1 is not limited to the configuration shown in Figure 1, and any configuration in which the build head 4 moves in at least three dimensions relative to the build table 5 is acceptable).

[0032] Furthermore, the 3D printer 1 includes a first drive unit 6 that moves the build head 4 in the X-axis and Z-axis directions within the build chamber 2, a second drive unit 7 that moves the build table 5 in the Y-axis direction within the build chamber 2, and a control unit 8 that controls both drive units 6, 7, etc., based on 3D build data such as STL data.

[0033] Then, based on the control by the control unit 8, the build head 4 moves in three dimensions relative to the build table 5, and resin (molten resin) is extruded from the nozzle 11 of the build head 4 during this movement. As this extruded resin hardens and solidifies, the resin is layered on the build table 5, creating a three-dimensional object W of the desired shape.

[0034] Here, the build head 4 of the single-nozzle head fused deposition modeling 3D printer 1 is, for example, of the fused resin extrusion type, and has a single nozzle 11 that extrudes resin melted by heat from a heating means (not shown) inside the build head 4.

[0035] In other words, the resin, heated and melted by a heating means such as a heater (not shown), is extruded by an extrusion means (not shown) such as a gear inside the build head 4, and discharged (discharged) from the discharge port of one nozzle 11 for discharging the build material in the direction of the central axis of the discharge port, for example, downwards. Note that the heating means and extrusion means may be provided outside the build head 4 instead of inside it.

[0036] Furthermore, the object manufactured by the 3D printer 1 of this embodiment has a molded part having a shape defined based on the folio curve R shown as an example in Figure 2. The molded part may be a linear body or a continuum thereof having a loop shape defined based on the folio curve R, or it may be a solid shape having an outer edge shape defined based on the folio curve R.

[0037] Here, the orthophylline curve R, also known as the rose curve, is defined by the following equation (hereinafter collectively referred to as equation (1)) using the parameter t.

[0038] Xt = a·(b+r(t))·cos(c+d·t) Yt = e·(f+r(t))·sin(c+d·t) Zt=any

[0039] The X-axis, Y-axis, and Z-axis directions correspond to the X-axis, Y-axis, and Z-axis directions of 3D printer 1 (shown in Figure 1). Coefficients a and e are coefficients that set the scaling factor of the "petal" shape in the X-axis and Y-axis directions, and are non-zero numbers. Coefficients b and f are arbitrary coefficients for setting the radial width of the "petal". Number c is a coefficient that sets the starting angle of rotation in the X-axis and Y-axis directions, and is an arbitrary coefficient that allows for variations in the shape of the fossil curve. Coefficient d is a non-zero rational number. Preferably, a=e and b=f are set to make the fossil curve R symmetrical. Also, r(t) is set by setting g to an arbitrary positive number (preferably an integer of 1 or more), h to an arbitrary coefficient, and r to a positive rational number, preferably a rational number of 1 or more, and sin g (h+r·t) or cos g The formula is (h+r·t). g is a coefficient for setting the width of the "petal" shape; the larger the value, the thinner the "petal" shape becomes. The shape of the "petal" should preferably be set appropriately according to the cross-sectional shape of the molded part (molded object). Note that the sin and cos in r(t) above may be replaced by a finite Fourier series. By using a finite Fourier series, the outer shape of the "petal" becomes jagged, which not only improves the appearance but also makes it suitable for applications such as cutting tools by sharpening the tip. Furthermore, h is a coefficient for setting the start and / or end points of the regular leaf curve R, and r is a coefficient for setting the number of "petal" shapes. The parameter t is, for example, 0 to 2π [rad], but it may be arbitrarily changed according to the size of r, etc., as long as the desired shape can be obtained. Furthermore, Zt may be 0, or it may be a function with t as a parameter. As an example of Zt, considering the ease of fabrication of the fabrication part W1 (form W), for example, with k as an arbitrary coefficient, Zt = k, Zt = k·t, Zt = k·sin g (h+r·t), Zt=k·cos g(h+r·t), or any combination thereof, or a constant is preferably used. Also, for Zt, a finite Fourier series may be used instead of sin or cos. However, it is preferable to select coefficients b, f, h, rational numbers r, Zt, etc., so that the folio curve R does not become a trivial circle or torus knot. By selecting these coefficients, it is also possible to form a Reuleaux polygonal hole in the center of the molding section W1 (molded object W). When using the molding section W1 (molded object W) as a mesh, it is not very desirable to have a hole in the center, but in this case, it is possible to design and later attach another torus, folio curve, or something that can be inscribed inside. Also, the relationship between XT or YT and ZT may be separately defined using a parameter T different from the parameter t, so that an arbitrary curve is drawn in the XZ plane or YZ plane. For example, the folio curve R shown in Figure 2 is on the XY plane set at Zt=0, and shows an example where a=e, b=c=f=h=0, r=3 / 2, d=g=1, and t=0~4π [rad]. Depending on the range of the parameter t chosen, the folio curve R generally has a closed-loop shape.

[0040] As is obvious from equation (1), congruent folio curves R are formed even when the values ​​of Xt, Yt, and Zt are swapped. Furthermore, the folio curve R of this embodiment is also included when equation (1) is rotated arbitrarily in the three-dimensional direction. In addition, as is obvious from equation (1), an arbitrary constant may be added to any of Xt, Yt, and Zt, and the molded part W1 (molded object W) may be molded at any position on the build table 5 of the 3D printer 1.

[0041] In this embodiment, the 3D modeling data for the modeling unit is designed using formula (1) by a computer or the like, and the 3D printer 1 is driven to manufacture the modeled object based on the designed modeling data.

[0042] Next, we will explain the design method for the shaped object W.

[0043] When using equation (1), the modeling data for manufacturing the object W can be designed in four main ways.

[0044] The first design method involves creating the modeling data by adding thickness to a surface formed by connecting two adjacent folio curves with lines.

[0045] The second design method involves creating the modeling data by sweeping a predetermined cross-sectional shape along a regular curve. Sweeping refers to continuously moving a predetermined cross-sectional shape along a trajectory, in this case, along a regular curve.

[0046] The third design method involves forming the fabrication data for the fabricated part by joining cross-sectional shapes located at different positions along a folio curve.

[0047] The fourth design method involves creating the modeling data by adding thickness to the surface enclosed by the folio curve.

[0048] The first to third design methods are primarily used for designing molding data for manufacturing linear molding parts W1 (molded object W), as exemplified in Figures 5 to 44. In contrast, the fourth design method is used for designing molding data for manufacturing solid molding parts W1 (molded object W), as exemplified in Figures 45 to 57.

[0049] First, the first design method will be explained with reference to the drawings.

[0050] As shown in Figure 3(a), two adjacent, nearly similar folio curves R1 and R2 are used, and a line 15, for example a straight line, is used to connect them to form a surface 16. A non-self-intersecting line 15 is preferred. Then, as shown in Figure 3(b), thickness is added to this surface 16 in the normal direction to create a 3D model (solid model), thereby forming the modeling data D.

[0051] Regarding the thickness of the surface, it may be set so that it does not self-intersect, or it may be set so that a part of it self-intersects. The self-intersecting parts can be considered as intersections in a grid structure. Impact resistance can be improved by adding thickness to the self-intersecting parts, for example, at arbitrary locations. When increasing the thickness of the self-intersecting parts, operations such as increasing the extrusion rate of the 3D printer 1 can be performed.

[0052] The lines used in the first design method are not limited to straight lines, but may be any curve, such as a sine curve. Preferably, the folio curves R1 and R2 do not intersect each other. Furthermore, the values ​​of Zt for folio curves R1 and R2 do not need to be exactly the same; for example, they may be set so that the Zt of one gradually increases compared to the Zt of the other depending on the magnitude of t.

[0053] Next, the second design method will be explained with reference to the drawings.

[0054] As shown in Figure 4(a), the molding data D is formed by moving the center or centroid of a predetermined cross-sectional shape 21 along a sweep line 20 set by a folio curve, thereby creating a three-dimensional model as shown in Figure 4(b). The size of the cross-sectional shape 21 may be set so that no self-intersecting parts are formed in the molding area W1, or it may be set so that self-intersecting parts are formed in a part of the molding area W1. The self-intersecting parts become intersections in the lattice structure.

[0055] Preferably, the cross-sectional shape 21 has a side edge portion 22 that extends along the build table 5. That is, the side edge portion 22 is a portion that substantially does not have a Z-axis component. The shape of the side edge portion 22 is preferably a straight line, but is not limited to this, and may be a curve that approximates a straight line (large radius of curvature), or a shape that has a straight line or a curve that approximates a straight line as a tangent or envelope at the tip, such as a wave shape, zigzag shape, or saw shape, which extends along the build table 5. In this way, because the cross-sectional shape 21 of the build section W1 has a side edge portion 22 that extends along the build table 5 of the 3D printer 1, the build section W1 can be manufactured by the 3D printer 1 with the side edge portion 22 acting as a support portion for the build table surface (or the raft surface on the build table surface), so that the build section W1 (build object W) can be manufactured without supports.

[0056] For example, the cross-sectional shape 21 is shown as a hexagon, particularly a regular hexagon, but this shape can be arbitrarily selected from polygonal shapes such as triangles and squares, sectors, semi-circular shapes, or oval shapes such as circles and ellipses, or Reuleaux polygons. For example, by using a Reuleaux polygon cross-sectional shape 21, especially a Reuleaux triangle, it is possible to suppress material deformation when layering the material one layer at a time, especially in the case of 3-axis printing, and the shape is resistant to bending stress, which can also increase the fatigue resistance when the printed part W1 (printed object W) is used repeatedly. In the case of a Reuleaux polygon cross-sectional shape 21, for example, by making the "petal" shape a pointed shape such as a rugby ball shape or a jagged shape, it is suitable for use as a rotating cleaning brush, as it can easily reach corners of a room. Generally, if the angle of rise of the cross-section of the build plate W1 (build object W) is 45 degrees or less (for example, in the case of a dome-shaped ceiling section with a circular cross-section having a curved surface with an obtuse angle tangent to the build plate 5), layer collapse often occurs. In the case of a build plate W1 (build object W) with twists, spirals, or loop shapes, if the cross-sectional shape is made, for example, a Reuleaux polygon or the intersection of circles (a Boulean product), i.e., a rugby ball shape, it becomes easier to build without supports. Furthermore, by making the layer pitch finer, it becomes even easier to build without supports, and it is possible to reduce the effort of removing supports after building, as well as the building time and the amount of material used.

[0057] Furthermore, the cross-sectional shape 21 is not limited to a planar shape, but may also be a frame shape or the like, creating a hollow structure. By using a frame-shaped cross-sectional shape 21, the weight of the hollow structured part W1 (structured object W) can be reduced by selecting the appropriate fabrication material, and elasticity can also be further enhanced. Additionally, by creating a structured part W1 (structured object W) with a frame-shaped cross-sectional shape 21 and both ends, allowing fluid to pass through the interior between the ends, and by attaching or integrally fabricating a turbulence generating part such as a filter (filter material) or a spiral structured part W1 (for example, the structured part W1 in Figures 7 to 10 and 17 to 19 described later) inside the hollow structure, the overall curved structure allows for a space-saving design for fluid flow, resulting in a compact filtration mechanism. In this case, the periodic structure of the structured part W1 (structure W) stabilizes the fluid flow and suppresses stagnation.

[0058] Furthermore, the cross-sectional shape 21 may be swept while maintaining its perpendicularity to the folio curve, or, if it connects with another surface at the end of the folio curve, it may be extended or deformed so as to be flush with that surface and connected to it.

[0059] Figures 5 to 42 show examples of molded parts W1 (formed objects W) manufactured based on the molding data D designed by the first and second design methods. These molded parts W1 (formed objects W) constitute at least a part of a porous structure.

[0060] The examples shown in Figures 5(a) to 5(e) represent a molded part W1 (molded object W) that is shaped based on a folio curve set in equation (1) as Zt = k·cos(r·t)·sin(d·t), where a=e=k, r=3 / 4, d=g=1, and t=0~8π [rad]. In this example, the cross-sectional shape is rectangular, and the molding data can be designed using either the first or second design method.

[0061] Furthermore, the examples shown in Figures 6(a) to 6(e) have different cross-sectional shapes from the examples shown in Figures 5(a) to 5(e). In the second design method, the molding data was designed with a sweep line consisting of the same equation (1) but with a cross-sectional shape, for example, a circle.

[0062] These examples of molded parts W1 (formed object W) exhibit rotationally symmetrical folio curves when viewed from the X-axis and Z-axis directions, respectively, possessing particularly good aesthetics. Furthermore, they each have a spring-like shape, resulting in molded parts W1 (formed object W) with excellent cushioning and spring properties. Therefore, even if the molding material is rigid, the molded part W1 (formed object W) can be structurally expandable and contractible, possessing flexibility, elastic deformation performance, and impact resistance. This allows for, for example, a reduction in plasticizers or even the elimination of plasticizers altogether, contributing to environmental considerations.

[0063] Furthermore, the examples shown in Figures 7(a) to 7(c) are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve set in equation (1) as Zt=k(h+r·t), with a=e=k, r=1 / 2, d=g=1, and t=0~5π[rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0064] An example of this molded part W1 (formed object W) is a rotationally symmetrical folio curve when viewed from the Z-axis direction, and exhibits a spring-like or helical shape, resulting in a molded part W1 (formed object W) with excellent cushioning and spring properties. Furthermore, by making the cross-sectional shape a frame shape such as a double circle, it can also be used as a pipe-shaped turbulence generating means that randomly disrupts the flow pattern of the fluid passing through the interior and generates turbulence. Compared to pipes with a constant diameter, turbulence can be generated at a lower fluid velocity. Since flow resistance is proportional to the square of the fluid velocity, generating turbulence at a low fluid velocity can be expected to save energy required to generate turbulence. Because turbulence can be easily generated in the fluid passing through the interior, it functions suitably as a microbial cultivation device that can efficiently cultivate microorganisms such as aerobic bacteria on the inner surface by generating bubbles due to the turbulence. In addition, because it is helical, it is possible to construct a long flow path in a compact manner. Furthermore, by making the hollow structure W, which can be expanded and contracted to press against the inner surface of the pipe through which the fluid passes, movable in and out of the pipe, it can be effectively used as a microbial carrier or microbial cultivation device that allows for easy collection of microorganisms grown inside (e.g., plankton, which are food for fish and shellfish). In addition, the number of turns and length of the spiral can be easily adjusted by changing the range of t in equation (1), and the direction of the spiral can also be easily changed by changing the sign of the coefficient in equation (1), making the design easy.

[0065] Furthermore, in the example of the molding section W1 (molded object W) shown in Figures 5 to 7, it is possible to inscribe it in a rectangular parallelepiped as a unit cell. Also, by making the coefficients Xt and Zt in equation (1) the same, it is possible to inscribe it in a square, and depending on the shape, it is also possible to inscribe it in a cube.

[0066] Furthermore, by changing Zt and the coefficient r in equation (1), the shape of the molding unit W1 (molded object W) can be significantly altered. The examples shown in Figures 8(a) to 8(d) are molded based on a folio curve where a=e=k, r=1 / 20, d=g=1, and t=0~10π[rad], respectively, with the molding data designed using a circular cross-sectional shape in the second design method.

[0067] Furthermore, the shape of the fabricated part W1 (fabricated object W) can also be changed by setting the range of the parameter t. For example, the examples shown in Figures 10(a) to 10(d) are fabricated parts W1 (fabricated object W) that are fabricated based on a folio curve t=0~15π[rad] in the examples shown in Figures 9(a) to 9(d), and have a shape in which the central part in the Z-axis direction bulges out.

[0068] Furthermore, the example of the molded part W1 (molded object W) shown in Figures 11(a) to 11(d) is obtained by setting the range of the parameter t in equation (1) to 5π to 15π, as in the example shown in Figures 10(a) to 10(d). In this way, the shape can be greatly changed by setting the range of the parameter t. In this example, the shape is also approximately symmetrical in the Z-axis direction, so there is no directionality in the Z-axis direction, and for example, it is less likely to be installed in the wrong direction during use.

[0069] Furthermore, even when using the same coefficients and range of mediation numbers in equation (1), it is possible to change the shape by changing the cross-sectional shape in the second design method. For example, the example of the molded part W1 (molded object W) shown in Figures 12(a) to 12(e) is the same as the example shown in Figures 8(a) to 8(d), but the cross-sectional shape 21 is a sector shape. In this example, an example is shown where the cross-sectional shape is a sector with a central angle of π / 2 [rad], but the central angle may be any angle less than 2π [rad], preferably less than π [rad]. In this case, by making the straight portion 21a of the sector in the cross-sectional shape 21 a side edge that extends along the molding table 5, supportless molding becomes easier. Also, in the case of a cross-sectional shape 21 having a curved surface (curve) like a sector, it is possible to create a curved tapered surface at a constant rate, which has the advantage of making it easier to attach and detach when inserting it into a pipe, for example.

[0070] In the examples of the molded parts W1 (formed object W) shown in Figures 8 to 12, the molded parts W1 (formed object W) form a rotationally symmetrical folio curve when viewed from the Z-axis direction, and each exhibits a spring-like or spiral shape. They are expandable and contractible in the X-axis, Y-axis, and Z-axis directions, possessing excellent cushioning and spring properties, and are suitable for use as containers and the like. For example, in the examples shown in Figures 8 to 12, even if the molded material is rigid, it is structurally expandable and contractible, and because it is a gradually expanding spiral shape, it can be used as a container that can be folded into a bucket shape by compressing it in the Z-axis direction for space-saving storage, or as a support for linear, columnar, or cylindrical objects such as filters or candle holders. For example, the manufacturing example shown in Figure 13 is molded using acrylic as the molded material, but elasticity and other properties can be imparted regardless of the material's physical properties. Therefore, unlike, for example, a metal spring, it can be given a unique elasticity and is resistant to rust. Furthermore, by selecting the coefficients of Xt and Yt in equation (1) to create an elliptical shape when viewed from the Z-axis direction, it can be used as a mesh member that is less likely to fall into the pipe when placed at the entrance of a pipe, etc. Moreover, by creating a larger size, it can be used as a frame for folding tents, etc.

[0071] Furthermore, in the examples shown in Figures 8 to 12, the spiral spring shape, such as a bowl or dome, gradually expands from one end, which has the advantage of being less likely to slip out in the expanding direction, especially when the cross-sectional shape is a polygon such as a simple triangle.

[0072] Furthermore, by changing the coefficient r and the range of the parameter t accordingly, it is possible to manufacture a more complex shape for the molded part W1 (molded object W).

[0073] The examples shown in Figures 14 and 15 are fabricated parts W1 (printed object W) that are fabricated based on a folio curve with a=e=k, r=2, d=g=1, and t=0~2π [rad] in equation (1), and the first design method is used to design the fabrication data with the line being a sine curve. In this example, there is no front or back side to the fabricated part W1 (printed object W). The examples shown in Figures 15(a) to 15(d) are fabricated parts W1 (printed object W) that are fabricated based on a folio curve with a=e=k, r=5 / 2, d=g=1, and t=0~4π [rad], and the second design method is used to design the fabrication data with the cross-sectional shape being circular.

[0074] Furthermore, the molding section W1 may be a mesh (unit shape, unit cell), and a molded object W may be formed by combining multiple molding sections W1. For example, the examples shown in Figures 16(a) to 16(d) are molded objects W in which a molding section W1a molded based on the h=0 folio curve of equation (1) in the example shown in Figure 14 and a molding section W1b molded based on the h=π / 2 folio curve are connected so that their loop shapes interfere with each other. For example, the molding data for each is designed with a circular cross-sectional shape in the second design method.

[0075] Similarly, the examples shown in Figures 17(a) to 17(d) are fabricated objects W that combine a fabrication section W1a fabricated based on the h=0 folio curve in equation (1) of the example shown in Figure 14, a fabrication section W1c fabricated based on the h=π / 4 folio curve, a fabrication section W1d fabricated based on the h=2π / 4 folio curve, and a fabrication section W1e fabricated based on the h=3π / 4 folio curve. For example, the fabrication data is designed using a sine curve as the line in the first design method.

[0076] In the examples shown in Figures 16 and 17, the modeling data may be designed, for example, by rotating or mirroring the mesh multiple times.

[0077] In this way, by connecting multiple molding units W1 to form a molded object W, it becomes possible to manufacture molded objects W with more complex shapes.

[0078] In the example of the molded part W1 (molded object W) shown in Figures 14 to 17, the curves are rotationally symmetrical when viewed from the Z-axis direction and each exhibits a hollow spherical shape. The outer surface of the porous material can be used, for example, as a filter, net, cushion, buffer material to distribute pressure that follows shape changes between the wearer's skin and the orthotic device (prosthesis, artificial joint, etc.), rainwater storage tank, plant growing medium, water treatment filter material, and especially as at least part of a filter bed for water purification treatment. For example, when used as a buffer between the wearer's skin and the orthotic device, rubber is too elastic and can cause strong irritation to the wearer. Therefore, materials that take time to recover their elasticity, such as thermoplastic elastomers or soft urethane foam, are preferable. However, thermoplastic elastomers are inferior in durability and strength. By selecting an appropriate molding material and molding it with a 3D printer 1, it becomes possible to provide orthotic devices that conform to the wearer's shape. Because the molded part W1 (formed object W) is porous, it can provide appropriate pressure distribution and solve problems such as stuffiness when wearing the orthosis. It is also easy to wash and dry, which can lead to a reduction in skin problems for the wearer, for example. Furthermore, by making the lines in the first design method curved, especially sine curves, or by making the cross-sectional shape in the second design method a shape other than a circle, the surface area of ​​the outer surface of the molded part W1 (formed object W) can be increased compared to when the cross-sectional shape is circular, allowing this outer surface to function more effectively as a microbial carrier or filter. In addition, since the molded part W1 (formed object W) has a spherical appearance and partitions a space inside, it can also function as a holder that holds, for example, a separate sponge-like (e.g., made of urethane) filter member or any other arbitrary member in the space.

[0079] Furthermore, because the molded part W1 (molded object W) has an internal space, it can contain more air and can be suitably used as a laundry ball that produces good foam. In addition, by intentionally causing stringing (air cut) between the molded parts W1 during molding, it is possible to obtain even better foam through stringing. Therefore, it is also suitable for applications such as dishwashers.

[0080] Furthermore, in the example of the molding section W1 (molded object W) shown in Figures 14 to 17, it is possible to inscribe it within a cube as a unit cell.

[0081] Furthermore, since the molded section W1 (formed object W) exhibits different shapes when viewed from each direction, it is possible to create a bias in the ease with which fluids such as air and water pass through. By selecting an arrangement pattern according to the shape of each molded section W1, the outer surface of the formed object W can be effectively used as a filter. In addition, by creating a bias in the connecting structure of the molded sections W1, the elasticity and rigidity of the formed object W can also be manipulated as desired.

[0082] For example, Figure 18 shows an example in which the molded object W is attached to a duct section 25 through which a fluid, preferably a liquid, such as a pipe, passes. The molded object W, which has an outer edge based on a folio curve, has a shape in which the outer circumference is symmetrically inscribed with a predetermined circle when viewed, for example, in the Z-axis direction. Therefore, when inserted into an opening 26 such as an inlet or outlet with a circular cross-section in the duct section 25 by slightly compressing it toward the center, it is easily and stably attached as it is pressed and held inside the opening 26 by its return deformation.

[0083] When attaching this molded object W to the duct section 25, adhesive may be used, but if the water flow is weak, for example, adhesive may not be necessary. In that case, the molded object W can be slid to any position by hand or with a jig to move the mounting position, and the absence of adhesive can save time and cost.

[0084] For example, by creating the molded object W using a material that is resistant to dirt (has stain-resistant properties), it can be placed in the piping of a plant factory, such as one that circulates water and reuses the nutrient solution, and used as a mesh or filter material to separate impurities in the cultivation tank. Furthermore, since the molded object W is made of resin, it can be reused repeatedly by washing it with water. In particular, since the molded object W of this embodiment is easy to mold into a symmetrical shape, it is possible to make it difficult to install it in the wrong direction. Also, by molding the molded object W to the dimensions of existing piping, it can be easily applied even in plant factories where the piping cannot be easily changed (water flow cannot be easily stopped), and if molded to the desired size, it can be easily installed horizontally to the piping. In addition, since the loop shape of the molded part W1 can be used as a hook or grip, installation and replacement are easy even when installed deep inside the piping, making it easy to use as a filter material that requires frequent replacement and maintenance. For example, in actual use, sound insulation material or shock absorbing material made of urethane or the like may be attached to the molded object W. Furthermore, it can be suitably used as furniture, soundproofing structures, waste adsorbents, and microbial carriers.

[0085] Furthermore, if the molded object W is attached to an air intake such as a range hood or exhaust fan, where gas flows instead of water, it can narrow the air passage, leading to improved suction power.

[0086] Furthermore, since these molded objects W are spherical, they can be suitably used as lampshades by, for example, placing a lamp (light source) inside. In other words, it is possible to configure lighting devices such as indirect lighting using the molded object W and a light source. For example, the molded object W may be suspended from a mounting surface such as a ceiling using a suspension material such as a rope, or it may be placed on any base (for example, the molded object W shown in Figure 19, which will be described later). In particular, as in the example shown in Figure 17, if the molded object W is shaped as a sine curve in the first design method, for example, it becomes possible to achieve a wide variety of light distribution designs by utilizing diffuse reflection and shadows from the molded part W1. In that case, by using a heat-resistant material as the molding material, it is possible to withstand the heat dissipation of the lamp, and by appropriately selecting the refractive index and transparency, or by including reflective materials such as glitter or glossy materials, it becomes possible to achieve light distribution with good design aesthetics. Furthermore, by adjusting the thickness of the nozzle 11 (shown in Figure 1) of the 3D printer 1 and the printing speed, for example, it is possible to intentionally induce stringing (air cut) during printing, thereby utilizing the stringing effect to create fantastical lighting effects through random shadows caused by the stringing. By generating stringing in a way that connects each vertex (by selecting arbitrary vertices), so to speak, in a string-wrapped mandala-like manner, the printed object W can function as a porous structure such as a microbial carrier or filter, or as a lampshade, which has a rotationally symmetrical shape, is aesthetically pleasing, and offers excellent variations.

[0087] In the examples shown in Figures 14 to 17, by actually adding k to Zt, it becomes possible to create the intersection points of the molded parts W1 so that they are located on the build table 5, thereby further improving the moldability.

[0088] Furthermore, if 3D printer 1 is a 6-axis printer, it can print not only in the XY plane but also along contours defined by the YZ plane. Because this movement is composed of curves using continuous functions, the absence of corners results in seamless movement and faster printing speed. This effect can be similarly achieved even when adding axes such as rotation and travel axes to the 6-axis 3D printer 1, resulting in 7-axis, 8-axis, or more multi-axis printing.

[0089] Furthermore, the example shown in Figures 19(a) and 19(b) is a molded object W (Figure 19(b)) produced by designing the molding data for a circular cross-sectional shape in the second design method, based on a folio curve R (Figure 19(a)) where Zt=k·cos(r·t) is set in equation (1) and a=e=-k, b=g, h=π / 2, r=3, d=g=1, t=0~π / 2 [rad], and then arranging and connecting multiple molded objects W1 at equal angles around the Z axis. In this example, the molded object W is formed rotationally symmetrically when viewed from the Z-axis direction and has a pedestal-like appearance, making it suitable for use as a vessel or the like.

[0090] Furthermore, the examples shown in Figures 20(a) to 20(d) are modeling data D based on a folio curve set in equation (1) as Zt=k·t, with a=e=k, b=g, r=3 / 2, d=g=1, and t=0~10π[rad], where, for example, the Zt of the two folio curves used in the first design method are made to match over the entire range of the parameter t to maintain a flat state. In the example shown in Figure 20, the line 15 used in the first design method is shaped like a sine curve, but line 15 may be any line such as a straight line.

[0091] Furthermore, in the examples shown in Figures 21(a) to 21(d) and Figures 22(a) to 22(d), the same folio curves are used as in the example shown in Figure 20. However, in the examples shown in Figures 21(a) to 21(d), the difference in Zt between the two folio curves used in the first design method increases as the parameter t increases, while in the examples shown in Figures 22(a) to 22(d), the difference in Zt between the two folio curves used in the first design method decreases as the parameter t increases. In these examples, the line 15 used in the first design method is, for example, a straight line.

[0092] In the example of the molding data D shown in Figures 20 to 22, the molded part W1 (molded object W) forms a rotationally symmetrical folio curve when viewed from the Z-axis direction, and each part exhibits a spring-like shape that can expand and contract in the Z-axis direction, thus enabling the creation of a molded part W1 (molded object W) with excellent spring properties and cushioning. Therefore, even if the molding material is rigid, the molded part W1 (molded object W) can be structurally expandable and deformable, and can possess flexibility, elastic deformation performance, and impact resistance.

[0093] Furthermore, each of the above examples can be suitably used as a microbial carrier or microbial cultivation device that can efficiently produce plankton and other food for aquatic life by, for example, placing the molded part W1 (molded object W) inside a pipe through which a liquid such as water passes or inside a container that stores a liquid such as water, and rotating it using an appropriate rotating device, thereby agitating the liquid and allowing microorganisms to attach and grow.

[0094] Furthermore, Figures 23(a) to 23(d) show a second design method based on the same folio curve as the example shown in Figure 20, but with a sector-shaped cross-section. In this example, the cross-sectional shape is sector-shaped, and by making the straight portion of the sector the side edge extending along the build table 5, supportless fabrication becomes easier.

[0095] Furthermore, based on the same folio curve as the example shown in Figure 20, the cross-sectional shape used in the second design method is set to a circular shape, and examples of multiple connected meshes (unit shapes, unit cells) are shown in Figures 24 and 25.

[0096] The example shown in Figures 24(a) to 24(d) is a mesh in which two build sections W1, W1 with a phase difference of 180° around the Z axis are connected at their endpoints to form a build section W1f (Figure 26), and eight of these are connected on the same circumference. In the illustrated example, a circular space is formed in the central part, but this space may be filled by a separate, arbitrary connecting structure connected to the build section W1f.

[0097] Furthermore, the examples shown in Figures 25(a) to 25(d) involve creating a mesh by connecting the endpoints of two mirror-symmetrical molding sections W1, W1 (Figure 27), and then connecting multiple such meshes, for example three each, in the X-axis and Y-axis directions.

[0098] In the examples of the fabricated objects W shown in Figures 24 and 25, the objects have high rigidity and exhibit different physical properties in each part.

[0099] Furthermore, in the example of the molded object W shown in Figures 26 and 27, it forms a rotationally symmetrical folio curve when viewed from the Z-axis direction, and exhibits a spring-like shape that can expand and contract in the Z-axis direction, resulting in a structurally expandable and deformable molded object W with excellent springiness and cushioning properties (shown in Figures 28(a) and 28(b)). It can also be used as a frame for wheels, handles, etc., and, due to its excellent aesthetics, can be used as a picture frame by utilizing the outer edge as a hanging part. Moreover, it is a porous material that can be used as filter media, nets, cushions, accessories, rainwater storage tanks, plant growing media, water treatment filter media, and especially as at least a part of a filter bed for water purification treatment. In addition, unlike general urethane cushions, it can maintain breathability even when compressed by the load of sitting, for example. Furthermore, because it is porous, it can be washed completely, and showers can be used from the back, reducing the burden on caregivers as it eliminates the need to turn over people or pets. The smaller surface area in contact with the skin allows for more areas to be washed, making it less prone to mold and easier to keep clean. Additionally, the non-slip surface makes it suitable for use as a washable cushion for elderly care or pets, or as a bath chair.

[0100] Furthermore, when the molded part W1 shown in Figures 26(a) and 26(b) is used as a standalone molded object W, for example, by suspending the central part of it to a hanging part, it can be suitably used as a holder for attaching the handle H of a hanging object such as an umbrella or walking stick from the outside or inside to the "petal" part, a holder for attaching a hanging object such as a bag via an S-hook or other hooking member, a clothes drying rack for hanging laundry via a hanger, or as a chandelier or indirect lighting fixture by using a light bulb as the hanging object. Moreover, when the molded part W1 shown in Figure 26 is used as a standalone molded object W, it expands and contracts in the Z-axis direction, so by shifting the "petal" part that attaches the hanging object in the circumferential direction, the hanging objects can be spaced apart, and the molded part W1 gradually expands in the Z-axis direction due to the weight of the hanging object, resulting in different hanging heights for the hanging objects. Therefore, for example, if the hanging items are laundry, the items are less likely to overlap, allowing them to dry faster. Also, the portion of the "petal" that remains parallel even when extended in the Z-axis direction (Z) can be used as a flat drying area for laundry. Furthermore, since the molded object W is expandable and contractible in the Z-axis direction, it can be stored in a retracted state when not in use. In that case, it is best to secure it with fastening materials such as ribbons or elastic bands. Because the "petal" portion functions as a hanging part, the molded object W can also be used as interior decor (wall ornament) by hanging it on a wall.

[0101] Furthermore, for the molded object W shown in Figures 24 and 25, which is formed by arranging multiple molded parts W1, the physical properties differ depending on the arrangement. Therefore, by utilizing rotational symmetry during the design phase and designing only the desired parts as molded data D, excluding unnecessary parts, it is possible to manufacture a molded object W with the desired physical properties (strength). For example, in the case of the molded object W shown in Figure 24, the central part has a dense shape and high rigidity, while the outer edge has a sparse shape and high elasticity, and is composed of curves. As shown in Figure 29, if only the central part is molded, it has high strength, and because it is circular, it is strong against lateral forces. In addition, the rotationally symmetrical shape distributes the load, resulting in a lightweight molded object W that is also strong in the thickness direction. Moreover, it is suitable for use as a filter or carrier for food waste processing, for example, as the pointed parts can crush food waste. Furthermore, in the case of the molded object W shown in Figure 29, since the curved tip of the "petal" portion extends in the counterclockwise direction as shown in Figure 29(a), it exhibits particular strength when rotated in the counterclockwise direction, making it suitable for use as a rotating member used in a fixed direction, such as a handle or roller for a coffee grinder or sewing machine. As a roller, for example, it could be a leveling roller, or a cookie roller that creates a flower-like or wavy pattern on the dough using the cross-sectional portions C1 and C2. When used as a roller, it is suitable because it becomes inscribed in a circle by adjusting the coefficients a and e of Xt and Yt in equation (1). In addition, as another application, for example, by molding with a phosphorescent molding material, it can be suitable for use as annular objects such as Christmas wreaths that can glow even in dark environments, or it can be used as a security measure by installing it in the entrance or living room. Furthermore, as shown in Figure 30, if only the outer edge is molded, a lightweight and highly elastic molded object W can be obtained. Furthermore, the molded object W can be not only molded into a circular shape, but also, for example, if it is hollowed out into a Reuleaux polygon shape, it can be rotated by a motor or the like to be used as a cleaning tool that can remove dust from the corners of a room, or as a dishwasher brush that can remove dirt from every corner of dishes. It can also be suitably used, for example, to collect dead microorganisms and algae attached to hydroponic nutrient solution tanks.

[0102] In the case of the example of the molded object W shown in Figure 30, any structure or component can be inserted into the central opening. For example, by connecting or integrally molding a shaft member into the opening, it can be used as a hand mixer for stirring liquids such as milk or protein. By using a food-grade 3D printer 1 and using a hard sweet material such as chocolate or sugar (tortoiseshell candy) as the molding material to create the molded object W, it is possible to add sweetness to the liquid while simultaneously stirring. Furthermore, if the cross-sectional shape is frame-shaped and the object is molded into a hollow shape, it can be used as a straw, and if the cross-sectional shape is planar and the object is made into a solid, edible dish. In addition, if a molded part defined by, for example, a torus knot or a Lissajous curve is inserted into the opening, the molded object W can be molded in a single continuous line. Furthermore, the diameter of the opening is arbitrary. By setting a large opening and utilizing only the curved linear molded part W1 on the outer edge, and inserting a general plate-shaped molded part inside the opening, the stress acting on the outer edge of this plate-shaped molded part is relieved, thus preventing warping during molding. After molding, the molded part W1 on the outer edge can be broken off and removed, resulting in a molded object W with suppressed warping and good molding accuracy. In the case of large molded objects, general support shapes, especially grid shapes, tend to break easily when removed and are often sharp. However, as in this embodiment, by integrally molding the support with the molded object W using a curved structure without corners that utilizes a continuous function, not only is the molding speed faster, but safety during operation and the burden on the operator are also reduced. Moreover, if the 3D printer 1 is pellet-type, the removed support can be reused by crushing it again, which also contributes to environmental considerations. Furthermore, the molded objects W shown in Figures 29 and 30 have a cute appearance and are aesthetically pleasing.

[0103] Furthermore, the examples shown in Figures 31 to 33 are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve with a=e>k, b=f, d=3 / 4, r=1, and t=0~8π [rad], with consideration given to the ease of fabrication by 3D printer 1. The examples shown in Figures 31(a) to 31(d) and Figures 32(a) to 32(d) each have a rectangular cross-sectional shape, and the fabrication data can be designed using either the first design method or the second design method. In addition, the examples shown in Figures 33(a) to 33(d) are fabrication data designed with a circular cross-sectional shape using the second design method.

[0104] Examples of these molded parts W1 (molded object W) exhibit a complex shape that forms a rotationally symmetrical folio curve when viewed from the Z-axis direction, and has an outer edge 27 that gradually expands from the Z-axis position toward the -Z-axis direction and is folded back toward the +Z-axis direction. This not only has a good aesthetic appearance but is also porous and can be used as filter media, nets, cushions, buffers to distribute pressure that follows shape changes between the wearer's skin and orthotics (prostheses, artificial joints, etc.), rainwater storage tanks, plant growing media, water treatment filter media, and especially as at least part of a filter bed for water purification treatment. As shown in Figure 34, when fabricating with the 3D printer 1, supportless fabrication is easily achieved by adjusting Xt, Yt, and Zt in equation (1) so that the lower end of the outer edge 27 is positioned on the build table 5 to support the molded object W. Furthermore, load-bearing capacity and impact resistance can be added by adjusting the cross-sectional shape of the fabrication data to increase its thickness. Furthermore, since the molding section W1 (molded object W) has a shape in which its outer circumference is symmetrically inscribed with a predetermined circle when viewed from the Z-axis direction, for example, as shown in Figure 35(a), when inserted into the inner surface of a cylindrical placement section 28 that forms a conduit through which a fluid, especially a liquid, passes, by slightly compressing it toward the center, it deforms back and is pressed against the inner surface for secure attachment, thus allowing for easy and stable installation. Moreover, because the molding section W1 (molded object W) has a symmetrical shape, it is less likely for the operator to make a mistake in the installation direction. Furthermore, since each molding section W1 is formed linearly, it is easy to remove by holding the molding section W1. Also, as shown in Figure 35(b), if the molding section W1 (molded object W) is larger than the placement section 28, it is possible to invert the molded object W and hook the outer edge 27 onto the placement section 28 to hold it in place.

[0105] Furthermore, the examples shown in Figures 36(a) to 36(e) are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve set in equation (1) as Zt=k·cos(h+r·t), with a=e=k, b=f, r=1 / 2, d=g=1, and t=0~4π[rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0106] Furthermore, the examples shown in Figures 37(a) to 37(e) are fabrication units W1 (fabricated object W) that are fabricated based on a folio curve set in equation (1) as Zt=k·sin(h+d·t), with a=e=k, b=f, r=1 / 2, d=g=1, and t=0~4π[rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0107] Furthermore, the examples shown in Figures 38(a) to 38(d) are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve set in equation (1) as Zt=k·sin(h+r·t), with a=e=k, b=f, r=5 / 2, d=g=1, and t=0~4π[rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0108] The examples of the molded parts W1 (formed object W) shown in Figures 36 to 38 form a rotationally symmetrical folio curve when viewed from the Z-axis direction, and exhibit different shapes when viewed from each direction, allowing for bias in the ease with which fluids such as air and water can pass through. For example, the molded parts W1 (formed object W) can be effectively used as a filter. Furthermore, in the case of the molded parts W1 (formed object W) shown in Figure 38, since there are no corners in the path, it can be used as a support stand for luggage or the like with an excellent design, on which luggage can be placed, and the upper half or lower half can be used as a conical filter.

[0109] Furthermore, compared to a structure in which linear lattice structures are regularly connected, when multiple molded parts W1 are connected by intersecting loop shapes, the connection positions can be set arbitrarily. By appropriately selecting the molding material, it is possible to provide connecting parts with various properties, thereby setting the performance of the molded object W. For example, by adding thickness to the connecting parts at arbitrary locations, it is possible to provide a molded object W with excellent impact resistance.

[0110] Furthermore, the examples shown in Figures 39(a) to 39(e) are examples of a fabricated section W1 (fabricated object W) that is fabricated based on a folio curve set in equation (1) where Zt=kt, a=e, b=f, r=3 / 2, d=g=1, and t=0~π[rad], and the cross-sectional shape 21 is rugby ball-shaped, formed at the intersection of two circles CI1 and CI2. The two circles CI1 and CI2 may have the same diameter or different diameters. Also, the closer the distance between the centers of circles CI1 and CI2, the more rounded the cross-sectional shape 21 becomes, and the further apart the distance between the centers, the sharper the cross-sectional shape 21 becomes. In other words, the cross-sectional shape 21 can be easily controlled by arbitrarily setting the diameters of the intersecting circles CI1 and CI2 and the distance between their centers. This fabricated section W1 (fabricated object W) constitutes at least a part of a porous structure, similar to the examples above. Furthermore, the arc-shaped portion 21b of the cross-sectional shape 21 forms a smooth curved surface in the fabricated section W1 (fabricated object W), and functions as a tapered portion (guide portion) when inserted into a pipe, for example, when used as a filter (filter material). In addition, by making the cross-sectional shape 21 more rounded, it becomes possible to adjust the angle so that the contact area with respect to the displacement between the upper and lower layers of the fabricated material due to the inclination of the arc-shaped portion 21b of the cross-sectional shape 21 increases when stacking, thereby suppressing (mitigating) the rise angle from the build table 5 and facilitating supportless fabrication.

[0111] The linearly formed molding section W1 may form a connecting section that links multiple structural sections 29, 29, as shown in the example in Figure 40. The structural sections 29 may have any shape, and the structural sections 29 do not need to have the same shape as each other, but preferably, they should be shaped so that they can be formed in a single continuous line by the nozzle 11 of the 3D printer 1, so that the entire structure, including the molding section W1, can be continuously fabricated by the 3D printer 1. Furthermore, since the molding section W1 that forms the connecting section is a linear body, for example, the structural sections 29, 29 can be connected by the molding section W1 and stored in a space-saving and stable manner, and when needed, the molding section W1 can be broken to separate and use the structural sections 29, 29. Depending on the size of the 3D printer 1, the buildable section W1 can be used for a wide range of applications, from small portable or emergency tableware that can be made by separating the buildable section W1 by breaking it, for example, by making one structural section 29 spoon-shaped and the other structural section 29 fork-shaped, to large structural sections 29 such as traffic cones and poles. For example, if the structural section 29 is a traffic cone or pole, it is possible to design and build a hole with a diameter that allows the structural section 29 to be inserted in advance, and then use the broken part as a connecting part to connect the structural sections 29 side by side. Furthermore, the structural section 29 can be made to be lightweight while being able to be built integrally with the buildable section W1 by using a continuous curve that can be expressed parametrically, such as a Lissajous curve, trochoid, or logarithmic spiral. In this way, by preferably making all or part of the structural section 29 and the buildable section W1 into shapes that can be expressed as continuous functions, not only can the size and shape be arbitrarily designed by simply changing coefficients, but the build speed is also fast because the nozzle 11 moves seamlessly. Furthermore, a spiral-shaped molded object W (molding part W1) having a petal shape as shown in Figures 7 and 20 to 23 may be used to connect structural parts 29 such as traffic cones and poles in a chain-like manner. In this case, the petal shapes of the molded objects W (molding part W1) will easily interlock with each other, preventing the connecting parts from coming apart.

[0112] Furthermore, the molding section W1 is not limited to having a three-dimensional structure in the Z-axis direction; for example, Figures 41 and 42 show examples of planar molding sections W1 (molded object W).

[0113] The examples shown in Figures 41(a) to 41(c) are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve set by equation (1) where Zt=k, a=e, r=8, d=g=1, and t=0~2π [rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0114] Furthermore, the examples shown in Figures 42(a) to 42(c) are fabrication parts W1 (fabricated object W) that are fabricated based on a folio curve set in equation (1) where Zt=k, a=e, r=2, d=3, g=1, and t=0~2π [rad], and the fabrication data was designed with a circular cross-sectional shape in the second design method.

[0115] In these examples, supportless fabrication is easily achieved by appropriately setting Zt according to the thickness, etc. Furthermore, since the fabrication section W1 (fabricated object W) has a shape in which the outer circumference is inscribed symmetrically with respect to a predetermined circle when viewed from the Z-axis direction, it can be easily and stably attached by pressing it into a cylindrical placement section that forms a conduit through which a fluid, especially a liquid, passes. The outer edge is pressed and held along the inner surface, and the central part is curved toward the back of the placement section. It can be used as a filter or net, or as a conduit cover if the diameter is the same as or greater than that of the conduit, thus achieving the same effects as in the examples shown in Figure 31, etc. In particular, in the example shown in Figure 41, fabrication can be achieved in a short time by preferably using a thick nozzle 11 that is close to the thickness of the desired fabricated object W. Also, in the example shown in Figure 42, the larger number of "petal" parts allows it to be fitted to the inner circumference of placement sections of various diameters. In addition, by selecting the fabrication material, cross-sectional thickness, etc., and fabricating in large dimensions, these examples can be suitably used as cushions, etc.

[0116] Next, the third design method will be explained with reference to the drawings.

[0117] As shown in Figure 43, the molding data D is formed by joining these cross-sectional shapes 21 along a line 22 defined by a folio curve that connects the centers of cross-sectional shapes 21 set at different positions, for example, on different planes P1 and P2. In the illustrated example, the cross-sectional shapes 21 are the same, but they may be different. Also, although an example is given where planes P1 and P2 are orthogonal to each other, their angles are not specified. Furthermore, the cross-sectional shapes 21 are not limited to planar shapes, but may also be curved, and at least one of the cross-sectional shapes 21 may be a point. Moreover, the cross-sectional shapes 21 are not limited to the two that constitute the molding section W1 (molded object W), but may also be formed by sequentially connecting cross-sectional shapes 21 at multiple intermediate positions.

[0118] Figures 44(a) to 44(d) show examples of a molded part W1 (molded object W) manufactured based on molding data designed by the third design method. In this example, based on the folio curve set in equation (1) where Zt=kt, a=e, b=f, r=3 / 2, d=g=1, and t=0~π[rad], each cross-sectional shape is made into a Reuleaux triangle, and the cross-sectional shapes that lie on mutually orthogonal planes are molded to connect each other. As a result, the shape has side edges that extend along the molding table 5. In this example shown in Figure 44, supportless molding becomes easier.

[0119] Furthermore, the fourth design method will be explained with reference to the drawings.

[0120] In the fourth design method, multiple surfaces are formed using folio curves, and the modeling data is designed by filling in the regions enclosed by these surfaces.

[0121] For example, in the example shown in Figure 45, a surface is formed using a folio curve and lines that intersect the folio curve. As shown in Figure 45(a), a closed arbitrary folio curve R is set, and the folio curve R is divided into multiple ranges of t, for example, in half, and a surface is formed enclosed by the folio curve R and the straight lines 30 connecting the endpoints of these ranges. The example shown in Figure 45(a) is a folio curve R set in equation (1) as Zt=k·cos(h+r·t), with a=e=k, b=f, r=2, d=g=1, and t=0~π[rad]. The folio curve R is divided into two ranges: a first range Ra consisting of t from 0 to 0.5π[rad] and a second range Rb consisting of t from 0.5π to π[rad]. A straight line 30 is set connecting the endpoints of these ranges. A surface 31 (Figure 45(b)) consisting of the straight line 30 and the first range Ra, a surface 32 (Figure 45(c)) consisting of the straight line 30 and the second range Rb, and a surface 33 (Figure 45(d)) consisting of the first range Ra and the second range Rb are combined to fill the region closed by these surfaces 31~33 and design a solid shape data D1 (Figure 45(e)). Then, the molding data D1 is repeatedly designed within the range of the necessary parameter t, or, if the molding part W1 (molded object W) to be manufactured has a symmetrical shape, the molding data D1 is used as the base shape and is rotated or mirrored multiple times, and a Boolean sum is taken to form the molding data D of the solid-shaped molding part W1 (molded object W) having a folio curve R as its outer edge shape. In this embodiment, for example, the molding data D shown in Figure 45(f) is designed by mirroring the molding data D1 with respect to the YZ plane and taking a Boolean sum.

[0122] Figures 46(a) to 46(d) show examples of the molded part W1 (molded object W) fabricated based on this molding data D. This example of the molded part W1 (molded object W) has a block shape with a spherical envelope whose outer edge is a rotationally symmetrical folio curve when viewed from the Z-axis direction, and which has four protruding arms 35 projecting in the radial direction. For example, by using a hard molding material, it is suitable for applications such as toys and laundry balls. In particular, when used as a laundry ball, it can be reused by molding it with a resin containing fine powder of stain-resistant or pyroelectric substances. Also, because of its symmetrical shape, it promotes water flow, making it easier to remove dirt from laundry. In addition, when molded with a soft material, it can be used for balls, pet toys, etc.

[0123] Furthermore, Figures 47 to 51 show examples of the molded part W1 (molded object W) manufactured based on the molding data designed by the fourth design method.

[0124] The examples shown in Figures 47(a) to 47(e) are similar to the folio curves that constitute the molded part W1 (molded object W) shown in Figure 45. In equation (1), Zt = k·cos(h+r·t)·cos3t is set, and the molded part W1 (molded object W) is molded based on a folio curve with a=e>k, b=f, d=3 / 4, r=1, and t=0~8π [rad]. The molded part W1 (molded object W) is molded based on solid molding data D designed using the same method as the example shown in Figure 45. The outer edge shape of this molded part W1 (molded object W) forms a folio curve that is rotationally symmetric when viewed from the Z-axis direction, and exhibits a skirt-like or hat-like shape that gradually expands in the Z-axis direction. In addition, since many rib portions 36 extending in the Z-axis direction are formed on the back side of the molded part W1 (molded object W), it has great strength against external forces in the Z-axis direction in particular.

[0125] Furthermore, Figures 48(a) to 48(d) show examples of a molded object W in which the molding section W1 shown in Figure 47 is made into a mesh and multiple sections are connected. This molded object W is formed by stacking multiple molding sections W1, for example, three, in the Z-axis direction. This molded object W is suitably used, for example, as a lampshade. In this case, by using a material with heat resistance, for example, it can withstand the heat dissipation of the lamp, and by appropriately selecting the refractive index and transparency, or by including reflective materials such as glitter or glossy materials, it is possible to achieve light distribution with good design. In addition, in the molded object W shown in Figure 48, it is also possible to further improve the aesthetics and design by rotating the molding section W1 around the Z-axis by a predetermined angle and connecting them.

[0126] Furthermore, the examples shown in Figures 49(a) to 49(d) are examples of a molded part W1 (molded object W) in which a part of the molded part W1 shown in Figure 47 has been deleted. In the example shown in Figure 49, a part of the molding data of the molded part W1 shown in Figure 47 may be deleted, or the molding data formed with the parameter t range set to, for example, π / 12 to 11π / 12 [rad] may be rotated and duplicated around the Z axis to form the molded part W1 (molded object W). The outer edge shape forms a rotationally symmetrical folio curve when viewed from the Z axis direction, and exhibits a skirt-like or hat-like shape that gradually expands in the Z axis direction, and a through hole 37 in the Z axis direction is formed in the center.

[0127] Furthermore, Figures 50(a) to 50(e) show examples of a molded object W formed by connecting multiple mesh molded parts W1 shown in Figure 49. This molded object W is formed by connecting multiple molded parts W1 shown in Figure 49 in the X-axis and Y-axis directions, for example, three at equal intervals. This molded object W can be used individually, for example as shown in Figure 51(a), and is suitable for use as a base-shaped support for supporting objects 38 such as eggs, spheres, cylindrical objects, rolls of fabric, rolled paper, bobbins, and threads, which are inserted or fitted into regularly arranged through holes 37, or as a plant cultivation support for supporting plant seedlings and bulbs. Since the molded part W1 (molded object W) fabricated using the 3D printer 1 has rigidity, it can also be used as a plant cultivation medium (cultivation mat) that can be reused after harvesting cultivated plants by removing entangled roots etc. with a high-pressure washer. Therefore, unlike conventional cultivation media such as urethane mats and agar, it can be used as a reusable, environmentally friendly plant cultivation medium. In particular, when the 3D printer 1 is pellet-type, by mixing materials such as colorants like carbon black, UV absorbers, light-scattering materials like zinc oxide, and other materials that can block light into the raw material for molding, or by coating the surface with these materials, it is possible to inhibit photosynthesis by algae, cyanobacteria, and photosynthetic bacteria, thereby exhibiting an anti-algal effect, preventing water pollution, stabilizing water quality, and, depending on the molding material, supplying trace essential elements, thus promoting plant growth. Furthermore, since the supported objects 38 can be spaced apart, it is suitable for storing objects 38 made of heat-sensitive materials, for example. It can also be suitably used when supporting plant seedlings or bulbs, as spacing them apart prevents adjacent plants from competing for nutrients. Furthermore, for example, by harvesting plants, crushing the molded material W along with the remaining roots and stems, scattering it on the soil, and covering it with water or a gel such as an agar medium containing fertilizer or microorganisms, the decaying roots and stems become fertilizer, and the molded material W prevents water evaporation, promoting the activity of decomposing organisms such as bacteria, fungi, and soil organisms, thereby regenerating the soil. In particular, by using biodegradable plastics such as PLA as the molding material to create the molded material W while maintaining the necessary strength, the environmental impact in such applications can be further reduced.

[0128] Furthermore, as shown in Figure 51(b), for example, the object to be supported 38 may be supported by sandwiching it from above and below at the through-holes 37 of the pair of molded parts W, or multiple molded parts W may be stacked in the Z-axis direction to hold the object to be supported 38.

[0129] Furthermore, since the molded object W formed from resin can be reused as a support, it is more economical and has a smaller environmental impact compared to disposable supports made from paper or other materials.

[0130] Furthermore, the modeling data designed by the fourth design method is not limited to curved surfaces, but may also be planar. For example, in the example shown in Figure 52(a), a planar surface 40 shown in Figure 52(b) is formed using the contour of a folio curve R set in equation (1) with Zt=k, a=e, b=f, d=3, r=2, and t=0~2π[rad], and then the solid modeling data D shown in Figure 52(c) is designed by adding thickness to the surface 40. Note that, considering symmetry, for example, the modeling data D may be designed by forming a surface only in the range of t=0~0.5π[rad] in the folio curve of equation (1), adding thickness to that surface, and then mirror-copying it to the XZ plane and YZ plane and taking a Boolean sum. The examples shown in Figures 53(a) and 53(b) are modeling parts W1 (modeling object W) that have been fabricated based on the modeling data D shown in Figure 52. This example of a molded part W1 (molded object W) has a thin plate shape in which the outer edge shape forms a rotationally symmetrical bilate curve when viewed from the Z-axis direction, and has four bulges 41 that project radially in an arc shape. For example, by molding it on a large scale using a soft molding material, it can be used for the body of an umbrella or garden parasol with a good petal-like appearance and design, or, because it can be folded, it can be used for tents in times of disaster.

[0131] Furthermore, based on the molding data D of the example shown in Figure 52(c), it is also possible to fabricate a molded part with arbitrary holes. For example, the examples shown in Figures 54(a) and 54(b) show that holes 42 are formed by cutting out a polygon, for example, a rhombus (diamond shape), from the surface of the molding data. For example, by making the shape of the holes 42 a rhombus with its major axis in the radial direction of the molded object W as viewed from the Z-axis direction, the holes 42 can be fabricated without using support material, and the shape retention is best. The arrangement of the holes 42 can be arbitrary, but in this embodiment they are equally or substantially equally distributed in the circumferential direction on multiple concentric circles. This example of a molded part W1 (molded object W) is suitable for applications such as filters by fabricating it thinly using a soft molding material. As shown in Figure 55, when the molded object W is folded symmetrically and compactly and inserted into the placement section 28, it deforms back and the outer edge of the bulging portion 41 is pressed against the inner surface of the placement section 28, allowing for stable attachment, and it can be suitably attached to a conical-shaped placement section 28. For example, by making the placement section 28 a coffee dripper, the molded object W can be used as a coffee filter. In this case, a tacky resin or adhesive can be applied in advance to at least one of the parts of the molded object W and the placement section 28 that come into contact with each other, making attachment more stable. Furthermore, by forming the molded object W with a molded material that has stain resistance, for example, it can be washed with water and reused repeatedly. In addition, by appropriately adjusting each coefficient of equation (1), the above-mentioned molded object W can be suitably used as an umbrella valve, a foldable funnel, a drying stand that also serves as a funnel, a vase, a menstrual cup, a portable urine collector, etc.

[0132] Furthermore, the examples shown in Figures 56(a) and 56(b) show that the holes 42 were formed using the folio curve R (shown in Figure 52(a)) which formed the molding data D (shown in Figure 52(c)). These holes 42 were formed based on a sketch obtained by offsetting the folio curve R (shown in Figure 52(a)).

[0133] Furthermore, by changing the offset contour of the sketch, it is possible to form the shape as shown in the examples in Figures 57(a) to 57(c). In other words, the shape and size of the hole 42 can be changed according to the offset contour.

[0134] Examples of these molded parts W1 (molded objects W) include, for example, those suitable for use as filter media by being molded thinly using a soft molding material, and also suitable for use as at least a part of furniture or cushions with good design by appropriately selecting the molding material. Furthermore, by molding with a molding material with a low specific gravity, it is possible to use it as furniture or a cushion under normal circumstances, and as a life-saving rifling (float) in times of disaster. Compared to general life-saving floats that are filled with air when needed, this molded object W can be used immediately and does not pose a risk of bursting due to contact with floating debris, for example, making it particularly suitable for use in times of disaster.

[0135] Furthermore, the bulging portion 41 surrounding the hole 42 can be designed arbitrarily, such as a honeycomb shape or a grid shape, by setting the infill rate to any pattern in general slicer software, and the coarseness of these shapes can also be set.

[0136] Furthermore, the holes 42 do not need to be the same shape, nor do they need to be arranged regularly. For example, by adjusting the diameter of the nozzle 11 (shown in Figure 1) of the 3D printer 1 and the printing speed, it is possible to intentionally induce stringing (air cut) during printing, thereby easily forming randomly shaped holes 42 in a random arrangement between the stringed sections. For example, the example shown in Figure 58 shows a printed section W1 (printed object W) shown in Figure 30, in which holes 42 were formed by printing while causing stringing.

[0137] Furthermore, the molded object W (molding section W1) can also be applied to the foam generating means (foam generating device) 44 shown in Figures 59(a) and 59(b). The foam generating means 44 generates foam, particularly fine bubbles (microbubbles, nanobubbles), in a liquid. The foam generating means 44 comprises a main body 49 having an upstream portion 46, a downstream portion 47, and a connecting portion 48 that connects them. The upstream portion 46, the downstream portion 47, and the connecting portion 48 are each formed in a cylindrical shape and are integrally formed coaxially. In the direction through which the fluid passes, they are arranged in the order of upstream portion 46, connecting portion 48, and downstream portion 47 from one end to the other. The upstream portion 46 has the largest inner diameter, the downstream portion 47 has an inner diameter smaller than or equal to that of the upstream portion 46, and the connecting portion 48 has an inner diameter considerably smaller than that of the upstream portion 46 and the downstream portion 47. While it is preferable for the downstream portion 47 to have a smaller inner diameter, it may be the same diameter as the upstream portion 46. Regarding the inner diameter, a reduced-diameter portion 50 is formed, gradually decreasing from the upstream portion 46 to the connecting portion 48, and an expanded-diameter portion 51 is formed, gradually increasing from the connecting portion 48 to the downstream portion 47. In the main body portion 49, the pressure difference resulting from these changes in inner diameter allows for the generation of foam using the Venturi effect. The molded object W (molded portion W1) is integrally molded with the main body portion 49, or attached to the main body portion 49, within at least one of the upstream portion 46 and the downstream portion 47. For example, the upstream portion 46 preferably uses the examples of the molded object W shown in Figures 46, 37, and 38, and the downstream portion 47 preferably uses the examples of the molded object W shown in Figures 8 to 10 and 20 to 22. In this example, in addition to the Venturi effect caused by the change in the inner diameter of the main body portion 49, turbulence is generated by the molded object W (molded portion W1), making it possible to generate fine bubbles. Furthermore, a porous mesh member (filter) may be attached to the downstream end of the downstream portion 47 or inside the connecting portion 48 to further reduce the size of the bubbles. This mesh member is formed, for example, by stacking three or more layers of mesh-like members having fine pores. By attaching this mesh member, it is possible to increase or decrease the bubble diameter depending on the mesh size.The mesh member is preferably removable from the main body 49, or has a gripping portion that can be rotated and adjusted, and is preferably changeable as appropriate depending on the application of the foam generating means 44. The mesh shape may be a general lattice structure, one that can increase the surface area such as a gyroid, one that uses torus knots, Lissajous curves, or trochoids, or of course, one that uses a follicular curve.

[0138] The foam generated by the foam generating means 44 described above is shown in Figure 60(a). Compared to the comparative example shown in Figure 60(b) (foam generated by a general aeration device), it can be seen that the foam generated by this embodiment shown in Figure 60(a) is more uniform and finer.

[0139] This foam generating means 44 can be widely used for supplying air to the downstream side. For example, in aeration tanks in wastewater treatment (water treatment), it can increase the dissolved oxygen necessary for microorganisms to purify wastewater, and can also be used to agitate sludge in the tank, enabling a uniform supply of oxygen to the water. In addition, it can perform roles such as adsorption of organic matter such as oil and sterilization, and in hydroponics, it can increase dissolved oxygen, supply oxygen to plant roots, prevent root rot, and can also be used to cultivate microorganisms such as plankton that serve as food for aquatic organisms such as shrimp and shellfish. Therefore, it can be suitably used in aquatic farming and hydroponics systems that integrate hydroponics and aquariums.

[0140] Furthermore, the foam generating means 44 can also be applied to washing machines. By generating foam in the detergent water supplied to the washing machine using the foam generating means 44, the cleaning power can be improved. Additionally, by generating foam in the rinse water using the foam generating means 44, it becomes possible to remove organic matter and mineral components through coagulation and sedimentation.

[0141] Furthermore, the foam generating means 44 can also be attached to and applied to showers and water taps. In this case, in addition to the cleaning effect of the foam, splashing of water when it hits the skin or water receiving area (plate pan) can also be suppressed.

[0142] Furthermore, when connecting the molding units W1, in addition to connecting them in a way that causes them to interfere with each other, if at least a portion of the molding units W1 form a closed loop shape, a method may be used to connect them in a chain-like manner so that the closed loop shapes do not intersect.

[0143] Furthermore, the multiple molded parts W1 that connect to form the molded object W may each have the same shape, be mirror-symmetrical, or be of different sizes (at least one of the coefficients a, e, and k in equation (1) is different).

[0144] According to the embodiments described above, having a molding section W1 (molded object W) with a curved structure whose shape is defined based on a regular curve allows for free molding of the molding section W1 and a free connection structure, thereby further improving the degree of freedom in molding. Furthermore, because of its curved structure, it is easier to grip than a linear structure and has no sharp corners, making it safer.

[0145] By utilizing equation (1), which is a continuous function, and appropriately selecting its coefficients and parameters, it becomes possible to manufacture the molding section W1, i.e., the molded object W, which exhibits a complex shape that differs greatly depending on the viewing angle, in any arbitrary shape. Furthermore, as explained above, the variations in the molding of the molding section W1, i.e., the molded object W, can be easily increased.

[0146] In particular, since the folio curve is a rotationally symmetric shape that is uniformly inscribed in a circle, the molded part W1 (formed object W), which has an external shape defined based on the folio curve, can be easily installed by fitting its outer part into a pipe or opening with a circular internal shape. Furthermore, because of its rotationally symmetric shape, the molded part W1 (formed object W) can also be suitably used as a flow straightening plate. For example, by installing the molded part W1 (formed object W) in the middle of the flow path of the working fluid, it is possible to allow flow with low flow resistance in the forward direction (forward flow) but block reverse flow (backflow) (flow straightening operation), making it suitable for stirring and other applications. It can prevent stagnation and uneven flow within the liquid column when liquid is passed through, and when used in a filtration device, for example, it can improve the purification efficiency, so a filtration device equipped with a flow straightening plate can be widely used for liquid purification applications such as water treatment and medical applications. In addition, the molding section W1 (molded object W) can also be used as a fluid rectifier for air, such as for ventilation fans, airplane propellers, fan blades, ceiling fans and air circulators that circulate air.

[0147] Furthermore, by selecting Xt, Yt, and Zt in equation (1), the above-mentioned molding unit W1 (molded object W) can be made to have a shape that does not require support material, such as overhangs or bridges extending horizontally to the build table surface, and can be manufactured without supports using the 3D printer 1. In addition, when multiple molding units W1 are connected to form the molded object W, more complex shapes can be manufactured without supports.

[0148] Furthermore, the fused deposition modeling (FDM) 3D printers used to manufacture the various types of molded objects (models) mentioned above can also be large pellet-type 3D printers with a nozzle diameter of 10 mm or more. These large 3D printers can use inexpensive, readily available, general-purpose pellet-shaped thermoplastic resins (such as recycled pellets) as the molding material, rather than specialized filament resins.

[0149] Furthermore, the manufacturing equipment for the molded object is not limited to fused deposition modeling (FDM) 3D printers; for example, stereolithography (DLP or SLA) 3D printers are also acceptable, as are 3D printers that use metal as the material, such as SLM or DED.

[0150] Furthermore, the 3D printing apparatus is not limited to a configuration in which the build head (extrusion means) having a nozzle for extruding the build material is movable in the X-axis and Z-axis directions and the build table is movable in the Y-axis direction. It is sufficient if the build head is movable in at least three dimensions relative to the build table. For example, the build head may be movable in the X-axis and Y-axis directions and the build table may be movable in the Z-axis direction, or the build head may be provided at the tip of a robot arm (preferably a robot arm of a 6-axis robot) and be movable in any direction including the three directions of the X-axis, Y-axis, and Z-axis. In particular, 3D printing apparatuses with a rotatable build table are also preferred. Supportless printing is possible in 3-axis and 6-axis 3D printers, which leads to a reduction in printing time (improvement in the printing speed of the printed object W) because supports are not printed. For example, if the 3D printing device is a 6-axis 3D printer, the printing speed of the object W can be improved because, if the nozzle 11 does not interfere with the printing section W1 (object W), it is possible to trace a continuous folio curve in a single stroke. In particular, in the case of 8-axis and 9-axis 3D printers, the effect of improving the printing speed by tracing a continuous folio curve, which has no corners and moves seamlessly and periodically, is significant. [Explanation of Symbols]

[0151] 1. A 3D printer using the fused deposition modeling (FDM) method, which is a device for manufacturing shaped objects. 5. Build Table 15 lines 16 Surfaces 21 Cross-sectional shape 22 Side edge 29 Structural section CI1, CI2 yen D Modeling data R positive leaf curve W Sculpture W1 Modeling Department

Claims

1. A molded object produced by a molded object manufacturing device, It has a molded part with a shape defined based on a regular curve. A sculptural object characterized by the following features.

2. The molded part has a loop shape defined based on a regular curve. The molded object according to feature 1.

3. The molded part is a solid with an outer edge shape defined based on a regular curve. The molded object according to feature 1.

4. It is composed of multiple interconnected molding sections. The molded object according to feature 1.

5. Multiple molded parts are either identical in shape or mirror-image symmetrical to each other. The molded object according to feature 4.

6. The multiple molded parts have different sizes and shapes from each other. The molded object according to feature 4.

7. The cross-sectional shape of the molding section has side edges that extend along the molding table of the molding machine. The molded object according to feature 1.

8. The cross-sectional shape of the molded part is a Reuleaux polygon. The molded object according to feature 1.

9. The cross-sectional shape of the molded part is the intersection of two circles. The molded object according to feature 1.

10. Constituting at least part of a porous structure The molded object according to feature 2.

11. Forming at least part of the mesh The molded object according to feature 2.

12. The outer surface forms at least a part of the filter material. The molded object according to feature 2.

13. A connecting part that links multiple structural parts together. The molded object according to feature 2.

14. A method for designing a molded object according to claim 1, The 3D modeling data for the modeling part is formed by setting a thickness on a surface created by connecting adjacent folio curves with lines. A method for designing molded objects characterized by the features described herein.

15. A method for designing a molded object according to claim 1, The molding data for the molding part is formed by sweeping a predetermined cross-sectional shape along a regular curve. A method for designing molded objects characterized by the features described herein.

16. A method for designing a molded object according to claim 1, The 3D modeling data for the modeling part is formed by joining cross-sectional shapes located at different positions along a regular curve. A method for designing sculptural objects characterized by the following:

17. A method for designing a molded object according to claim 1, The molding data for the molded part is formed by setting the thickness of the surface enclosed by the regular curve. A method for designing molded objects characterized by the features described herein.

18. A molded object is manufactured by a molded object manufacturing apparatus based on molded data formed by any one of claims 14 to 17. A method for manufacturing a molded object characterized by the following features.

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