Methods of shaping objects

Abstract

The present invention provides a molded object that enhances its strength against forces acting in a specific direction within the horizontal plane. [Solution] A method for creating a molded object by layering cement-based materials comprises a first layer forming step for forming a first layer constituting the molded object, which includes a first protrusion forming step for discharging cement-based material from an additive manufacturing machine to form a first protrusion; a second protrusion forming step for forming a second protrusion, which includes forming a second protrusion at a position adjacent to the first protrusion on the first line, with the direction in which a first line passing through the center of the first protrusion and the center of the second protrusion extends being defined as the first direction; and a third protrusion forming step for forming a third protrusion, which includes forming a third protrusion at a position adjacent to the first and second protrusions, with the direction being perpendicular to the first direction in the horizontal direction being defined as the second direction, which is offset in the second direction relative to the first line.

Description

Technical Field

[0001] The present disclosure relates to a method for forming an object by laminating a cement-based material with a laminating machine.

Background Art

[0002] An object formed by laminating a cement-based material has a problem that its strength against a force acting in the horizontal direction is low. To address such a problem, Patent Document 1 discloses a technique of simultaneously penetrating an upper layer and a lower layer formed by laminating a cement-based material with a reinforcing material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the technique described in Patent Document 1, since a step of inserting a reinforcing material is required in addition to the step of laminating a cement-based material, the number of man-hours required for forming an object increases.

[0005] In view of the above problems, the present disclosure aims to provide a method for forming an object that can increase the strength against a force acting in one direction in the horizontal direction (for example, the longitudinal direction of the object) while suppressing an increase in man-hours.

Means for Solving the Problems

[0006] To achieve the above objective, the present disclosure is a method for manufacturing a molded object, comprising: a first layer manufacturing step for manufacturing an arbitrary first layer constituting the molded object, comprising: a first convex portion forming step for discharging the cement-based material from the additive manufacturing machine to form a first convex portion that is raised above the surrounding area; and a second convex portion forming step for discharging the cement-based material from the additive manufacturing machine to form a second convex portion that is raised above the surrounding area, wherein a line extending horizontally passing through the center of the first convex portion and the center of the second convex portion is defined as a first line, and the first The first layer forming step includes: a second protrusion forming step, in which the direction in which the line extends is defined as the first direction, and the second protrusion is formed on the first line at a position adjacent to the first protrusion; and a third protrusion forming step, in which the cement-based material is extruded from the additive manufacturing machine to form a third protrusion that is raised higher than the surrounding area, wherein, in which the direction perpendicular to the first direction in the horizontal direction is defined as the second direction, the third protrusion is offset in the second direction with respect to the first line and is formed at a position adjacent to the first protrusion and the second protrusion, respectively. [Effects of the Invention]

[0007] The method for fabricating objects according to this disclosure makes it possible to provide a fabricated object that has increased strength (e.g., shear strength) against a force acting in a second direction (one of the horizontal directions). [Brief explanation of the drawing]

[0008] [Figure 1] This diagram schematically shows an example of the configuration of an additive manufacturing machine. [Figure 2] This is a perspective view illustrating an example of a sculpted object. [Figure 3] This is a flowchart showing a method for fabricating an object according to one embodiment. [Figure 4] This figure illustrates an example of the first protrusion formation step according to one embodiment. [Figure 5]This figure illustrates an example of the second protrusion formation step according to one embodiment. [Figure 6] This is a perspective view showing the first and second protrusions according to one embodiment. [Figure 7] This figure illustrates an example of a third protrusion formation step according to one embodiment. [Figure 8] This figure illustrates an example of a second layer fabrication step according to one embodiment. [Figure 9] This is a perspective view showing the arrangement of the first, second, and third protrusions according to one embodiment. [Figure 10] This is a flowchart of the first protrusion formation step according to another embodiment. [Figure 11A] This figure illustrates an example of a movement step according to another embodiment. [Figure 11B] This figure illustrates an example of a proximity step according to another embodiment. [Figure 11C] This figure illustrates an example of a discharge step according to another embodiment. [Figure 11D] This figure illustrates an example of a discharge stop step according to another embodiment. [Figure 11E] This figure illustrates an example of a separation step according to another embodiment. [Figure 12] This is a flowchart of the second protrusion formation step according to another embodiment. [Figure 13] This is a flowchart of the third protrusion formation step according to another embodiment. [Figure 14] This is a top view showing the arrangement of the first, second, and third protrusions according to another embodiment. [Figure 15] This is a flowchart of the fourth protrusion formation step according to another embodiment. [Figure 16] This is a diagram illustrating the configuration of the first layer according to yet another embodiment. [Modes for carrying out the invention]

[0009] Hereinafter, a method for fabricating a shaped object according to an embodiment of the present disclosure will be described based on the drawings. Such an embodiment shows one aspect of the present disclosure, does not limit this disclosure, and can be arbitrarily changed within the scope of the technical idea of this disclosure.

[0010] The method for fabricating a shaped object according to the present disclosure fabricates a shaped object by laminating a cement-based material with a laminating machine. First, referring to FIG. 1, an example of the configuration of the laminating machine 1 will be described.

[0011] <Laminating Machine> FIG. 1 is a diagram schematically showing an example of the configuration of the laminating machine 1. As shown in FIG. 1, the laminating machine 1 includes a nozzle 2 and a moving mechanism 4. In the form illustrated in FIG. 1, the laminating machine 1 further includes a supply pump 6 and a control device 8. The cement-based material M is, for example, mortar or concrete, and is manufactured by kneading water, cement, aggregates, etc. The cement-based material M may be made from limestone having calcium carbonate as a main component, or may be made from raw materials such as gypsum, fly ash, blast furnace slag, molten slag, siliceous admixture, sewage incineration sludge, kaolin, incineration ash, etc.

[0012] The nozzle 2 has a discharge port 2a formed at its tip, and discharges the cement-based material M from this discharge port 2a. The moving mechanism 4 moves the nozzle 2 in an arbitrary direction. In the form illustrated in FIG. 1, the moving mechanism 4 is an arm that supports the nozzle 2. The arm is electrically connected to the control device 8 and moves the nozzle 2 in an arbitrary direction according to an instruction from the control device 8.

[0013] The supply pump 6 supplies the cement-based material M to the nozzle 2. The supply pump 6 is electrically connected to the control device 8 and supplies the nozzle 2 with a component amount of the cement-based material M according to an instruction from the control device 8.

[0014] The control device 8 is a device for controlling the amount of cement-based material M discharged from the nozzle 2 and the movement of the nozzle 2 in order to fabricate an object 100 having a desired shape. The control device 8 is a computer such as an electronic control device, and includes, for example, a processor such as a CPU or GPU (not shown), memory such as ROM or RAM, and an I / O interface. The control device 8 transmits instructions to each component of the additive manufacturing machine 1 (the arm and supply pump 6 described above) by having the processor operate (calculate, etc.) according to the instructions of a program loaded into memory. In some embodiments, the control device 8 is configured to receive signals for understanding the status of each component. In some embodiments, the control device 8 is a cloud server located in a cloud environment.

[0015] <Sculpture> Figure 2 is a schematic perspective view showing an example of the fabricated object 100. In this disclosure, as shown in Figure 2, the case where the fabricated object 100 is a wall 100A (100) is used as an example, where the longitudinal direction (width) of the wall 100A in the horizontal direction is defined as the front-to-back direction D1, the short direction (thickness) of the wall 100A in the horizontal direction is defined as the left-to-right direction D2, and the height direction of the wall 100A is defined as the up-and-down direction D3. The wall 100A is fabricated by stacking multiple layers by the additive manufacturing machine 1, and includes an arbitrary first layer L1 that constitutes the wall 100A and a second layer L2 that is stacked on this first layer L1. Note that the fabricated object 100 is not limited to a wall 100A, but may also be a column, floor, beam, ceiling, etc. The fabricated object 100 is not limited to including multiple layers, and may consist only of the first layer L1.

[0016] <How to create a model> The following describes a method for fabricating a wall 100A using the additive manufacturing machine 1 described above. Figure 3 is a flowchart of a fabrication method according to one embodiment. As shown in Figure 3, the fabrication method includes a first layer fabrication step S1 for fabricating an arbitrary first layer L1 that constitutes the wall 100A. In one embodiment, as illustrated in Figure 3, the fabrication method further includes a second layer fabrication step S2 after the first layer fabrication step S1, in which cement-based material M is extruded from the additive manufacturing machine 1 to fabricate a second layer L2 that is laminated on the first layer L1.

[0017] In one embodiment, the first layer L1 is stacked on the foundation 110 (see Figure 4). In other words, the first layer L1 is the base layer, located at the lowest of the multiple layers that make up the wall 100A. In some embodiments, the first layer L1 is located above the base layer.

[0018] As shown in Figure 3, the first layer fabrication step S1 includes a first protrusion formation step S11, a second protrusion formation step S12, and a third protrusion formation step S13.

[0019] Figure 4 is a diagram illustrating an example of the first protrusion formation step S11 according to one embodiment. In the first protrusion formation step S11, cement-based material M is extruded from the additive manufacturing machine 1 to form a first protrusion 10 that is raised higher than the surrounding area. In one embodiment, as illustrated in Figure 4, in the first protrusion formation step S11, the first protrusion 10 is formed by extruding cement-based material M while moving the nozzle 2 forward along the front-rear direction D1 (first direction D11, which will be described later). The additive manufacturing machine 1 moves the nozzle 2 forward from the first position p1 located at the rear end of the first protrusion 10 while gradually increasing the extrusion amount of cement-based material M until the extrusion amount reaches a predetermined amount. Then, once the extrusion amount reaches a predetermined amount, the additive manufacturing machine 1 moves the nozzle 2 forward to the second position p2 located at the front end of the first protrusion 10 while gradually decreasing the extrusion amount. As a result, as shown in Figure 4, the first layer L1 comes to include the first protrusion 10 that is raised higher than the surrounding area. Furthermore, the first layer L1 includes multiple protrusions that are higher than the surrounding area behind the first protrusion 10. These multiple protrusions are arranged continuously along the front-to-back direction D1. In other words, the surface of the first layer L1 has an uneven shape along the front-to-back direction D1.

[0020] Figure 5 is a diagram illustrating an example of the second protrusion formation step S12 according to one embodiment. In the second protrusion formation step S12, cement-based material M is extruded from the additive manufacturing machine 1 to form a second protrusion 20 that is raised higher than the surrounding area. In one embodiment, as illustrated in Figure 5, in the second protrusion formation step S12, the cement-based material M is extruded while the nozzle 2 is moved forward along the front-rear direction D1 (first direction D11, which will be described later) to form the second protrusion 20. The additive manufacturing machine 1 moves the nozzle 2 forward from the third position p3 located at the rear end of the second protrusion 20 while gradually increasing the extrusion amount of cement-based material M until the extrusion amount reaches a predetermined amount. Then, once the extrusion amount reaches the predetermined amount, the additive manufacturing machine 1 moves the nozzle 2 forward to the fourth position p4 located at the front end of the second protrusion 20 while gradually decreasing the extrusion amount. As a result, as shown in Figure 5, the first layer L1 comes to include the second protrusion 20 that is raised higher than the surrounding area. The first protrusion 10 and the second protrusion 20 may have different or the same height positions at their vertices.

[0021] Figure 6 is a perspective view showing a first protrusion 10 and a second protrusion 20 according to one embodiment. A horizontal line extending from the center 11 of the first protrusion 10 and the center 21 of the second protrusion 20, viewed from the vertical direction D3, is defined as the first line X1, and the direction in which the first line X1 extends is defined as the first direction D11. Furthermore, the direction perpendicular to the first direction D11 in the horizontal direction is defined as the second direction D12. In one embodiment, the first direction D11 is the same direction (parallel) as the front-rear direction D1. The second direction D12 is the same direction (parallel) as the left-right direction D2.

[0022] In one embodiment, as illustrated in Figure 6, the second protrusion 20 is formed on the first line X1 at a position adjacent to the first protrusion 10. In one embodiment, the first protrusion formation step S11 and the second protrusion formation step S12 are performed continuously while the nozzle 2 is moved along the first line X1. That is, the first layer molding step S1 starts forming the second protrusion 20 as soon as the formation of the first protrusion 10 is completed. For this reason, as illustrated in Figure 5, the second position p2 and the third position p3 are at the same position in the front-rear direction D1. In some embodiments, the second position p2 and the third position p3 are offset from each other in the front-rear direction D1. In some embodiments, the third position p3 is forward of the second position p2.

[0023] Figure 7 is a diagram illustrating an example of the third protrusion formation step S13 according to one embodiment. In the third protrusion formation step S13, cement-based material M is extruded from the additive manufacturing machine 1 to form a third protrusion 30 that is raised higher than the surrounding area. In one embodiment, in the third protrusion formation step S13, the nozzle 2 is offset to the left (one of the second directions D12) with respect to the first line X1. Then, as illustrated in Figure 7, the cement-based material M is extruded while the nozzle 2 is moved forward along the front-rear direction D1 (first direction D11) to form the third protrusion 30. The additive manufacturing machine 1 moves the nozzle 2 forward from the fifth position p5 located at the rear end of the third protrusion 30 while gradually increasing the extrusion amount of cement-based material M until the extrusion amount reaches a predetermined amount. The fifth position p5 is located between the first position p1 and the second position p2. Then, once the extrusion rate reaches a predetermined amount, the additive manufacturing machine 1 gradually reduces the extrusion rate while moving the nozzle 2 forward to the sixth position p6 located at the front end of the third protrusion 30. The sixth position p6 is located between the third position p3 and the fourth position p4. As a result, as shown in Figure 7, the first layer L1 includes the third protrusion 30, which is raised higher than the surrounding area. This third protrusion 30 is offset to the left (to one side of the second direction D12) with respect to the first line X1. In the embodiment illustrated in Figure 7, the third protrusion 30 is formed adjacent to the first protrusion 10 and the second protrusion 20, respectively, such that they partially overlap each other when viewed from the second direction D12.

[0024] Figure 8 is a diagram illustrating an example of the second layer molding step S2 according to one embodiment. In one embodiment, as illustrated in Figure 8, in the second layer molding step S2, the nozzle 2 is moved along the front-rear direction D1 (first direction D11) while maintaining the distance h from the discharge port 2a to the first layer L1 within a predetermined range, and a constant amount of cement-based material M is discharged from the nozzle 2 to form the second layer L2. In other words, in the second layer molding step S2, the nozzle 2 is moved alternately upward or downward. For this reason, as illustrated in Figure 8, the second layer L2 has an engaging portion 50 that protrudes downward, and the engaging portion 50 is formed to engage with each of the multiple protrusions (including the first protrusion 10 and the second protrusion 20) of the first layer L1.

[0025] (Effects / Actions) The operation and effects of a molding method according to one embodiment will be described. Figure 9 is a perspective view showing the arrangement of the first protrusion 10, the second protrusion 20, and the third protrusion 30 according to one embodiment. As illustrated in Figure 9, according to one embodiment, the first protrusion 10, the second protrusion 20, and the third protrusion 30 are arranged in a staggered pattern. More specifically, the third protrusion 30 partially overlaps with the first protrusion 10 and the second protrusion 20 when viewed from the left-right direction D2 (second direction D12). Furthermore, since the wall 100A includes a first layer L1 in which the first protrusion 10, the second protrusion 20, and the third protrusion 30 are arranged in a staggered pattern, the strength against forces acting in the left-right direction D2 can be increased. In addition, the molding method according to this disclosure has been modified in the lamination process of the cement-based material M to increase the strength against forces acting in the left-right direction D2, and for example, the insertion process of reinforcing material as described in Patent Document 1 is unnecessary. Therefore, the method for manufacturing molded objects according to this disclosure can suppress an increase in man-hours.

[0026] Furthermore, this disclosure is not limited to the case where the third protrusion 30 partially overlaps with each of the first protrusion 10 and the second protrusion 20 when viewed from the left-right direction D2. In some embodiments, the third protrusion 30 partially overlaps with one of the first protrusion 10 and the second protrusion 20 when viewed from the left-right direction D2. In some embodiments, the third protrusion 30 does not overlap with each of the first protrusion 10 and the second protrusion 20 when viewed from the left-right direction D2.

[0027] According to one embodiment, the second layer L2 is fabricated in the second layer fabrication step S2, thereby enabling the engagement portion 50 of the second layer L2 to engage with the first protrusion 10 and the second protrusion 20 of the first layer L1, respectively. Therefore, even if a force is applied to the wall 100A in the front-rear direction D1 (first direction D11), the displacement of the second layer L2 relative to the first layer L1 is suppressed. In other words, it is possible to provide a wall 100A that has increased strength against forces acting in the front-rear direction D1.

[0028] According to one embodiment, in the second layer molding step S2, a constant amount of cement-based material M is discharged from the nozzle 2 while moving the nozzle 2 forward while maintaining the interval h within a predetermined range. As a result, the second layer L2, which is engaged with the first layer L1 and has a length D3 in the vertical direction maintained, can be easily molded.

[0029] According to one embodiment, in the first protrusion formation step S11, the amount of cement-based material M is increased or decreased while the nozzle 2 is moved forward, so that the first layer L1 including the first protrusion 10 can be easily fabricated. According to one embodiment, in the first layer fabrication step S1, the cement-based material M is continuously discharged from the nozzle 2 while the nozzle 2 is moved along the first line X1, so that the first layer L1 including the first protrusion 10 and the second protrusion 20 can be easily fabricated.

[0030] In one embodiment, the cement-based material M was discharged while the nozzle 2 was moved in the forward / backward direction D1 to form the first protrusion 10, the second protrusion 20, and the third protrusion 30, respectively. However, this disclosure does not limit the method for forming the first protrusion 10, the second protrusion 20, and the third protrusion 30 to this embodiment.

[0031] An example of another method for forming the first protrusion 10, the second protrusion 20, and the third protrusion 30 will be described. Figure 10 is a flowchart of the first protrusion forming step S11 according to another embodiment. As illustrated in Figure 10, the first protrusion forming step S11 according to another embodiment includes a moving step S11a, a proximity step S11b, a discharge step S11c, a discharge stop step S11d, and a separation step S11e.

[0032] Figure 11A is a diagram illustrating an example of a moving step S11a according to another embodiment. In another embodiment, as illustrated in Figure 11A, the moving step S11a moves the nozzle 2 to above a first predetermined position p11 on the first surface 111 of the foundation 110 on which the first layer L1 is laid. The first predetermined position p11 is the position where the first protrusion 10 is to be formed, for example, the position of the center 11 of the first protrusion 10. No cement-based material M is discharged from the nozzle 2 in the moving step S11a.

[0033] Figure 11B is a diagram illustrating an example of the proximity step S11b according to another embodiment. In another embodiment, as illustrated in Figure 11B, the proximity step S11b moves the nozzle 2, which has been moved to a first predetermined position p11 by the movement step S11a, downward to bring it closer to the first surface 111.

[0034] Figure 11C is a diagram illustrating an example of the discharge step S11c according to another embodiment. In another embodiment, as illustrated in Figure 11C, the discharge step S11c discharges the cement-based material M from the nozzle 2 toward the first surface 111 while maintaining the position of the nozzle 2 that has approached the first surface 111 by the proximity step S11b.

[0035] Figure 11D is a diagram illustrating an example of a discharge stop step S11d according to another embodiment. In another embodiment, as illustrated in Figure 11D, the discharge stop step S11d stops the discharge of the cement-based material M when the upper end p20 of the cement-based material M discharged onto the first surface 111 by the discharge step S11c is located above the discharge port 2a of the nozzle 2. In other words, the discharge of the cement-based material M is stopped when the tip of the nozzle 2 is embedded in the cement-based material M discharged onto the first surface 111.

[0036] Figure 11E is a diagram illustrating an example of a separation step S11e according to another embodiment. In another embodiment, as illustrated in Figure 11E, in the separation step S11e, the nozzle 2, which has stopped discharging the cement-based material M by the discharge stop step S11d, is moved upward to separate it from the first surface 111. As a result, the tip of the nozzle 2 is pulled away from the cement-based material M discharged onto the first surface 111, and a recessed portion 13 is formed in the first convex portion 10, with the upper surface sloping downwards as it approaches the center 11 of the first convex portion 10.

[0037] In another embodiment, the discharge stop step S11d stops the discharge of the cement-based material M when the length h2 from the upper end p20 to the first surface 111 is 10% or more of the diameter of the discharge port 2a. This makes it possible to create a first layer L1 that has sufficient strength against forces acting in the second direction.

[0038] Figure 12 is a flowchart of the second protrusion formation step S12 according to another embodiment. In another embodiment, the second protrusion formation step S12 is performed after the first protrusion formation step S11. As illustrated in Figure 12, the second protrusion formation step S12 according to another embodiment includes a second movement step S12a, a second proximity step S12b, a second discharge step S12c, a second discharge stop step S12d, and a second separation step S12e.

[0039] In the second movement step S12a, the nozzle 2, which was separated from the first surface 111 by the separation step S11e, is moved from the first predetermined position p11 to above the second predetermined position p12 on the first surface 111. The second predetermined position p12 is the position where the second protrusion 20 is to be formed, for example, the position of the center 21 of the second protrusion 20. No cement-based material M is discharged from the nozzle 2 in the second movement step S12a.

[0040] In the second proximity step S12b, the nozzle 2, which has been moved to the second predetermined position p12 by the second movement step S12a, is moved downward to approach the first surface 111. In the second discharge step S12c, while maintaining the position of the nozzle 2 that has approached the first surface 111 by the second proximity step S12b, the cement-based material M is discharged from the nozzle 2 toward the first surface 111.

[0041] In the second discharge stop step S12d, the discharge of the cement-based material M is stopped when the upper end of the cement-based material M discharged onto the first surface 111 by the second discharge step S12c is located above the discharge port 2a of the nozzle 2. In the second separation step S12e, the nozzle 2, which has stopped discharging the cement-based material M by the second discharge stop step S12d, is separated from the first surface 111. As a result, the second protrusion 20 forms a recessed portion 23 whose upper surface slopes downward as it approaches the center 21 of the second protrusion 20.

[0042] Figure 13 is a flowchart of the third protrusion formation step S13 according to another embodiment. In another embodiment, the third protrusion formation step S13 is performed after the second protrusion formation step S12. As illustrated in Figure 13, the third protrusion formation step S13 according to another embodiment includes a third movement step S13a, a third proximity step S13b, a third discharge step S13c, a third discharge stop step S13d, and a third separation step S13e.

[0043] In the third movement step S13a, the nozzle 2, which was separated from the first surface 111 by the second separation step S12e, is moved from the second predetermined position p12 to above the third predetermined position p13 on the first surface 111. The third predetermined position p13 is the position where the third protrusion 30 is to be formed, for example, the position of the center 31 of the third protrusion 30. No cement-based material M is discharged from the nozzle 2 in the third movement step S13a.

[0044] In the third proximity step S13b, the nozzle 2, which has been moved to a third predetermined position p13 by the third movement step S13a, is moved downward to approach the first surface 111. In the third discharge step S13c, while maintaining the position of the nozzle 2 that has approached the first surface 111 by the third proximity step S13b, the cement-based material M is discharged from the nozzle 2 toward the first surface 111.

[0045] In the third discharge stop step S13d, the discharge of the cement-based material M is stopped when the upper end of the cement-based material M discharged onto the first surface 111 by the third discharge step S13c is located above the discharge port 2a of the nozzle 2. In the third separation step S13e, the nozzle 2, which has stopped discharging the cement-based material M by the third discharge stop step S13d, is separated from the first surface 111. As a result, the third protrusion 30 has a recessed portion 33 formed such that its upper surface slopes downward as it approaches the center 31 of the third protrusion 30.

[0046] Figure 14 is a top view showing the arrangement of the first protrusion 10, the second protrusion 20, and the third protrusion 30 according to another embodiment. As shown in Figure 14, the first line segment Y1 connects the center 11 of the first protrusion 10 and the center 21 of the second protrusion 20, the second line segment Y2 connects the center 21 of the second protrusion 20 and the center 31 of the third protrusion 30, and the third line segment Y3 connects the center 11 of the first protrusion 10 and the center 31 of the third protrusion 30. The region on the first layer L1 that is triangularly partitioned by the first line segment Y1, the second line segment Y2, and the third line segment Y3 is defined as the first region R1.

[0047] In another embodiment, the second layer formation step S2 includes a fourth protrusion formation step S14 in which cement-based material M is extruded from the additive manufacturing machine 1 into the first region R1 to form a fourth protrusion 40 that is raised above the surrounding area. Figure 15 is a flowchart of the fourth protrusion formation step S14 according to another embodiment. As illustrated in Figure 15, the fourth protrusion formation step S14 according to another embodiment includes a fourth movement step S14a, a fourth proximity step S14b, a fourth extrusion step S14c, a fourth extrusion stop step S14d, and a fourth separation step S14e.

[0048] In the fourth movement step S14a, the nozzle 2 is moved to above the fourth predetermined position p14 on the first surface 111 of the foundation 110. At this time, the nozzle 2 is located above the upper surface of the first layer L1. The fourth predetermined position p14 is the position where the fourth protrusion 40 is to be formed, for example, the position of the center 41 of the fourth protrusion 40. In some embodiments, the fourth predetermined position p14 is the centroid position of the triangular first region R1. In the fourth movement step S14a, no cement-based material M is discharged from the nozzle 2.

[0049] In the fourth proximity step S14b, the nozzle 2, which has been moved to the fourth predetermined position p14 by the fourth movement step S14a, is moved downward to bring it closer to the upper surface of the first layer L1. In the fourth discharge step S14c, while maintaining the position of the nozzle 2 that has been brought closer to the upper surface of the first layer L1 by the fourth proximity step S14b, the cement-based material M is discharged from the nozzle 2 toward the upper surface of the first layer L1.

[0050] In the fourth discharge stop step S14d, the discharge of the cement-based material M is stopped when the upper end of the cement-based material M discharged onto the upper surface of the first layer L1 by the fourth discharge step S14c is located above the discharge port 2a of the nozzle 2. In the fourth separation step S14e, the nozzle 2, which has stopped discharging the cement-based material M by the fourth discharge stop step S14d, is separated from the upper surface of the first layer L1. As a result, the fourth protrusion 40 forms a recessed portion 43 (not shown) whose upper surface slopes downward as it approaches the center 41 of the fourth protrusion 40.

[0051] According to another embodiment, a first layer L1 in which a first protrusion 10, a second protrusion 20, and a third protrusion 30 are arranged in a staggered pattern can be easily fabricated. According to yet another embodiment, a second layer L2 including engaging portions 50 that engage with the first protrusion 10 and the second protrusion 20 of the first layer L1 can be easily fabricated.

[0052] In another embodiment, the second protrusion formation step S12 was performed after the first protrusion formation step S11 and before the third protrusion formation step S13, but the disclosure is not limited to this embodiment. The disclosure does not limit the order in which the first protrusion 10, the second protrusion 20, and the third protrusion 30 are formed. In some embodiments, the third protrusion formation step S13 is performed after the first protrusion formation step S11 and before the second protrusion formation step S12.

[0053] In another embodiment, the first protrusion forming step S11 formed the first protrusion 10 such that a recess 13 was formed on the upper surface of the first protrusion 10, but the disclosure is not limited to this embodiment. Figure 16 is a diagram illustrating the configuration of the first layer L1 according to yet another embodiment.

[0054] In yet another embodiment, in the discharge stop step S11d of the first protrusion formation step S11, the discharge of the cement-based material M, which is discharged onto the first surface 111 by the discharge step S11c, is stopped before it reaches the discharge port 2a of the nozzle 2 in the vertical direction D3. For this reason, the first protrusion 10 has a hemispherical shape. Similarly, in the second discharge stop step S12d of the second protrusion formation step S12, the discharge of the cement-based material M, which is discharged onto the first surface 111 by the second discharge step S12c, is stopped before it reaches the discharge port 2a of the nozzle 2 in the vertical direction D3. For this reason, the second protrusion 20 has a hemispherical shape. In the third discharge stop step S13d of the third protrusion formation step S13, the discharge of the cement-based material M, which is discharged onto the first surface 111 by the third discharge step S13c, is stopped before it reaches the discharge port 2a of the nozzle 2 in the vertical direction D3. For this reason, the third protrusion 30 has a hemispherical shape.

[0055] In yet another embodiment, the first convex formation step S11 forms a plurality of convex portions (including a first convex portion 10 and a second convex portion 20) aligned along a first direction D11, and the second convex formation step S12 forms a plurality of convex portions (including a third convex portion 30) aligned along the first direction D11 on a second line X2 obtained by offsetting the first line X1 to one side of the second direction D12. As illustrated in Figure 16, in yet another embodiment, the first layer L1 includes a plurality of convex portions aligned along the first direction D11 on the nth line Xn (where n is a natural number greater than or equal to 3).

[0056] The contents described in each of the above embodiments can be understood, for example, as follows:

[0057] [1] The method for manufacturing the object relating to this disclosure is: A method for creating a molded object (100) by layering cement-based material (M) in an additive manufacturing machine (1), A first layer fabrication step (S1) in which an arbitrary first layer (L1) constituting the aforementioned fabricated object is fabricated, The first protrusion forming step (S11) involves extruding the cement-based material from the additive manufacturing machine to form a first protrusion (10) that is raised higher than the surrounding area, A second protrusion forming step in which the cement-based material is extruded from the additive manufacturing machine to form a second protrusion (20) that is raised higher than the surrounding area, wherein a line extending horizontally passing through the center (11) of the first protrusion and the center (21) of the second protrusion is defined as a first line (X1), and the direction in which the first line extends is defined as a first direction (D11), and the second protrusion is formed on the first line at a position adjacent to the first protrusion. The first layer fabrication step includes a third protrusion forming step in which the cement-based material is extruded from the additive fabrication machine to form a third protrusion (30) that is raised higher than the surrounding area, wherein when the direction perpendicular to the first direction in the horizontal direction is defined as the second direction (D12), the third protrusion (30) is formed at a position offset in the second direction with respect to the first line and adjacent to the first protrusion and the second protrusion, respectively.

[0058] According to the method described in [1] above, a molded object is produced that includes a first layer in which the first, second, and third protrusions are arranged in a staggered pattern (the third protrusion partially overlaps with the first and second protrusions when viewed from the second direction). Therefore, it is possible to provide a molded object with increased strength against forces acting in the second direction. Furthermore, the molded object manufacturing method according to this disclosure is designed to increase strength against forces acting in the second direction by modifying the lamination process of cement-based materials, and does not require, for example, the insertion process of reinforcing material as described in Patent Document 1. Therefore, the molded object manufacturing method according to this disclosure can suppress an increase in man-hours.

[0059] [2] In some embodiments, the method described in [1] above, The process further includes a second layer formation step, in which the cement-based material is extruded from the additive manufacturing machine after the first layer formation step to form a second layer to be laminated on the first layer.

[0060] According to the method described in [2] above, the second layer is engaged with the first layer. Therefore, even if a force is applied to the fabricated object in the first direction, the displacement of the second layer relative to the first layer is suppressed. In other words, it is possible to provide a fabricated object that has increased strength against forces acting in the first direction.

[0061] [3] In some embodiments, the method described in [2] above, The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The second layer forming step involves forming the second layer by discharging a constant amount of the cement-based material from the nozzle while moving the nozzle along the first direction, maintaining the distance from the discharge port to the first layer within a predetermined range.

[0062] According to the method described in [3] above, a second layer that engages with the first layer can be easily fabricated.

[0063] [4] In some embodiments, the method described in [2] above, The second layer forming step includes a fourth protrusion forming step in which the cement-based material is extruded from the additive manufacturing machine into a region on the first layer defined by a first line segment connecting the center of the first protrusion and the center of the second protrusion, a second line segment connecting the center of the second protrusion and the center of the third protrusion, and a third line segment connecting the center of the first protrusion and the center of the third protrusion, thereby forming a fourth protrusion that is raised higher than the surrounding area.

[0064] According to the method described in [4] above, a second layer that engages with the first layer can be easily fabricated.

[0065] [5] In some embodiments, the method described in any one of [1] to [4] above, The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The first protrusion forming step involves discharging the cement-based material while moving the nozzle along the first direction to form the first protrusion.

[0066] According to the method described in [5] above, the first layer including the first protrusion can be easily fabricated.

[0067] [6] In some embodiments, the method described in [5] above, The first protrusion formation step and the second protrusion formation step are performed continuously while moving the nozzle along the first line.

[0068] According to the method described in [6] above, a first layer including the first and second protrusions can be easily fabricated.

[0069] [7] In some embodiments, the method described in any one of [1] to [3] above, The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The first step of forming the protrusion is: A moving step of moving the nozzle to a position above a first predetermined position on the first surface on which the first layer is stacked, A proximity step brings the nozzle, which has been moved to the first predetermined position by the aforementioned movement step, closer to the first surface, A discharge step in which the cement-based material is discharged from the nozzle toward the first surface while maintaining the position of the nozzle that has approached the first surface by the proximity step, A discharge stop step that stops the discharge of the cement-based material when the upper end of the cement-based material discharged to the first surface by the discharge step is located above the discharge port of the nozzle, The method includes a separation step of separating the nozzle, which has stopped discharging the cement-based material by the discharge stop step, from the first surface.

[0070] According to the method described in [7] above, the first layer including the first protrusion can be easily fabricated.

[0071] [8] In some embodiments, the method described in [7] above, After the first protrusion formation step, the second protrusion formation step is performed. The second protrusion formation step is: The process includes a second movement step of moving the nozzle to a position above a second predetermined position on the first surface.

[0072] According to the method described in [8] above, a second protrusion can be formed after the first protrusion.

[0073] [9] In some embodiments, the method described in [7] above, After the first protrusion formation step, the third protrusion formation step is performed. The third step of forming the protrusion is: This includes a third movement step of moving the nozzle to a position above a third predetermined position on the first surface.

[0074] According to the method described in [9] above, a third protrusion can be formed after the first protrusion. [Explanation of Symbols]

[0075] 1. Additive Manufacturing Machine 2 nozzles 2a Discharge port 4 Moving mechanism 6. Supply pump 8 Control device 10 First protrusion 11 Center of the first convex part 13 Recessed portion on the upper surface of the first protrusion 20 Second protrusion 21 Center of the second convex part 23 Recessed portion on the upper surface of the second protrusion 30 Third protrusion 31 Center of the third convex part 33 Recessed portion on the upper surface of the third protrusion 40 Fourth protrusion 41 Center of the fourth convex part 43 Recessed portion on the upper surface of the fourth protrusion 50 Engagement part 100 Sculptures 100A Wall 110 Basics 111 Page 1 D1 Anteroposterior direction D2 Left / right direction D3 Vertical direction D11 1st direction D12 2nd direction L1 1st layer L2 2nd layer M Cement-based materials R1 1st area S1 First layer molding step S2 Second layer molding step S11 First protrusion formation step S11a Movement step S11b Proximity Step S11c Discharge Step S11d Discharge stop step S11e Separation step S12 Step for forming the second protrusion S12a Second Movement Step S12b Second proximity step S12c Second discharge step S12d Second discharge stop step S12e Second separation step S13 Step for forming the third protrusion S13a Third Movement Step S13b Third proximity step S13c Third Discharge Step S13d Third discharge stop step S13e Third Separation Step S14 Step for forming the fourth protrusion S14a Fourth Movement Step S14b Fourth proximity step S14c Fourth discharge step S14d Fourth discharge stop step S14e Fourth Separation Step X1 Line 1 X2 2nd Line Y1 First line segment Y2 Second Line Segment Y3 Third Line Segment h interval p1 1st position p2 2nd position p3 3rd position p4 4th position p5 5th position p6 6th position p11 First predetermined position p12 Second designated position p13 Third designated position p14 Fourth designated position p20 top

Claims

1. A method for creating objects by layering cement-based materials in an additive manufacturing machine, A first layer fabrication step in which an arbitrary first layer constituting the aforementioned fabricated object is fabricated, A first protrusion forming step involves extruding the cement-based material from the additive manufacturing machine to form a first protrusion that is raised higher than the surrounding area, A second protrusion forming step comprising extruding the cement-based material from the additive manufacturing machine to form a second protrusion that is raised higher than the surrounding area, wherein a line extending horizontally passing through the center of the first protrusion and the center of the second protrusion is defined as a first line, and the direction in which the first line extends is defined as a first direction, and the second protrusion is formed on the first line at a position adjacent to the first protrusion. A first layer fabrication step comprising: a third protrusion forming step in which the cement-based material is extruded from the additive fabrication machine to form a third protrusion that is raised higher than the surrounding area, wherein, when the direction perpendicular to the first direction in the horizontal direction is defined as the second direction, the third protrusion is formed offset in the second direction with respect to the first line and adjacent to the first and second protrusions, respectively. Modeling method.

2. The process further includes a second layer formation step, in which, after the first layer formation step, the cement-based material is extruded from the additive manufacturing machine to form a second layer to be laminated onto the first layer. The method for creating a molded object according to claim 1.

3. The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The second layer forming step involves forming the second layer by discharging a constant amount of the cement-based material from the nozzle while moving the nozzle along the first direction, maintaining the distance from the discharge port to the first layer within a predetermined range. The method for creating a molded object according to claim 2.

4. The second layer forming step includes a fourth protrusion forming step in which the cement-based material is extruded from the additive manufacturing machine into a region on the first layer defined by a first line segment connecting the center of the first protrusion and the center of the second protrusion, a second line segment connecting the center of the second protrusion and the center of the third protrusion, and a third line segment connecting the center of the first protrusion and the center of the third protrusion, thereby forming a fourth protrusion that is raised higher than the surrounding area. The method for creating a molded object according to claim 2.

5. The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The first protrusion forming step involves discharging the cement-based material while moving the nozzle along the first direction to form the first protrusion. A method for creating a molded object according to any one of claims 1 to 4.

6. The first protrusion formation step and the second protrusion formation step are performed continuously while moving the nozzle along the first line. The method for creating a molded object according to claim 5.

7. The additive manufacturing machine includes a nozzle having an outlet for dispensing the cement-based material, and a moving mechanism for moving the nozzle. The first step of forming the protrusion is, A moving step of moving the nozzle to a position above a first predetermined position on the first surface on which the first layer is stacked, A proximity step is made to bring the nozzle, which has been moved to the first predetermined position by the movement step, closer to the first surface. A discharge step in which the cement-based material is discharged from the nozzle toward the first surface while maintaining the position of the nozzle that has approached the first surface by the proximity step, A discharge stop step that stops the discharge of the cement-based material when the upper end of the cement-based material discharged to the first surface by the discharge step is located above the discharge port of the nozzle, The method includes a separation step of separating the nozzle, which has stopped discharging the cement-based material by the discharge stop step, from the first surface. A method for creating a molded object according to any one of claims 1 to 4.

8. After the first protrusion formation step, the second protrusion formation step is performed. The second protrusion formation step is: The process includes a second movement step of moving the nozzle to a position above a second predetermined position on the first surface, The method for creating a molded object according to claim 7.

9. After the first protrusion formation step, the third protrusion formation step is performed. The third step of forming the protrusion is as follows: This includes a third movement step of moving the nozzle to a position above a third predetermined position on the first surface, The method for creating a molded object according to claim 7.

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