Three-dimensional shaping device

Abstract

This technology provides a mechanism for switching between the discharge of plasticizing material and fiber material from a nozzle. [Solution] The three-dimensional molding apparatus comprises a plasticizing unit, a fiber material supply unit, a first connecting passage through which the plasticizing material passes, a second connecting passage through which the fiber material passes, a flow path through which the plasticizing material that has passed through the first connecting passage and the fiber material that has passed through the second connecting passage can pass, a material switching unit that switches the communication between the first connecting passage, the second connecting passage and the flow path, a nozzle that discharges the plasticizing material and fiber material that have passed through the flow path, and a control unit. The control unit controls the material switching unit in order to switch between a first mode in which the first connecting passage and the flow path are in communication and the second connecting passage and the flow path are not, a second mode in which the first connecting passage and the flow path are not in communication and the second connecting passage and the flow path are in communication, a third mode in which both the first and second connecting passages are in communication with the flow path, and a fourth mode in which neither the first nor the second connecting passage is in communication with the flow path.

Description

Technical Field

[0001] The present disclosure relates to a three-dimensional shaping apparatus.

Background Art

[0002] Patent Document 1 discloses a three-dimensional shaping apparatus that introduces a second fiber material longer than the first fiber material into a plasticized material containing the first fiber material and a thermoplastic resin, and shapes a three-dimensional shaped object containing the first fiber material and the second fiber material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a three-dimensional shaping apparatus, switching between discharging a plasticized material and discharging a fiber material from a nozzle has not been studied.

Means for Solving the Problems

[0005] According to a first embodiment of this disclosure, a three-dimensional molding apparatus is provided. This three-dimensional molding apparatus includes a plasticizing unit that plasticizes at least a portion of a material including a thermoplastic resin to produce a plasticizable material, a fiber material supply unit that supplies a fiber material, a first communication passage communicating with the plasticizing unit and through which the plasticizable material passes, a second communication passage communicating with the fiber material supply unit and through which the fiber material passes, a flow path through which the plasticizable material that has passed through the first communication passage and the fiber material that has passed through the second communication passage can pass, a material switching unit connected to the first communication passage, the second communication passage and the flow path, and which switches the communication between the first communication passage, the second communication passage and the flow path, and a flow path that communicates with the flow path and supplies the plasticizable material and the fiber material that has passed through the flow path. The apparatus comprises a nozzle for discharging material onto a stage, the plasticizing unit, the fiber material supply unit, and the material switching unit, and a control unit that controls these to fabricate a three-dimensional object containing the plasticizing material on the stage, wherein the control unit controls the material switching unit to switch between a first mode in which the first communication passage and the flow path are in communication and the second communication passage and the flow path are not; a second mode in which the first communication passage and the flow path are not in communication and the second communication passage and the flow path are in communication; a third mode in which both the first and second communication passages are in communication with the flow path; and a fourth mode in which neither the first nor the second communication passage is in communication with the flow path. [Brief explanation of the drawing]

[0006] [Figure 1] This is an explanatory diagram showing the schematic configuration of the three-dimensional molding apparatus in the first embodiment. [Figure 2] This is an explanatory diagram showing the general configuration of the molding section. [Figure 3] This is a perspective view showing the schematic configuration of a flat screw. [Figure 4] This is a schematic plan view of the barrel. [Figure 5] This is a perspective view of the rotating member. [Figure 6] This diagram illustrates the angular position of the rotating member around the axis of rotation in the first mode. [Figure 7]This diagram illustrates the angular position of the rotating member around the axis of rotation in the second mode. [Figure 8] This diagram illustrates the angular position of the rotating member around the axis of rotation in the third mode. [Figure 9] This diagram illustrates the angular position of the rotating member around the axis of rotation in the fourth mode. [Figure 10] This is an explanatory diagram showing an example of the schematic configuration of the molding section in another embodiment. [Modes for carrying out the invention]

[0007] A. First Embodiment: Figure 1 is an explanatory diagram showing the schematic configuration of the three-dimensional molding apparatus 10 in the first embodiment. Figure 1 shows arrows representing the mutually orthogonal X, Y, and Z directions. The X and Y directions are parallel to the horizontal plane. The Z direction is parallel to the vertical direction. The X, Y, and Z directions in Figure 1 and the X, Y, and Z directions in other figures point to the same directions. When specifying the direction, the positive direction, which is the direction pointed to by the arrow, is denoted as "+", and the negative direction, which is the direction opposite to the direction pointed to by the arrow, is denoted as "-", and both positive and negative signs are used in the direction notation. The +Z direction is also called "up", and the -Z direction is also called "down".

[0008] The three-dimensional molding apparatus 10 is a device that creates three-dimensional objects using a material extrusion method. The three-dimensional molding apparatus 10 comprises a molding unit 20 that generates and extrudes plasticizable material, a molding stage 30 that serves as the base for the three-dimensional object, a moving mechanism 40 that controls the extrusion position of the plasticizable material, and a control unit 50 for controlling each part of the three-dimensional molding apparatus 10. Figure 2 is an explanatory diagram showing the schematic configuration of the molding unit 20. The parts of the three-dimensional molding apparatus 10 will be described below with reference to Figures 1 and 2.

[0009] The molding unit 20, under the control of the control unit 50, extrudes plasticizable material, which is obtained by plasticizing a material in a solid state, onto the stage 30. The molding unit 20 includes a plasticizable material introduction unit 21, a fiber material introduction unit 22, a material switching unit 23, and an extrusion unit 24.

[0010] The plasticizing material introduction unit 21 generates plasticizing material and guides the generated plasticizing material to the material switching unit 23. The plasticizing material introduction unit 21 comprises a material supply unit 101, a plasticizing unit 110, and a first connecting passage 170.

[0011] The material supply unit 101 supplies material MR to the plasticizing unit 110. The material supply unit 101 is composed of, for example, a hopper that contains the material MR. The material supply unit 101 is connected to the plasticizing unit 110 via a material supply passage 105. The material MR is fed into the material supply unit 101 in the form of pellets, powder, etc. Examples of materials MR include thermoplastic resins such as ABS (acrylonitrile butadiene styrene), PEEK (polyether ether ketone), and PP (polypropylene). Inorganic materials such as metals and ceramics may also be included in the material MR.

[0012] The plasticizing unit 110 plasticizes at least a portion of the material MR supplied from the material supply unit 101 to produce a paste-like plasticized material that exhibits fluidity. In this embodiment, "plasticization" is a concept that includes melting and refers to changing a solid state to a fluid state. Specifically, in the case of materials that undergo a glass transition, plasticization means raising the temperature of the material to above the glass transition point. In the case of materials that do not undergo a glass transition, plasticization means raising the temperature of the material to above the melting point. The plasticizing unit 110 comprises a drive motor 120, a reduction gear 130, a flat screw 140, and a barrel 150. The flat screw 140 is also called a rotor, scroll, or simply a screw. The barrel 150 is also called the screw face section.

[0013] The flat screw 140 is housed in a screw case 148. The flat screw 140 is connected to a drive motor 120 via a reduction gear 130, and rotates within the screw case 148 around the rotation axis RX by the rotational driving force generated by the drive motor 120. In this embodiment, the direction of the rotation axis RX is along the X direction. The rotation of the flat screw 140 by the drive motor 120 is controlled by a control unit 50. A barrel 150 is positioned on the -X side of the flat screw 140. The flat screw 140 may also be directly connected to the drive motor 120 without going through the reduction gear 130.

[0014] Figure 3 is a perspective view showing the schematic configuration of the flat screw 140. The flat screw 140 has a substantially cylindrical shape in which the height in the direction along its central axis is smaller than its diameter. The central axis of the flat screw 140 coincides with the rotation axis RX. On the groove-forming surface 141 of the flat screw 140 facing the barrel 150, a spiral groove 143 is formed, centered on the central portion 142. The groove 143 communicates with a material input port 144 formed on the side of the flat screw 140. The material MR supplied from the material supply unit 101 is supplied to the groove 143 through the material input port 144. The groove 143 is formed by being separated by a protruding portion 145. Figure 3 shows an example in which three grooves 143 are formed, but the number of grooves 143 may be one or two or more. Note that the groove 143 is not limited to a spiral shape, but may also be helical or involute curved, or may extend in an arc from the central portion 142 toward the outer circumference.

[0015] As shown in Figure 2, the barrel 150 is equipped with a barrel heater 155 for heating the material MR supplied into the groove 143 of the flat screw 140. The temperature of the barrel heater 155 is controlled by the control unit 50.

[0016] FIG. 4 is a schematic plan view of the barrel 150. The barrel 150 has an opposing surface 153 that faces the groove forming surface 141 of the flat screw 140. A communication hole 151 that penetrates the barrel 150 in the X direction is formed at the center of the opposing surface 153. A plurality of guide grooves 154 that are connected to the communication hole 151 and extend spirally from the communication hole 151 toward the outer periphery are formed on the opposing surface 153. Note that the barrel 150 may not be provided with the guide grooves 154. Further, the guide grooves 154 may not be connected to the communication hole 151.

[0017] The material MR supplied to the groove 143 of the flat screw 140 is plasticized between the flat screw 140 and the barrel 150 by the rotation of the flat screw 140 and the heating of the barrel heater 155, and flows along the groove 143 and the guide groove 154 by the rotation of the flat screw 140, and is guided to the central portion 142 of the flat screw 140. The plasticized material that has flowed into the central portion 142 flows out from the communication hole 151 provided at the center of the barrel 150 to the first communication path 170. Note that in the plasticized material, not all types of substances constituting the plasticized material may be plasticized. The plasticized material only needs to be converted into a state having fluidity as a whole by plasticizing at least some types of substances constituting the plasticized material.

[0018] The first communication path 170 is a linearly extending hole formed in a member 180 disposed on the -X direction side of the barrel 150. In the present embodiment, the axis of the first communication path 170 is along the X direction. One end of the first communication path 170 is connected to the communication hole 151, and the other end of the first communication path 170 is connected to the material switching unit 23. That is, the first communication path 170 communicates with the plasticizing unit 110. The plasticized material generated in the plasticizing unit 110 passes through the first communication path 170 and flows out to the material switching unit 23.

[0019] The fiber material introduction section 22 includes a fiber material supply section 210 and a second connecting passage 220. The fiber material supply section 210 supplies fiber material FB to the material switching section 23. The fiber material supply section 210 includes a storage section 211, a transport roller 212, and a transport path 213. The storage section 211 houses the fiber material FB wound on a reel. The transport roller 212 is a pair of rollers that grip the fiber material FB supplied from the storage section 211. The transport roller 212 is located below the storage section 211. As the transport roller 212 rotates around its axis while gripping the fiber material FB, the fiber material FB is transported from the storage section 211 to the material switching section 23. In this embodiment, the direction along the axis of the transport roller 212 is the Y direction. The rotation of the transport roller 212 is controlled by the control unit 50. The transport path 213 is a cylindrical member located below the transport roller 212, through which the fiber material FB sent from the storage unit 211 passes. The fiber material supply unit 210 does not necessarily have a transport path 213. Furthermore, the method of transporting the fiber material FB is not limited to the method described above. For example, the fiber material FB may be transported from the storage unit 211 to the material switching unit 23 by a motor rotating a reel on which the fiber material FB is wound.

[0020] The second connecting passage 220 is a linearly extending hole formed in the block 180. In this embodiment, the axis of the second connecting passage 220 is along the Z direction. One end of the second connecting passage 220 is connected to the transport path 213, and the other end of the second connecting passage 220 is connected to the material switching section 23. That is, the second connecting passage 220 is in communication with the fiber material supply section 210. The fiber material FB supplied from the fiber material supply section 210 passes through the second connecting passage 220 and is transported to the material switching section 23. The axis of the second connecting passage 220 and the axis of the transport path 213 coincide. In this embodiment, the fiber material FB is transported along the -Z direction from the storage section 211 to the material switching section 23 so as not to bend before reaching the material switching section 23.

[0021] The fiber material FB is composed of fiber bundles in which multiple fibers are bundled together. In this embodiment, the fiber material FB has a structure in which multiple carbon fibers are bundled together with a sizing agent. The fiber material FB may be composed of fiber materials other than carbon fibers, for example, glass fibers. The fiber material FB may also be composed of various fibers having a higher modulus of elasticity than material MR. The fiber material FB may also be composed of a single fiber. Furthermore, the fiber material FB may be a material in which multiple fibers are bundled together or a single fiber is impregnated with a thermoplastic resin. The diameter of the fiber material FB can be, for example, 5 μm or more and less than or equal to the hole diameter of the nozzle opening 431 described later. Here, the diameter of the fiber material FB corresponds to the dimension of the maximum width in a cross section perpendicular to the longitudinal direction of the fiber bundle constituting the fiber material FB.

[0022] An insulating material 250 is provided between the second connecting passage 220 and the plasticizing section 110. In this embodiment, the insulating material 250 is a cylindrical member and is embedded in the block 180 so as to surround the second connecting passage 220. The insulating material 250 is made of, for example, ceramic, glass fiber, PTFE (polytetrafluoroethylene), etc. Note that the insulating material 250 only needs to be provided between the second connecting passage 220 and the plasticizing section 110, and may be embedded in the block 180 between the second connecting passage 220 and the barrel 150, or it may be provided between the block 180 and the barrel 150.

[0023] The material switching unit 23 is connected to the first communication passage 170, the second communication passage 220, and the flow path 410, which will be described later, and switches the communication between the first communication passage 170, the second communication passage 220, and the flow path 410. The material switching unit 23 includes a substantially cylindrical rotating member 310 that is rotatable about a rotation axis AX that intersects the axial direction of the flow path 410. The rotating member 310 is located inside a first hole 320 formed in the block 180. Here, the first hole 320 is a through hole that penetrates the block 180 in the Y direction and communicates with the first communication passage 170, the second communication passage 220, and the flow path 410. Note that the first hole 320 may not be a through hole, but a hole with a bottom surface provided from the +Y direction side of the block 180 toward the -Y direction, or a hole with a bottom surface provided from the -Y direction side of the block 180 toward the +Y direction. The rotating member 310 is positioned inside the first hole 320 such that its rotation axis AX is aligned with the Y direction. The rotating member 310 is driven by the first drive unit 330 under the control of the control unit 50. The first drive unit 330 is configured, for example, by a stepping motor. The control unit 50 uses the first drive unit 330 to control the rotation angle of the rotating member 310 around the rotation axis AX. The detailed structure of the rotating member 310 will be described later.

[0024] The discharge section 24 comprises a flow path 410, a suction section 420, a nozzle 430, and a nozzle heater 440. The flow path 410 is a linearly extending hole formed on the -Z direction side of the material switching section 23 in the block 180. The axis of the flow path 410 is along the Z direction. That is, the axial direction of the flow path 410 is along the axial direction of the second connecting passage 220. Also, the axial direction of the flow path 410 intersects with the axial direction of the first connecting passage 170. The flow path 410 is connected to the material switching section 23, and plasticizing material that has passed through the first connecting passage 170 and fibrous material FB that has passed through the second connecting passage 220 can pass through it.

[0025] The nozzle 430 is located at the lower end of the block 180. The nozzle 430 communicates with the flow path 410 and discharges the plasticizing material and fibrous material FB that have passed through the flow path 410 from the nozzle opening 431 at its tip toward the stage 30.

[0026] The nozzle heater 440 is positioned around the portion of the flow path 410 located near the nozzle 430. The nozzle heater 440 heats the plasticizing material in the flow path 410 near the nozzle 430. The temperature of the nozzle heater 440 is controlled by the control unit 50.

[0027] The suction unit 420 suppresses the trailing phenomenon, where the plasticizing material dangles from the nozzle opening 431 in a string-like manner, by temporarily sucking the plasticizing material in the flow path 410 when the discharge of the plasticizing material from the nozzle 430 stops. The suction unit 420 comprises a branched flow path 421, a plunger 422, and a plunger drive unit 423. The branched flow path 421 is a linearly extending hole formed in the block 180 and is connected to the flow path 410. In this embodiment, the direction in which the branched flow path 421 extends is the X direction. The plunger 422 is an axial member and is arranged within the branched flow path 421. The plunger drive unit 423 generates a driving force that instantaneously reciprocates the plunger 422 within the branched flow path 421 under the control of the control unit 50. The plunger drive unit 423 is composed of an actuator such as a solenoid mechanism, a piezoelectric element, or a motor. When the control unit 50 temporarily interrupts the discharge of the plasticizing material from the nozzle 430, it controls the plunger drive unit 423 to instantaneously move the plunger 422 so that the tip of the plunger 422 moves from the connection point between the flow path 410 and the branch flow path 421 to a recessed position within the branch flow path 421. As a result, a portion of the plasticizing material in the flow path 410 is drawn into the branch flow path 421, creating negative pressure in the flow path 410. When no fiber material FB is present in the flow path 410 and only the plasticizing material is present, the control unit 50 moves the plunger 422 to draw in the plasticizing material in the flow path 410. Note that the discharge unit 24 does not necessarily have to be equipped with a suction unit 420.

[0028] As shown in Figure 1, the stage 30 is positioned opposite the nozzle opening 431 of the nozzle 430. The molding surface 31 of the stage 30 opposite the nozzle opening 431 is positioned parallel to the X,Y direction, i.e., the horizontal direction. The stage 30 may be equipped with a stage heater to suppress the rapid cooling of the plasticizing material extruded onto the stage 30.

[0029] The moving mechanism 40 changes the relative position between the stage 30 and the nozzle 430 under the control of the control unit 50. In this embodiment, the position of the nozzle 430 is fixed, and the moving mechanism 40 moves the stage 30. The moving mechanism 40 is composed of a three-axis positioner that moves the stage 30 in three axes in the X, Y, and Z directions by the driving force of three servo motors. In this specification, unless otherwise specified, movement of the nozzle 430 means moving the nozzle 430 or the discharge unit 24 relative to the stage 30.

[0030] In other embodiments, instead of moving the stage 30 with the moving mechanism 40, a configuration may be adopted in which the stage 30 is fixed in position and the moving mechanism 40 moves the nozzle 430 relative to the stage 30. Alternatively, a configuration may be adopted in which the moving mechanism 40 moves the stage 30 in the Z direction and the nozzle 430 in the X and Y directions, or in which the moving mechanism 40 moves the stage 30 in the X and Y directions and the nozzle 430 in the Z direction. Even with these configurations, the relative positional relationship between the nozzle 430 and the stage 30 can be changed.

[0031] The control unit 50 is a control device that controls the operation of the entire three-dimensional molding apparatus 10. The control unit 50 is composed of a computer comprising a CPU 51, a storage device 52, and an input / output interface for inputting and outputting signals to and from the outside. The control unit 50 performs the function of executing molding processes for molding a three-dimensional object by having the CPU 51 execute programs and instructions loaded into the main storage device. In the molding process, the control unit 50 controls the plasticizing unit 110, the fiber material supply unit 210, the material switching unit 23, the discharge unit 24, and the moving mechanism 40 according to the molding data for molding the three-dimensional object, thereby molding a three-dimensional object containing plasticizing material on the stage 30. In other embodiments, instead of being composed of a computer, the control unit 50 may be realized by a configuration that combines multiple circuits to realize at least some of each function.

[0032] Figure 5 is a perspective view of the rotating member 310. The rotating member 310 has a through hole 311 through which the plasticizing material and the fibrous material FB can pass. The through hole 311 is a hole that penetrates the rotating member 310 in a direction intersecting the rotation axis AX. The through hole 311 has a first opening 312 and a second opening 313. The first opening 312 is connectable to the first communication passage 170 and the second communication passage 220. The second opening 313 is connectable to the flow path 410 and communicates with the first opening 312. The opening area of ​​the first opening 312 is larger than the opening area of ​​the second opening 313. Here, the opening area of ​​the first opening 312 refers to the surface area of ​​the outer circumferential surface of the rotating member 310 that is reduced by the formation of the first opening 312. The same applies to the opening area of ​​the second opening 313. The rotating member 310 is also called a butterfly valve.

[0033] The control unit 50 controls the material switching unit 23 to switch between the first mode, the second mode, the third mode, and the fourth mode. Specifically, the control unit 50 rotates the rotating member 310 around the rotation axis AX to switch between the first mode, the second mode, the third mode, and the fourth mode. Here, the first mode is a mode in which the first communication passage 170 and the flow path 410 are in communication, but the second communication passage 220 and the flow path 410 are not in communication. The second mode is a mode in which the first communication passage 170 and the flow path 410 are not in communication, but the second communication passage 220 and the flow path 410 are in communication. The third mode is a mode in which both the first communication passage 170 and the second communication passage 220 are in communication with the flow path 410. The fourth mode is a mode in which neither the first communication passage 170 nor the second communication passage 220 are in communication with the flow path 410.

[0034] Figures 6 to 9 illustrate the angular position of the rotating member 310 around the rotation axis AX in the four modes described above. Hereinafter, the end of the first connecting passage 170 connected to the material switching section 23 will be referred to as the first connecting passage opening 171, the end of the second connecting passage 220 connected to the material switching section 23 will be referred to as the second connecting passage opening 221, and the end of the flow path 410 connected to the material switching section 23 will be referred to as the flow path opening 411.

[0035] Figure 6 shows the angular position of the rotating member 310 around the rotation axis AX in the first mode. In the first mode, the control unit 50 rotates the rotating member 310 to a position where at least a portion of the first communication passage opening 171 overlaps with at least a portion of the first opening 312, the second communication passage opening 221 does not overlap with the first opening 312, and at least a portion of the flow path opening 411 overlaps with at least a portion of the second opening 313. Therefore, in the first mode, the plasticizing material in the first communication passage 170 flows out into the flow path 410 through the through hole 311 of the rotating member 310, but the fibrous material FB in the second communication passage 220 is not transported to the flow path 410. Consequently, in the first mode, only the plasticizing material is discharged from the nozzle 430. The amount of plasticizing material discharged from the nozzle 430 is controlled, for example, by the control unit 50 controlling the rotational speed of the flat screw 140, thereby adjusting the amount of plasticizing material generated in the plasticizing unit 110.

[0036] Figure 7 shows the angular position of the rotating member 310 around the rotation axis AX in the second mode. In the second mode, the control unit 50 rotates the rotating member 310 to a position where the first communication passage opening 171 and the first opening 312 do not overlap, at least a portion of the second communication passage opening 221 and at least a portion of the first opening 312 overlap, and at least a portion of the flow path opening 411 and at least a portion of the second opening 313 overlap. Therefore, in the second mode, the plasticizing material in the first communication passage 170 does not flow into the flow path 410, but the fibrous material FB in the second communication passage 220 is conveyed to the flow path 410 through the through hole 311 of the rotating member 310. Consequently, in the second mode, only the fibrous material FB is discharged from the nozzle 430. The amount of fibrous material FB discharged from the nozzle 430 is controlled by the control unit 50 controlling the rotation speed of the conveying roller 212.

[0037] Figure 8 shows the angular position of the rotating member 310 around the rotation axis AX in the third mode. In the third mode, the control unit 50 rotates the rotating member 310 to a position where at least a portion of the first communication passage opening 171 overlaps with at least a portion of the first opening 312, at least a portion of the second communication passage opening 221 overlaps with at least a portion of the first opening 312, and at least a portion of the flow path opening 411 overlaps with at least a portion of the second opening 313. Therefore, in the third mode, the plasticizing material in the first communication passage 170 flows out into the flow path 410 through the through hole 311 of the rotating member 310, and the fibrous material FB in the second communication passage 220 is transported to the flow path 410 through the through hole 311 of the rotating member 310. Consequently, in the third mode, the plasticizing material and the fibrous material FB are discharged from the nozzle 430.

[0038] Figure 9 shows the angular position of the rotating member 310 around the rotation axis AX in the fourth mode. In the fourth mode, the control unit 50 rotates the rotating member 310 to a position where the first communication passage opening 171 and the first opening 312 do not overlap, and the second communication passage opening 221 and the first opening 312 do not overlap. Therefore, in the fourth mode, the plasticizing material in the first communication passage 170 does not flow into the flow path 410, and the fibrous material FB in the second communication passage 220 is not transported to the flow path 410. Consequently, in the fourth mode, neither the plasticizing material nor the fibrous material FB is discharged from the nozzle 430.

[0039] The control unit 50 switches between modes according to the fabrication data for creating the three-dimensional object. The control unit 50 switches between modes so that, for example, fiber material FB is extruded into the parts of the three-dimensional object where the strength is to be improved. The parts of the three-dimensional object where the strength is to be improved are, for example, the outer surface of the three-dimensional object.

[0040] When cutting the fiber material FB, the control unit 50 rotates the rotating member 310 from a position where at least a portion of the second passage opening 221 and at least a portion of the first opening 312 overlap to a position where the second passage opening 221 and the first opening 312 do not overlap. For example, the control unit 50 rotates the rotating member 310 from the position shown in Figure 7 to the position shown in Figure 6. As a result, the fiber material FB is cut by bending near the second passage opening 221. Cutting the fiber material FB refers to changing from a state in which the fiber material FB is discharged from the nozzle 430 to a state in which the fiber material FB is not discharged from the nozzle 430. For example, switching from the second mode to the first mode, or from the third mode to the fourth mode, constitutes cutting the fiber material FB.

[0041] According to the first embodiment described above, the control unit 50 controls the material switching unit 23 in order to switch between a first mode in which the first communication passage 170 communicating with the plasticizing unit 110 and the flow path 410 communicating with the nozzle 430 are in communication, and the second communication passage 220 communicating with the fiber material supply unit 210 and the flow path 410 are not in communication; a second mode in which the first communication passage 170 and the flow path 410 are not in communication, and the second communication passage 220 and the flow path 410 are in communication; a third mode in which the first communication passage 170 and the second communication passage 220 are in communication with the flow path 410; and a fourth mode in which neither the first communication passage 170 nor the second communication passage 220 are in communication with the flow path 410.

[0042] Furthermore, in this embodiment, the material switching unit 23 has a first opening 312 that can be connected to the first communication passage 170 and the second communication passage 220, and a second opening 313 that communicates with the first opening 312 and can be connected to the flow path 410, and the opening area of ​​the first opening 312 is larger than the opening area of ​​the second opening 313. Therefore, compared to the case where the opening area of ​​the first opening 312 is smaller than the opening area of ​​the second opening 313, it is possible to easily switch between the discharge of the plasticizing material and the discharge of the fibrous material FB from the nozzle 430.

[0043] Furthermore, in this embodiment, the material switching unit 23 includes a rotating member 310 that can rotate around a rotation axis RX intersecting the axial direction of the flow path 410. The rotating member 310 has through holes 311 through which the plasticizing material and the fibrous material FB can pass, and the through holes 311 have a first opening 312 and a second opening 313. Therefore, a single member can switch between discharging the plasticizing material from the nozzle 430 and discharging the fibrous material FB.

[0044] Furthermore, in this embodiment, in the first mode, the control unit 50 rotates the rotating member 310 to a position where at least a portion of the first passage opening 171 and at least a portion of the first opening 312 overlap, the second passage opening 221 and the first opening 312 do not overlap, and at least a portion of the flow path opening 411 and at least a portion of the second opening 313 overlap. As a result, in the first mode, only the plasticizing material can be discharged from the nozzle 430.

[0045] Furthermore, in this embodiment, in the second mode, the control unit 50 rotates the rotating member 310 to a position where the first communication passage opening 171 and the first opening 312 do not overlap, at least a portion of the second communication passage opening 221 and at least a portion of the first opening 312 overlap, and at least a portion of the flow path opening 411 and at least a portion of the second opening 313 overlap. As a result, in the second mode, only the fibrous material FB can be discharged from the nozzle 430.

[0046] Furthermore, in this embodiment, in the third mode, the control unit 50 rotates the rotating member 310 to a position where at least a portion of the first communication passage opening 171 overlaps with at least a portion of the first opening 312, at least a portion of the second communication passage opening 221 overlaps with at least a portion of the first opening 312, and at least a portion of the flow path opening 411 overlaps with at least a portion of the second opening 313. As a result, in the third mode, both the plasticizing material and the fibrous material FB can be discharged from the nozzle 430.

[0047] Furthermore, in this embodiment, the control unit 50 rotates the rotating member 310 in the fourth mode so that the first connecting passage opening 171 and the first opening 312 do not overlap, and the second connecting passage opening 221 and the first opening 312 do not overlap. Therefore, in the fourth mode, neither the plasticizing material nor the fibrous material FB can be discharged from the nozzle 430.

[0048] Furthermore, in this embodiment, when cutting the fiber material FB, the control unit 50 rotates the rotating member 310 from a position where at least a portion of the second passage opening 221 and at least a portion of the first opening 312 overlap to a position where the second passage opening 221 and the first opening 312 do not overlap. Therefore, the fiber material FB can be cut by rotating the rotating member 310.

[0049] Furthermore, in this embodiment, the heat insulating material 250 is provided between the second communication passage 220 and the plasticizing section 110. Therefore, the influence of the heat from the plasticizing section 110 on the fibrous material FB passing through the second communication passage 220 can be reduced.

[0050] Furthermore, in this embodiment, the axial direction of the second communication passage 220 is aligned with the axial direction of the flow path 410. Therefore, the possibility of the fibrous material FB breaking during the process of being supplied from the second communication passage 220 through the material switching section 23 to the flow path 410 can be reduced.

[0051] Furthermore, in this embodiment, the nozzle heater 440 is positioned around the portion of the flow path 410 located near the nozzle 430. Therefore, the plasticizing material can be heated just before it is discharged from the nozzle 430, allowing for more stable discharge of the plasticizing material from the nozzle 430.

[0052] B. Other embodiments: (B-1) In the above embodiment, the axial direction of the second communication passage 220 is along the axial direction of the flow path 410. However, the axial direction of the second communication passage 220 does not have to be along the axial direction of the flow path 410. Figure 10 is an explanatory diagram showing an example of the schematic configuration of the molding section 20b in another embodiment. In the example shown in Figure 10, the axial direction of the flow path 410 is along the Z direction, and the axial direction of the second communication passage 220 is inclined at 45° from the Z axis in the XZ plane. Note that the axial direction of the second communication passage 220 is not limited to 45°, but may be inclined at any angle greater than 0° and less than or equal to 90° from the Z axis in the XZ plane.

[0053] (B-2) In the above embodiment, the opening area of ​​the first opening 312 is larger than the opening area of ​​the second opening 313. In contrast, the opening area of ​​the first opening 312 does not have to be larger than the opening area of ​​the second opening 313.

[0054] (B-3) In the above embodiment, the control unit 50 rotates the rotating member 310 to a position in the first mode where at least a part of the first passage opening 171 and at least a part of the first opening 312 overlap, the second passage opening 221 and the first opening 312 do not overlap, and at least a part of the flow path opening 411 and at least a part of the second opening 313 overlap. In contrast, the control unit 50 does not have to rotate the rotating member 310 to a position in the first mode where at least a part of the first passage opening 171 and at least a part of the first opening 312 overlap, the second passage opening 221 and the first opening 312 do not overlap, and at least a part of the flow path opening 411 and at least a part of the second opening 313 overlap.

[0055] (B-4) In the above embodiment, the control unit 50 rotates the rotating member 310 to a position in the second mode where the first communication passage opening 171 and the first opening 312 do not overlap, at least a part of the second communication passage opening 221 and at least a part of the first opening 312 overlap, and at least a part of the flow path opening 411 and at least a part of the second opening 313 overlap. In contrast, the control unit 50 does not have to rotate the rotating member 310 to a position in the second mode where the first communication passage opening 171 and the first opening 312 do not overlap, at least a part of the second communication passage opening 221 and at least a part of the first opening 312 overlap, and at least a part of the flow path opening 411 and at least a part of the second opening 313 overlap.

[0056] (B-5) In the above embodiment, the control unit 50 rotates the rotating member 310 to a position in the third mode where at least a part of the first passage opening 171 overlaps with at least a part of the first opening 312, at least a part of the second passage opening 221 overlaps with at least a part of the first opening 312, and at least a part of the flow path opening 411 overlaps with at least a part of the second opening 313. In contrast, the control unit 50 does not have to rotate the rotating member 310 to a position in the third mode where at least a part of the first passage opening 171 overlaps with at least a part of the first opening 312, at least a part of the second passage opening 221 overlaps with at least a part of the first opening 312, and at least a part of the flow path opening 411 overlaps with at least a part of the second opening 313.

[0057] (B-6) In the above embodiment, the control unit 50 rotates the rotating member 310 to a position in the fourth mode where the first connecting passage opening 171 and the first opening 312 do not overlap, and the second connecting passage opening 221 and the first opening 312 do not overlap. In contrast, the control unit 50 does not have to rotate the rotating member 310 to a position in the fourth mode where the first connecting passage opening 171 and the first opening 312 do not overlap, and the second connecting passage opening 221 and the first opening 312 do not overlap.

[0058] (B-7) In the above embodiment, when cutting the fiber material FB, the control unit 50 rotates the rotating member 310 from a position where at least a part of the second passage opening 221 and at least a part of the first opening 312 overlap to a position where the second passage opening 221 and the first opening 312 do not overlap. In contrast, the molding unit 20 may also be equipped with a cutting unit, and the control unit 50 may control the cutting unit to cut the fiber material FB. The cutting unit may be composed of, for example, a cutter blade or a laser emission mechanism.

[0059] (B-8) In the above embodiment, a heat insulating material 250 is provided between the second connecting passage 220 and the plasticizing section 110. However, a heat insulating material 250 may not be provided between the second connecting passage 220 and the plasticizing section 110.

[0060] (B-9) In the above embodiment, the discharge unit 24 is equipped with a nozzle heater 440. However, the discharge unit 24 does not need to be equipped with a nozzle heater 440.

[0061] (B-10) In the above embodiment, the amount of plasticizing material discharged from the nozzle 430 is controlled, for example, by the control unit 50 controlling the rotational speed of the flat screw 140. Alternatively, the amount of plasticizing material discharged from the nozzle 430 may be controlled by the control unit 50 controlling the rotation angle of the rotating member 310 around the rotation axis AX.

[0062] (B-11) In the above embodiment, the first connecting passage 170 and the second connecting passage 220 are straight-lined holes. In contrast, at least one of the first connecting passage 170 and the second connecting passage 220 may be a bent hole.

[0063] (B-12) In the above embodiment, the control unit 50 rotates the rotating member 310 in the fourth mode to a position where the first communication passage opening 171 and the first opening 312 do not overlap, and the second communication passage opening 221 and the first opening 312 do not overlap. Alternatively, the control unit 50 may rotate the rotating member 310 in the fourth mode to a position where neither the first opening 312 nor the second opening 313 overlaps with the flow path opening 411.

[0064] C. Other forms: This disclosure is not limited to the embodiments described above, and can be implemented in various forms without departing from its spirit. For example, this disclosure can also be implemented in the following forms. The technical features in the embodiments described below that correspond to the technical features in each of the forms described below can be replaced or combined as appropriate in order to solve some or all of the problems of this disclosure, or to achieve some or all of the effects of this disclosure. Furthermore, if such technical features are not described as essential in this specification, they can be deleted as appropriate.

[0065] (1) According to a first embodiment of the present disclosure, a three-dimensional molding apparatus is provided. The three-dimensional molding apparatus includes a plasticizing unit that plasticizes at least a portion of a material including a thermoplastic resin to produce a plasticizable material, a fiber material supply unit that supplies a fiber material, a first communication passage communicating with the plasticizing unit and through which the plasticizable material passes, a second communication passage communicating with the fiber material supply unit and through which the fiber material passes, a flow path through which the plasticizable material that has passed through the first communication passage and the fiber material that has passed through the second communication passage can pass, a material switching unit connected to the first communication passage, the second communication passage and the flow path, and which switches the communication between the first communication passage, the second communication passage and the flow path, and a flow path that communicates with the flow path and supplies the plasticizable material and the fiber material that has passed through the flow path. The apparatus comprises a nozzle for discharging material onto a stage, the plasticizing unit, the fiber material supply unit, and the material switching unit, and a control unit that controls these to fabricate a three-dimensional object containing the plasticizing material on the stage, wherein the control unit controls the material switching unit to switch between a first mode in which the first communication passage and the flow path are in communication and the second communication passage and the flow path are not; a second mode in which the first communication passage and the flow path are not in communication and the second communication passage and the flow path are in communication; a third mode in which both the first and second communication passages are in communication with the flow path; and a fourth mode in which neither the first nor the second communication passage is in communication with the flow path. This configuration allows for switching between the discharge of plasticizing material and fibrous material from the nozzle.

[0066] (2) In the above embodiment, the material switching section has a first opening that can be connected to the first communication passage and the second communication passage, and a second opening that communicates with the first opening and can be connected to the flow path, wherein the opening area of ​​the first opening may be larger than the opening area of ​​the second opening. With this configuration, it is possible to easily switch between dispensing plasticizing material and dispensing fibrous material from the nozzle, compared to the case where the opening area of ​​the first opening is smaller than the opening area of ​​the second opening.

[0067] (3) In the above embodiment, the material switching section comprises a rotating member that can rotate about a rotation axis intersecting the axial direction of the flow path, the rotating member has through holes through which the plasticizing material and the fiber material can pass, and the through holes may have the first opening and the second opening. With this configuration, a single component can switch between dispensing plasticizing material and fibrous material from the nozzle.

[0068] (4) In the above configuration, the control unit may rotate the rotating member to a position in the first mode where at least a part of the first passage opening, which is the end of the first passage connected to the material switching unit, overlaps with at least a part of the first opening, the second passage opening, which is the end of the second passage connected to the material switching unit, does not overlap with the first opening, and at least a part of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a part of the second opening. With this configuration, in the first mode, only the plasticizing material can be discharged from the nozzle.

[0069] (5) In the above configuration, the control unit may rotate the rotating member to a position in the second mode where the first passage opening, which is the end of the first passage connected to the material switching unit, does not overlap with the first opening, at least a part of the second passage opening, which is the end of the second passage connected to the material switching unit, overlaps with at least a part of the first opening, and at least a part of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a part of the second opening. With this configuration, in the second mode, only fibrous material can be discharged from the nozzle.

[0070] (6) In the above configuration, the control unit may rotate the rotating member to a position in the third mode where at least a portion of the first passage opening, which is the end of the first passage connected to the material switching unit, overlaps with at least a portion of the first opening; at least a portion of the second passage opening, which is the end of the second passage connected to the material switching unit, overlaps with at least a portion of the first opening; and at least a portion of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a portion of the second opening. In this configuration, in the third mode, both the plasticizing material and the fibrous material can be discharged from the nozzle.

[0071] (7) In the above configuration, the control unit may rotate the rotating member to a position in the fourth mode where the first passage opening, which is the end of the first passage connected to the material switching unit, does not overlap with the first opening, and the second passage opening, which is the end of the second passage connected to the material switching unit, does not overlap with the first opening. With this configuration, in the fourth mode, neither the plasticizing material nor the fibrous material can be discharged from the nozzle.

[0072] (8) In the above embodiment, when cutting the fiber material, the control unit may rotate the rotating member from a position where at least a part of the second passage opening, which is the end of the second passage connected to the material switching unit, and at least a part of the first opening overlap, to a position where the second passage opening and the first opening do not overlap. In this configuration, the fibrous material can be cut by rotating the rotating member.

[0073] (9) In the above embodiment, a heat insulating material may be further provided between the second connecting passage and the plasticizing portion. This configuration reduces the influence of heat from the plasticizing section on the fibrous material passing through the second passage.

[0074] (10) In the above embodiment, the axial direction of the second connecting passage may be in the direction along the axial direction of the flow path. This configuration reduces the possibility of the fibrous material breaking during the process of being supplied from the second connecting passage through the material switching section to the flow path.

[0075] (11) In the above embodiment, a nozzle heater may be further provided, which is arranged around the portion of the flow path located near the nozzle. With this configuration, the plasticizing material can be heated immediately before being discharged from the nozzle, allowing for more stable discharge of the plasticizing material from the nozzle. [Explanation of symbols]

[0076] 10...3D modeling device, 20,20b...Modeling section, 21...Plasticizing material introduction section, 22...Fiber material introduction section, 23...Material switching section, 24...Discharge section, 30...Stage, 31...Modeling surface, 40...Movement mechanism, 50...Control unit, 51...CPU, 52...Memory device, 101...Material supply section, 105...Material supply path, 110...Plasticizing section, 120...Drive motor, 130...Reduction gear, 140...Flat screw, 141...Groove forming surface, 142...Center section, 143...Groove, 144...Material input port, 145...Protruding section, 148...Screw case, 150...Barrel, 151...Communication hole, 153...Opposite surface, 154...Guide groove, 155...Barrel heater, 170...First connecting passage, 171...First connecting passage opening, 180...Block, 210...Fiber material supply section, 211...Storage section, 212...Conveyor roller, 213...Conveyor path, 220...Second connecting passage, 221...Second connecting passage opening, 250...Insulation material, 310...Rotating member, 311...Through hole, 312...First opening, 313...Second opening, 320...First hole, 330...First drive section, 410...Flow path, 411...Flow path opening, 420...Suction section, 421...Branching flow path, 422...Plunger, 423...Plunger drive section, 430...Nozzle, 431...Nozzle opening, 440...Nozzle heater, AX...Rotating shaft, FB...Fiber material, MR...Material, RX...Rotating shaft

Claims

1. A plasticizing unit that plasticizes at least a portion of a material containing a thermoplastic resin to produce a plasticized material, A fiber material supply unit that supplies fiber materials, A first connecting passage that communicates with the plasticizing section and through which the plasticizing material passes, A second connecting passage is provided, which is in communication with the fiber material supply section and through which the fiber material passes. A flow path through which the plasticizing material that has passed through the first connecting passage and the fiber material that has passed through the second connecting passage can pass, A material switching unit is connected to the first connecting passage, the second connecting passage, and the flow path, and switches the communication between the first connecting passage, the second connecting passage, and the flow path. A nozzle that communicates with the aforementioned flow path and discharges the plasticizing material and the fiber material that have passed through the aforementioned flow path onto a stage, The system comprises a control unit that controls the plasticizing unit, the fiber material supply unit, and the material switching unit to fabricate a three-dimensional object containing the plasticizing material on the stage, The control unit controls the material switching unit in order to switch between a first mode in which the first communication passage and the flow path are in communication and the second communication passage and the flow path are not; a second mode in which the first communication passage and the flow path are not in communication and the second communication passage and the flow path are in communication; a third mode in which both the first and second communication passages are in communication with the flow path; and a fourth mode in which neither the first nor the second communication passage is in communication with the flow path. Three-dimensional printing equipment.

2. A three-dimensional molding apparatus according to claim 1, The material switching section is A first opening that can be connected to the first connecting passage and the second connecting passage, It has a second opening that communicates with the first opening and is connectable to the flow path, The opening area of ​​the first opening is larger than the opening area of ​​the second opening. Three-dimensional printing equipment.

3. A three-dimensional molding apparatus according to claim 2, The material switching section includes a rotating member that can rotate about a rotation axis intersecting the axial direction of the flow path, The rotating member has through holes through which the plasticizing material and the fiber material can pass, The through hole has the first opening and the second opening, Three-dimensional printing equipment.

4. A three-dimensional molding apparatus according to claim 3, In the first mode, the control unit rotates the rotating member to a position where at least a portion of the first passage opening, which is the end of the first passage connected to the material switching unit, overlaps with at least a portion of the first opening, the second passage opening, which is the end of the second passage connected to the material switching unit, does not overlap with the first opening, and at least a portion of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a portion of the second opening. Three-dimensional printing equipment.

5. A three-dimensional molding apparatus according to claim 3, In the second mode, the control unit rotates the rotating member to a position where the first passage opening, which is the end of the first passage connected to the material switching unit, does not overlap with the first opening, at least a portion of the second passage opening, which is the end of the second passage connected to the material switching unit, overlaps with at least a portion of the first opening, and at least a portion of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a portion of the second opening. Three-dimensional printing equipment.

6. A three-dimensional molding apparatus according to claim 3, In the third mode, the control unit rotates the rotating member to a position where at least a portion of the first passage opening, which is the end of the first passage connected to the material switching unit, overlaps with at least a portion of the first opening; at least a portion of the second passage opening, which is the end of the second passage connected to the material switching unit, overlaps with at least a portion of the first opening; and at least a portion of the flow path opening, which is the end of the flow path connected to the material switching unit, overlaps with at least a portion of the second opening. Three-dimensional printing equipment.

7. A three-dimensional molding apparatus according to claim 3, In the fourth mode, the control unit rotates the rotating member to a position where the first passage opening, which is the end of the first passage connected to the material switching unit, does not overlap with the first opening, and the second passage opening, which is the end of the second passage connected to the material switching unit, does not overlap with the first opening. Three-dimensional printing equipment.

8. A three-dimensional molding apparatus according to claim 3, When cutting the fiber material, the control unit rotates the rotating member from a position where at least a portion of the second passage opening, which is the end of the second passage connected to the material switching unit, and at least a portion of the first opening overlap, to a position where the second passage opening and the first opening do not overlap. Three-dimensional printing equipment.

9. A three-dimensional molding apparatus according to claim 1, The system further comprises an insulating material provided between the second connecting passage and the plasticizing portion. Three-dimensional printing equipment.

10. A three-dimensional molding apparatus according to claim 1, The axial direction of the second connecting passage is in the direction of the axial direction of the flow path. Three-dimensional printing equipment.

11. A three-dimensional molding apparatus according to claim 1, The system further comprises a nozzle heater positioned around the portion of the flow path located near the nozzle. Three-dimensional printing equipment.

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