Method for manufacturing three-dimensional object and three-dimensional modeling device

Abstract

To provide a method for manufacturing a three-dimensional molded article and a three-dimensional molding device which can improve strength of a three-dimensional molded article.SOLUTION: A method for manufacturing a three-dimensional molded article includes: a plasticization step of plasticizing at least a part of a molding material containing a first fiber material and a thermoplastic resin, and generating a plasticization material discharged from a nozzle opening for molding a three-dimensional molded article; a fiber introduction step including at least either one of a step of introducing a second material longer than the first fiber material into the molding material or the plasticization material before discharged from the nozzle opening, and a step of introducing the second fiber material into the plasticization material after discharged from the nozzle opening; and a molding step of molding a three-dimensional molded article containing the first fiber material and the second fiber material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a three-dimensional object and a three-dimensional printing apparatus. [Background technology]

[0002] There are various known manufacturing methods for forming a three-dimensional object by injecting a plasticized material, which is a plasticized thermoplastic resin, from a nozzle onto a stage. For example, the following Patent Document 1 discloses a technique for forming a three-dimensional object containing a fiber material therein by introducing a fiber material, such as carbon fiber, into a thermoplastic resin softened by heating a thermoplastic resin such as a filament, and injecting the softened thermoplastic resin from a nozzle. By introducing a fiber material into the interior, as in the technique of Patent Document 1, the strength of the three-dimensional object can be increased. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 15 / 182675 Brochure Summary of the Invention [Problem to be solved by the invention]

[0004] When a three-dimensional object is formed by introducing a continuous linear fiber material as in the technique of Patent Document 1, it is easy to improve the strength of the fiber material in the length direction. However, there are cases where the strength of the fiber material in a direction intersecting the length direction is not sufficiently improved. Thus, in the technique of forming a three-dimensional object by introducing a fiber material, there is still room for improvement in terms of improving the strength of the three-dimensional object in various directions. [Means for solving the problem]

[0005] The present invention has been made to solve the above-mentioned problems, and can be realized as the following application examples.

[0006] A method for manufacturing a three-dimensional object according to an application example of the present invention includes a plasticization process for plasticizing at least a portion of a modeling material containing a first fiber material and a thermoplastic resin to generate a plasticized material to be discharged from a nozzle opening for modeling a three-dimensional object; a fiber introduction step including either a step of introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening, or a step of introducing the second fiber material into the plasticized material after it is discharged from the nozzle opening; and a modeling process for modeling the three-dimensional object containing the first fiber material and the second fiber material.

[0007] In addition, in a manufacturing method of a three-dimensional object according to another application example of the present invention, the modeling step includes: a first modeling process for forming a first portion which is a part of the three-dimensional object and contains the first fiber material and the second fiber material; and a second modeling process for forming a second portion that is a part of the three-dimensional object, the second portion including the first fiber material and not including the second fiber material.

[0008] In a method for manufacturing a three-dimensional object according to another application example of the present invention, the modeling step includes: a moving step of relatively moving a stage supporting the three-dimensional object and a nozzle unit having the nozzle opening; The method also includes an introduction speed control process for changing an introduction speed at which the second fiber material is introduced into the modeling material or the plasticizing material in accordance with the relative movement speed between the nozzle portion and the stage in the movement process.

[0009] In a method for manufacturing a three-dimensional object according to another application example of the present invention, the plasticizing step includes a plasticizing device including: a flat screw having a groove forming surface on which a groove portion is formed; a facing portion having an opposing surface facing the groove forming surface and having a communication hole communicating with the nozzle opening formed therein; and a heater for heating the flat screw or the facing portion, The method includes a step of plasticizing the shaping material supplied between the flat screw and the facing portion and guiding the material to the communicating hole by rotating the flat screw and heating the heater.

[0010] In a method for manufacturing a three-dimensional object according to another application example of the present invention, a through hole that opens in the groove formation surface and communicates with the communication hole is formed in the flat screw, The fiber introducing step includes a step of introducing the second fiber material through the through holes into the plasticized material before it is discharged from the nozzle opening.

[0011] A method for manufacturing a three-dimensional object according to another application example of the present invention includes a pressure control step of controlling the pressure in the through hole to be higher than the pressure in the communicating hole.

[0012] In a method for manufacturing a three-dimensional object according to another application example of the present invention, an introduction groove is formed in the groove formation surface or the facing surface, the introduction groove introducing the second fiber material from a side of the flat screw or the facing portion to the communicating hole, The fiber introducing step includes a step of introducing the second fiber material into the modeling material through the introduction groove.

[0013] A method for producing a three-dimensional object according to another application example of the present invention includes a cutting step of cutting the second fiber material.

[0014] In addition, in a method for manufacturing a three-dimensional object according to another application example of the present invention, the cutting process includes a step of cutting the second fiber material by operating a discharge amount control mechanism that is provided upstream of the nozzle opening and controls the discharge amount of the plasticizing material.

[0015] In a method for manufacturing a three-dimensional object according to another application example of the present invention, the discharge amount control mechanism is driven by a motor, The fiber introduction step includes a step of transmitting the driving force generated by the motor to a conveying section of the second fiber material and using the driving force as a conveying force for the second fiber material.

[0016] Furthermore, a three-dimensional printing apparatus according to an application example of the present invention includes a plasticizing unit that generates a plasticized material for printing a three-dimensional object by plasticizing at least a part of a printing material including a first fiber material and a thermoplastic resin; a discharge section having a nozzle opening for discharging the plasticized material; and a fiber introduction section having either a function of introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening, or a function of introducing the second fiber material into the plasticized material after it is discharged from the nozzle opening; a control unit that controls the plasticizing unit, the discharging unit, and the fiber introduction unit to form the three-dimensional object containing the first fiber material and the second fiber material; has. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the first embodiment. [Diagram 2] FIG. 2 is a schematic perspective view showing the configuration of a flat screw. [Diagram 3] FIG. 3 is a schematic plan view showing the configuration of the opposing surface in the opposing portion. [Figure 4] FIG. 4 is a schematic diagram showing how a three-dimensional object is formed. [Diagram 5] FIG. 5 is a flowchart showing steps executed in the modeling process according to the first embodiment. [Figure 6] FIG. 6 is a schematic cross-sectional view of a modeling layer formed in the modeling process of the first embodiment. [Figure 7] FIG. 7 is a flowchart showing steps executed in the modeling process according to the second embodiment. [Figure 8] FIG. 8 is a schematic cross-sectional view of a three-dimensional object formed by the modeling process of the second embodiment. [Figure 9] FIG. 9 is a flowchart showing steps executed in the modeling process according to the third embodiment. [Figure 10] FIG. 10 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the fourth embodiment. [Figure 11] FIG. 11 is a flowchart showing steps executed in the modeling process according to the fourth embodiment. [Figure 12] FIG. 12 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the fifth embodiment. [Figure 13] FIG. 13 is a schematic plan view showing the configuration of the opposing surface in the opposing portion of the fifth embodiment. [Figure 14] FIG. 14 is a flowchart showing steps executed in the modeling process according to the fifth embodiment. [Figure 15] FIG. 15 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the sixth embodiment. [Figure 16] FIG. 16 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the seventh embodiment. [Figure 17] FIG. 17 is a schematic diagram showing the configuration of a discharge amount control mechanism of the seventh embodiment. [Figure 18] FIG. 18 is a schematic diagram showing a mechanism by which the discharge amount control mechanism of the seventh embodiment cuts a fiber material. [Figure 19] FIG. 19 is a schematic diagram showing the configuration of a discharge amount control mechanism according to the eighth embodiment. [Figure 20] FIG. 20 is a schematic diagram showing a mechanism by which the discharge amount control mechanism of the eighth embodiment cuts a fiber material. [Figure 21] FIG. 21 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the ninth embodiment. [Figure 22] FIG. 22 is a flowchart showing steps executed in the modeling process of the ninth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for producing a three-dimensional object and a three-dimensional modeling apparatus according to the present invention will be described in detail with reference to the embodiments shown in the accompanying drawings.

[0019] [1] First embodiment Fig. 1 is a schematic diagram showing the configuration of a three-dimensional printing apparatus 100a that executes a manufacturing method for a three-dimensional object in a first embodiment. Arrows indicating mutually orthogonal X, Y, and Z directions are shown in Fig. 1. The X and Y directions are parallel to a horizontal plane, and the Z direction is opposite to the direction of gravity. Arrows indicating the X, Y, and Z directions are also shown as necessary in other figures to be referred to later so as to correspond to Fig. 1.

[0020] The three-dimensional printing apparatus 100a includes a control unit 10, a discharge unit 20, and a printing stage unit 70. Under the control of the control unit 10, the three-dimensional printing apparatus 100a forms a three-dimensional object by stacking modeling layers formed by the discharge unit 20 discharging a plasticized material onto the printing stage unit 70. Hereinafter, the "three-dimensional object" will also be referred to simply as the "modeled object", and the "three-dimensional printing apparatus" will also be referred to as the "printing apparatus".

[0021] The control unit 10 controls the overall operation of the modeling apparatus 100a and executes a modeling process for modeling an object. In the first embodiment, the control unit 10 is configured by a computer including one or more processors (CPUs) and a main memory device (RAM). The control unit 10 performs various functions by the processor executing programs and instructions loaded onto the main memory device. At least a part of the functions of the control unit 10 may be realized by a hardware circuit.

[0022] The discharge unit 20 includes a material generation unit 21, a fiber introduction unit 23, and a nozzle unit 25. The material generation unit 21 plasticizes at least a portion of the modeling material PM containing a first fiber material FBa and a thermoplastic resin to generate a plasticized material. The first fiber material FBa and the plasticized material will be described later. The fiber introduction unit 23 introduces a second fiber material FBb into the plasticized material generated by the material generation unit 21. The second fiber material FBb will be described later. The nozzle unit 25 discharges the plasticized material. Below, the configurations of the material generation unit 21, the nozzle unit 25, and the fiber introduction unit 23 will be described in more detail in this order.

[0023] The material generating unit 21 includes a material supplying unit 30 and a plasticizing unit 35. The material supplying unit 30 supplies the modeling material PM, which is a raw material for generating the plasticized material, to the plasticizing unit 35. In this embodiment, the material supplying unit 30 is configured as a so-called hopper, and includes a material accommodation unit 31 that accommodates the modeling material PM that has been input, and a communication passage 32 that is connected to an outlet at the bottom of the material supplying unit 30 and that guides the modeling material PM from the material supplying unit 30 to the plasticizing unit 35.

[0024] The molding material PM is fed into the material supply unit 30 in the form of pellets. The molding material PM contains a thermoplastic resin as a main component. Examples of the thermoplastic resin contained in the molding material PM include polypropylene resin (PP), polyethylene resin (PE), polyacetal resin (POM), polyvinyl chloride resin (PVC), polyamide resin (PA), acrylonitrile-butadiene-styrene resin (ABS), polylactic acid resin (PLA), polyphenylene sulfide resin (PPS), polyether ether ketone (PEEK), and polycarbonate (PC). In addition to the thermoplastic resin, the molding material PM fed into the material supply unit 30 may contain pigments, metals, ceramics, and the like. The molding material PM does not have to be fed into the material supply unit 30 as pellets, and may be fed in the form of a solid material such as powder.

[0025] As described above, the molding material PM contains the first fiber material FBa in addition to the thermoplastic resin. In this embodiment, the first fiber material FBa is mixed into the pellets fed into the material supply unit 30. The first fiber material FBa is, for example, made of carbon fiber. The first fiber material FBa may be made of a fiber material other than carbon fiber, for example, made of glass fiber. The first fiber material FBa may also be made of various fibers having a higher elastic modulus than the resin material.

[0026] The fiber diameter of the first fiber material FBa can be, for example, 5 μm or more and 20 μm or less. In this specification, the "fiber diameter" of the fiber material corresponds to the maximum width dimension in a cross section perpendicular to the length direction of the fiber material. Therefore, for example, when the cross section of the fiber material is substantially circular, the fiber diameter corresponds to the maximum diameter of the circle. When the cross section of the fiber material is substantially rectangular, the fiber diameter corresponds to the longer of the lengths of the sides of the rectangle. When the cross section of the fiber material is substantially elliptical, the fiber diameter corresponds to the major axis of the ellipse. In this embodiment, the first fiber material FBa is not composed of fiber bundles, and the fiber diameter of the first fiber material FBa corresponds to the fiber diameter of a single fiber material. In another embodiment, when the first fiber member FBa is composed of fiber bundles, the fiber diameter of the first fiber member FBa corresponds to the fiber diameter of the fiber bundle.

[0027] The length of the first fiber material FBa may be, for example, 5 mm or less. The length of the first fiber material FBa is preferably smaller than the maximum dimension of the pellets to be mixed. This allows a larger number of first fiber materials FBa to be mixed into the pellets. In addition, the length of the first fiber material FBa is preferably smaller than the hole diameter Dn of the nozzle opening 28 described below. This allows the plasticizing material containing the first fiber material FBa to be discharged smoothly from the nozzle opening 28.

[0028] In other embodiments, the first fiber material FBa does not have to be mixed in the pellets. For example, the first fiber material FBa may be fed into the material supply section 30 separately from the pellets of the thermoplastic resin, and kneaded with the thermoplastic resin in the plasticizing section 35 described below. With this configuration, the content of the first fiber material FBa in the thermoplastic resin can be appropriately adjusted.

[0029] The plasticizing unit 35 plasticizes at least a portion of the thermoplastic resin contained in the modeling material PM supplied from the material supply unit 30 to generate a plasticized material, and sends the plasticized material to the nozzle unit 25. The plasticizing unit 35 can also be referred to as a plasticizing device 35. The plasticizing unit 35 has a screw case 36, a drive motor 37, a flat screw 40, and a facing unit 50.

[0030] The flat screw 40 is a substantially cylindrical screw whose axial height along the rotation axis RX is smaller than its diameter. The rotation axis RX coincides with the central axis of the flat screw 40. In FIG. 1, the rotation axis RX of the flat screw 40 is illustrated by a dashed line. The flat screw 40 is disposed on the facing portion 50 so that the rotation axis RX is parallel to the Z direction, and rotates in the circumferential direction. A spiral groove portion 42 is formed on the lower surface 41 of the flat screw 40 facing the facing portion 50, which extends from the side surface to the rotation axis RX. Hereinafter, the lower surface 41 of the flat screw 40 is also referred to as the "groove forming surface 41". The communication passage 32 of the material supply portion 30 is connected to the groove portion 42 on the side surface of the flat screw 40. The specific configuration of the flat screw 40 will be described later.

[0031] The flat screw 40 is housed in the screw case 36. An upper surface 43 of the flat screw 40 is connected to the drive motor 37. The flat screw 40 rotates in the screw case 36 by a rotational driving force generated by the drive motor 37. The drive motor 37 is driven under the control of the control unit 10.

[0032] The facing portion 50 is also called a barrel, and is configured by a substantially cylindrical member whose height along its central axis is smaller than its diameter. In this embodiment, the facing portion 50 is disposed so that its central axis coincides with the rotation axis RX of the flat screw 40.

[0033] The facing part 50 has an opposing surface 51 facing the groove forming surface 41 of the flat screw 40. A space is formed between the groove portion 42 of the groove forming surface 41 and the facing surface 51 of the facing part 50. The modeling material PM supplied from the material supply part 30 flows into this space from the side surface of the flat screw 40. The modeling material PM supplied to the space in the groove portion 42 is guided to the center of the flat screw 40 by the rotation of the spiral groove portion 42 when the flat screw 40 rotates.

[0034] A heater 52 for heating the molding material PM is embedded in the facing surface 51 of the facing part 50. The heater 52 heats the flat screw 40 or the facing part 50. In another embodiment, the heater 52 may be embedded in the flat screw 40 or may be disposed separately from the flat screw 40 or the facing part 50. In addition, a communication hole 53 penetrating the facing part 50 along its central axis is provided in the center of the facing surface 51. As described later, the communication hole 53 communicates with the nozzle opening 28 via the introduction flow path 26 and the nozzle flow path 27 of the nozzle part 25. The communication hole 53 forms a flow path with a substantially circular cross section. The molding material PM supplied to the groove part 42 of the flat screw 40 is heated by the heater 52, and the thermoplastic resin contained therein is plasticized and converted into a plasticized material, and the molding material PM is guided along the groove part 42 to the communication hole 53 opening at the center of the facing surface 51 by the rotation of the flat screw 40. The downstream end of the communication hole 53 is connected to the nozzle portion 25. The plasticized material produced by the rotation of the flat screw 40 is supplied to the nozzle portion 25 through the communication hole 53.

[0035] The nozzle portion 25 includes an introduction flow passage 26, a nozzle flow passage 27, a nozzle opening 28, and a discharge amount control mechanism 80. The introduction flow passage 26 is connected to the downstream end of the communication hole 53 of the facing portion 50, and is provided linearly from the downstream end of the communication hole 53 along the Z direction. The introduction flow passage 26 forms a flow passage with a substantially circular cross section, and is provided so that its central axis coincides with the rotation axis RX of the flat screw 40. In this embodiment, the diameter of the introduction flow passage 26 is substantially equal to the diameter of the communication hole 53 of the facing portion 50.

[0036] The nozzle flow path 27 is connected to the downstream end of the introduction flow path 26 and is provided linearly from the downstream end of the introduction flow path 26 along the Z direction. The nozzle flow path 27 forms a flow path with a substantially circular cross section and is provided so that its central axis coincides with the rotation axis RX of the flat screw 40. The nozzle flow path 27 is reduced in diameter at its downstream end. In this embodiment, the diameter of the nozzle flow path 27 is substantially equal to the diameter of the introduction flow path 26 except for its downstream end. The nozzle opening 28 is an opening having a hole diameter Dn that opens in the Z direction and is provided at the downstream end of the nozzle flow path 27. The hole diameter Dn of the nozzle opening 28 can be, for example, 50 μm or more and 3 mm or less. In other embodiments, the hole diameter Dn may be smaller than 50 μm or larger than 3 mm. The plasticized material introduced from the material generating unit 21 to the nozzle unit 25 is discharged from the nozzle opening 28 via the introduction flow path 26 and the nozzle flow path 27.

[0037] The introduction flow passage 26 is provided with a discharge amount control mechanism 80. The discharge amount control mechanism 80 controls the flow rate of the plasticizing material in the introduction flow passage 26 to control the discharge amount of the plasticizing material from the nozzle opening 28. In this embodiment, the discharge amount control mechanism 80 is configured by a butterfly valve, which is a valve body that rotates in the introduction flow passage 26 under the control of the control unit 10. The opening area of ​​the introduction flow passage 26 changes depending on the rotation angle of the butterfly valve. The control unit 10 controls the rotation angle of the valve body to control the flow rate of the plasticizing material in the introduction flow passage 26. The discharge amount control mechanism 80 can close the introduction flow passage 26 so that the flow of the plasticizing material in the introduction flow passage 26 is stopped. Note that the discharge amount control mechanism 80 does not have to be provided in the introduction flow passage 26, and may be provided in the nozzle flow passage 27. In addition, the discharge amount control mechanism 80 does not have to be provided in the nozzle portion 25, and may be provided in the communication hole 53 of the facing portion 50, for example. The discharge amount control mechanism 80 may be omitted, or may be realized by a configuration other than a butterfly valve.

[0038] The fiber introduction unit 23 has a function of introducing a second fiber material FBb, which is longer than the first fiber material FBa, into the plasticized material before it is discharged from the nozzle opening 28 under the control of the control unit 10. In this embodiment, the second fiber material FBb is composed of a continuous linear member wound around a reel 62, which will be described later, and is introduced into the shaped object with a continuous length up to a cutting point by a cutting unit 66, which will be described later. The second fiber material FBb is introduced into the shaped object with a length equivalent to one pass, which will be described later, for example.

[0039] The second fiber material FBb is composed of a fiber bundle in which a plurality of fibers are bundled. In this embodiment, the second fiber material FBb has a configuration in which a plurality of carbon fibers are bundled by a bundling agent. In other embodiments, the second fiber material FBb may not be composed of carbon fibers, and may be composed of, for example, glass fibers. The second fiber material FBb may also be composed of various fibers having a higher elastic modulus than the resin material. The fiber diameter of the second fiber material FBb can be, for example, 10 μm or more and the hole diameter Dn of the nozzle opening 28 or less. If the hole diameter Dn of the nozzle opening 28 is larger than 500 μm, the fiber diameter of the second fiber material FBb can be 500 μm or less. The fiber diameter of the second fiber material FBb corresponds to the maximum width dimension in a cross section perpendicular to the length direction of the fiber bundle constituting the second fiber material FBb.

[0040] The fiber introducing section 23 includes a conveying section 60 that conveys the second fiber material FBb to introduce it. The conveying section 60 includes a storage section 63 that stores the second fiber material FBb wound around a reel 62, a conveying path 65 that sends out the second fiber material FBb from the storage section 63, and a cutting section 66 that cuts the second fiber material FBb.

[0041] The storage section 63 is provided with a conveying motor (not shown) that generates a conveying force to rotate the reel 62 and send out the second fiber material FBb through the conveying path 65. The rotation speed of the conveying motor is controlled by the control section 10. The conveying path 65 is configured of a cylindrical tubular member through which the second fiber material FBb is inserted. In this embodiment, the conveying path 65 is connected to the introduction flow path 26 so that the second fiber material FBb can be introduced into the plasticized material passing through the introduction flow path 26. In addition, the conveying path 65 is connected to the introduction flow path 26 downstream of the discharge amount control mechanism 80.

[0042] The fiber introduction section 23 sends out the second fiber material FBb to the introduction flow path 26 through the conveying path 65. The sent out second fiber material FBb is introduced into the plasticizing material flowing through the introduction flow path 26, and is discharged together with the plasticizing material from the nozzle opening 28. The formation of a shaped object by discharging the plasticizing material will be described later.

[0043] The cutting unit 66 is installed near the entrance of the transport path 65 in the storage unit 63, and cuts the second fiber material FBb sent out to the transport path 65 under the control of the control unit 10. The cutting unit 66 can be configured, for example, by a mechanism in which a cutter blade is protruded by a solenoid mechanism to cut the second fiber material FBb. In another embodiment, the cutting unit 66 may be configured to cut the second fiber material FBb by emitting a laser. The control unit 10 can adjust the length of the second fiber material FBb included in the shaped object by controlling the timing at which the cutting unit 66 cuts the second fiber material FBb. In this embodiment, the second fiber material FBb is introduced into the shaped object with a length of at least 10 mm or more.

[0044] The modeling stage unit 70 is installed at a position facing the nozzle opening 28 of the discharge unit 20. The modeling stage unit 70 includes a stage 72 that supports a model, a modeling table 73 placed on the stage 72, and a moving mechanism 75 configured to be able to move the stage 72 in the X, Y, and Z directions. The stage 72 is made of a plate-like member and has a stage surface 72s arranged along the horizontal direction. The modeling table 73 is made of a plate-like member and placed on the stage surface 72s to receive the plasticized material discharged from the nozzle opening 28. The moving mechanism 75 is configured as a three-axis positioner that moves the stage 72 in three axial directions, that is, the X, Y, and Z directions, and includes three motors M that generate driving forces under the control of the control unit 10. The control unit 10 controls the moving mechanism 75 to relatively move the nozzle unit 25 and the stage 72 in the modeling process.

[0045] In another embodiment, instead of a configuration in which the moving mechanism 75 moves the stage 72, a configuration in which the moving mechanism 75 moves the nozzle portion 25 relative to the stage 72 while the position of the stage 72 is fixed may be employed. Even with such a configuration, the stage 72 and the nozzle portion 25 can be moved relatively. Also, in another embodiment, a configuration in which the moving mechanism 75 moves each of the stage 72 and the nozzle portion 25 to change the relative positions of the two may be employed.

[0046] Fig. 2 is a schematic perspective view showing the configuration of the flat screw 40 as viewed from the groove forming surface 41 side. In Fig. 2, the rotation axis RX of the flat screw 40 is shown by a dashed line. In this embodiment, the flat screw 40 has three grooves 42 arranged in parallel and extending in a spiral arc toward the central portion 45 of the flat screw 40. Each groove 42 is defined by three ridges 44 extending in a spiral shape toward the recess of the central portion 45.

[0047] The number of grooves 42 of the flat screw 40 does not have to be three. The flat screw 40 may have only one groove 42, or may have two or more grooves 42. Any number of convex ridges 44 may be provided in accordance with the number of grooves 42. The grooves 42 need not necessarily extend in a spiral shape as long as they extend in a spiral arc.

[0048] One end of the groove 42 opens on the side surface of the flat screw 40 and constitutes a material inlet 46 that receives the modeling material PM supplied from the communicating passage 32. The groove 42 continues to a central portion 45 of the flat screw 40, and the other end of the groove 42 is connected to the central portion 45 of the flat screw 40. The central portion 45 of the flat screw 40 constitutes a recess in which a plasticized material obtained by plasticizing the thermoplastic resin of the modeling material PM gathers.

[0049] 3 is a schematic plan view showing the configuration of the facing surface 51 in the facing portion 50. As described above, the facing surface 51 faces the groove forming surface 41 of the flat screw 40. At the center of the facing surface 51, the above-mentioned communication hole 53 for supplying the plasticized material that has flowed into the central portion 45 of the flat screw 40 to the nozzle portion 25 is opened. In the facing surface 51, a plurality of guide grooves 55 are formed, one end of which is connected to the communication hole 53 and which extend in a spiral shape from the communication hole 53 toward the outer periphery. The guide grooves 55 have the function of guiding the plasticized material to the communication hole 53.

[0050] The heater 52 shown in FIG. 1 is embedded inside the facing part 50. The plasticization of the thermoplastic resin in the plasticizing part 35 is achieved by heating by the heater 52 of the facing part 50 and by rotation of the flat screw 40. According to the molding apparatus 100a of the first embodiment, the flat screw 40 is used to realize a compact device configuration for plasticizing the thermoplastic resin. In addition, according to the molding apparatus 100a of the first embodiment, the pressure and flow rate of the plasticizing material supplied to the nozzle part 25 can be easily controlled by controlling the rotation of the flat screw 40. Therefore, the accuracy of discharging the plasticizing material from the nozzle part 25 can be improved, and the molding accuracy of the molded object can be improved.

[0051] Fig. 4 is a schematic diagram showing how a modeling object OB is formed by stacking modeling layers ML formed by discharging the plasticized material MM from the nozzle openings 28 in the modeling apparatus 100a. For convenience, in Fig. 4, the first fiber material FBa is indicated by only a reference symbol as being included in the plasticized material MM and the modeling layers ML, and the second fiber material FBb is indicated by a dashed line.

[0052] In the modeling process of the modeling apparatus 100a, the plasticized material MM is discharged from the nozzle opening 28 while the nozzle unit 25 and the stage 72 are moved relatively in the horizontal direction. As a result, the plasticized material MM is linearly deposited on the stage 72 so as to trace the movement trajectory of the nozzle opening 28, and a modeling layer ML containing the first fiber material FBa and the second fiber material FBb is formed. The modeled object OB is formed by further discharging the plasticized material MM on the modeling layer ML to stack the modeling layers ML.

[0053] In the modeling apparatus 100a, a gap G is maintained between the nozzle opening 28 and an upper surface OBt of the modeling object OB being modeled. Here, the "upper surface OBt of the modeling object OB" refers to a portion on which the plasticizing material MM discharged from the nozzle opening 28 is to be deposited in the vicinity of a position directly below the nozzle opening 28. The gap G is adjusted by the movement mechanism 75 changing the relative position between the stage 72 and the nozzle opening 28 in the Z direction.

[0054] The size of the gap G is preferably equal to or smaller than the hole diameter Dn of the nozzle opening 28 shown in FIG. 1, and more preferably equal to or smaller than 0.8 times the hole diameter Dn. In this way, the plasticized material MM discharged from the nozzle opening 28 can be deposited on the upper surface OBt of the object OB while ensuring a sufficient contact surface with the upper surface OBt of the object OB being modeled. As a result, it is possible to prevent gaps from being generated in the cross section of the modeling layer ML and to prevent the shape of the upper surface OBt of the object OB from being distorted, and it is possible to ensure the strength of the object OB and reduce the surface roughness. In addition, in a configuration in which a heater is provided around the nozzle opening 28, by forming the gap G, the heater can appropriately control the temperature drop of the upper surface OBt of the object OB, and it is possible to prevent a decrease in adhesion between the stacked modeling layers ML. Therefore, it is possible to ensure the interlayer strength of the object OB. In addition, by forming the gap G, it is possible to prevent discoloration and deterioration caused by overheating of the deposited plasticized material MM by the heater.

[0055] On the other hand, the size of the gap G is preferably 0.5 times or less, and particularly preferably 0.3 times or less, of the hole diameter Dn. This allows the plasticized material MM to be deposited at the intended location with high precision. In addition, this makes it possible to suppress a decrease in the adhesion of the plasticized material MM to the upper surface OBt of the modeled object OB when the plasticized material MM is discharged onto the upper surface OBt, and to suppress a decrease in the adhesion between the stacked modeling layers ML.

[0056] In this embodiment, the plasticized material MM solidifies as the temperature decreases after it is discharged from the nozzle opening 28. In other embodiments, the plasticized material MM may be a material that is hardened by a sintering process in a sintering furnace after the modeling of the modeled object OB is completed. Also, the plasticized material MM may be a material that is photo-hardened by irradiation with an ultraviolet laser after it is discharged from the nozzle opening 28. In this case, the modeling apparatus 100a may be equipped with a laser irradiation device for hardening the plasticized material MM.

[0057] 5 is a flowchart showing steps executed in the modeling process of the modeling apparatus 100a. This modeling process is executed based on modeling data for forming the modeling layer ML that constitutes the modeled object OB. The modeling data is generated based on three-dimensional shape data that represents the shape of the modeled object OB, such as three-dimensional CAD data. The modeling data includes, for example, information on the position of the modeling layer ML in the modeled object OB, information on the dimensions of the modeling layer ML, information on the movement path of the nozzle opening 28, information on the discharge amount of the plasticizing material, and the like.

[0058] The process P10 is a process executed by the plasticizer 35 of the material generator 21 under the control of the controller 10. The process P10 corresponds to a plasticization process in which at least a part of the modeling material PM containing the first fiber material FBa and a thermoplastic resin is plasticized to generate a plasticized material. In this embodiment, as described above, the plasticization of the thermoplastic resin is performed using the flat screw 40. The process P10 includes a process of introducing the modeling material PM of the material supply unit 30 into the groove portion 42 of the flat screw 40 while rotating the flat screw 40 facing the facing portion 50, and guiding at least a part of the thermoplastic resin contained in the modeling material PM to the communication hole 53 of the facing portion 50 while plasticizing it in the groove portion 42. That is, the process P10 includes a process of guiding at least a part of the thermoplastic resin supplied between the flat screw 40 and the facing portion 50 to the communication hole 53 while plasticizing it by rotating the flat screw 40 and heating the heater 52. As described above, the use of the flat screw 40 in the plasticizing step realizes a reduction in size of the plasticizing unit 35. Furthermore, since the pressure and flow rate of the plasticizing material supplied to the nozzle unit 25 can be easily controlled by controlling the rotation of the flat screw 40, it is possible to improve the discharge accuracy of the plasticizing material MM by the nozzle unit 25, and thus the modeling accuracy of the shaped object can be improved. The plasticizing unit 35 continues the plasticizing step of step P10 at least while the following steps P20 to P50 are being performed.

[0059] Steps P20 to P50 correspond to one pass of the modeling apparatus 100a. A "pass" refers to a processing unit in which the nozzle opening 28 is scanned while continuously discharging the plasticizing material from the nozzle opening 28 without interruption, to form one continuous modeling portion on the stage 72. One modeling layer ML is formed by performing a series of operations from steps P20 to P50 one or more times. In the modeling process of this embodiment, steps P20 to P50 are repeated until all the stacked modeling layers ML have been formed and modeling of the modeled object OB is completed.

[0060] Steps P20 to P40 constitute a series of operations of the modeling apparatus 100a when forming the modeling layer ML by discharging the plasticizing material from the nozzle opening 28 while moving the nozzle part 25 relatively to the stage 72. The modeling apparatus 100a executes step P40 while executing step P20 and step P30.

[0061] Step P20 is a step executed by the moving mechanism 75 under the control of the control unit 10, and corresponds to a moving step of relatively moving the stage 72 and the nozzle unit 25. Under the control of the control unit 10, the moving mechanism 75 relatively moves the stage 72 and the nozzle opening 28 at a relative moving speed that is determined in advance based on the modeling data.

[0062] The process P30 is a process executed by the fiber introduction unit 23 of the discharge unit 20 under the control of the control unit 10. The process P30 corresponds to a fiber introduction process of introducing the second fiber material FBb into the plasticized material before it is discharged from the nozzle opening 28.

[0063] In process P40, the discharge unit 20 discharges the plasticized material from the nozzle opening 28 under the control of the control unit 10. The discharge unit 20 discharges the plasticized material from the nozzle opening 28 at a discharge amount per unit time that is determined in advance based on the modeling data. The control unit 10 controls the number of rotations of the flat screw 40 and the aperture of the discharge amount control mechanism 80 to control the discharge amount of the plasticized material per unit time.

[0064] In step P50, the control unit 10 stops the discharge of the plasticizing material from the nozzle opening 28 when the formation of one modeling layer ML is completed. The control unit 10 first stops the introduction of the second fiber material FBb by the fiber introduction unit 23, and cuts the second fiber material FBb by the cutting unit 66. Next, the control unit 10 controls the discharge amount control mechanism 80 to stop the supply of the plasticizing material to the nozzle unit 25. This completes the formation of one pass of the modeling layer ML. Step P50 includes a cutting step of cutting the second fiber material FBb. This makes it easy to adjust the length of the second fiber material FBb and control the stopping of the introduction of the second fiber material FBb.

[0065] As described above, a series of operations from steps P20 to P50 is performed one or more times to form one modeling layer ML, and steps P20 to P50 are repeated until all modeling layers ML are formed. Steps P10 to P50 correspond to a modeling process for forming a modeled object OB by stacking modeling layers ML containing the first fiber material FBa and the second fiber material FBb.

[0066] FIG. 6 is a schematic cross-sectional view showing a cross section along the stacking direction of an example of a modeling layer ML formed by the modeling process of this embodiment. The modeling layer ML is composed of a plasticized material MM to which a first fiber material FBa and a second fiber material FBb are introduced. The modeling layer ML is introduced in a central portion thereof with a single continuous linear second fiber material FBb. The modeling object formed by the modeling process of this embodiment has an increased overall strength because each modeling layer ML contains the second fiber material FBb. In addition, the strength of each modeling layer ML constituting the modeling object in the length direction of the second fiber material FBb is increased by the second fiber material FBb. In addition, in each modeling layer ML, the first fiber material FBa is present around the second fiber material FBb while facing in various directions and being entangled in some places. This increases the strength of each modeling layer ML in various directions. In this way, in each modeling layer ML, two types of fiber materials FBa and FBb with different lengths are mixed in the plasticized material in a combination that complements each other in strength in various directions, thereby increasing the strength of the entire model in various directions.

[0067] As described above, in the manufacturing method performed by the modeling apparatus 100a of the first embodiment, the modeling step of discharging the plasticized material from the nozzle opening 28 to form a three-dimensional object includes a fiber introducing step of introducing the second fiber material FBb into the plasticized material so that the second fiber material FBb, which is longer than the first fiber material FBa, is contained in the plasticized material after being discharged from the nozzle opening 28. According to this manufacturing method, the first fiber material FBa and the second fiber material FBb, which have different lengths, can be combined and mixed in the three-dimensional object so as to reinforce each other's strength in various directions. Therefore, the strength of the three-dimensional object in various directions can be easily improved.

[0068] [2] Second embodiment Fig. 7 is a flowchart of steps executed in the forming process in the second embodiment. Fig. 8 is a schematic cross-sectional view showing a cross section along the stacking direction of an example of a formed object OBa formed by the forming process in the second embodiment. The forming process in the second embodiment is executed by the forming apparatus 100a shown in Fig. 1 described in the first embodiment.

[0069] In the modeling process of the second embodiment, a model OBa is formed having a first portion Pf that is a part of the model OBa and includes the first fiber material FBa and the second fiber material FBb, and a second portion Ps that is a part of the model OBa and includes the first fiber material FBa and does not include the second fiber material FBb. In the second embodiment, the first portion Pf is a portion that constitutes the outer shell of the model OBa, and the second portion Ps is a portion that constitutes the internal structure of the model OBa surrounded by the outer shell.

[0070] Step P10 corresponds to the plasticization step in the second embodiment, and is performed in the same manner as described in the first embodiment. Step P10 continues at least while the following steps P20 to P70 are being performed.

[0071] The steps P20 to P51 are steps for one pass when forming the first modeling layer MLa included in the first region Pf, and are repeated until the formation of all modeling layers MLa included in the first region Pf is completed. The steps P20 to P51 correspond to a first modeling step for forming the first region Pf including the first fiber material FBa and the second fiber material FBb. The steps P20 to P51 are similar to the steps P20 to P40 described in the first embodiment, except that the step P41 is included instead of the step P40. The step P41 is performed in the same manner as the step P40 described in the first embodiment, except that the step P41 forms the first modeling layer MLa that constitutes the first region Pf. The step P20 corresponds to a moving step, and the step P30 corresponds to a fiber introduction step.

[0072] When the formation of the first region Pf is completed, in step P51, the introduction of the second fiber material FBb by the fiber introduction section 23 is stopped in order to form the second region Ps.

[0073] Steps P60 to P70 are steps for one pass when forming the second modeling layer MLb included in the second region Ps, and are repeated until the formation of all modeling layers MLa included in the second region Ps is completed. Step P60 corresponds to a moving step in which the stage 72 and the nozzle opening 28 are moved relatively to each other, and is executed in the same manner as step P20. In step P70, the nozzle unit 25, under the control of the control unit 10, ejects a plasticizing material that includes the first fiber material FBa and does not include the second fiber material FBb from the nozzle opening 28. This forms the second modeling layer MLb included in the second region Ps. Steps P60 to P70 correspond to a second modeling step in which the second region Ps that includes the first fiber material FBa and does not include the second fiber material FBb is formed.

[0074] As described above, the modeling process of the second embodiment has a modeling process including a first modeling process of forming a first portion Pf and a second modeling process of forming a second portion Ps. According to the modeling process of the second embodiment, the first portion Pf including both the first fiber material FBa and the second fiber material FBb and the second portion Ps not including the second fiber material FBb can be selectively formed. That is, for example, a portion requiring strength can be formed as the first portion Pf including both of the two types of fiber materials FBa and FBb, and a portion that may have low strength can be formed as the second portion Ps not including the second fiber material FBb. Therefore, the degree of freedom of modeling by the modeling apparatus 100a can be increased. In addition, it is also possible to reduce modeling costs by saving the amount of the second fiber material FBb used.

[0075] In the modeling process of the second embodiment, as described above, the first portion Pf forms the outer shell of the modeled object OBa, and the second portion Ps forms the internal structure of the modeled object OBa. This configuration can increase the strength of the outer shell of the modeled object OBa, while omitting the introduction of the second fiber material FBb into the internal structure, thereby reducing the manufacturing cost of the modeled object OBa. In the modeling process of the second embodiment, the volume of the second modeling layer MLb of the second portion Ps may be made larger than the volume of the first modeling layer MLa of the first portion Pf. In this way, the time required to model the internal structure can be shortened, and the productivity of the modeled object OBa can be further improved.

[0076] [3] Third embodiment Fig. 9 is a flowchart showing steps executed in the modeling process in the third embodiment. Fig. 9 is almost the same as the flowchart in Fig. 5 described in the first embodiment, except that step P25 is added. The modeling process in the third embodiment is executed by the modeling apparatus 100a shown in Fig. 1 described in the first embodiment.

[0077] Step P25 is executed when the second fiber material FBb is introduced into the plasticized material in the fiber introduction step of step P30. Step P25 corresponds to an introduction speed control step in which the control unit 10 controls the introduction speed at which the second fiber material FBb is introduced into the plasticized material in accordance with the relative movement speed between the nozzle unit 25 and the stage 72 in step P20. The "introduction speed" corresponds to the length of the second fiber material FBb sent from the conveying path 65 to the flow path of the plasticized material per unit time. In the third embodiment, the control unit 10 sets a target value for the introduction speed of the second fiber material FBb to be larger as the relative movement speed between the nozzle unit 25 and the stage 72 is higher, and controls the rotation speed of the reel 62 on which the second fiber material FBb is wound in accordance with the target value of the introduction speed.

[0078] In this way, by controlling the introduction speed of the second fiber material FBb according to the relative movement speed between the nozzle portion 25 and the stage 72, it is possible to prevent the amount and state of the second fiber material FBb introduced into the modeling layer ML from fluctuating due to changes in the relative movement speed between the nozzle portion 25 and the stage 72. In addition, since the introduction speed of the second fiber material FBb is controlled to be greater as the relative movement speed between the nozzle portion 25 and the stage 72 increases, it is possible to prevent the introduction of the second fiber material FBb into the plasticized material from being unable to keep up with the speed at which the modeling layer ML is formed.

[0079] [4] Fourth embodiment Fig. 10 is a schematic diagram showing the configuration of a modeling apparatus 100b in the fourth embodiment. The modeling apparatus 100b in the fourth embodiment is substantially the same as the modeling apparatus 100a in the first embodiment shown in Fig. 1, except for the following points. In the modeling apparatus 100b in the fourth embodiment, a through hole 47 is provided in the flat screw 40. In addition, a fiber introduction section 23 is provided above the plasticization section 35, and a pressure control section 90 is added.

[0080] In the fourth embodiment, the flat screw 40 is provided with a through hole 47 penetrating from the upper surface 43 to the center part 45 of the groove forming surface 41 at a position where the rotation axis RX passes. The through hole 47 opens in the groove forming surface 41 and communicates with the communication hole 53 of the facing part 50. In addition, the storage part 63 of the conveying part 60 of the fiber introduction part 23 is disposed on the drive motor 37 of the flat screw 40, and the conveying path 65 passes through the drive shaft of the drive motor 37 and is connected to the through hole 47 of the flat screw 40. As a result, the second fiber material FBb is introduced into the plasticized material through the through hole 47 of the flat screw 40 in the fiber introduction step.

[0081] The pressure control unit 90 is configured by a pump. The pressure control unit 90 is connected to the storage unit 63 of the conveying unit 60, and controls the pressure in the through hole 47 of the flat screw 40 through the storage unit 63 and the conveying path 65 under the control of the control unit 10.

[0082] FIG. 11 is a flowchart showing steps executed by the modeling apparatus 100c in the modeling process of the fourth embodiment. FIG. 11 is almost the same as the flowchart of FIG. 5 described in the first embodiment, except that step P5 is added. Step P5 corresponds to a pressure control step in which the control unit 10 controls the pressure control unit 90 to control the pressure in the through hole 47 of the flat screw 40 to be higher than the pressure in the communication hole 53 of the facing part 50. The pressure in the communication hole 53 is controlled by the control unit 10 controlling the rotation speed of the flat screw 40. Step P5 is started before the generation of the plasticized material is started in step P10, and is continued while the plasticized material is generated in the plasticizing part 35. In the fourth embodiment, the second fiber material FBb is the plasticized material that is plasticized through the plasticizing step of step P10 and then collected in the center part 45 of the flat screw 40 in step P40, and is introduced into the plasticized material before it is discharged from the nozzle opening 28 in step P40.

[0083] According to the molding apparatus 100c of the fourth embodiment, the second fiber material FBb can be smoothly introduced into the communication hole 53 of the facing portion 50 through the through hole 47 of the flat screw 40. In addition, since the pressure in the through hole 47 of the flat screw 40 is controlled by the pressure control unit 90 to be higher than the pressure in the communication hole 53 of the facing portion 50, the plasticized material in the central portion 45 can be prevented from flowing into the through hole 47.

[0084] [5] Fifth embodiment Fig. 12 is a schematic diagram showing the configuration of a modeling apparatus 100c of the fifth embodiment. The modeling apparatus 100c of the fifth embodiment is substantially the same as the modeling apparatus 100a of the first embodiment, except for the following points. In the modeling apparatus 100c, an introduction groove 57 is provided on the facing surface 51 of the facing part 50, and the transport path 65 of the fiber introduction part 23 is connected to the introduction groove 57 instead of the introduction flow path 26 of the nozzle part 25. In Fig. 12, the introduction groove 57 is shown by a dashed line for convenience.

[0085] 13 is a schematic plan view showing the configuration of the facing surface 51 of the facing portion 50 of the fifth embodiment. In addition to a plurality of guide grooves 55 that guide the plasticized material to the central communicating hole 53, the facing surface 51 is provided with an introduction groove 57 for introducing the second fiber material FBb. The introduction groove 57 is formed from the outer circumferential end of the facing surface 51 to the communicating hole 53 so as to avoid interference with the guide groove 55. The introduction groove 57 makes it possible to introduce the second fiber material FBb from the side of the flat screw 40 or the facing portion 50 to the communicating hole 53.

[0086] FIG. 14 is a flowchart showing steps executed by the modeling apparatus 100c in the modeling process of the fifth embodiment. FIG. 14 is almost the same as the flowchart of FIG. 5 described in the first embodiment, except that steps P7 and P8 are added instead of step P10, and step P30 is omitted. In the modeling apparatus 100c, the second fiber material FBb is supplied to the flat screw 40 of the plasticizing section 35 together with the modeling material PM before plasticization supplied from the material supplying section 30. That is, in the modeling apparatus 100c of the fifth embodiment, the fiber introducing section 23 has a function of introducing the second fiber material FBb into the modeling material PM, and the second fiber material FBb is introduced into the modeling material PM in step P7 of the modeling process of the fifth embodiment. In the following step P8, at least a part of the modeling material PM into which the second fiber material FBb has been introduced is plasticized in the flat screw 40 of the plasticizing section 35, and a plasticized material containing the second fiber material FBb is generated. Step P7 in the fifth embodiment corresponds to a fiber introducing step of introducing the second fiber material FBb into the modeling material PM. Steps P7 and P8 in the fifth embodiment correspond to the plasticizing step in the modeling process of the fifth embodiment, and the fiber introducing step of step P7 is interpreted as being performed in the plasticizing step.

[0087] According to the fifth embodiment of the molding apparatus 100c and its molding process, the second fiber material FBb introduced into the molding material PM can be guided to the communicating hole 53 by utilizing the rotational force of the flat screw 40, and then ejected from the nozzle opening 28, which is efficient.

[0088] [6] Sixth embodiment FIG. 15 is a schematic diagram showing the configuration of a modeling apparatus 100d of the sixth embodiment. The modeling apparatus 100d of the sixth embodiment is substantially the same as the modeling apparatus 100a of the first embodiment except for the following points. In the modeling apparatus 100d, the transport path 65 of the fiber introduction section 23 is inserted into the screw case 36 and is configured to be connectable to the groove portion 42 from the side of the flat screw 40. In the sixth embodiment, the groove portion 42 of the flat screw 40 functions as an introduction groove 57 that introduces the second fiber material FBb from the side of the flat screw 40 or the facing portion 50 to the communication hole 53. According to the modeling apparatus 100d of the sixth embodiment, as in the modeling apparatus 100c of the fifth embodiment, the second fiber material FBb can be introduced to the communication hole 53 through the introduction groove 57 by utilizing the rotational force of the flat screw 40 and discharged from the nozzle opening 28, which is efficient.

[0089] [7] Seventh embodiment FIG. 16 is a schematic diagram showing the configuration of a modeling apparatus 100e of the seventh embodiment. The modeling apparatus 100e of the seventh embodiment is substantially the same as the modeling apparatus 100a of the first embodiment, except for the following points. In the modeling apparatus 100e, the cutting unit 66 provided in the storage unit 63 of the fiber introduction unit 23 is omitted. In addition, the modeling apparatus 100e is provided with a discharge amount control mechanism 80a that is provided upstream of the nozzle opening 28 and controls the amount of plasticizing material discharged from the nozzle opening 28. As described later, the discharge amount control mechanism 80a of the seventh embodiment has a function as a cutting unit that cuts the second fiber material FBb. Furthermore, the modeling apparatus 100e includes a motor 88 that generates a driving force, and a gear unit 89 that switches the destination of the driving force of the motor 88 to the discharge amount control mechanism 80a or the conveying unit 60 of the fiber introduction unit 23. The motor 88 is, for example, a stepping motor. The switching of the destination of the driving force of the motor 88 by the control unit 10 will be described later.

[0090] FIG. 17 is a schematic diagram showing the configuration of a discharge amount control mechanism 80a of the seventh embodiment. FIG. 17 is a schematic diagram showing a state in which the discharge amount control mechanism 80a opens a flow path and the second fiber material FBb passes through the opened flow path. The discharge amount control mechanism 80a includes a butterfly valve 81, which is a valve body that rotates in the introduction flow path 26, and a cutter blade 82 provided around the butterfly valve 81. The butterfly valve 81 rotates by the driving force of a motor 88 shown in FIG. 16, and changes the opening area of ​​the introduction flow path 26 according to the rotation angle. The control unit 10 controls the discharge amount of the plasticizing material from the nozzle opening 28 by the rotation angle of the butterfly valve 81. The cutter blade 82 is provided at a position close to the rotation area of ​​the butterfly valve 81.

[0091] Fig. 18 is a schematic diagram for explaining the mechanism by which the discharge amount control mechanism 80a cuts the second fiber material FBb. Fig. 18 shows a schematic diagram of the butterfly valve 81 of the discharge amount control mechanism 80a rotating from the state shown in Fig. 17 to cut the second fiber material FBb. When the control unit 10 rotates the butterfly valve 81 to close the introduction flow passage 26, the second fiber material FBb is sandwiched between the end of the butterfly valve 81 during rotation and the cutter blade 82, and is pressed against the cutter blade 82 and cut. After the second fiber material FBb is cut, the butterfly valve 81 continues to rotate to close the introduction flow passage 26.

[0092] The modeling apparatus 100e of the seventh embodiment executes the modeling process through the steps shown in FIG. 5 described in the first embodiment. In the modeling process, the control unit 10 controls the driving of the motor 88 and controls the gear unit 89 to switch the transmission destination of the driving force generated by the motor 88. When the second fiber material FBb is introduced in the fiber introduction step of the step P30, the control unit 10 transmits the driving force generated by the motor 88 to the conveying unit 60 through the gear unit 89, and uses it to convey the second fiber material FBb. When the control unit 10 starts discharging the plasticizing material from the nozzle opening 28 in the step P40, the control unit 10 temporarily switches the transmission destination of the driving force generated by the motor 88 to the discharge amount control mechanism 80a through the gear unit 89 in order to adjust the discharge amount. Thereby, the butterfly valve 81 of the discharge amount control mechanism 80a can be rotated by the driving force generated by the motor 88, and the discharge amount of the plasticizing material can be controlled. Furthermore, when the control unit 10 stops the discharge of the plasticizing material in step P50, it switches the destination of the driving force generated by the motor 88 from the conveying unit 60 to the discharge amount control mechanism 80a and rotates the butterfly valve 81. This causes the second fiber material FBb to be cut and stops the discharge of the plasticizing material from the nozzle opening 28. In this way, step P50 includes a cutting step of cutting the second fiber material FBb by operating the discharge amount control mechanism 80a.

[0093] According to the modeling apparatus 100e of the seventh embodiment, it is possible to reduce the size of the apparatus configuration because the conveying section 60 of the fiber introduction section 23 and the discharge amount control mechanism 80a can be driven by a common motor 88. Also, according to the modeling apparatus 100e of the seventh embodiment, the discharge amount control mechanism 80a can stop the discharge of the plasticizing material at the same time as cutting the second fiber material FBb, so that the controllability of the discharge of the plasticizing material from the nozzle opening 28 is further improved.

[0094] [8] Eighth embodiment Fig. 19 is a schematic diagram showing a configuration of a discharge amount control mechanism 80b included in a modeling apparatus 100f according to an eighth embodiment. Fig. 19 shows a state in which a rod 83 of the discharge amount control mechanism 80b is located at an initial position described below and a second fiber material FBb is fed to a nozzle flow path 27.

[0095] The modeling apparatus 100f of the eighth embodiment has almost the same configuration as the modeling apparatus 100e of the seventh embodiment, except for the points described below. The modeling apparatus 100f includes a discharge amount control mechanism 80b having a different configuration from the discharge amount control mechanism 80a described in the seventh embodiment. The discharge amount control mechanism 80b of the eighth embodiment is provided in the nozzle flow path 27. The discharge amount control mechanism 80b realizes a function of opening and closing the nozzle flow path 27 to control the discharge amount of the modeling material and a function of cutting the second fiber material FBb by moving the rod 83 in a direction intersecting the nozzle flow path 27 by a plunger mechanism. Although not shown, the modeling apparatus 100f has a butterfly valve similar to the discharge amount control mechanism 80 described in the first embodiment upstream of the discharge amount control mechanism 80b, and the discharge of the plasticizing material from the nozzle opening 28 can be stopped by opening and closing the butterfly valve.

[0096] The discharge amount control mechanism 80b includes a rod 83 that performs piston-like motion in a direction intersecting the nozzle flow path 27, a drive mechanism 84 that drives the rod 83, a recess 86 provided on the inner wall surface of the nozzle flow path 27, and a cutter blade 82 provided in the recess 86. The rod 83 moves in a branch flow path 85 that is connected to the nozzle flow path 27. The discharge amount control mechanism 80b of the eighth embodiment receives the drive force of the rod 83 from a motor 88 that is also used for the conveying unit 60 shown in FIG. 16, similar to the discharge amount control mechanism 80a of the seventh embodiment. The drive mechanism 84 converts the rotational motion generated by the motor 88 into linear motion to instantaneously move the rod 83.

[0097] First, the control mechanism of the discharge amount of the plasticizing material by the discharge amount control mechanism 80b will be described. When the rod 83 is instantaneously moved to a position deep in the branch flow path 85, the plasticizing material is drawn into the branch flow path 85 as the rod 83 moves. This generates a negative pressure in the nozzle flow path 27, and the plasticizing material discharged from the nozzle opening 27 is drawn back to the nozzle flow path 27, so that the discharge of the plasticizing material from the nozzle opening 28 can be temporarily stopped. Conversely, when the rod 83 is moved from a position deep in the branch flow path 85 toward the nozzle flow path 27, the plasticizing material in the branch flow path 85 is pushed out into the nozzle flow path 27, so that the discharge amount of the plasticizing material can be temporarily increased. In this way, the discharge amount control mechanism 80b can control the discharge amount of the plasticizing material from the nozzle opening 28 by moving the rod 83.

[0098] Next, a cutting mechanism of the second fiber material FBb by the discharge amount control mechanism 80b will be described. The rod 83 can move instantaneously so as to protrude from the branch flow path 85 into the nozzle flow path 27. The tip of the rod 83 protruding into the nozzle flow path 27 is received by the recess 86. This movement of the rod 83 protruding toward the recess 86 cuts the second fiber material FBb as described below.

[0099] Fig. 20 is a schematic diagram for explaining a mechanism by which the discharge amount control mechanism 80b of the eighth embodiment cuts the second fiber material FBb. Fig. 20 shows a schematic diagram of the state in which the rod 83 of the discharge amount control mechanism 80b moves from the state shown in Fig. 19 in a direction protruding into the nozzle flow path 27 to cut the second fiber material FBb. As described above, the cutter blade 82 is provided in the recess 86 that receives the tip of the rod 83. When the rod 83 moves instantaneously toward the recess 86, the second fiber material FBb is sandwiched between the tip of the rod 83 and the cutter blade 82 in the recess 86, and is pressed against the cutter blade 82 to be cut.

[0100] The control unit 10 of the molding apparatus 100f drives the discharge amount control mechanism 80b as follows when closing the butterfly valve provided upstream thereof to stop the discharge of the plasticizing material from the nozzle opening 28, and when opening the butterfly valve to resume the discharge of the plasticizing material. While the plasticizing material is being discharged from the nozzle opening 28, the rod 83 of the discharge amount control mechanism 80b is in a position where the tip of the rod 83 blocks the outlet of the branch flow path 85, as shown in Fig. 19. Hereinafter, this position is also referred to as the "initial position."

[0101] When the control unit 10 closes the butterfly valve, it drives the discharge amount control mechanism 80b to instantaneously move the rod 83 from the initial position toward the recessed portion 86 so that the rod 83 protrudes from the initial position into the nozzle flow path 27, thereby cutting the second fiber material FBb. After that, the rod 83 is instantaneously moved to a position deeper in the branch flow path 85 without any gap, thereby generating a negative pressure in the nozzle flow path 27. This causes the plasticized material that has flowed out from the nozzle opening 28 to be pulled back into the nozzle flow path 27, so that it is possible to prevent excess plasticized material from hanging like strings from the nozzle opening 28 after the discharge of the plasticized material has stopped.

[0102] When the butterfly valve is opened to resume the discharge of the plasticizing material, the control unit 10 returns the rod 83, which is located deep in the branch flow path 85, to its initial position, thereby returning the plasticizing material that has been drawn into the branch flow path 85 to the nozzle flow path 27. This makes it possible to temporarily increase the discharge amount of the plasticizing material when the discharge of the plasticizing material from the nozzle opening 28 is resumed. This makes it possible to suppress a delay in resuming the discharge of the plasticizing material due to an insufficient amount of plasticizing material supplied to the nozzle flow path 27 when the discharge of the plasticizing material is resumed.

[0103] In this way, according to the discharge amount control mechanism 80b, when the discharge of the plasticizing material from the nozzle opening 28 is stopped, the outflow of the plasticizing material from the nozzle opening 28 can be quickly stopped while cutting the second fiber material FBb. Furthermore, when the discharge of the plasticizing material from the nozzle opening 28 is resumed, the rod 83 pushes out the plasticizing material in the branch flow path 85, and the discharge amount of the plasticizing material from the nozzle opening 28 can be quickly restored to the target value. In other words, according to the discharge amount control mechanism 80b, higher responsiveness of the discharge unit 20 to the discharge control of the plasticizing material by the control unit 10 can be realized.

[0104] As described above, according to the modeling apparatus 100f of the eighth embodiment, similarly to the modeling apparatus 100e of the seventh embodiment, the conveying unit 60 and the discharge amount control mechanism 80b can be driven by a common motor 88, so that the device configuration can be reduced in size. In addition, the discharge amount control mechanism 80b can further improve the controllability of the discharge of the plasticizing material including the second fiber material FBb.

[0105] [9] Ninth embodiment Fig. 21 is a schematic diagram showing the configuration of a modeling apparatus 100g in the ninth embodiment. The modeling apparatus 100g in the ninth embodiment is substantially the same as the modeling apparatus 100a in the first embodiment shown in Fig. 1 except for the following points. In the modeling apparatus 100g in the ninth embodiment, the transport path 65 of the fiber introduction unit 23 is connected downstream of the nozzle opening 28. The fiber introduction unit 23 is fixed to the nozzle portion 25 so as to be movable relative to the stage 72 together with the nozzle opening 28. In the modeling apparatus 100g, the fiber introduction unit 23 has a function of introducing the second fiber material FBb into the plasticized material after it has been discharged from the nozzle opening 28.

[0106] FIG. 22 is a flowchart showing steps executed by the modeling apparatus 100g in the modeling process of the ninth embodiment. FIG. 22 is substantially the same as the steps of the modeling process shown in FIG. 5 described in the first embodiment, except that step P30 is omitted and step P45 is added after step P40 instead. In the modeling process of the ninth embodiment, after the plasticized material is discharged from the nozzle opening 28 in step P40, the fiber introduction unit 23 introduces the second fiber material FBb into the plasticized material after it has been discharged from the nozzle opening 28 in step P45. Step P45 corresponds to a fiber introduction step of introducing the second fiber material FBb into the plasticized material so that the second fiber material FBb longer than the first fiber material FBa is included in the plasticized material after it has been discharged from the nozzle opening 28. In the ninth embodiment, steps P20 to P50 including the fiber introduction step of step P45 correspond to a modeling step of modeling an object including the first fiber material FBa and the second fiber material FBb.

[0107] According to the modeling apparatus 100g of the ninth embodiment, it is easy to provide the fiber introduction section 23 later. Moreover, according to the modeling apparatus 100g of the ninth embodiment, since the second fiber material FBb does not pass through the nozzle opening 28, the fiber diameter of the second fiber material FBb can be made larger than the hole diameter Dn of the nozzle opening 28. In the ninth embodiment, the fiber diameter of the second fiber material FBb can be set to, for example, 10 μm or more and 500 μm or less.

[0108]

[10] Other embodiments The various configurations described in the above embodiments can be modified, for example, as follows. All of the other embodiments described below are positioned as examples of modes for carrying out the present invention, similar to the above embodiments.

[0109] [10-1] Other embodiment 1 In each of the above embodiments, the continuous second fiber material FBb wound around the reel 62 may not be used. The finely cut second fiber material FBb may be introduced into the plasticized material so as to be contained in the plasticized material after being discharged from the nozzle opening 28, the finely cut second fiber material FBb being longer than the first fiber material FBa. The finely cut second fiber material FBb may be introduced into the modeling material PM together with the first fiber material FBa. The finely cut second fiber material FBb may be introduced into the plasticized material before being discharged from the nozzle opening 28 by being poured into the center portion 45 of the flat screw 40 through the conveying path 65 shown in FIG. 9 or the like.

[0110] [10-2] Other embodiment 2 In each of the above-described embodiments, instead of using the flat screw 40 to plasticize the thermoplastic resin to produce the plasticized material contained in the plasticized material, the plasticized material may be produced by other methods. For example, the plasticized material may be produced using an in-line screw.

[0111] [10-3] Other embodiment 3 In the second embodiment described above, the first portion Pf does not have to form an outer periphery of the object, and the second portion Ps does not have to form an internal structure of the object. The first portion Pf may be a portion of the internal structure of the object, and the second portion Ps may be a portion that forms the outer periphery.

[0112] [10-4] Other embodiment 4 In the above fourth embodiment, the pressure control unit 90 may be omitted. In this case, in order to suppress the inflow of the plasticizing material from the flat screw 40 into the conveying path 65 for the second fiber material FBb, for example, a configuration in which a portion where the gap between the through hole 47 and the second fiber material FBb is narrowed is locally provided, or a configuration in which a check valve structure for suppressing the inflow of the plasticizing material into the conveying path 65 is provided may be adopted.

[0113] [10-5] Other embodiment 5 In the above sixth embodiment, the flat screw 40 may be formed with an introduction groove 57 for introducing the second fiber material FBb, in addition to the groove portion 42 that functions as a flow path for the plasticizing material.

[0114] [10-6] Other embodiment 6 In the above ninth embodiment, the fiber introduction section 23 does not have to be fixed to the nozzle portion 25. The fiber introduction section 23 may be configured by, for example, a robot that embeds the second fiber material FBb into the plasticized material discharged onto the stage 72 under the control of the control section 10.

[0115] [10-7] Other embodiment 7 The configurations described in each of the above embodiments can be appropriately extracted and combined. For example, the modeling process of the second embodiment shown in FIG. 7 may be performed in any of the modeling apparatuses 100b, 100c, 100d, 100e, 100f, and 100g of the fourth, fifth, sixth, seventh, eighth, and ninth embodiments. The introduction speed control process of the process P25 in the third embodiment may be applied to each of the above embodiments other than the third embodiment. When the introduction speed control process is applied to the fifth or sixth embodiment, the introduction speed is the speed at which the second fiber material FBb is introduced into the modeling material. The through hole 47 of the flat screw 40 in the fourth embodiment or the introduction groove 57 in the fifth or sixth embodiment may be added to the modeling apparatuses 100a, 100e, and 100f of the first embodiment or other embodiments. The pressure control unit 90 in the fourth embodiment may be applied to each of the transport units 60 in each of the above embodiments. In this case, the pressure control unit 90 may control the pressure in each conveying path 65 to be higher than the pressure in the flow path of the plasticizing material. The configuration in which the gear unit 89 in the seventh and eighth embodiments switches the destination of the driving force of the motor 88, and the configuration of the discharge amount control mechanisms 80a, 80b having the function of cutting the second fiber material FBb may be applied to embodiments other than the seventh and eighth embodiments.

[0116] [10-8] Other embodiment 8 The discharge amount control mechanism 80b of the above-described eighth embodiment may be configured to include a shutter valve capable of closing the nozzle flow path 27, instead of the rod 83. In this case, the drive mechanism 84 moves the shutter valve toward the recess 86 and causes it to be received in the recess 86, thereby closing the nozzle flow path 27 and stopping the discharge of the plasticizing material from the nozzle opening 28 while cutting the second fiber material FBb.

[0117] [10-9] Other embodiment 9 In each of the above embodiments, a manufacturing method of a three-dimensional object including the following steps may be applied. The manufacturing method of the three-dimensional object is a manufacturing method of a three-dimensional object performed by a three-dimensional printing device that manufactures a three-dimensional object by stacking modeling layers, and includes a selection step of selecting a fiber material according to the thickness of the modeling layer from among a plurality of types of fiber materials with different fiber diameters, and a modeling step of ejecting a modeling material including the fiber material selected in the selection step from a nozzle opening to form the modeling layer. According to the manufacturing method of this form, a fiber material having an appropriate fiber diameter for the thickness of the modeling layer is selected from among a plurality of types of fiber materials by the three-dimensional printing device and introduced into the modeling layer. Thus, a fiber material having an appropriate fiber diameter can be included in the modeling layer, and the strength of the three-dimensional object can be increased. In addition, it is possible to suppress a decrease in productivity of the three-dimensional object due to the effort required for replacing and loading fiber materials having different fiber diameters into the three-dimensional printing device.

[0118] [10-10] Other embodiments 10 In each of the above embodiments, a manufacturing method of a three-dimensional object including the following steps may be applied. The manufacturing method of the three-dimensional object includes a plasticizing step of plasticizing at least a part of a modeling material including a thermoplastic resin to generate a plasticized material, a fiber introduction step including at least one of a step of introducing a coated fiber material, which is a fiber material coated with a coating material, into the plasticized material after it has been discharged from a nozzle opening, or a step of introducing the coated fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening, and a modeling step of modeling a three-dimensional object including the coated fiber material. According to this embodiment of the manufacturing method, in the fiber introduction step, the coating material that coats the surface of the coated fiber material can prevent air bubbles from adhering to the surface of the fiber material and mixing into the plasticized material. Therefore, it is possible to prevent air bubbles from mixing into the plasticized material and reducing the strength of the three-dimensional object.

[0119]

[11] Summary (1) A method for manufacturing a three-dimensional object as one embodiment of the present invention includes a plasticizing process for plasticizing at least a portion of a modeling material containing a first fiber material and a thermoplastic resin to generate a plasticized material to be ejected from a nozzle opening for modeling a three-dimensional object, and a fiber introducing process having either a process for introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is ejected from the nozzle opening, or a process for introducing the second fiber material into the plasticized material after it has been ejected from the nozzle opening; and a modeling step of modeling the three-dimensional object containing the first fiber material and the second fiber material. According to this embodiment of the method for manufacturing a three-dimensional object, the first fiber material and the second fiber material having different lengths can be combined and mixed in the three-dimensional object so as to mutually reinforce the strength in various directions. Therefore, the strength of the three-dimensional object in various directions can be easily improved.

[0120] (2) In the manufacturing method of the above aspect, the modeling step may include a first modeling step of forming a first portion of the three-dimensional object, the first portion including the first fiber material and the second fiber material, and a second modeling step of forming a second portion of the three-dimensional object, the first portion including the first fiber material and the second fiber material but not including the second fiber material. According to this aspect of the manufacturing method of a three-dimensional object, it is possible to selectively form the first portion including both the first fiber material and the second fiber material, and the second portion not including the second fiber material having a long length. This increases the degree of freedom in modeling the three-dimensional object.

[0121] (3) In the manufacturing method of the above aspect, the modeling step may include a moving step of relatively moving a stage supporting the three-dimensional object and a nozzle unit having the nozzle opening, and an introduction speed control step of changing an introduction speed at which the second fiber material is introduced into the modeling material or the plasticizing material in accordance with the relative movement speed between the nozzle unit and the stage in the moving step. According to this aspect of the manufacturing method of a three-dimensional object, it is possible to suppress fluctuations in the amount and state of the fiber material introduced into the modeling layer due to changes in the relative movement speed between the nozzle unit and the stage during modeling of the three-dimensional object.

[0122] (4) In the manufacturing method of the above embodiment, the plasticization step may include a step of guiding the modeling material supplied between the flat screw and the facing part to the communicating hole while plasticizing the modeling material by rotating the flat screw and heating the heater in a plasticization device having a flat screw having a groove forming surface on which a groove portion is formed, a facing part having an opposing surface facing the groove forming surface and having a communication hole communicating with the nozzle opening, and a heater for heating the flat screw or the facing part. According to the manufacturing method of this embodiment, the use of a flat screw in the plasticization step makes it possible to reduce the size of the device that realizes the plasticization step. In addition, by controlling the rotation of the flat screw, it is possible to easily control the pressure and flow rate of the plasticization material supplied to the nozzle opening, thereby further improving the discharge accuracy of the plasticization material and the modeling accuracy of the three-dimensional object.

[0123] (5) In the above-described method for manufacturing a three-dimensional object, the flat screw may have a through hole that opens in the groove forming surface and communicates with the communication hole, and the fiber introducing step may include a step of introducing the second fiber material through the through hole into the plasticized material before it is discharged from the nozzle opening. According to this manufacturing method, the fiber material can be smoothly introduced into the communication hole of the facing part through the through hole of the flat screw.

[0124] (6) The method for manufacturing a three-dimensional object of the above aspect may include a pressure control step of controlling the pressure in the through holes to be higher than the pressure in the communicating holes. According to this aspect of the manufacturing method, the pressure in the through holes is controlled to be high, thereby preventing the plasticizing material from flowing into the through holes and inhibiting the introduction of the second fiber material.

[0125] (7) In the method for manufacturing a three-dimensional object of the above aspect, an introduction groove that introduces the second fiber material from a side of the flat screw or the opposing portion to the communicating hole may be formed in the groove forming surface or the opposing surface, and the fiber introduction step may include a step of introducing the second fiber material into the modeling material through the introduction groove. According to this aspect of the manufacturing method, the second fiber material can be introduced into the communicating hole by utilizing the rotational force of the flat screw and can be discharged from the nozzle opening, which is efficient.

[0126] (8) The manufacturing method of the above aspect may further include a cutting step of cutting the second fiber material. According to this aspect of the manufacturing method, by cutting the second fiber material, it is possible to easily adjust the length of the second fiber material, control the stopping of the introduction of the second fiber material, and the like.

[0127] (9) In the manufacturing method of the above aspect, the cutting step may include a step of cutting the second fibrous material by operating a discharge amount control mechanism that is provided upstream of the nozzle opening and controls the discharge amount of the plasticizing material. According to the manufacturing method of this aspect, the discharge amount control mechanism can efficiently control the introduction of the fibrous material into the plasticizing material as well as the discharge amount of the plasticizing material.

[0128] (10) In the method for manufacturing a three-dimensional object according to the above aspect, the discharge amount control mechanism may be driven by a motor, and the fiber introducing step may include a step of transmitting a driving force generated by the motor to a conveying unit for the second fiber material and using the driving force as a conveying force for the second fiber material. According to this aspect of the manufacturing method, the conveying unit and the discharge amount control mechanism can be driven by a common motor, which allows the device configuration to be miniaturized.

[0129] (11) A three-dimensional printing device as one embodiment of the present invention includes a plasticizing unit that plasticizes at least a portion of a modeling material, the plasticizing unit including a first fiber material and a thermoplastic resin, to generate a plasticized material for modeling a three-dimensional object; a discharge unit having a nozzle opening that discharges the plasticized material; a fiber introduction unit that has either a function of introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening, or a function of introducing the second fiber material into the plasticized material after it is discharged from the nozzle opening; and a control unit that controls the plasticizing unit, the discharge unit, and the fiber introduction unit to model the three-dimensional object including the first fiber material and the second fiber material. According to this form of the three-dimensional device, a first fiber material having a short length and a second fiber material having a long length can be combined and mixed into the plasticized material so that the strengths of the first fiber material and the second fiber material complement each other, so that the strength of the three-dimensional object can be easily improved in various directions. [Explanation of symbols]

[0130] 10...control section, 20...discharge section, 21...material generating section, 23...fiber introduction section, 25...nozzle section, 26...introduction flow path, 27...nozzle flow path, 28...nozzle opening, 30...material supply section, 31...material storage section, 32...connecting path, 35...plasticizing section, 36...screw case, 37...driving motor, 40...flat screw, 41...groove forming surface, 42...groove section, 43...upper surface, 44...ridge section, 45...center section, 46...material inlet, 47...through hole, 50...facing section, 51...facing surface, 52...heater, 53...communicating hole, 55...guide groove, 57...introduction groove, 60...transport section, 60a...first transport section, 60b...second transport section, 60c...third transport section, 62...reel, 63...storage section, 65...transport path, 66...cutting section, 70... Modeling stage section, 72...stage, 72s...stage surface, 73...modeling table, 75...movement mechanism, 80, 80a, 80b...discharge amount control mechanism, 81...butterfly valve, 82...cutter blade, 83...rod, 84...driving mechanism, 85...branching flow path, 86...recess, 88...motor, 89...gear section, 90...pressure control section, 100a, 100b, 100c, 100d, 100e, 100f...three-dimensional modeling device, FBa...first fiber material, FBb...second fiber material, Dn...hole size, G...gap, ML...modeling layer, MLa...first modeling layer, MLb...second modeling layer, MM...plasticized material, OB, OBa...three-dimensional model, OBt...upper surface, Pf...first part, Ps...second part, PM...modeling material, RX...rotation axis

Claims

1. a plasticizing step of plasticizing at least a portion of a modeling material including a first fiber material and a thermoplastic resin to generate a plasticized material to be discharged from a nozzle opening for modeling a three-dimensional object; a fiber introduction step including either a step of introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening, or a step of introducing the second fiber material into the plasticized material after it is discharged from the nozzle opening; and a modeling process of modeling the three-dimensional object containing the first fiber material and the second fiber material, The fiber diameter of the first fiber material is 5 μm or more and 20 μm or less. A method for manufacturing three-dimensional objects.

2. The molding process includes: a first modeling process for forming a first portion which is a part of the three-dimensional object and contains the first fiber material and the second fiber material; and a second modeling process for forming a second portion, which is a part of the three-dimensional object, the second portion including the first fiber material and not including the second fiber material. The method for producing a three-dimensional object according to claim 1 .

3. The molding process includes: a moving step of relatively moving a stage supporting the three-dimensional object and a nozzle unit having the nozzle opening; and an introduction speed control process for changing an introduction speed at which the second fiber material is introduced into the modeling material or the plasticizing material in accordance with a relative movement speed between the nozzle portion and the stage in the movement process. The method for producing a three-dimensional object according to claim 1 or 2.

4. The plasticizing step is performed in a plasticizing device having a flat screw having a groove forming surface on which a groove is formed, a facing portion having an opposing surface facing the groove forming surface and having a communication hole communicating with the nozzle opening, and a heater for heating the flat screw or the facing portion, a step of plasticizing the modeling material supplied between the flat screw and the facing portion by rotating the flat screw and heating the flat screw with the heater, and guiding the modeling material to the communicating hole, The method for producing a three-dimensional object according to any one of claims 1 to 3.

5. a through hole is formed in the flat screw, the through hole opening in the groove forming surface and communicating with the communication hole; The fiber introducing step includes a step of introducing the second fiber material through the through hole into the plasticized material before it is discharged from the nozzle opening. The method for producing a three-dimensional object according to claim 4 .

6. a pressure control step of controlling the pressure in the through hole to be higher than the pressure in the communicating hole; The method according to claim 5 .

7. an introduction groove is formed in the groove forming surface or the opposing surface to introduce the second fiber material from a side of the flat screw or the opposing surface to the communication hole; The fiber introduction step includes a step of introducing the second fiber material into the modeling material through the introduction groove, The method for producing a three-dimensional object according to claim 4 .

8. A cutting step of cutting the second fiber material. The method for producing a three-dimensional object according to any one of claims 1 to 7.

9. The cutting step includes a step of cutting the second fiber material by operating a discharge amount control mechanism that is provided upstream of the nozzle opening and controls a discharge amount of the plasticizing material. The method for producing a three-dimensional object according to claim 8 .

10. The discharge amount control mechanism is driven by a motor, The fiber introduction step includes a step of transmitting a driving force generated by the motor to a conveying section of the second fiber material and using the driving force as a conveying force for the second fiber material. The method for producing a three-dimensional object according to claim 9 .

11. The length of the first fiber material is 5 mm or less. The method for producing a three-dimensional object according to claim 1 .

12. The fiber diameter of the second fiber material is 10 μm or more and is equal to or less than the hole diameter of the nozzle opening. The method for producing a three-dimensional object according to claim 1 .

13. a plasticizing unit that plasticizes at least a portion of a modeling material including a first fiber material and a thermoplastic resin to generate a plasticized material for modeling a three-dimensional object; a discharge section having a nozzle opening for discharging the plasticizing material; a fiber introduction section having either a function of introducing a second fiber material longer than the first fiber material into the modeling material or the plasticized material before it is ejected from the nozzle opening, or a function of introducing the second fiber material into the plasticized material after it is ejected from the nozzle opening; a control unit that controls the plasticizing unit, the discharging unit, and the fiber introduction unit to form the three-dimensional object containing the first fiber material and the second fiber material, The fiber diameter of the first fiber material is 5 μm or more and 20 μm or less. Three-dimensional printing equipment.

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