Method and apparatus for manufacturing three-dimensional objects

Abstract

To eliminate the possibility of occurrence of a gap in a three-dimensional molded article, when the three-dimensional molded article is produced by discharging a molding material from a discharge unit toward a molding surface.SOLUTION: In a method for manufacturing a three-dimensional molded article, when the amount of a molding material MM to be discharged toward a molding surface 311 per unit movement of a discharge unit 60 is set as a discharged molding amount MA, in a layer forming process of forming a layer ML on the molding surface 311, if a second partially molded article PO2 to be molded is molded not adjacent to a first partially molded article PO1 to be molded first but with a gap from each other, the second partially molded article PO2 is molded with the discharged molding amount MA as a first discharged molding amount MA1, and if the second partially molded article PO2 is adjacent to the first partially molded article PO1, the second partially molded article PO2 is molded with the discharged molding amount MA as a second discharge molding amount MA2 which is larger than the first discharged molding amount MA1.SELECTED DRAWING: Figure 11

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] Patent Document 1 discloses a method for manufacturing a three-dimensional object, in which a nozzle for extruding a modeling material is moved along a build path for constructing each layer of the three-dimensional object. The build path includes a peripheral path and a bulk cluster path disposed inside the peripheral path. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2009-525207 Summary of the Invention [Problem to be solved by the invention]

[0004] The method of manufacturing a three-dimensional object described in Patent Document 1 discloses that areas that cannot be filled by the bulk cluster path are identified as void areas, and additional remaining paths are generated in the void areas to suppress gaps. However, it is desirable to form the object in such a way that gaps are not generated in the first place. [Means for solving the problem]

[0005] The manufacturing method of a three-dimensional object is a method of manufacturing a three-dimensional object by discharging a modeling material from a discharging unit toward a modeling surface of a table, and includes a plasticizing process of plasticizing at least a part of the material to generate the modeling material, and a layer forming process of forming a layer on the modeling surface by discharging the modeling material toward the modeling surface while moving the discharging unit along a partial path based on modeling data, thereby forming a layer on the modeling surface, and the amount of the modeling material discharged toward the modeling surface per unit movement amount of the discharging unit is calculated. When the amount of the modeling material dispensed is defined as the discharged modeling amount, in the layer formation process, if a second partial object formed along the partial path is not adjacent to a first partial object formed earlier and is formed with a gap between them, the second partial object is formed using the discharged modeling amount as a first discharged modeling amount, and if the second partial object is adjacent to the first partial object, the second partial object is formed using the discharged modeling amount as a second discharged modeling amount, and the second discharged modeling amount is greater than the first discharged modeling amount when measured under the same conditions.

[0006] The three-dimensional printing apparatus includes a plasticizing unit that plasticizes at least a portion of a material to generate a printing material, a discharging unit that discharges the printing material toward a printing surface of a table, a moving mechanism that changes a relative position between the discharging unit and the printing surface, and a control unit. The control unit causes the moving mechanism to change the relative position while causing the discharging unit to discharge the printing material toward the printing surface, thereby printing a plurality of partial objects along a plurality of partial paths, and when an amount of the printing material discharged toward the printing surface per unit movement amount of the discharging unit is defined as an ejected printing amount, The control unit adjusts the extruded forming amount by controlling any one of the plasticization unit, the extruder unit, and the movement mechanism, and when a second partial object formed along the partial path is not adjacent to a first partial object formed earlier and is formed with a gap between them, the control unit forms the second partial object using the extruded forming amount as a first extruded forming amount, and when the second partial object is adjacent to the first partial object, the control unit forms the second partial object using the extruded forming amount as a second extruded forming amount that is larger than the first extruded forming amount when measured under the same conditions. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram showing a schematic configuration of a three-dimensional printing apparatus according to an embodiment of the present disclosure. [Diagram 2] FIG. 4 is a schematic perspective view showing the configuration of a groove forming surface side of a flat screw. [Diagram 3] FIG. 2 is a top view showing the configuration of the side of the barrel facing the screw. [Figure 4] FIG. 1 is a schematic diagram showing how a three-dimensional object is formed. [Diagram 5] 6 is a flowchart showing a process flow when executing modeling of a three-dimensional object. [Figure 6] 6 is a flowchart showing a process for generating modeling data. [Figure 7] FIG. 11 is a plan view showing an example of an arrangement of partial objects for forming one layer. [Figure 8] FIG. 11 is a plan view showing a state in which a second partial object that is not adjacent to the first partial object in the modeling data has been modeled. [Figure 9] FIG. 11 is a plan view showing a state in which a second partial object adjacent to a first partial object has been formed in accordance with the forming data. [Figure 10] FIG. 11 is a plan view showing a state in which a first partial object and second partial objects adjacent to each other on both sides have been formed in accordance with the forming data. [Figure 11] 10 is a flowchart showing a process for determining the amount of material to be discharged when forming a partial object based on the result of a determination process. [Figure 12] 10 is a plan view showing a state in which the second partial object in FIG. 9 is formed by the second discharging amount. FIG. [Figure 13] 11 is a plan view showing a state in which the second partial object in FIG. 10 has been formed by a third discharging amount. FIG. [Figure 14] 10 is a plan view showing a state in which the width of the first partial object in FIG. 9 is formed narrower than the line width of the forming data. [Figure 15] 10 is a flowchart showing the flow of a partial object forming process according to the second embodiment. [Figure 16]10 is a plan view showing a state in which the second partial object of FIG. 9 is printed based on the changed printing data. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, the present invention will be described based on an embodiment. In each drawing, the same members are given the same reference numerals, and duplicated explanations will be omitted.

[0009] In addition, in each figure, X, Y, and Z represent three spatial axes that are mutually orthogonal. In this specification, the directions along these axes are the X-axis direction, the Y-axis direction, and the Z-axis direction. When specifying the direction, the positive direction is "+" and the negative direction is "-", and the direction notation is both positive and negative, with the direction indicated by the arrow in each figure being the + direction and the opposite direction to the arrow being the - direction. The X and Y directions are directions along the horizontal direction, and the Z direction indicates the vertical direction. The +Z direction indicates the vertical downward direction, and the -Z direction indicates the vertical upward direction. Furthermore, the three spatial axes of X, Y, and Z that are not limited to the positive and negative directions will be described as the X-axis, Y-axis, and Z-axis.

[0010] 1. Embodiment 1 As shown in Fig. 1, in this embodiment, the three-dimensional modeling apparatus 100 includes a modeling unit 200, a table 300, a moving mechanism 400, and a control unit 500. Under the control of the control unit 500, the three-dimensional modeling apparatus 100 discharges a modeling material MM from a discharging unit 60 provided in the modeling unit 200 toward the table 300, while driving the moving mechanism 400 to change the relative positions of the discharging unit 60 and the table 300, thereby forming a three-dimensional object having a desired shape on a modeling surface 311 of the table 300. The modeling material MM is sometimes referred to as a molten material. A detailed configuration of the modeling unit 200 will be described later.

[0011] The movement mechanism 400 changes the relative position between the discharge unit 60 and the printing surface 311. In this embodiment, the movement mechanism 400 changes the relative position between the discharge unit 60 and the printing surface 311 by moving the table 300 relative to the printing unit 200. Note that the change in the relative position of the discharge unit 60 with respect to the printing surface 311 may also be referred to as the movement of the discharge unit 60. Also, the relative movement speed of the discharge unit 60 with respect to the printing surface 311 may also be referred to as the movement speed of the discharge unit 60. In this embodiment, for example, moving the table 300 in the +X direction can be rephrased as moving the discharge unit 60 in the -X direction.

[0012] The moving mechanism 400 in this embodiment is configured with a three-axis positioner that moves the table 300 in three axial directions, namely, the X, Y, and Z directions, by the driving forces of three motors. Each motor is driven under the control of the control unit 500. Note that the moving mechanism 400 may be configured to change the relative position between the discharge unit 60 and the modeling surface 311 by moving the modeling unit 200, instead of the table 300. Also, the moving mechanism 400 may be configured to change the relative position between the discharge unit 60 and the modeling surface 311 by moving both the table 300 and the modeling unit 200.

[0013] The control unit 500 is configured by a computer including one or more processors, a storage device, and an input / output unit that inputs and outputs signals to and from the outside. In this embodiment, the control unit 500 executes a modeling process for forming a three-dimensional object by controlling the operation of the modeling unit 200 and the moving mechanism 400 by the processor executing a program or command loaded onto the storage device. The operation includes changing the three-dimensional relative positions of the modeling unit 200 and the table 300. The control unit 500 may be configured by a combination of multiple circuits instead of a computer. As will be described later, the control unit 500 also functions as a data processing device that processes data for forming a three-dimensional object. In another embodiment, a data processing device separate from the control unit 500 may be provided.

[0014] The modeling unit 200 includes a material supply section 20 which is a supply source of material MR, a plasticization section 30 which plasticizes at least a portion of the material MR supplied from the material supply section 20 to convert it into modeling material MM, a discharge section 60 having a nozzle hole 69 which discharges the modeling material MM supplied from the plasticization section 30, a discharge amount adjustment mechanism 70 which adjusts the flow rate of the modeling material MM discharged from the nozzle hole 69, a suction section 80, and a measurement section 90.

[0015] The material supply unit 20 contains the material MR in a state such as pellets or powder. In this embodiment, for example, a thermoplastic resin formed into pellets is used as the material MR. The material supply unit 20 in this embodiment is configured by a hopper. A connection path 22 that connects the material supply unit 20 and the plasticizing unit 30 is provided below the material supply unit 20. The material supply unit 20 supplies the material MR to the plasticizing unit 30 via the connection path 22. Details of the material MR will be described later.

[0016] The plasticizing unit 30 has a screw case 31, a drive motor 32, a flat screw 40, and a barrel 50. The flat screw 40 is an example of a screw. The plasticizing unit 30 plasticizes the solid-state material MR supplied from the material supply unit 20 to generate a paste-like modeling material MM that exhibits fluidity, and supplies the paste-like modeling material MM to the discharge unit 60.

[0017] In this embodiment, "plasticization" means that the material MR having thermoplasticity is melted by applying heat. Also, "melting" means not only that the material MR having thermoplasticity is heated to a temperature equal to or higher than the melting point and becomes liquid, but also that the material MR having thermoplasticity is heated to a temperature equal to or higher than the glass transition point and softens, thereby exhibiting fluidity.

[0018] The screw case 31 is a housing for accommodating the flat screw 40. A barrel 50 is fixed to the lower surface of the screw case 31, and the flat screw 40 is accommodated in a space surrounded by the screw case 31 and the barrel 50. A drive motor 32 is fixed to the upper surface of the screw case 31. A rotating shaft of the drive motor 32 is connected to the upper surface 41 side of the flat screw 40. The drive motor 32 is driven under the control of a control unit 500.

[0019] The flat screw 40 has a generally cylindrical shape with a height in the direction along the central axis RX smaller than its diameter. The flat screw 40 is disposed in the screw case 31 so that the central axis RX is parallel to the Z-axis. The flat screw 40 rotates about the central axis RX in the screw case 31 by the torque generated by the drive motor 32. The flat screw 40 has a groove forming surface 42 on which a groove portion 45 is formed on the opposite side to the top surface 41 in the direction along the central axis RX. The specific configuration of the groove forming surface 42 side of the flat screw 40 will be described later.

[0020] The barrel 50 is disposed below the flat screw 40. The barrel 50 has a screw-facing surface 52 facing the groove forming surface 42 of the flat screw 40. The barrel 50 has a communication hole 56 that communicates with the discharge section 60 on the central axis RX of the flat screw 40. The barrel 50 has a heater 58 built in at a position facing the groove section 45 of the flat screw 40. The temperature of the heater 58 is controlled by the control section 500. The specific configuration of the screw-facing surface 52 side of the barrel 50 will be described later.

[0021] The discharge unit 60 is fixed to the lower surface of the barrel 50. The discharge unit 60 has a supply passage 62 and a nozzle 61. The supply passage 62 connects between the plasticizing unit 30 and the nozzle 61, and supplies the modeling material MM from the plasticizing unit 30 to the nozzle 61.

[0022] The supply flow path 62 has a first supply port 65, a cross hole 66, and a second supply port 67. The first supply port 65 and the second supply port 67 extend in the Z-axis direction. The cross hole 66 extends in the Y-axis direction intersecting the first supply port 65 and the second supply port 67. The upper end of the first supply port 65 is connected to the communication hole 56 of the barrel 50, and the lower end of the first supply port 65 is connected to the cross hole 66. The upper end of the second supply port 67 is connected to the cross hole 66, and the lower end of the second supply port 67 is connected to the nozzle 61. The cross hole 66 houses a discharge amount adjustment mechanism 70, which will be described later. The modeling material MM supplied from the communication hole 56 of the barrel 50 to the first supply port 65 flows in this order through the cross hole 66, the second supply port 67, and the nozzle 61.

[0023] The nozzle 61 is provided with a nozzle flow path 68 and a nozzle hole 69. The nozzle flow path 68 is a flow path provided in the nozzle 61. The nozzle flow path 68 is connected to a second supply port 67. The nozzle hole 69 is a portion with a reduced flow path cross section provided at the end of the nozzle flow path 68 on the side communicating with the atmosphere. The modeling material MM supplied from the second supply port 67 to the nozzle flow path 68 is discharged from the nozzle hole 69. In this embodiment, the opening shape of the nozzle hole 69 is circular. Note that the opening shape of the nozzle hole 69 is not limited to a circle, and may be, for example, a rectangle or a polygon other than a rectangle.

[0024] The discharge amount adjustment mechanism 70 is provided in the supply flow path 62 and adjusts the amount of the modeling material MM discharged from the nozzle 61. The amount of the modeling material MM discharged from the nozzle 61 per unit time is sometimes called the discharge amount. In this embodiment, the discharge amount adjustment mechanism 70 is configured by a butterfly valve. The discharge amount adjustment mechanism 70 includes a drive shaft 71, which is an axial member, and a plate-shaped valve body 72 that rotates with the rotation of the drive shaft 71. The drive shaft 71 is inserted into the cross hole 66 so that the direction along the central axis of the drive shaft 71 and the flow direction of the modeling material MM in the supply flow path 62 intersect.

[0025] The discharge amount adjustment mechanism 70 functions as a flow rate adjustment mechanism that adjusts the flow rate of the modeling material MM flowing through the supply flow path 62. Specifically, the discharge amount adjustment mechanism 70 adjusts the flow rate of the modeling material MM flowing through the supply flow path 62 by changing the rotation angle of the valve body 72 to adjust the ease of flow of the modeling material MM through the supply flow path 62. The discharge amount is adjusted by adjusting the flow rate of the modeling material MM flowing through the supply flow path 62. The valve body 72 is an example of an adjustment valve.

[0026] Controlling the discharge amount adjustment mechanism 70 to increase the discharge amount is sometimes referred to as opening the discharge amount adjustment mechanism 70. Controlling the discharge amount adjustment mechanism 70 to decrease the discharge amount is sometimes referred to as closing the discharge amount adjustment mechanism 70. The degree of rotation of the valve body 72 is sometimes referred to as the opening degree. When the plate-shaped surface of the valve body 72 becomes perpendicular to the flow direction of the modeling material MM in the supply flow path 62 due to the rotation of the drive shaft 71, the opening degree becomes 0, the plasticizing unit 30 and the nozzle 61 do not communicate with each other, and the discharge of the modeling material MM from the nozzle 61 is stopped. When the plate-shaped surface of the valve body 72 becomes parallel to the flow direction of the modeling material MM in the supply flow path 62, the opening degree becomes 100, the plasticizing unit 30 and the nozzle 61 communicate with each other, and the modeling material MM is discharged. In this way, the discharge amount adjustment mechanism 70 also controls the start and stop of the discharge of the modeling material MM from the nozzle 61.

[0027] The suction unit 80 is configured to be able to suck the modeling material MM in the supply flow passage 62. By sucking the modeling material MM in the supply flow passage 62, the suction unit 80 reduces the residual pressure in the supply flow passage 62 after the valve body 72 of the discharge amount adjustment mechanism 70 is closed, and suppresses leakage of the modeling material MM from the nozzle 61 that has stopped discharging the modeling material MM. The suction unit 80 has a cylindrical cylinder 81, a plunger 82 housed in the cylinder 81, and a plunger drive unit 83 that drives the plunger 82. The cylinder 81 is connected to a position in the supply flow passage 62 between the valve body 72 and the nozzle hole 69.

[0028] In this embodiment, the plunger driving unit 83 is configured by a motor that is driven under the control of the control unit 500, and a rack and pinion that converts the rotation of the motor into translational movement along the X-axis that is the axial direction of the cylinder 81. The plunger driving unit 83 may be configured by a motor that is driven under the control of the control unit 500, and a ball screw that converts the rotation of the motor into translational movement along the axial direction of the cylinder 81, or may be configured by an actuator such as a solenoid mechanism or a piezoelectric element.

[0029] When the plunger 82 moves in the -X direction away from the supply flow passage 62, negative pressure is created inside the cylinder 81, so that the modeling material MM in the region between the valve body 72 and the nozzle hole 69 in the supply flow passage 62 is sucked into the cylinder 81. On the other hand, when the plunger 82 moves in the +X direction approaching the supply flow passage 62, the modeling material MM in the cylinder 81 is pushed out into the supply flow passage 62 by the plunger 82.

[0030] The measuring unit 90 measures the dimensions of the formed three-dimensional object. The measuring unit 90 is provided near the nozzle 61. The measuring unit 90 of this embodiment has a measurement light emitting unit near the nozzle 61, and is configured by a non-contact three-dimensional digitizer that measures the shape of the three-dimensional object using laser light or the like. The measuring unit 90 is not particularly limited as long as it can measure the contour shape of the formed three-dimensional object as viewed from the -Z direction, and may be fixed near the nozzle 61 or may be movably provided at a position away from the discharge unit 60. For example, the measuring unit 90 may have an image sensor near the nozzle 61, and may measure the contour shape of the three-dimensional object from image data of the captured three-dimensional object.

[0031] Fig. 2 is a schematic perspective view showing the configuration of the groove forming surface 42 side of the flat screw 40. In Fig. 2, the position of the central axis RX of the flat screw 40 is indicated by a dashed line. As described with reference to Fig. 1, the groove forming surface 42 is provided with a groove portion 45.

[0032] The central portion 47 of the groove forming surface 42 of the flat screw 40 is configured as a recess to which one end of the groove portion 45 is connected. The central portion 47 faces the communication hole 56 of the barrel 50 shown in Fig. 1. The central portion 47 intersects with the central axis RX.

[0033] The grooves 45 of the flat screw 40 form what is called a scroll groove. The grooves 45 extend in an arc-like spiral shape from a central portion 47 toward the outer periphery of the flat screw 40. The grooves 45 may be configured to extend in a spiral shape. The groove forming surface 42 is provided with protruding ribs 46 that form side walls of the grooves 45 and extend along each of the grooves 45.

[0034] The groove portion 45 continues to a material inlet 44 formed on a side surface 43 of the flat screw 40. This material inlet 44 is a portion that receives the material MR supplied via the connection path 22 of the material supply unit 20.

[0035] 2 shows an example of a flat screw 40 having three grooves 45 and three ridges 46. The number of grooves 45 and ridges 46 provided on the flat screw 40 is not limited to three. The flat screw 40 may be provided with only one groove 45, or may be provided with two or more grooves 45. Furthermore, any number of ridges 46 may be provided in accordance with the number of grooves 45.

[0036] 2 shows an example of a flat screw 40 in which the material introduction ports 44 are formed in three places. The number of material introduction ports 44 provided in the flat screw 40 is not limited to three. The flat screw 40 may have the material introduction port 44 provided in only one place, or may have the material introduction port 44 provided in two or more places.

[0037] 3 is a top view showing the configuration of the screw-opposing surface 52 side of the barrel 50. As described above, a communication hole 56 communicating with the discharge portion 60 is formed in the center of the screw-opposing surface 52. A plurality of guide grooves 54 are formed around the communication hole 56 in the screw-opposing surface 52. One end of each guide groove 54 is connected to the communication hole 56, and extends in a spiral shape from the communication hole 56 toward the outer periphery of the screw-opposing surface 52. Each guide groove 54 has the function of guiding the modeling material MM to the communication hole 56.

[0038] As described above, in the three-dimensional modeling apparatus 100, the plasticizing unit 30 plasticizes the solid-state material MR supplied to the groove portion 45 of the rotating flat screw 40 to generate modeling material MM, which is then supplied to the discharge portion 60. The amount of modeling material MM supplied to the discharge portion 60 per unit time can be changed by adjusting the number of rotations per unit time of the flat screw 40. For example, increasing the number of rotations per unit time of the flat screw 40 increases the amount of modeling material MM supplied to the discharge portion 60 per unit time.

[0039] As shown in FIG. 4, the control unit 500 discharges the modeling material MM from the nozzle 61 of the discharge unit 60 toward the modeling surface 311 while moving the discharge unit 60. Specifically, the control unit 500 discharges the modeling material MM from the nozzle 61 while moving the nozzle 61 in a direction along the modeling surface 311 while maintaining the distance between the modeling surface 311 and the nozzle 61. The modeling material MM discharged from the nozzle 61 is continuously deposited in the moving direction of the nozzle 61. As a result, a linear modeled object LP that extends linearly along the moving path of the nozzle 61 is formed. The movement of the discharge unit 60 while discharging the modeling material MM is sometimes referred to as scanning. The scanning direction of the discharge unit 60 is sometimes referred to as the scanning direction.

[0040] The control unit 500 forms layers ML by repeating the above-mentioned scanning by the nozzle 61. After forming one layer ML, the control unit 500 moves the nozzle 61 in the -Z direction. Thereafter, a three-dimensional object is formed by stacking a further layer ML on the previously formed layer ML.

[0041] Next, a process flow when the control unit 500 executes a modeling process for a three-dimensional object in this embodiment will be described with reference to the flowchart shown in Fig. 5. In this embodiment, the process flow when the control unit 500 executes a modeling process for a three-dimensional object corresponds to a manufacturing method for a three-dimensional object.

[0042] When a user performs a predetermined start operation on an operation panel provided on the three-dimensional printing apparatus 100 or an external computer connected to the three-dimensional printing apparatus 100, the control unit 500 executes the modeling process. By executing the modeling process, the three-dimensional printing apparatus 100 starts manufacturing a three-dimensional object.

[0043] In the modeling process, the control unit 500 appropriately controls the modeling unit 200 and the moving mechanism 400 in accordance with the modeling data, and forms a three-dimensional object by stacking layers of the modeling material MM on the modeling surface 311. The modeling data will be described in detail later.

[0044] In step S110, the control unit 500 executes a modeling data generating process. In the modeling data generating process, the control unit 500 analyzes 3D CAD data, which is shape data of a three-dimensional object input from the outside, and generates modeling data. The modeling data generating process will be described later in detail. Note that it is sufficient that the modeling data is generated before the modeling material MM is discharged from the discharge unit 60 toward the modeling surface 311 in the layer forming process described later. For this reason, the control unit 500 may execute the modeling data generating process between the plasticizing process and the layer forming process described later. Alternatively, the control unit 500 may generate modeling data in the layer forming process, and discharge the modeling material MM from the discharge unit 60 toward the modeling surface 311 based on the generated modeling data.

[0045] In step S120, the control unit 500 executes a plasticization process. In the plasticization process, the control unit 500 causes the plasticization unit 30 to plasticize at least a portion of the solid-state material MR supplied to the groove portion 45 of the rotating flat screw 40, to generate the modeling material MM, and supplies the modeling material MM toward the discharge unit 60.

[0046] In step S130, the control unit 500 executes a layer formation process. In the layer formation process, the control unit 500 repeats scanning while discharging the modeling material MM from the discharging unit 60 based on the modeling data, to form a layer ML of the modeling material MM discharged onto the modeling surface 311.

[0047] In step S140, the control unit 500 executes a stacking process. In the stacking process, the control unit 500 forms one layer ML based on the modeling data, and then moves the nozzle 61 in the -Z direction. Thereafter, a three-dimensional object is formed by stacking an additional layer ML on the previously formed layer ML.

[0048] After executing the process of step S140, the control unit 500 ends the process for executing the formation process of a three-dimensional object.

[0049] Next, a process flow when the control unit 500 executes the modeling data generating step in this embodiment will be described with reference to the flowchart shown in Fig. 6. In step S111, the control unit 500 executes a layer data generating process. In step S111, the control unit 500 analyzes the three-dimensional CAD data, and generates layer data by slicing the three-dimensional object into multiple layers along the XY plane.

[0050] After executing the process of step S111, the control unit 500 executes a process of generating path data in step S112. In step S112, the control unit 500 generates a partial path PR. The partial path PR refers to a path along which the discharge unit 60 moves while discharging the modeling material MM in order to form a partial object PO on the modeling surface 311. The partial object PO is a part of a linear object LP. Each partial path PR is, for example, a linear path. In this embodiment, in step S112, the control unit 500 generates path data having a plurality of partial paths PR based on the outer shell shape of the three-dimensional object. Note that a change in the position of the discharge unit 60 relative to the modeling surface 311 may also be referred to as the movement of the discharge unit 60. Therefore, the movement of the discharge unit 60 relative to the modeling surface 311 while discharging the modeling material MM due to the movement of the table 300 may also be referred to as the discharge unit 60 moving while discharging the modeling material MM.

[0051] After executing the process of step S112, the control unit 500 determines the line width W of the partial path PR in step S113. The line width W refers to the width of the modeling material MM discharged onto the modeling surface 311 in a direction intersecting the scanning direction. In this embodiment, the control unit 500 generates line width information in step S113. The line width information is information for discharging the modeling material MM with the determined line width W in each partial path PR. In other words, the line width information is information for realizing the determined line width W.

[0052] In this embodiment, the line width information includes a line width W, discharge amount information, and movement speed information. The discharge amount information is information that represents the discharge amount of the modeling material MM in each partial path PR. The movement speed information is information that represents the movement speed at which the discharge unit 60 moves while discharging the modeling material MM in each partial path PR. Note that the relative movement speed of the discharge unit 60 with respect to the modeling surface 311 when the table 300 moves and the discharge unit 60 moves relative to the modeling surface 311 while discharging the modeling material MM is also referred to as the movement speed at which the discharge unit 60 moves while discharging the modeling material MM. The control unit 500 determines the line width W in each generated partial path PR, and generates modeling data for one layer ML. The modeling data for one layer ML is data that has path data and line width information. The control unit 500 generates modeling data for all layers. The line width W and the line width information will be described in detail later.

[0053] After executing the process of step S113, the control unit 500 ends the process of executing the modeling data generating process.

[0054] Next, the details of the generation of the printing data in the above-mentioned printing data generation process and the formation of the layer ML in the layer formation process will be described with reference to Fig. 7 and Fig. 8. In Fig. 7 and Fig. 8, the outline and line width W of the partial object PO in the printing data are shown by two-dot chain lines, the partial path PR in the printing data is shown by dashed lines, the partial object PO formed based on the printing data is shown by hatching, and the partial path PR used in forming the partial object PO is shown by a solid line. In addition, the outer shape LD of the object in the layer ML is shown by a thick solid line.

[0055] Fig. 7 shows an example of the printing data generated to form one layer ML in the printing data generating process. In the printing data shown in Fig. 7, one layer ML is formed by printing a first partial object PO1, a second partial object PO2, a third partial object PO3, and a fourth partial object PO4 in this order. The first partial object PO1 is an example of a partial object PO that is printed before the second partial object PO2. In the printing data shown in Fig. 7, the first partial object PO1 is defined by a partial path PR1, line widths W1 and Wh1, and distances D1 and Dh1, the second partial object PO2 is defined by a partial path PR2, line width W2, and distance D2, the third partial object PO3 is defined by a partial path PR3, line width W3, and distance D3, and the fourth partial object PO4 is defined by a partial path PR4, line width W1, and distance D1.

[0056] Fig. 8 shows, by hatching, a first partial object PO1 that is formed based on the modeling data of the first partial object PO1 from the modeling data shown in Fig. 7, and a second partial object PO2 that is formed based on the modeling data of the second partial object PO2 after the first partial object PO1 is formed. In the layer formation step, the control unit 500 discharges the modeling material MM from the nozzle 61 of the discharging unit 60 onto the modeling surface 311 so as to obtain the line widths W1, Wh1 of the first partial object PO1 while moving the discharging unit 60 along the partial path PR1, based on the modeling data of the first partial object PO1.

[0057] After the first partial object PO1 has been formed, the control unit 500 discharges the modeling material MM from the nozzle 61 of the discharging unit 60 onto the modeling surface 311 so as to obtain the line width W2 of the second partial object PO2, while moving the discharging unit 60 along the partial path PR2, based on the modeling data of the second partial object PO2. As shown in Fig. 7, when one layer ML is formed by a third partial object PO3 and a fourth partial object PO4 in addition to the first partial object PO1 and the second partial object PO2, the control unit 500 forms one layer ML by similarly forming the third partial object PO3 and the fourth partial object PO4 after forming the second partial object PO2.

[0058] In this embodiment, the control unit 500 controls the modeling unit 200 and the moving mechanism 400 so that the line width W of the modeling material MM discharged from the nozzle 61 of the discharging unit 60 onto the modeling surface 311 becomes the line width W of the partial modeled object PO determined in the modeling data generation process.

[0059] In this embodiment, when changing the line width W, the control unit 500 changes the amount of the modeling material MM discharged or the moving speed of the discharge unit 60, or both. The amount of the modeling material MM discharged onto the modeling surface 311 per unit movement amount of the discharge unit 60 along the modeling surface 311 changes due to the change in the discharge amount and the moving speed, and the line width W changes. Hereinafter, when the control unit 500 discharges the modeling material MM onto the modeling surface 311 while moving the discharge unit 60 along the partial path PR, the amount of the modeling material MM discharged onto the modeling surface 311 per unit movement amount of the discharge unit 60 is sometimes referred to as the discharged modeling amount MA. The control unit 500 determines line width information for realizing the desired line width W, for example, by calculating the discharge amount and the moving speed for discharging the modeling material MM at the desired line width W on the partial path PR. Furthermore, for example, the control unit 500 stores data regarding the relationship between the amount of the modeling material MM discharged and the line width W, and the relationship between the moving speed of the discharge unit 60 and the line width W, which have been obtained in advance through experiments or the like, in a storage device as data MAD, and determines line width information for realizing the desired line width based on the data MAD.

[0060] For example, when the line width W is set to a line width W1 larger than the line width Wn, the control unit 500 increases the discharged shaping amount MA by performing at least one of the following: making the discharge amount of the shaping material MM larger than when the line width W is controlled to the line width Wn, and making the movement speed of the discharge unit 60 slower than when the line width W is controlled to the line width Wn. When increasing the discharge amount of the shaping material MM, the control unit 500 increases the discharged shaping amount MA by performing at least one of the following: increasing the number of rotations per unit time of the flat screw 40 of the plasticizing unit 30, and increasing the opening degree of the valve body 72 of the discharge amount adjustment mechanism 70. Therefore, the discharge amount information in this embodiment includes the number of rotations per unit time of the flat screw 40 of the plasticizing unit 30 and the opening degree of the valve body 72 of the discharge amount adjustment mechanism 70. For this reason, the control unit 500 changing at least one of the number of rotations per unit time of the flat screw 40 and the opening degree of the valve body 72 in order to realize the desired line width W may be referred to as changing the discharge amount of the modeling material MM. Also, the control unit 500 changing at least one of the discharge amount of the modeling material MM and the movement speed of the discharge unit 60 in order to realize the desired line width W may be referred to as changing the discharged modeling amount MA. Also, for example, the control unit 500 setting the discharge amount and the movement speed of the discharge unit 60 so that the discharged modeling amount MA is the first discharged modeling amount MA1 may be referred to as setting the discharged modeling amount MA to the first discharged modeling amount MA1.

[0061] On the other hand, the inventors of the present application have found that even if the discharged forming amount MA is the same, the line width W of the formed second partial object PO2 differs depending on whether or not the second partial object PO2 is adjacent to the first partial object PO1 formed first. Here, the second partial object PO2 being adjacent to the first partial object PO1 means that at least a part of the second partial object PO2 is adjacent to and in contact with the first partial object PO1. Specifically, when the second partial object PO2 is adjacent to the first partial object PO1 formed first, the line width W2 of the formed second partial object PO2 is smaller than when the second partial object PO2 is not adjacent to the first partial object PO1. This is thought to be because the first partial object PO1, which is formed first, acts as a resistance to the flow of the modeling material MM discharged from the discharge section 60, so that the amount of material discharged when forming the second partial object PO2 is less than the amount in the modeling data.

[0062] For example, when a second partial object PO2 that is not adjacent to a first partial object PO1 to be formed first is formed using the first discharged formation amount MA1 as in the forming data shown in Fig. 7, the line width W of the formed second partial object PO2 becomes the line width W2 of the second partial object PO2 in the forming data, as shown by hatching in Fig. 8. In this case, when a second partial object PO2 that is adjacent to the contour on the -Y direction side of the first partial object PO1 to be formed first is formed using the first discharged formation amount MA1 as in the forming data shown in Fig. 9, the line width W of the formed second partial object PO2 becomes the line width W2e which is smaller than the line width W2 of the second partial object PO2 in the forming data, as shown by hatching in Fig. 9.

[0063] At this time, as shown in Fig. 9, the distance W2f between the contour on the +Y direction side of the formed second partial object PO2 and the partial path PR2 of the second partial object PO2 becomes smaller than half the line width W2 of the second partial object PO2 in the printing data, so that the line width W of the formed second partial object PO2 becomes a line width W2e that is smaller than the line width W2 of the second partial object PO2 in the printing data. For this reason, when the third partial object PO3 is printed based on the printing data in the state shown in Fig. 9, a gap G1 is generated between the second partial object PO2 and the third partial object PO3. As a result, there is a risk of a gap being generated in the three-dimensional object.

[0064] Furthermore, when a second partial object PO2, which is adjacent on both sides of the contour in the Y-axis direction of the first partial object PO1 to be formed first, is formed with the first discharging formation amount MA1 as in the forming data shown in Fig. 10, the line width W of the formed second partial object PO2 becomes line width W2g, which is smaller than the line width W2 of the second partial object PO2 in the forming data, as indicated by hatching in Fig. 10. Furthermore, the line width W2g is smaller than the line width W2e.

[0065] 10, the distance W2h between the position of the contour on the -Y direction side of the formed second partial object PO2 and the partial path PR2 of the second partial object PO2 is smaller than half the line width W2 of the second partial object PO2 in the forming data. For this reason, a gap G2 is generated between the contour on the -Y direction side of the second partial object PO2 and the first partial object PO1. As a result, there is a risk of a gap being generated in the three-dimensional object.

[0066] Furthermore, the distance W2k between the position of the contour on the +Y direction side of the formed second partial object PO2 and the partial path PR2 of the second partial object PO2 is smaller than half the line width W2 of the second partial object PO2 in the forming data. For this reason, a gap G3 is generated between the contour on the +Y direction side of the second partial object PO2 and the first partial object PO1. As a result, there is a risk of a gap being generated in the three-dimensional object.

[0067] In this embodiment, the ejection and molding amount MA when forming the second partial object PO2 is changed depending on whether or not the second partial object PO2 is adjacent to the first partial object PO1 formed earlier. In other words, the manufacturing method for a three-dimensional object includes, in the molding data generating step, a determination step of determining whether the second partial object PO2 is adjacent to the first partial object PO1 formed earlier, and changes the ejection and molding amount MA when forming the second partial object PO2 depending on whether or not the second partial object PO2 is adjacent to the first partial object PO1 formed earlier. In this embodiment, the control unit 500 obtains data on the relationship between the ejection amount of the molding material MM and the line width W, and the relationship between the movement speed of the ejection unit 60 and the line width W in advance by experiments or the like for the cases in which the partial object PO to be formed is adjacent to the partial object PO formed earlier and the cases in which it is not adjacent, and stores the data in the storage device as data MAD. The control unit 500 determines the discharge and modeling amount MA for achieving a desired line width W based on the data MAD.

[0068] Specifically, when the second partial object PO2 formed along the partial path PR2 is not adjacent to the first partial object PO1 formed first based on the arrangement of the partial object PO in the forming data, and is formed with a gap between them, the second partial object PO2 is formed using the first discharged forming amount MA1 as the discharged forming amount MA. The first discharged forming amount MA1 is the discharged forming amount MA such that the line width W of the formed second partial object PO2 becomes the line width W2 of the second partial object PO2 in the forming data when the second partial object PO2 is not adjacent to the first partial object PO1 formed first.

[0069] Then, when the second partial object PO2 is adjacent to the first partial object PO1 on one side, the second partial object PO2 is formed using the discharged forming amount MA as the second discharged forming amount MA2. The second discharged forming amount MA2 is larger than the first discharged forming amount MA1 when measured under the same conditions. The second discharged forming amount MA2 is the discharged forming amount MA such that, when the second partial object PO2 is adjacent to the first partial object PO1, which is formed first, the line width W of the formed second partial object PO2 becomes the line width W2 of the second partial object PO2 in the forming data. As a result, even if the second partial object PO2 is adjacent to the first partial object PO1 on one side, by forming the second partial object PO2 by setting the discharged forming amount MA to the second discharged forming amount MA2, it is possible to prevent gaps from occurring between the second partial object PO2 and the first partial object PO1, and between the third partial object PO3, which is formed after the second partial object PO2, and the second partial object PO2, as shown in Figure 12.

[0070] Furthermore, when the second partial object PO2 is adjacent to the first partial object PO1 on both sides, the second partial object PO2 is formed using the third discharged formation amount MA3 as the discharged formation amount MA. The third discharged formation amount MA3 is larger than the second discharged formation amount MA2 when measured under the same conditions. The third discharged formation amount MA3 is the discharged formation amount MA such that, when the second partial object PO2 is adjacent to the first partial object PO1, which is formed first, the line width W of the formed second partial object PO2 becomes the line width W2 of the second partial object PO2 in the formation data. As a result, even if the second partial object PO2 is adjacent to the first partial object PO1 on both sides, by setting the discharged printing amount MA to the third discharged printing amount MA3 and printing the second partial object PO2, it is possible to prevent a gap from occurring between the second partial object PO2 and the first partial object PO1, as shown in Figure 13.

[0071] Next, with reference to the flowchart shown in FIG. 11, a process flow for determining the discharged molding amount MA when forming the second partial object PO2 based on the result of the above-mentioned determination step will be described.

[0072] In step S511, the control unit 500 executes a determination step in which it is determined whether the second partial object PO2 is adjacent to the first partial object PO1. If the second partial object PO2 is not adjacent to the first partial object PO1 in step S511, the result of step S511 is NO. The control unit 500 transitions the process to step S513.

[0073] In step S513, the control unit 500 sets the discharged and formed object amount MA when forming the second partial object PO2 to the first discharged and formed object amount MA1.

[0074] In step S511, if the second partial object PO2 is adjacent to the first partial object PO1, the result of step S511 is YES. The control unit 500 transitions the process to step S512.

[0075] In step S512, the control unit 500 executes a determination step of determining whether the second partial object PO2 is adjacent to the first partial object PO1 on both sides. In step S512, if the second partial object PO2 is adjacent to the first partial object PO1 on one side but not on both sides, step S512 becomes NO. The control unit 500 transitions the process to step S515.

[0076] In step S515, the control unit 500 sets the discharged and formed amount MA when forming the second partial object PO2 to a second discharged and formed amount MA2 that is greater than the first discharged and formed amount MA1.

[0077] In step S512, if the second partial object PO2 is adjacent to the first partial object PO1 on both sides, the result of step S512 is YES, and the control unit 500 transitions the process to step S514.

[0078] In step S514, the control unit 500 sets the discharged forming amount MA when forming the second partial object PO2 to a third discharged forming amount MA3 that is greater than the first discharged forming amount MA1 and the second discharged forming amount MA2.

[0079] Once the control unit 500 has set the discharge and molding amount MA when forming the second partial object PO2, it ends the process of executing the process of determining the discharge and molding amount MA when forming the second partial object PO2 based on the result of the judgment process.

[0080] As described above, according to the method for manufacturing a three-dimensional object and the three-dimensional printing apparatus 100 according to the first embodiment, the following effects can be obtained.

[0081] The manufacturing method of the three-dimensional object is a manufacturing method of the three-dimensional object by discharging the modeling material MM from the discharging unit 60 toward the modeling surface 311 of the table 300, and includes a plasticizing process of plasticizing at least a part of the material MR to generate the modeling material MM, and a layer forming process of forming a layer ML on the modeling surface 311 by discharging the modeling material MM toward the modeling surface 311 while moving the discharging unit 60 along the partial path PR based on modeling data. When the amount of the modeling material MM to be discharged is defined as the discharged modeling amount MA, in the layer formation process, if the second partial object PO2 formed along the partial path PR2 is not adjacent to the first partial object PO1 formed earlier, but is formed with a gap between them, the discharged modeling amount MA is defined as the first discharged modeling amount MA1 to form the second partial object PO2, and if the second partial object PO2 is adjacent to the first partial object PO1, the discharged modeling amount MA is defined as the second discharged modeling amount MA2 to form the second partial object PO2, and the second discharged modeling amount MA2 is greater than the first discharged modeling amount MA1 when measured under the same conditions. According to this, the ejection molding amount MA when forming the second partial object PO2 is changed depending on whether the second partial object PO2 is adjacent to the first partial object PO1 or not, thereby preventing gaps from occurring in the three-dimensional object.

[0082] In the manufacturing method of the three-dimensional object, in the layer formation step, when the second partial object PO2 is adjacent to the first partial object PO1 on both sides, the second partial object PO2 is formed by setting the discharged and formed amount MA to a third discharged and formed amount MA3 that is greater than the second discharged and formed amount MA2, and the third discharged and formed amount MA3 is greater than the second discharged and formed amount MA2 when measured under the same conditions. According to this, the discharged and formed amount MA when forming the second partial object PO2 is changed depending on the state of adjacency between the second partial object PO2 and the first partial object PO1, and therefore it is possible to prevent gaps from being generated in the three-dimensional object.

[0083] The method for manufacturing a three-dimensional object includes a determination step of determining whether or not the second partial object PO2 is adjacent to the first partial object PO1, based on the modeling data for modeling the partial object PO. This makes it easy to determine whether or not the second partial object PO2 is adjacent to the first partial object PO1.

[0084] The method for manufacturing a three-dimensional object controls the discharged and molded amount MA by adjusting at least one of the rotation speed of the flat screw 40, which adjusts the amount of the molded material MM supplied per unit time to the discharge section 60, the opening degree of the valve body 72, which adjusts the ease of flow of the molded material MM supplied to the discharge section 60, and the relative movement speed of the discharge section 60 with respect to the molding surface 311. This makes it possible to easily control the discharged and molded amount MA.

[0085] The three-dimensional printing apparatus 100 includes a plasticizing unit 30 that plasticizes at least a portion of the material MR to generate a printing material MM, a discharging unit 60 that discharges the printing material MM toward a printing surface 311 of a table 300, a moving mechanism 400 that changes the relative position between the discharging unit 60 and the printing surface 311, and a control unit 500. The control unit 500 controls the moving mechanism 400 to change the relative position while causing the discharging unit 60 to discharge the printing material MM toward the printing surface 311, thereby printing a plurality of partial objects PO along a plurality of partial paths PR, and defines the amount of printing material MM discharged toward the printing surface 311 per unit movement amount of the discharging unit 60 as an extruded printing amount MA. When this is the case, the control unit 500 adjusts the extruded molding amount MA by controlling any one of the plasticization unit 30, the extruder unit 60, and the moving mechanism 400, and if the second partial object PO2 formed along the partial path PR2 is not adjacent to the first partial object PO1 formed earlier and is formed with a gap between them, the control unit 500 forms the second partial object PO2 with the extruded molding amount MA set to the first extruded molding amount MA1, and if the second partial object PO2 is adjacent to the first partial object PO1, the control unit 500 forms the second partial object PO2 with the extruded molding amount MA2 set to be larger than the first extruded molding amount MA1 when measured under the same conditions. According to this, the ejection molding amount MA when forming the second partial object PO2 is changed depending on whether the second partial object PO2 is adjacent to the first partial object PO1 or not, thereby preventing gaps from occurring in the three-dimensional object.

[0086] The three-dimensional modeling apparatus 100 has a flat screw 40 in the plasticizing unit 30, capable of adjusting the amount of modeling material MM supplied per unit time to the discharge unit 60 by changing the rotation speed, and a valve body 72 in a supply flow passage 62, which supplies the modeling material MM from the plasticizing unit 30 to the discharge unit 60, capable of adjusting the ease of flow of the modeling material MM in the supply flow passage 62 by changing the opening degree, and the control unit 500 adjusts the discharged modeling amount MA by changing any one of the rotation speed of the flat screw 40, the opening degree of the valve body 72, and the relative movement speed of the discharge unit 60 with respect to the modeling surface 311. This makes it possible to easily control the discharged modeling amount MA.

[0087] Here, the material MR of the three-dimensional object used in the above-mentioned three-dimensional printing apparatus 100 will be described. In the three-dimensional printing apparatus 100, a three-dimensional object can be printed using various materials as main materials, such as thermoplastic materials, metal materials, ceramic materials, etc. Here, the "main material" refers to the material MR that is the core of the shape of the three-dimensional object, and refers to a material that occupies 50% by weight or more in the three-dimensional object. The above-mentioned printing material MM includes those main materials melted alone, and those in which some components contained together with the main material are melted and turned into a paste.

[0088] When a thermoplastic material is used as the main material, the material is plasticized in the plasticizing unit 30 to generate the modeling material MM.

[0089] As the material having thermoplasticity, for example, the following thermoplastic resin materials can be used. <Examples of thermoplastic resin materials> General-purpose engineering plastics such as 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), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate, as well as engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyether ether ketone.

[0090] The thermoplastic material may contain additives such as pigments, metals, ceramics, wax, flame retardants, antioxidants, and thermal stabilizers. The thermoplastic material is plasticized in the plasticizing section 30 by the rotation of the flat screw 40 and the heat of the heater 58, and is converted into a molten state. The modeling material MM generated by melting the thermoplastic material is discharged from the nozzle 61, and then hardens as the temperature drops.

[0091] It is desirable that the thermoplastic material be heated to or above its glass transition point and in a completely molten state before being injected from the nozzle 61. For example, when ABS resin is used, it is desirable that the temperature of the resin is about 200° C. when it is discharged from the nozzle 61.

[0092] In the three-dimensional modeling apparatus 100, for example, the following metal materials may be used as the main material instead of the above-mentioned thermoplastic materials. In this case, it is preferable that a component that melts when generating the modeling material MM is mixed with a powder material made by powdering the following metal materials, and the powder material is fed into the plasticizing unit 30 as the material MR. <Examples of metal materials> A single metal, or an alloy containing one or more of the following metals: magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), or nickel (Ni). <Alloy examples> Maraging steel, stainless steel, cobalt chrome molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chrome alloy.

[0093] In the three-dimensional printing apparatus 100, a ceramic material can be used as the main material instead of the above-mentioned metal materials. As the ceramic material, for example, oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, etc., and non-oxide ceramics such as aluminum nitride, etc. can be used. When the above-mentioned metal materials or ceramic materials are used as the main material, the printing material MM discharged onto the printing surface 311 may be hardened by sintering.

[0094] The powder material of the metallic material or the ceramic material fed into the material supply unit 20 as the material MR may be a mixed material in which a single metal powder, an alloy powder, or a ceramic material powder is mixed with a plurality of types of powder. The powder material of the metallic material or the ceramic material may be coated with, for example, the thermoplastic resin exemplified above or a thermoplastic resin other than the above. In this case, the thermoplastic resin may be melted in the plasticizing unit 30 to exhibit fluidity.

[0095] For example, the following solvents can be added to the powder material of the metal material or ceramic material fed as the material MR to the material supply unit 20. The solvent can be one or a combination of two or more selected from the following. <Examples of solvents> water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetate esters such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide-based solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and 2,6-lutidine; tetraalkylammonium acetates (for example, tetrabutylammonium acetate, etc.); and ionic liquids such as butyl carbitol acetate.

[0096] In addition, for example, the following binders can be added to the powder material of the metal material or ceramic material fed into the material supply unit 20 as the material MR. <Example of binder> Acrylic resin, epoxy resin, silicone resin, cellulose-based resin or other synthetic resin, or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) or other thermoplastic resin.

[0097] 2. Embodiment 2 Next, a method for manufacturing a three-dimensional object according to a second embodiment of the present disclosure will be described. Note that the same reference numerals will be used to denote the same parts as those in the three-dimensional printing apparatus 100 and the method for manufacturing a three-dimensional object according to the first embodiment, and the description thereof will be omitted.

[0098] The three-dimensional printing apparatus 100 of this embodiment is the same as the three-dimensional printing apparatus 100 of embodiment 1. In this embodiment, the flow of the process when the control unit 500 executes the printing process of a three-dimensional object is the same as that of embodiment 1, except for the layer formation step, which is different from embodiment 1. In the layer formation step executed by the control unit 500 in embodiment 1, after the first partial object PO1 is printed based on the printing data of the first partial object PO1, the second partial object PO2 is printed based on the printing data of the second partial object PO2.

[0099] For example, in the layer formation process, the shape of the first partial object PO1 formed based on the forming data shown in Fig. 7 may differ from the first partial object PO1 in the forming data, as shown in Fig. 14. In the example shown in Fig. 14, as indicated by hatching, the line width W on the +X direction side from the center of the formed first partial object PO1 is a line width W1m which is smaller than the line width W1 of the first partial object PO1 in the forming data.

[0100] In this case, when the second partial object PO2 is formed based on the formation data in the layer formation step, a gap G4 may occur between the first partial object PO1 and the second partial object PO2, which may result in a gap occurring in the three-dimensional object.

[0101] In the layer formation step in this embodiment, the control unit 500 models the first partial object PO1 based on the modeling data of the first partial object PO1, and then uses the measurement unit 90 to measure the shape of the first partial object PO1. The control unit 500 executes a determination step based on the measurement value of the line width W of the modeled first partial object PO1 and the modeling data. The control unit 500 then models the second partial object PO2 taking into account the result of the determination step. This makes it possible to model the second partial object PO2 taking into account the shape of the modeled first partial object PO1, thereby making it possible to prevent gaps from being generated in the three-dimensional object.

[0102] Next, the process flow when the control unit 500 forms the first partial object PO1 and the second partial object PO2 in the layer formation step of this embodiment will be described with reference to the flowchart shown in Fig. 15. In this embodiment, the process flow when the control unit 500 executes the process of forming a three-dimensional object, including the process of forming the first partial object PO1 and the second partial object PO2, corresponds to a method of manufacturing a three-dimensional object.

[0103] In step S531, the control unit 500 shapes the first partial object PO1 based on the shape data of the first partial object PO1 in the shape data. After executing step S531, the control unit 500 transitions the process to step S532.

[0104] In step S532, the control unit 500 performs shape measurement of the formed first partial object PO1 by the measurement unit 90. The shape measurement of the formed first partial object PO1 includes measurement of the line width W of the first partial object PO1. After executing step S532, the control unit 500 transitions to the process of step S533.

[0105] In step S533, the control unit 500 determines whether or not it is necessary to change the printing data of the second partial object PO2 generated in the printing data generating process. In step S533, based on the measurement value of the line width W of the formed first partial object PO1 and the printing data generated in the printing data generating process, it determines whether or not it is necessary to change the printing data of the second partial object PO2 by determining whether or not the second partial object PO2 to be formed next is adjacent to the formed first partial object PO1.

[0106] In other words, the manufacturing method of a three-dimensional object of this embodiment executes a judgment process in the layer formation process to determine whether the second partial object PO2 to be formed next is adjacent to the formed first partial object PO1 based on the measured value of the line width W of the formed first partial object PO1 and the printing data generated in the printing data generation process.

[0107] For example, when the first partial object PO1 is modeled as shown in FIG. 12, the measured value of the line width W of the modeled first partial object PO1 is the same as the line width W1 of the first partial object PO1 in the modeling data. In this case, based on the modeling data generated in the modeling data generating process, it is determined that the second partial object PO2 is adjacent to the first partial object PO1. Also, based on the measured value of the line width W of the modeled first partial object PO1 and the modeling data generated in the modeling data generating process, it is determined that the second partial object PO2 to be modeled next is adjacent to the modeled first partial object PO1. In this case, the control unit 500 determines that it is not necessary to change the modeling data of the second partial object PO2, and step S533 becomes NO. The control unit 500 proceeds to step S535.

[0108] On the other hand, for example, when the first partial object PO1 is modeled as shown in Fig. 14, the measured value of the line width W of the modeled first partial object PO1 will be a line width W1m that is smaller than the line width W1 of the first partial object PO1 in the modeling data. There is also a risk that a gap G4 will be generated between the modeled first partial object PO1 and the second partial object PO2 in the modeling data. In this case, based on the modeling data generated in the modeling data generating process, it is determined that the second partial object PO2 is adjacent to the first partial object PO1. On the other hand, based on the measured value of the line width W of the modeled first partial object PO1 and the modeling data generated in the modeling data generating process, it is determined that the second partial object PO2 modeled in accordance with the modeling data generated in the modeling data generating process is not adjacent to the first partial object PO1. In this case, the control unit 500 determines that it is necessary to change the formation data of the second partial object PO2, and the result of step S533 becomes YES. The control unit 500 then shifts the process to step S534.

[0109] In step S534, the control unit 500 changes the molding data of the second partial object PO2 generated in the molding data generating step so that the second partial object PO2 to be formed approaches the formed first partial object PO1. For example, in step S534, as shown in Fig. 16, the control unit 500 changes the partial path PR2 of the second partial object PO2 generated in the molding data generating step to a partial path PR2n. In other words, the control unit 500 changes the distance D2 from the reference position RP to the partial path PR2 of the second partial object PO2 to a distance D2n that is smaller than the distance D2. That is, in the layer forming step, the control unit 500 executes a step of changing the partial path PR2 of the second partial object PO2 included in the molding data to a side where the second partial object PO2 to be formed approaches the formed first partial object PO1.

[0110] In addition, when the control unit 500 prints the second partial object PO2 adjacent to the third partial object PO3 in the printing data, as shown by hatching in Figure 16, in addition to changing the partial path PR2 described above, the control unit 500 may also change the second discharge printing amount MA2 of the second partial object PO2 included in the printing data.

[0111] Also, for example, in step S534, the control unit 500 may change the second discharged modeling amount MA2 of the second partial object PO2 included in the modeling data to a larger value so that the second partial object PO2 to be modeled is adjacent to the modeled first partial object PO1. In other words, the control unit 500 may execute a step of changing the second discharged modeling amount MA2 of the second partial object PO2 included in the modeling data to a larger value in the layer formation step.

[0112] After executing step S534, the control unit 500 shifts the process to step S535. In step S535, the control unit 500 forms the second partial object PO2 based on the formation data of the second partial object PO2. When executing step S535 after executing step S534, the control unit 500 forms the second partial object PO2 based on the formation data changed in the layer formation process. In other words, the control unit 500 controls the discharged formation amount MA by changing the formation data in the layer formation process. Also, when step S533 becomes NO and step S535 is executed, the control unit 500 forms the second partial object PO2 based on the formation data generated in the formation data generation process.

[0113] When the control unit 500 executes the process of step S535, the process for forming the first partial object PO1 and the second partial object PO2 in the layer formation step ends.

[0114] As described above, according to the method for manufacturing a three-dimensional object and the three-dimensional printing apparatus 100 according to the second embodiment, the following effects can be obtained.

[0115] In the manufacturing method of the three-dimensional object, when the width of the partial object PO in a direction intersecting with the partial path PR is defined as a line width W, the determination step determines whether or not the second partial object PO2 is adjacent to the first partial object PO1, based on the shaping data and a measurement value of the line width W of the shaped first partial object PO1. This makes it possible to accurately determine whether or not the second partial object PO2 is adjacent to the first partial object PO1.

[0116] The manufacturing method of the three-dimensional object includes a step of changing a partial path PR2 of the second partial object PO2 included in the shaping data to a side where the second partial object PO2 to be formed approaches the first partial object PO1, when it is determined in the determination step that the second partial object PO2 is adjacent to the first partial object PO1 based on the shaping data and that the second partial object PO2 is not adjacent to the first partial object PO1 based on the shaping data and the measurement values, and the second partial object PO2 is formed based on the changed shaping data in the layer formation step. According to this, when it is determined that the second partial object PO2 is not adjacent to the first partial object PO1, the second partial object PO2 is formed closer to the first partial object PO1, thereby preventing the occurrence of gaps in the three-dimensional object.

[0117] The manufacturing method of the three-dimensional object includes a step of changing the second discharged modeling amount MA2 of the second partial object PO2 included in the modeling data to a larger value when it is determined in the determination step that the second partial object PO2 is adjacent to the first partial object PO1 based on the modeling data and that the second partial object PO2 is not adjacent to the first partial object PO1 based on the modeling data and the measurement values, and the second partial object PO2 is modeled based on the changed modeling data in the layer forming step. According to this, when it is determined that the second partial object PO2 is not adjacent to the first partial object PO1, the second discharged modeling amount MA2 of the second partial object PO2 is changed to a larger value, and the second partial object PO2 is modeled, thereby preventing the generation of gaps in the three-dimensional object.

[0118] In the method for manufacturing a three-dimensional object, the layer forming step controls the discharged and shaping amount MA by changing the shaping data, which makes it possible to easily control the discharged and shaping amount MA.

[0119] The three-dimensional printing apparatus 100 includes a measuring unit 90 capable of measuring the line width W of the printed partial object PO, and the control unit 500 determines whether the second partial object PO2 is adjacent to the first partial object PO1 based on the printing data and the measured value of the line width W of the first partial object PO1 measured by the measuring unit 90. This makes it possible to accurately determine whether the second partial object PO2 is adjacent to the first partial object PO1.

[0120] The manufacturing method of a three-dimensional object and the three-dimensional printing apparatus 100 according to the above-mentioned embodiment of the present invention are basically configured as described above, but it is of course possible to modify or omit some of the configurations without departing from the gist of the present invention. Furthermore, the above-mentioned embodiment and other embodiments described below can be combined with each other to the extent that they are not technically inconsistent. Other embodiments will be described below.

[0121] In the first embodiment, the control unit 500 does not have to execute the determination step in the modeling data generation step. In this case, for example, in the modeling data generation step, the control unit 500 sets the discharged modeling amount MA when modeling the second partial object PO2 to the first discharged modeling amount MA1, regardless of the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data. Then, in the layer formation step, the control unit 500 may execute the determination step based on the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data, and change the discharged modeling amount MA when modeling the second partial object PO2 based on the result of the determination step.

[0122] In the first embodiment, the control unit 500 does not have to execute the determination step in the modeling data generating step. In this case, for example, the control unit 500 executes the determination step in the layer forming step based on the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data, and determines the discharged modeling amount MA for achieving the desired line width W based on the result of the determination step and the data MAD. Then, the control unit 500 may model the second partial object PO2 based on the determined discharged modeling amount MA. In this case, the line width information does not have to include information other than the line width W.

[0123] In the second embodiment, the control unit 500 does not have to execute the determination step in the modeling data generating step. In this case, for example, in the modeling data generating step, the control unit 500 sets the discharged modeling amount MA when modeling the second partial object PO2 to the third discharged modeling amount MA3, regardless of the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data. Then, in the layer forming step, the control unit 500 may execute the determination step based on the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data and the measured value of the line width W of the first partial object PO1 that was previously modeled, and change the discharged modeling amount MA when modeling the second partial object PO2 based on the result of the determination step.

[0124] In the second embodiment, the control unit 500 may change the modeling data of the second partial object PO2 based on the result of the determination step in the layer formation step, and may not model the second partial object PO2 based on the changed modeling data. For example, in the layer formation step, the control unit 500 executes the determination step based on the arrangement of the first partial object PO1 and the second partial object PO2 in the modeling data and the measured value of the line width W of the previously modeled first partial object PO1. If it is determined in the determination step that the second partial object PO2 is adjacent to the first partial object PO1 based on the modeling data and that the second partial object PO2 is not adjacent to the first partial object PO1 based on the modeling data and the measured value of the line width W of the modeled first partial object PO1, the control unit 500 determines either the partial path PR2 or the discharged modeling amount MA for the second partial object PO2 to be adjacent to the first partial object PO1. Then, the control unit 500 may form the second partial object PO2 based on either the determined partial path PR2 or the discharged formation amount MA, without changing the formation data. In this case, the line width information does not need to include information other than the line width W.

[0125] In the first embodiment, the three-dimensional printing apparatus 100 does not necessarily have to include the measuring unit 90.

[0126] In the above embodiment, the control unit 500 may set the line width W to the line width W1, which is larger than the line width Wn, by increasing the temperature of the heater 58 of the plasticizing unit 30. Alternatively, the control unit 500 may set the line width W to the line width W1, which is larger than the line width Wn, by decreasing the distance in the Z-axis direction between the modeling surface 311 and the nozzle 61.

[0127] In the above embodiment, the control unit 500 does not need to include a storage device. In this case, the control unit 500 may execute a modeling process for forming a three-dimensional object by controlling the operations of the modeling unit 200 and the moving mechanism 400 by a processor executing a program or instructions stored in a storage device provided outside the three-dimensional modeling apparatus 100. [Explanation of symbols]

[0128] 20...material supply section, 22...connection passage, 30...plasticizing section, 31...screw case, 32...driving motor, 40...flat screw, 41...upper surface, 42...groove forming surface, 43...side surface, 44...material inlet, 45...groove section, 46...ridge section, 47...center section, 50...barrel, 52...screw facing surface, 54...guide groove, 56...communicating hole, 58...heater, 60...discharge section, 61...nozzle, 62...supply flow path, 65...first supply port, 66...cross hole, 67...second supply port, 68...nozzle flow path, 69...nozzle hole, 70...discharge amount adjustment mechanism, 71...drive shaft, 72...valve body, 80...suction section, 81...cylinder, 82...plunger, 83...plasticizer Angler drive unit, 90... measurement unit, 100... three-dimensional printing device, 200... printing unit, 300... table, 311... printing surface, 400... movement mechanism, 500... control unit, D1, D2, D2n, D3, W2f, W2h, W2k... distance, G1, G2, G3, G4... gap, MA... discharged printing amount, MA1... first discharged printing amount, MA2... second discharged printing amount, MA3... third discharged printing amount, PO... partial printing object, PO1... first partial printing object, PO2... second partial printing object, PO3... third partial printing object, PO4... fourth partial printing object, PR, PR1, PR2, PR3, PR4, PR2n... partial path, W, W1, W1m, W2, W2e, W3... line width.

Claims

1. A three-dimensional object is manufactured by discharging a modeling material from a discharging part onto the modeling surface of a table. A method for manufacturing a three-dimensional object, comprising the steps of: a plasticizing step of plasticizing at least a portion of the material to form the building material; Based on the modeling data, the modeling material is dispensed while the discharging unit is moved along a partial path. By discharging the liquid toward the modeling surface, a plurality of partial objects are modeled along the partial path, A layer forming step of forming a layer on the modeling surface, The amount of the modeling material discharged toward the modeling surface per unit movement amount of the discharge part is The amount of production is The modeling data includes first modeling data for modeling a first partial object to be modeled first; second modeling data for forming a second partial object that is formed after the first partial object; and In the layer forming step, The second partial object in the second modeling data is a first partial object in the first modeling data. When the first part is not adjacent to the second part and there is a gap between them, the amount of the first part is The second portion is molded as a quantity, The second partial object in the second modeling data is When the second part is adjacent to the first part, the amount of the second part to be discharged and formed is set as the second amount of the second part to be discharged and formed. Partial sculptures are created, The second discharged and shaped amount is larger than the first discharged and shaped amount when measured under the same conditions. stomach, A method for manufacturing three-dimensional objects.

2. The method for producing a three-dimensional object according to claim 1, In the layer forming step, When the second partial object is adjacent to the first partial object on both sides, the amount of the object to be discharged is is set as a third dispensing and forming amount greater than the second dispensing and forming amount, and the second partial object is formed. 、 The third discharged and shaped amount is larger than the second discharged and shaped amount when measured under the same conditions. A method for manufacturing a three-dimensional object.

3. The method for producing a three-dimensional object according to claim 1 or 2, comprising the steps of: In the layer forming step, The ejection and shaping amount is controlled by changing the shaping data. A method for manufacturing three-dimensional objects.

4. A method for producing a three-dimensional object according to any one of claims 1 to 3, comprising the steps of: A screen for adjusting the amount of the modeling material supplied to the discharge portion per unit time A control valve for controlling the rotation speed of the nozzle and the ease of flow of the modeling material supplied to the discharge portion. and at least one of the opening degree of the discharge portion and the relative movement speed of the discharge portion with respect to the modeling surface is adjusted. By adjusting the amount of the discharged material, the amount of the discharged material is controlled. A method for manufacturing three-dimensional objects.

5. a plasticizer for plasticizing at least a portion of the material to generate a modeling material; A discharge unit that discharges the modeling material toward a modeling surface of a table; a moving mechanism that changes a relative position between the discharge unit and the modeling surface; The ejection unit is caused to move the moving mechanism while changing the relative position based on the modeling data. The modeling material is discharged toward the modeling surface to form a partial model along a plurality of partial paths. and a control unit that executes a forming process to form a plurality of The modeling data includes first modeling data for modeling a first partial object to be modeled first; second modeling data for forming a second partial object that is formed after the first partial object; and The control unit is The amount of the modeling material discharged toward the modeling surface per unit movement amount of the discharge part is When the amount of the molded object is set to be the amount of the molded object, the control unit controls the plasticizing unit, the discharging unit, and the moving mechanism. By controlling any one of the above, the amount of the discharged product is adjusted, The second partial object in the second modeling data is a first partial object in the first modeling data. When the first part is not adjacent to the second part and there is a gap between them, the amount of the first part is The second portion is molded as a quantity, The second partial object in the second modeling data is When the second part is adjacent to the first part, the amount of the second part to be discharged and formed is set as the second amount of the second part to be discharged and formed. Partial sculptures are created, The second discharged and shaped amount is larger than the first discharged and shaped amount when measured under the same conditions. stomach, Three-dimensional printing equipment.

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