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 suppress decrease in strength of a three-dimensional molded article due to mixing of air bubbles.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 thermoplastic resin, and generating a plasticization material; a fiber introduction step including at least any one of a step of introducing a coating fiber material that is a fiber material coated with a coating material, into the plasticization material after discharged from a nozzle opening, and a step of introducing the coating fiber material into the molding material or the plasticization material before discharged from the nozzle opening; and a molding step of molding the three-dimensional molded article containing the coating 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, such as a filament, which has been heated and softened, and injecting the filament 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 3D object is produced by introducing a fiber material into a plasticized material obtained by plasticizing a thermoplastic resin as in the technique of Patent Document 1, the plasticized material may not adhere to the surface of the fiber material, resulting in the inclusion of air bubbles in the plasticized material. Such inclusion of air bubbles may cause a decrease in the strength of the 3D object produced. [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 step of plasticizing at least a part of a modeling material containing a thermoplastic resin to generate a plasticized material; a fiber introduction step including at least one of the steps 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 the nozzle opening; or introducing the coated fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening; a modeling step of modeling a three-dimensional object including the coated fiber material; Equipped with.

[0007] In the method for manufacturing a three-dimensional object according to another application example of the present invention, the absolute value of the difference between the SP value of the thermoplastic resin and the SP value of the coating material is 5.0 or less.

[0008] In a method for manufacturing a three-dimensional object according to another application example of the present invention, the coating material contains the same type of thermoplastic resin as the thermoplastic resin contained in the plasticizing material.

[0009] In addition, a method for manufacturing a three-dimensional object according to another application example of the present invention includes a coating process, prior to the fiber introduction process, in which the fiber material is passed through a storage section in which the coating material is stored, thereby generating the coated fiber material.

[0010] In a method for producing a three-dimensional object according to another application example of the present invention, the plasticizing step includes: A plasticizing device comprising: 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, The method includes a step of plasticizing at least a portion of the thermoplastic resin supplied between the flat screw and the facing portion by rotation of the flat screw and heating by the heater, and guiding the thermoplastic resin to the communicating hole.

[0011] 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 opposing surface, the introduction groove introducing the fiber material from a side of the flat screw or the opposing portion into the communication hole, The fiber introduction step introduces the coated fiber material into the shaping material through the introduction groove.

[0012] 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 coated fiber material into the plasticized material through the through holes.

[0013] In a method for manufacturing a three-dimensional object according to another application example of the present invention, the fiber introducing step includes a pressure control step of controlling the pressure in the through holes to be higher than the pressure in the communicating holes.

[0014] 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 moving step of relatively moving a stage on which the three-dimensional object is supported and a nozzle unit having the nozzle opening; The method also includes a fiber introduction control process for changing the introduction speed at which the coated fiber material is introduced into the modeling material or the plasticizing material depending on the relative movement speed between the nozzle portion and the stage in the movement process.

[0015] In addition, a method for manufacturing a three-dimensional object according to another application example of the present invention includes a cutting step of cutting the fiber material before or after the fiber introducing step.

[0016] 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 coated 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.

[0017] 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 coated fiber material and using it to convey the coated fiber material.

[0018] A three-dimensional modeling apparatus according to an application example of the present invention includes: a plasticizing unit that plasticizes at least a portion of a modeling material including a thermoplastic resin to generate a plasticized material; A discharge portion having a nozzle opening; a fiber introduction section having at least one of the following functions: a function 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 the nozzle opening, or a function of introducing the coated fiber material into the modeling material or the plasticized material before it is discharged from the nozzle opening; and a control unit that controls the plasticizing unit, the discharging unit, and the fiber introduction unit to form a three-dimensional object that includes the coated fiber material. [Brief description of the drawings]

[0019] [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 schematic cross-sectional view showing the structure of a fiber material. [Figure 6] FIG. 6 is a flowchart showing steps executed in the modeling process according to the first embodiment. [Figure 7] FIG. 7 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the second embodiment. [Figure 8]FIG. 8 is a flowchart showing steps executed in the modeling process according to the second embodiment. [Figure 9] FIG. 9 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the third embodiment. [Figure 10] FIG. 10 is a flowchart showing steps executed in the modeling process according to the fourth embodiment. [Figure 11] FIG. 11 is a schematic view showing the configuration of a three-dimensional modeling apparatus according to the fifth embodiment. [Figure 12] FIG. 12 is a flowchart showing steps executed in the modeling process according to the fifth embodiment. [Figure 13] FIG. 13 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the sixth embodiment. [Figure 14] FIG. 14 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the seventh embodiment. [Figure 15] FIG. 15 is a schematic diagram showing the configuration of a discharge amount control mechanism of the seventh embodiment. [Figure 16] FIG. 16 is a schematic diagram showing a mechanism by which the discharge amount control mechanism of the seventh embodiment cuts a fiber material. [Figure 17] FIG. 17 is a schematic diagram showing the configuration of a discharge amount control mechanism according to the eighth embodiment. [Figure 18] FIG. 18 is a schematic diagram showing a mechanism by which the discharge amount control mechanism of the eighth embodiment cuts a fiber material. [Figure 19] FIG. 19 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to the ninth embodiment. [Figure 20] FIG. 20 is a flowchart showing steps executed in the modeling process according to the ninth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] 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.

[0021] [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.

[0022] 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".

[0023] 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.

[0024] 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 part of a modeling material containing a thermoplastic resin to generate a plasticized material. The plasticized material will be described later. The fiber introduction unit 23 introduces a fiber material FB into the plasticized material generated by the material generation unit 21. In this embodiment, the fiber material FB is configured as a coated fiber material whose surface is coated with a coating material to be described later. The fiber material FB 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.

[0025] 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, 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 storage unit 31 that stores the modeling material that is 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 from the material supplying unit 30 to the plasticizing unit 35.

[0026] The molding material is fed into the material supply unit 30 in the form of pellets. The molding material contains a thermoplastic resin as a main component. Examples of the thermoplastic resin contained in the molding material 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), polycarbonate (PC), and the like. In addition to the above-mentioned thermoplastic resin, pigments, metals, ceramics, and the like may be mixed into the molding material fed into the material supply unit 30. The molding material 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.

[0027] The plasticizing unit 35 plasticizes at least a portion of the thermoplastic resin contained in the modeling material 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.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] 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 part 42 of the groove forming surface 41 and the opposing surface 51 of the facing part 50. The modeling material supplied from the material supply part 30 flows into this space from the side surface of the flat screw 40. The modeling material supplied to the space in the groove part 42 is guided to the center of the flat screw 40 by the rotation of the spiral groove part 42 when the flat screw 40 rotates.

[0032] A heater 52 for heating the modeling material is embedded in the facing surface 51 of the facing portion 50. The heater 52 heats the flat screw 40 or the facing portion 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 portion 50. A communication hole 53 penetrating the facing portion 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 portion 25. The communication hole 53 forms a flow path with a substantially circular cross section. The modeling material supplied to the groove portion 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 modeling material is guided to the communication hole 53 opening at the center of the facing surface 51 along the groove portion 42 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.

[0033] In this embodiment, an introduction groove 57 is provided on the opposing surface 51 of the opposing part 50 to introduce the fiber material FB from the side of the flat screw 40 or the opposing part 50 to the communication hole 53. For convenience, the introduction groove 57 is illustrated by a dashed line in Fig. 1. The configuration of the introduction groove 57 will be described later.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] The fiber introduction section 23 has a function of introducing the fiber material FB into the plasticized material before it is discharged from the nozzle opening 28 under the control of the control section 10. In this embodiment, the fiber material FB is composed of a continuous linear member wound around a reel 62 described later. The fiber material FB is also composed of a fiber bundle in which a plurality of fibers are bundled. In this embodiment, the fiber material FB has a configuration in which a plurality of carbon fibers are bundled by a bundling agent. In other embodiments, the fiber material FB does not have to be composed of carbon fiber, and may be composed of, for example, glass fiber, or various fibers having a higher elastic modulus than the resin material.

[0038] The fiber diameter of the fiber material FB can be, for example, 10 μm or more and the hole diameter Dn of the nozzle opening 28 or less. In this embodiment, since the hole diameter Dn of the nozzle opening 28 is 3 mm or less as described above, the fiber diameter of the fiber material FB can be 3 mm 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. Also, 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 cross section perpendicular to the length direction of the fiber material FB has a substantially circular shape. In this embodiment, the surface of the fiber material FB is covered with a coating material CM in advance. The coating material CM will be described later.

[0039] The fiber introduction section 23 includes a conveying section 60 that conveys the fiber material FB to introduce it. The conveying section 60 includes a storage section 63 that accommodates the fiber material FB wound around a reel 62, a conveying path 65 that sends out the fiber material FB from the storage section 63, and a cutting section 66 that cuts the fiber material FB.

[0040] The storage section 63 is provided with a conveying motor (not shown) that rotates the reel 62 to generate a conveying force for sending the fiber material FB to the conveying path 65. The rotation speed of the conveying motor is controlled by the control section 10. The conveying path 65 is configured by a cylindrical tubular member through which the fiber material FB is inserted. In this embodiment, the conveying path 65 is connected to the introduction groove 57 of the facing section 50. The fiber material FB conveyed to the introduction groove 57 through the conveying path 65 is introduced into the modeling material supplied to the material inlet 46 of the flat screw 40 at the inlet of the introduction groove 57. The fiber material FB is guided to the communication hole 53 along the introduction groove 57 by the rotation of the flat screw 40 and the flow of the plasticized material toward the communication hole 53 as the plasticization progresses, and is discharged from the nozzle opening 28 together with the plasticized material. The formation of a model by discharging the plasticized material will be described later.

[0041] The cutting unit 66 is installed in the middle of the conveying path 65, and cuts the fiber material FB sent out through the conveying 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 fiber material FB. In another embodiment, the cutting unit 66 may be configured to cut the fiber material FB by emitting a laser.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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 supplied from the communication 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 gathers.

[0047] 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.

[0048] A 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, the use of the flat screw 40 realizes a miniaturized device configuration for plasticizing the thermoplastic resin. In addition, according to the molding apparatus 100a, 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 object can be improved.

[0049] As described above, the opposing surface 51 of the facing part 50 is further provided with the introduction groove 57. The introduction groove 57 is formed from the outer circumferential end of the opposing surface 51 to the communicating hole 53 so as to avoid interference with the guide groove 55. As described above, the fiber introduction part 23 introduces the fiber material FB from the side of the flat screw 40 into the introduction groove 57, and guides it along the introduction groove 57 to the communicating hole 53.

[0050] 4 is a schematic diagram showing how a modeling object OB is formed by stacking modeling layers ML formed by discharging a plasticized material MM from a nozzle opening 28 in the modeling apparatus 100a. For convenience, the fiber material FB is shown by a dashed line in FIG.

[0051] In the modeling process of the modeling apparatus 100a, the plasticized material MM is discharged from the nozzle opening 28 together with the fiber material FB 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 with the fiber material FB contained therein, so as to trace the movement trajectory of the nozzle opening 28, thereby forming a modeling layer ML. The modeled object OB is formed by further discharging the plasticized material MM on the modeling layer ML to stack the modeling layers ML.

[0052] 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.

[0053] 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 the 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 the shape of the deposited plasticized material MM from being distorted, discolored, or deteriorated due to overheating by the heater.

[0054] 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.

[0055] 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.

[0056] 5 is a schematic cross-sectional view showing a cut surface passing through the central axis of the fiber material FB introduced by the fiber introduction section 23. In this embodiment, the surface of the fiber material FB is covered with the coating material CM. This makes it possible to prevent air bubbles from adhering to the surface of the fiber material FB and becoming mixed into the plasticized material when the fiber material FB introduced into the modeling material is mixed with the plasticized material in the flat screw 40. This makes it possible to prevent air bubbles from becoming mixed into the plasticized material and causing a decrease in the strength of the modeled object.

[0057] Although the covering material CM preferably covers the entire surface of the fiber material FB, it is not necessary for the covering material CM to completely cover the entire surface of the fiber material FB. A part of the fiber material FB may be exposed from the covering material CM. For example, 50% or more of the surface area of ​​the fiber material FB may be exposed from the covering material CM.

[0058] The covering material CM is made of a material that is more compatible with the plasticizing material than the surface of the fiber material FB, and in this embodiment, the absolute value of the difference between the SP value of the thermoplastic resin contained in the modeling material and the SP value of the covering material CM is 5.0 or less. The "SP value" is also called the solubility parameter, and is a physical property value that indicates the ease of dissolving a polymeric material in a solvent. In general, the closer the SP value of a polymeric material is to a solvent, the more easily the polymeric material will dissolve. The absolute value is preferably 3.0 or less, and more preferably 1.0 or less. This makes it easier for the surface of the fiber material FB to be compatible with the plasticizing material, and further suppresses the inclusion of air bubbles in the plasticizing material.

[0059] In this embodiment, the covering material CM includes the same type of thermoplastic resin as the thermoplastic resin of the plasticizing material. When the thermoplastic resin of the plasticizing material is ABS, the covering material CM includes ABS. Alternatively, when the thermoplastic resin of the plasticizing material is ABS, the covering material CM may include polystyrene, nylon, PEEK, or the like. When the thermoplastic resin of the plasticizing material is nylon, the covering material CM includes nylon. Alternatively, when the thermoplastic resin of the plasticizing material is nylon, the covering material CM may include ABS, polystyrene, PEEK, or the like. When the thermoplastic resin of the plasticizing material is polystyrene, the covering material CM includes polystyrene. Alternatively, when the thermoplastic resin of the plasticizing material is polystyrene, the covering material CM may include ABS, nylon, PEEK, or the like. This makes the covering material CM more compatible with the thermoplastic resin of the plasticizing material, and thus it is possible to further suppress the inclusion of air bubbles in the plasticizing material.

[0060] 6 is a flowchart showing steps executed in the modeling process of the modeling apparatus 100a. In the modeling process, the control unit 10 mainly controls the plasticizing unit 35, the discharging unit 20, and the fiber introducing unit 23 to model a model containing a fiber material FB, which is a coated fiber material. The modeling process is executed based on modeling data for forming modeling layers constituting the model. The modeling data is generated based on three-dimensional shape data representing the shape of the model, such as three-dimensional CAD data. The modeling data includes, for example, information on the position of the modeling layer in the model, information on the dimensions of the modeling layer, information on the movement path of the nozzle opening 28, information on the discharge amount of the plasticizing material, and the like.

[0061] Steps P10 and P20 correspond to a plasticization step in which at least a part of a modeling material containing a thermoplastic resin is plasticized to generate a plasticized material used for modeling an object. During the modeling process, steps P10 and P20 are executed in parallel. During the modeling process, step P10 is executed intermittently under the control of the control unit 10, and step P20 is continued during the modeling process, at least while steps P30 to P50 described below are executed.

[0062] Step P10 is a step executed by the fiber introduction unit 23 under the control of the control unit 10, and corresponds to a fiber introduction step. Step P10 corresponds to a step of introducing the fiber material FB covered with the coating material CM into the modeling material before it is discharged from the nozzle opening 28 in the plasticization step. In step P10, the fiber material FB covered with the coating material CM is introduced through the introduction groove 57 from a position on the side of the facing unit 50 and on the side of the flat screw 40. As described above, the fiber material FB is introduced at the inlet of the introduction groove 57 into the modeling material supplied from the material storage unit 31 to the material inlet 46 of the flat screw 40.

[0063] As described above, the fiber introduction step of step P10 is intermittently performed under the control of the control unit 10 during the execution of the modeling process. The fiber introduction unit 23 performs the introduction of the fiber material FB when a command to introduce the fiber material FB is issued from the control unit 10 during the execution of the discharge of the plasticizing material from the nozzle opening 28 in step P40 described below. Also, the fiber introduction unit 23 stops the introduction of the fiber material FB when a command to stop the introduction of the fiber material FB is issued from the control unit 10.

[0064] In the process P20, the plasticizing unit 35 of the material generating unit 21 plasticizes the modeling material 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 P20 includes a process of introducing the modeling material of the material supplying unit 30 into the groove portion 42 of the flat screw 40 while rotating the flat screw 40 facing the facing unit 50, and guiding at least a part of the thermoplastic resin contained in the modeling material to the communication hole 53 of the facing unit 50 while plasticizing it in the groove portion 42. That is, the process P20 includes a process of guiding at least a part of the thermoplastic resin supplied between the flat screw 40 and the facing unit 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 plasticization process realizes a reduction in the size of the plasticizing unit 35. In addition, by controlling the rotation of the flat screw 40, it is easy to control the pressure and flow rate of the plasticized material supplied to the nozzle portion 25, so that it is possible to improve the accuracy of the discharge of the plasticized material by the nozzle portion 25, and thereby improve the molding accuracy of the molded object.

[0065] In steps P10 to P20 of this embodiment, the fiber material FB introduced into the plasticized material discharged from the nozzle opening 28 is covered with the covering material CM, so that the inclusion of air bubbles in the plasticized material due to the poor compatibility between the thermoplastic resin of the plasticized material and the fiber material FB is effectively suppressed. In addition, in steps P10 to P20 of this embodiment, the fiber material FB covered with the covering material CM is sent to the communication hole 53 together with the plasticized material in which the plasticization is progressing by the flat screw 40. According to this configuration, the pressure in the groove portion 42 of the flat screw 40, which increases toward the communication hole 53, can be used to more suitably infuse the plasticized material into the fiber material FB. Therefore, the inclusion of air bubbles when the fiber material FB is introduced into the plasticized material can be further suppressed. In addition, the rotation of the flat screw 40 can be used to guide the fiber material FB to the communication hole 53, which is efficient.

[0066] Steps P30 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 the plasticizing material is continuously and uninterruptedly discharged from the nozzle opening 28 to form one continuous modeling portion on the stage 72. In the modeling apparatus 100a, one modeling layer is formed by performing a series of operations from steps P30 to P50 one or more times. In the modeling process of this embodiment, steps P30 to P50 are repeated until all the stacked modeling layers have been formed and modeling of the model is completed.

[0067] The modeling apparatus 100a executes the process P40 while executing the process P30.

[0068] Process P30 is a process executed by the moving mechanism 75 under the control of the control unit 10, and corresponds to a moving process 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 unit 25 at a relative movement speed that is determined in advance based on the modeling data.

[0069] Step P40 corresponds to a discharge step in which 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 opening of the discharge amount control mechanism 80 to control the discharge amount of the plasticized material per unit time.

[0070] In step P50, the control unit 10 stops the discharge of the plasticizing material from the nozzle opening 28 at the timing of completing one pass. The control unit 10 first cuts the fiber material FB by the cutting unit 66 and stops the introduction of the fiber material FB by the fiber introduction unit 23. 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 operation for one pass. In this way, the process P50 includes a cutting process of cutting the fiber material FB. This makes it easy to adjust the length of the fiber material FB introduced into the shaped object and to control the stopping of the introduction of the fiber material FB into the plasticizing material.

[0071] In the modeling apparatus 100a, a modeling layer is formed by discharging a plasticizing material from the nozzle opening 28 while moving the nozzle unit 25 relative to the stage 72. As described above, steps P30 to P50 are repeated until all modeling layers constituting the modeled object are formed, and a modeled object containing the fiber material FB, which is a coated fiber material, is modeled. Steps P30 to P50 correspond to modeling steps for forming modeling layers.

[0072] As described above, according to the manufacturing method of a modeled object performed by the modeling apparatus 100a of the first embodiment, the strength of the modeled object is increased by introducing the fiber material FB into the plasticized material that constitutes the modeled object. Furthermore, since the fiber material FB is introduced into the plasticized material while covered with the coating material CM, the introduction of air bubbles into the plasticized material is suppressed. Therefore, the reduction in the strength of the modeled object due to the introduction of air bubbles into the plasticized material is suppressed.

[0073] [2] Second embodiment 7 is a schematic diagram showing the configuration of a modeling apparatus 100b of the second embodiment. The modeling apparatus 100b of the second embodiment has substantially the same configuration as the modeling apparatus 100a of the first embodiment, except that the fiber material FB wound around the reel 62 is not covered with the coating material CM and a storage section 68 is added to the middle of the transport path 65. The coating material CM is stored in the storage section 68. The fiber material FB sent out through the transport path 65 passes through the coating material CM stored in the storage section 68, and thereby the surface of the fiber material FB is covered with the coating material CM.

[0074] FIG. 8 is a flowchart showing steps executed by the modeling apparatus 100b in the modeling process of the second embodiment. FIG. 8 is substantially the same as the flowchart of FIG. 6 described in the first embodiment, except for the addition of step P5. Step P5 corresponds to a coating step in which, before the fiber introduction step of step P10, the fiber material FB is passed through a storage section 68 in which the coating material CM is stored, thereby generating a fiber material FB as a coated fiber material. According to the modeling process of the second embodiment, the surface of the fiber material FB can be easily covered with the coating material CM. In addition, the coating process of the coating material CM is completed by simply transporting the fiber material FB, which is efficient.

[0075] [3] Third embodiment 9 is a schematic diagram showing the configuration of a modeling apparatus 100c in the third embodiment. The modeling apparatus 100c in the third embodiment is substantially the same as the modeling apparatus 100b in the second embodiment, except that the introduction groove 57 of the facing portion 50 is omitted, and the transport path 65 of the fiber introduction portion 23 is connected to the material inlet 46 of the flat screw 40 together with the communication passage 32 of the material supply portion 30. In the modeling apparatus 100c in the third embodiment, the groove portion 42 of the flat screw 40 functions as the introduction groove 57, and the fiber material FB covered with the coating material CM is guided to the communication hole 53 through the groove portion 42. The modeling apparatus 100c in the third embodiment can also achieve various actions and effects similar to those described in the second embodiment.

[0076] [4] Fourth embodiment Fig. 10 is a flowchart showing steps executed in the modeling process in the fourth embodiment. Fig. 10 is almost the same as the flowchart in Fig. 8 described in the second embodiment, except that step P35 is added. The modeling process in the fourth embodiment is executed by the modeling apparatus 100b shown in Fig. 7 described in the second embodiment.

[0077] Step P35 corresponds to a fiber introduction control step in which the control unit 10 controls the introduction speed at which the fiber material FB is introduced into the modeling material in accordance with the relative movement speed between the nozzle unit 25 and the stage 72. The "introduction speed" corresponds to the length of the fiber material FB sent out from the transport path 65 per unit time. In the fourth embodiment, the control unit 10 sets a target value for the introduction speed of the fiber material FB to be higher 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 around which the fiber material FB is wound in accordance with the target value of the introduction speed.

[0078] In this way, by controlling the introduction speed of the fiber material FB according to the relative movement speed between the nozzle portion 25 and the stage 72, it is possible to prevent fluctuations in the amount and state of the fiber material FB that is discharged from the nozzle opening 28 and introduced into the plasticized material that is deposited on the stage 72, which are caused by changes in the relative movement speed between the nozzle portion 25 and the stage 72. In addition, since the introduction speed of the fiber material FB is controlled to be greater as the relative movement speed between the nozzle portion 25 and the stage 72 is greater, it is possible to prevent the introduction of the fiber material FB into the plasticized material from being unable to keep up with the speed at which the modeling layer ML is formed.

[0079] [5] Fifth embodiment Fig. 11 is a schematic diagram showing the configuration of a modeling apparatus 100d in the fifth embodiment. The modeling apparatus 100d in the fifth embodiment is substantially the same as the modeling apparatus 100b in the second embodiment shown in Fig. 7 except for the following points. In the modeling apparatus 100d in the fifth embodiment, the facing section 50 is not provided with an introduction groove 57, and the flat screw 40 is provided with a through hole 47. In addition, the fiber introduction section 23 is provided above the plasticization section 35, and the transport path 65 of the fiber introduction section 23 is connected to the through hole 47 of the flat screw 40. Furthermore, a pressure control section 90 is added to the fiber introduction section 23.

[0080] The flat screw 40 of the molding apparatus 100d is provided with a through hole 47 penetrating from the upper surface 43 to the central portion 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 portion 50. In addition, the storage portion 63 of the conveying portion 60 of the fiber introduction portion 23 is disposed above 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 fiber material FB is introduced into the plasticized material in the central portion 45 of the flat screw 40 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. 12 is a flowchart showing steps executed by the modeling apparatus 100d in the modeling process of the fifth embodiment. Fig. 12 is almost the same as the flowchart of Fig. 8 described in the second embodiment, except for the points described below. In Fig. 12, step P15 is added, and steps P33 and P35 are provided between steps P30 and P40, instead of steps P5 and P10.

[0083] Step P15 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 P15 is started before the generation of the plasticized material in step P20 is started, and is continued while the plasticized material is being generated in the plasticizing part 35. Since the pressure control step of step P15 controls the pressure in the through hole 47 to be high, it is possible to prevent the plasticized material collected in the center part 45 of the flat screw 40 from flowing into the conveying path 65 of the fiber material FB through the through hole 47. Therefore, in the steps described below, it is possible to prevent the introduction of the fiber material FB into the plasticized material from being hindered.

[0084] Step P33 corresponds to the covering step of step P5 described in the second embodiment. In step P33, the fiber material FB sent from the storage section 63 of the fiber introduction section 23 to the transport path 65 is covered with the covering material CM when passing through the storage section 68.

[0085] In the fifth embodiment, steps P35 and P40 correspond to the discharge steps. In step P35, the fiber material FB, which is a coated fiber material coated with the coating material CM, is introduced into the plasticized material before being discharged from the nozzle opening 28. In step P35, the fiber material FB is introduced into the plasticized material collected in the center portion 45 of the flat screw 40 through the through hole 47 of the flat screw 40. In step P40, the plasticized material into which the fiber material FB has been introduced in step P35 is discharged from the nozzle opening 28.

[0086] According to the molding apparatus 100d of the fifth embodiment, the fiber material FB 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.

[0087] [6] Sixth embodiment FIG. 13 is a schematic diagram showing the configuration of a modeling apparatus 100e of the sixth embodiment. The modeling apparatus 100e of the sixth embodiment is substantially the same as the modeling apparatus 100b of the second embodiment except for the following points. In the modeling apparatus 100e of the sixth embodiment, the introduction groove 57 of the facing portion 50 is omitted, and the transport path 65 of the fiber introduction portion 23 is connected to the introduction flow path 26 of the nozzle portion 25. The transport path 65 is connected to the downstream side of the discharge amount control mechanism 80. The cutting portion 66 is provided in the storage portion 63 and is provided near the inlet of the transport path 65. According to the modeling apparatus 100e, the fiber material FB covered with the coating material CM can be introduced into the plasticized material that is supplied from the plasticizing portion 35 to the nozzle portion 25 and before being discharged from the nozzle opening 28. Even with the configuration of the sixth embodiment, it is possible to suppress the incorporation of air bubbles into the plasticized material due to the introduction of the fiber material FB, as in the above-mentioned embodiments. The transport path 65 of the fiber introduction section 23 may be connected to the nozzle flow path 27 instead of the introduction flow path 26.

[0088] [7] Seventh embodiment FIG. 14 is a schematic diagram showing the configuration of a modeling apparatus 100f of the seventh embodiment. The modeling apparatus 100f of the seventh embodiment is substantially the same as the modeling apparatus 100b of the second embodiment except for the following points. In the modeling apparatus 100f of the seventh embodiment, the cutting section 66 of the fiber introduction section 23 is omitted. In addition, in the modeling apparatus 100f, the discharge amount control mechanism 80a of the seventh embodiment is provided in the introduction flow path 26 instead of the discharge amount control mechanism 80. As described later, the discharge amount control mechanism 80a of the seventh embodiment has a function as a cutting section that cuts the fiber material FB in addition to a function of controlling the discharge amount of the plasticizing material from the nozzle opening 28. Furthermore, the modeling apparatus 100f includes a motor 88 that generates a driving force and a gear section 89 that switches the transmission destination of the driving force of the motor 88 to the discharge amount control mechanism 80a or the conveying section 60 of the fiber introduction section 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.

[0089] FIG. 15 is a schematic diagram showing the configuration of a discharge amount control mechanism 80a of the seventh embodiment. FIG. 15 is a schematic diagram showing a state in which the discharge amount control mechanism 80a opens a flow path and the fiber material FB 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. 14, 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.

[0090] Fig. 16 is a schematic diagram for explaining the mechanism by which the discharge amount control mechanism 80a cuts the fiber material FB. Fig. 16 shows a schematic diagram of the butterfly valve 81 of the discharge amount control mechanism 80a rotating from the state shown in Fig. 15 to cut the fiber material FB. When the control unit 10 rotates the butterfly valve 81 to close the introduction flow path 26, the fiber material FB 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 fiber material FB is cut, the butterfly valve 81 continues to rotate to close the introduction flow path 26.

[0091] The modeling apparatus 100f of the seventh embodiment executes a modeling process through the steps shown in Fig. 8 described in the second 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 destination of the driving force generated by the motor 88. When introducing the fiber material FB in the fiber introduction step of step P10, the control unit 10 transmits the driving force generated by the motor 88 to the transport unit 60 via the gear unit 89, and uses it to transport the fiber material FB.

[0092] When starting to discharge the plasticizing material from the nozzle opening 28 in step P40, the control unit 10 temporarily switches the destination of the driving force generated by the motor 88 to the discharge amount control mechanism 80a by the gear unit 89 in order to adjust the discharge amount. This allows the butterfly valve 81 of the discharge amount control mechanism 80a to be rotated by the driving force generated by the motor 88, thereby controlling the discharge amount of the plasticizing material.

[0093] 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 fibrous material FB to be cut and stops the discharge of the plasticizing material from the nozzle opening 28. In this way, the process P50 includes a cutting process of cutting the fibrous material FB, which is the coated fibrous material, by operating the discharge amount control mechanism 80a.

[0094] According to the modeling apparatus 100f 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 100f of the seventh embodiment, it is possible to further improve the controllability of the discharge of the plasticizing material from the nozzle opening 28 because the discharge amount control mechanism 80a can stop the discharge of the plasticizing material at the same time as cutting the fiber material FB.

[0095] [8] Eighth embodiment Fig. 17 is a schematic diagram showing a configuration of a discharge amount control mechanism 80b included in a molding apparatus 100g of an eighth embodiment. Fig. 17 shows a state in which a rod 83 of the discharge amount control mechanism 80b is located at an initial position described later and a fiber material FB is fed to a nozzle flow path 27.

[0096] The modeling apparatus 100g of the eighth embodiment has almost the same configuration as the modeling apparatus 100f of the seventh embodiment, except for the points described below. The modeling apparatus 100g 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 controlling the discharge amount of the plasticizing material and a function of cutting the fiber material FB by moving the rod 83 in a direction intersecting the nozzle flow path 27 by a plunger mechanism. Although not shown, the modeling apparatus 100g 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.

[0097] 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. 14, 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.

[0098] 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.

[0099] Next, a cutting mechanism of the fiber material FB 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 fiber material FB as described below.

[0100] Fig. 18 is a schematic diagram for explaining a mechanism by which a discharge amount control mechanism 80b of the eighth embodiment cuts the fiber material FB. Fig. 18 shows a schematic diagram of a state in which the rod 83 of the discharge amount control mechanism 80b moves from the state shown in Fig. 17 in a direction protruding into the nozzle flow path 27, cutting the fiber material FB. 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 fiber material FB 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 and cut.

[0101] The control unit 10 of the molding apparatus 100g 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. 17. Hereinafter, this position will also be referred to as the "initial position."

[0102] 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 fiber material FB. 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.

[0103] 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.

[0104] 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 fiber material FB. 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, it is possible to realize higher responsiveness of the discharge unit 20 to the discharge control of the plasticizing material by the control unit 10.

[0105] As described above, according to the modeling apparatus 100g of the eighth embodiment, similarly to the modeling apparatus 100f 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 configuration of the apparatus 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 fibrous material FB from the nozzle opening 28.

[0106] [9] Ninth embodiment Fig. 19 is a schematic diagram showing the configuration of a modeling apparatus 100h in the ninth embodiment. The modeling apparatus 100h in the ninth embodiment is substantially the same as the modeling apparatus 100b in the second embodiment shown in Fig. 7 except for the following points. In the modeling apparatus 100h 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 unit 25 so as to be movable relative to the stage 72 together with the nozzle unit 25. In the modeling apparatus 100h, the fiber introduction unit 23 has a function of introducing the fiber material FB, which is a coated fiber material, into the plasticized material after it has been discharged from the nozzle opening 28.

[0107] Fig. 20 is a flowchart showing steps executed by the modeling apparatus 100h in the modeling process of the ninth embodiment. Fig. 20 is substantially the same as the steps of the modeling process shown in Fig. 8 described in the second embodiment, except that instead of steps P5 and P10, steps P42 and P45 corresponding to steps P5 and P10 are provided between steps P40 and P50. Step P42 is a step of passing the fiber material FB through a storage section 68 in which the coating material CM is stored, to cover the fiber material FB with the coating material CM. Step P45 corresponds to a fiber introduction step of introducing the fiber material FB, which is the coated fiber material covered with the coating material CM, into the plasticized material after it has been discharged from the nozzle opening 28 in the discharge step of step P40.

[0108] According to the modeling apparatus 100h of the ninth embodiment, it is easy to provide the fiber introduction section 23 later. Moreover, in the modeling apparatus 100h of the ninth embodiment, the fiber diameter of the fiber material FB can be made larger than the hole diameter Dn of the nozzle opening 28 because the fiber material FB does not pass through the nozzle opening 28. In the ninth embodiment, the fiber diameter of the fiber material FB can be set to, for example, 10 μm or more and 500 μm or less.

[0109]

[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.

[0110] [10-1] Other embodiment 1 In each embodiment other than the first embodiment described above, the storage section 68 may be omitted, and a fiber material FB previously covered with a coating material CM may be used, as in the first embodiment. Also, in the first embodiment, the fiber introduction section 23 may be omitted, and the fiber material FB previously covered with a coating material CM may be finely divided and introduced into the modeling material in the material storage section 31. Also, the fiber material FB covered with the coating material CM and finely divided may be mixed into pellets to be fed into the material storage section 31.

[0111] [10-2] Other embodiment 2 In each of the above embodiments, in addition to the fiber material FB, a second fiber material other than the fiber material FB may be introduced into the modeling material or the plasticized material. The second fiber material may be introduced into the modeling material or the plasticized material by a second fiber introduction section having a configuration similar to the fiber introduction section 23 of the fiber material FB described in each of the above embodiments. The second fiber material may be a fiber material having a fiber diameter different from that of the fiber material FB, which is the first fiber material, or a fiber material having a length different from that of the fiber material FB, which is the first fiber material. The second fiber material may be composed of a different type of fiber from that of the fiber material FB, which is the first fiber material. The second fiber material may be introduced into the modeling material in the material storage section 31 in a state in which it is covered with the coating material CM and is finely divided. Also, the second fiber material may be mixed into the pellets to be charged into the material storage section 31 in a state in which it is covered with the coating material CM and is finely divided.

[0112] [10-3] Other embodiment 3 In each of the above embodiments, instead of using the flat screw 40 to plasticize the thermoplastic resin to produce 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.

[0113] [10-4] Other embodiment 4 In the above third embodiment, the flat screw 40 may be formed with an introduction groove 57 for introducing the fibrous material FB in addition to the groove portion 42 that functions as a flow path for the plasticizing material.

[0114] [10-5] Other embodiment 5 In the above-described fifth 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 fiber material FB, for example, a configuration in which a portion where the gap between the through hole 47 and the fiber material FB is narrowed may be locally provided, or a configuration in which a check valve structure for suppressing the inflow of the plasticizing material into the conveying path 65 may be provided. The check valve structure may be formed, for example, by annular packing.

[0115] [10-6] Other embodiment 6 In the above ninth embodiment, the fiber introduction unit 23 does not have to be fixed to the nozzle unit 25. The fiber introduction unit 23 may be configured by, for example, a robot that embeds the fiber material FB covered with the coating material CM into the plasticized material discharged onto the stage 72 under the control of the control unit 10.

[0116] [10-7] Other embodiment 7 The configurations described in each of the above embodiments can be appropriately extracted and combined. For example, in the modeling apparatus, in addition to the configuration of introducing the fiber material FB into the modeling material in the first and second embodiments, a configuration of introducing the fiber material FB into the plasticized material after it is discharged from the nozzle opening 28 in the ninth embodiment may be combined. Alternatively, in addition to the configuration of introducing the fiber material FB into the plasticized material before it is discharged from the nozzle opening 28 in the fifth and sixth embodiments, a configuration of introducing the fiber material FB into the plasticized material after it is discharged from the nozzle opening 28 in the ninth embodiment may be combined. The fiber introduction control process of process P35 shown in FIG. 10 in the fourth embodiment may be applied to each of the above embodiments other than the fourth embodiment. In addition, the pressure control unit 90 in the fifth 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 of each transport path 65 to be higher than the pressure of the flow path of the plasticized material. The configuration in which the gear portion 89 in the above-described 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 fiber material FB may be applied to embodiments other than the seventh and eighth embodiments.

[0117] [10-8] Other embodiment 8 The discharge amount control mechanism 80b of the above-mentioned 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 fiber material FB.

[0118] [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.

[0119] [10-10] Other embodiments 10 In each of the above embodiments, a method for manufacturing a three-dimensional object including the following steps may be applied. The method for manufacturing a three-dimensional object includes a plasticizing step of plasticizing at least a part 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 being discharged from the nozzle opening, or a step of introducing the second fiber material into the plasticized material after being discharged from the nozzle opening, and a modeling step of modeling the three-dimensional object including the first fiber material and the second fiber material. According to this manufacturing method, 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 reinforce each other in strength in various directions. Therefore, the strength of the three-dimensional object in various directions can be easily improved.

[0120]

[11] Summary (1) A method for producing a three-dimensional object according to one embodiment of the present invention includes a plasticizing step of plasticizing at least a part of a modeling material containing a thermoplastic resin to produce 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 becoming mixed into the plasticized material. Therefore, it is possible to prevent air bubbles from being mixed into the plasticized material, resulting in a decrease in the strength of the three-dimensional object.

[0121] (2) In the manufacturing method of the above embodiment, the absolute value of the difference between the SP value of the thermoplastic resin and the SP value of the coating material may be 5.0 or less. According to this manufacturing method, the affinity between the thermoplastic resin and the coating material can be increased, and the coating fiber material and the plasticizing material can be made to blend more easily. Therefore, it is possible to further prevent air bubbles from being mixed into the plasticizing material when the coating fiber material is introduced, which would cause a decrease in the strength of the three-dimensional object.

[0122] (3) In the manufacturing method of the above embodiment, the covering material may contain the same type of thermoplastic resin as the thermoplastic resin contained in the plasticizing material. According to this manufacturing method, since the thermoplastic resin and the covering material are the same type of material, the plasticizing material is more easily compatible with the surface of the covering fiber material. This can further prevent air bubbles from being mixed into the plasticizing material when the covering fiber material is introduced, which reduces the strength of the three-dimensional object.

[0123] (4) In the manufacturing method of the above aspect, a coating step may be included prior to the fiber introduction step, in which the fiber material is passed through a storage section in which the coating material is stored to produce the coated fiber material. According to this aspect of the manufacturing method, the surface of the fiber material can be easily covered with the coating material.

[0124] (5) In the manufacturing method of the above embodiment, the plasticization step may include a step of guiding at least a part of the thermoplastic resin supplied between the flat screw and the facing part to the communicating hole while plasticizing it by rotating the flat screw and heating the heater in a plasticization device including a flat screw having a groove forming surface on which a groove portion is formed, a facing part having a facing surface facing the groove forming surface and having a communicating 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, the control of the rotation of the flat screw makes it easier to 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.

[0125] (6) In the manufacturing method of the above embodiment, an introduction groove that introduces the fiber material from the side of the flat screw or the facing portion to the communicating hole may be formed on the groove forming surface or the facing surface, and the fiber introduction step may introduce the covering fiber material into the molding material through the introduction groove. According to this embodiment of the manufacturing method, the pressure in the groove of the flat screw that increases toward the communicating hole can be used to more suitably blend the plasticizing material with the surface of the covering fiber material. This further suppresses the introduction of air bubbles when the covering fiber material is introduced into the plasticizing material.

[0126] (7) In the manufacturing method of the above aspect, 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 coated fiber material into the plasticizing material through the through hole. According to the manufacturing method of this aspect, the coated fiber material can be smoothly introduced into the communication hole of the opposing part through the through hole of the flat screw.

[0127] (8) In the manufacturing method of the above aspect, the fiber introduction step may include a pressure control step of controlling the pressure in the through hole to be higher than the pressure in the communicating hole. According to this manufacturing method, the pressure in the through hole is controlled to be high, thereby preventing the plasticizing material from flowing into the through hole and impeding the introduction of the covering fiber material.

[0128] (9) In the manufacturing method of the above aspect, the modeling step may include a moving step of relatively moving a stage on which the three-dimensional object is supported and a nozzle unit having the nozzle opening, and a fiber introduction control step of changing an introduction speed at which the coating fiber material is introduced into the modeling material or the plasticizing material depending on the relative movement speed between the nozzle unit and the stage in the moving step. According to the manufacturing method of the three-dimensional object of this aspect, it is possible to suppress fluctuations in the amount and state of the fiber material contained in the discharged plasticizing material due to changes in the relative movement speed between the nozzle opening and the stage during modeling of the three-dimensional object. This allows the fiber material to be introduced into the three-dimensional object in a more stable state, and the strength of the three-dimensional object can be further increased.

[0129] (10) The manufacturing method of the above aspect may include a cutting step of cutting the fiber material before or after the fiber introducing step. According to this aspect of the manufacturing method, by cutting the fiber material, it is possible to easily adjust the length of the fiber material introduced into the three-dimensional object, or to control the stopping of the introduction of the fiber material into the plasticized material.

[0130] (11) In the manufacturing method of the above aspect, the cutting step may include a step of cutting the coated 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. According to this aspect of the manufacturing method, the discharge amount control mechanism can efficiently control the introduction of the coated fiber material into the plasticizing material as well as the discharge amount of the plasticizing material.

[0131] (12) 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 introduction step may include a step of transmitting a driving force generated by the motor to a conveying section of the coated fiber material for use in conveying the coated fiber material. According to this aspect of the manufacturing method, the conveying section and the discharge amount control mechanism can be driven by a common motor, making it possible to reduce the size of the device configuration.

[0132] (13) A three-dimensional modeling apparatus according to one embodiment of the present invention includes a plasticizing unit that plasticizes at least a part of a modeling material containing a thermoplastic resin to generate a plasticized material, a discharge unit having a nozzle opening, a fiber introduction unit having at least one of the following functions: a function 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 the nozzle opening, or a function of introducing the coated fiber material into the modeling material or the plasticized material before 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 form a three-dimensional model containing the coated fiber material. According to this embodiment of the three-dimensional modeling apparatus, when the coated fiber material is introduced into the plasticized material, the coating material can prevent air bubbles from adhering to the surface of the coated fiber material and becoming mixed into the plasticized material. Therefore, it is possible to prevent air bubbles from being mixed into the plasticized material, which causes a decrease in the strength of the three-dimensional model. [Explanation of symbols]

[0133] 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...drive 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...opposite section, 51...opposite surface, 52...heater, 53...connecting hole, 55...guide groove, 57...introduction groove, 60...transport section, 62...reel, 63...storage section, 65...transport path, 66...cutting section, 68...storage 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, 100g, 100h...three-dimensional modeling device, CM...coating material, Dn...hole size, FB...fiber material, G...gap, ML...modeling layer, MM...plasticized material, OB...three-dimensional model, OBt...upper surface, RX...rotation axis

Claims

1. At least a portion of the building material including the thermoplastic resin may be plasticized to produce a plasticized material. a plasticizing process; The fiber material is covered with a coating material on the plasticizing material after being discharged from the nozzle opening. or introducing a coated fiber material from the modeling material or the nozzle opening, introducing the coated fiber material into the plasticized material before it is discharged. A fiber introduction step having the steps of: a modeling step of modeling a three-dimensional object including the coated fiber material; Equipped with The method further includes a cutting step of cutting the fiber material before or after the fiber introduction step, The cutting step is provided upstream of the nozzle opening and controls the discharge amount of the plasticizing material. and cutting the coated fiber material by operating a discharge amount control mechanism. 、 A method for manufacturing three-dimensional objects.

2. The absolute value of the difference between the SP value of the thermoplastic resin and the SP value of the coating material is 5.0 or less. R, The method for producing a three-dimensional object according to claim 1 .

3. The coating material contains the same type of thermoplastic resin as the thermoplastic resin contained in the plasticizing material. include, The method for producing a three-dimensional object according to claim 1 or 2.

4. Prior to the fiber introduction step, the fiber material is passed through a storage section in which the coating material is stored.

4. The method according to claim 1, further comprising a coating step of forming the coated fiber material by passing the fiber through a coating medium.

13. The method for producing a three-dimensional object according to any one of claims 1 to 12.

5. The plasticizing step includes: A flat screw having a groove forming surface on which a groove is formed, and a counter screw facing the groove forming surface a facing portion having a facing surface and a communication hole communicating with the nozzle opening; A plasticizing device comprising: a heater for heating the outlet or the facing portion; The flat screw is rotated and heated by the heater. At least a part of the thermoplastic resin supplied between the screw and the facing portion is plasticized. and guiding the material into the communicating hole while rotating the material. The method for producing a three-dimensional object according to any one of claims 1 to 4.

6. The groove forming surface or the opposing surface is provided with a fiber material. An introduction groove is formed to lead from a side of the facing portion to the communication hole, The fiber introduction step includes introducing the coated fiber material into the modeling material through the introduction groove. do, The method for producing a three-dimensional object according to claim 5 .

7. The flat screw has a through hole that opens at the groove forming surface and communicates with the communication hole. Through holes are formed, The fiber introduction step includes introducing the coated fiber material into the plasticized material through the through holes. The method comprises the steps of: The method for producing a three-dimensional object according to claim 5 .

8. In the fiber introducing step, the pressure in the through hole is controlled to be higher than the pressure in the communicating hole. The method according to claim 7, further comprising a pressure control step.

9. The molding process includes: A stage on which the three-dimensional object is supported and a nozzle portion having the nozzle opening are relatively a moving step of moving the The nozzle unit is moved relative to the stage at a speed corresponding to the relative movement speed of the nozzle unit and the stage in the moving step. A fiber introduction method for changing an introduction rate of the coated fiber material into the molding material or the plasticizing material. A control step. The method for producing a three-dimensional object according to any one of claims 1 to 8.

10. The discharge amount control mechanism is driven by a motor, The fiber introduction step is a step of transmitting the driving force generated by the motor to the conveying section of the coated fiber material. and using the coated fiber material for conveying the coated fiber material. The method for producing a three-dimensional object according to any one of claims 1 to 9.

11. At least a portion of the building material including the thermoplastic resin may be plasticized to produce a plasticized material. A plasticizing section; A discharge portion having a nozzle opening; The plasticized material discharged from the nozzle opening is coated with a fiber having a coating material. A function of introducing a coated fiber material, which is a fiber material, or a function of introducing the molding material or the nozzle opening. and (b) introducing the coated fiber material into the plasticized material before it is discharged from the nozzle. A fiber introduction section having any one of the functions; A cutting unit that cuts the fiber material; The plasticizing section, the discharging section, and the fiber introducing section are controlled to form a fiber material including the coated fiber material. and a control unit for forming a three-dimensional object including the three-dimensional object. The cutting portion is provided upstream of the nozzle opening and controls the discharge amount of the plasticizing material. cutting the coated fiber material by operating a discharge amount control mechanism; Three-dimensional printing equipment.

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