OBJECT, METHOD FOR DESIGNING OBJECT, AND METHOD FOR MANUFACTURING OBJECT

Abstract

To provide a molded object capable of improving the degree of freedom in molding. [Solution] A structure W is manufactured by a 3D printer, and has structure portions W1a, W1b having a loop shape defined based on a torus knot, and the structure portions W1a, W1b form at least a part of a unit shape of the structure W.

Description

[Technical field]

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

[0002] 2. Description of the Related Art In recent years, fused deposition modeling 3D printers, for example, have become widely known as object manufacturing devices for manufacturing three-dimensional objects (see, for example, Patent Document 1).

[0003] When it comes to objects produced using 3D printers, there is a greater degree of design freedom than before and they can handle complex shapes; however, the more complex the shape, the more supports are required to support the parts of the model that need support during printing, and it is often difficult to remove supports that are no longer needed after printing.

[0004] Furthermore, when manufacturing objects using a 3D printer, a lattice structure has been used in the past (see, for example, Patent Document 2). A lattice structure is a structure in which branched lattices are periodically arranged, and the inside of the object can be made hollow, making it easy to reduce weight. However, since each element (edge) of this lattice structure is a straight-line structure, it lacks flexibility (elasticity), and it is necessary to combine multiple unit cells when forming a curved surface (curve). In addition, since the lattice structure has vertices, the connection direction (angle) is limited. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Special Publication No. 2000-500709 [Patent Document 2] JP 2015-93461 A Summary of the Invention [Problem to be solved by the invention]

[0006] Therefore, an object of the present invention is to provide a shaped object, a shaped object design method, and a shaped object manufacturing method that enable a greater degree of freedom in shaping. [Means for solving the problem]

[0007] A structure according to an embodiment of the present invention is a structure manufactured by a structure manufacturing apparatus, and has a structure portion having a loop shape defined based on a torus knot, and the structure portion forms at least a part of a unit shape of the structure.

[0008] The above-mentioned shaped object may be configured by connecting a plurality of shaped portions.

[0009] In the above-described shaped object, the multiple shaped portions may be connected so that the loop shapes intersect with each other.

[0010] In the above-described shaped object, the multiple shaped portions may be connected so that the closed loop shapes do not intersect with each other.

[0011] In the above-described shaped object, the multiple shaped portions may have the same shape or mirror-symmetric shapes.

[0012] In the above-described shaped object, the plurality of shaped portions may have shapes that are different in size from one another.

[0013] Moreover, the method for designing a molded object of the present invention forms molding data for a molded part by setting a thickness to a surface formed by connecting two adjacent torus knots with a line.

[0014] In the above-described object design method, the molding data for the molded portion may be formed by sweeping a predetermined cross-sectional shape along a torus knot having a loop shape.

[0015] Further, a method for manufacturing a model of an object according to the present invention is a method for manufacturing a model by using an apparatus for manufacturing a model, based on the modeling data formed by the above-described method for designing a model of an object.

[0016] In the above-described object manufacturing method, the object manufacturing apparatus may be a 3D printing apparatus using a fused deposition modeling method or a photolithography method. Effect of the Invention

[0017] According to the embodiment of the present invention, it is possible to further improve the freedom of design. [Brief description of the drawings]

[0018] [Figure 1] 1 is a front view showing a schematic diagram of a fused deposition model 3D printer, which is an apparatus for manufacturing a molded object according to an embodiment of the present invention. [Diagram 2] FIG. 1 is an explanatory diagram showing a torus knot. [Diagram 3] FIG. 1 shows a model produced using the 3D printer; (a) is a plan view from the Z-axis direction; (b) is a side view from the X-axis direction; (c) is a side view from the -Y-axis direction; (d) is an oblique view from one direction; and (e) is an oblique view from another direction. [Figure 4] FIG. 4 shows a first design method for one object shown in FIG. 3, where (a) is an oblique view showing a surface connecting two torus knots with a line, and (b) is an oblique view showing modeling data with thickness added to (a). [Diagram 5] FIG. 11 shows another object manufactured using a 3D printer based on modeling data designed by the first design method, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from the other direction. [Figure 6] FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the first design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from another direction, and (f) is a partially enlarged view thereof. [Figure 7]FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the first design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 8] FIG. 8 shows a first design method for yet another object shown in FIG. 7, where (a) is an oblique view showing a surface connecting two torus knots with a line, and (b) is an oblique view showing modeling data with thickness added to (a). [Figure 9] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 10] 10 shows a second design method for yet another object shown in FIG. 9, where (a) is an oblique view showing a torus knot that serves as a sweep line, (b) is an oblique view showing an enlarged portion of (a), (c) is an oblique view of printing data in which a cross-sectional shape is swept along the sweep line of (a), and (d) is an oblique view showing an example in which the side edge of the cross-sectional shape extends along the printing table. [Figure 11] FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from the other direction, and (f) is a cross-sectional view at a position equivalent to II in (b). [Figure 12] FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from the other direction, and (f) is a cross-sectional view at a position equivalent to II-II in (b). [Figure 13]FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from the other direction, and (f) is a cross-sectional view at a position equivalent to III-III in (b). [Figure 14] FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from the other direction, and (f) is a cross-sectional view at a position equivalent to IV-IV in (b). [Figure 15] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 16] FIG. 16 shows a first design method for yet another object shown in FIG. 15, where (a) is an oblique view showing a surface connecting two torus knots with a line, and (b) is an oblique view showing modeling data with thickness added to (a). [Figure 17] FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from another direction, (f) is an oblique view from yet another direction, (g) is an oblique view from yet another direction, and (h) is a cross-sectional view at a position equivalent to VV of (b). [Figure 18]FIG. 11 shows yet another object manufactured using a 3D printer based on modeling data designed by the second design method described above, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, (e) is an oblique view from another direction, (f) is an oblique view from yet another direction, (g) is an oblique view from yet another direction, and (h) is a cross-sectional view at a position equivalent to VI-VI in (b). [Figure 19] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view taken from the Z-axis direction, (b) is a side view taken from the X-axis direction, (c) is a side view taken from the -Y-axis direction, (d) is an oblique view taken from one direction, (e) is an oblique view taken from another direction, and (f) is a cross-sectional view taken at a position equivalent to VII-VII in (b). [Figure 20] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view taken from the Z-axis direction, (b) is a side view taken from the X-axis direction, (c) is a side view taken from the -Y-axis direction, (d) is an oblique view taken from one direction, (e) is an oblique view taken from another direction, and (f) is a cross-sectional view taken at a position equivalent to VIII-VIII in (b). [Figure 21] 19A and 19B are diagrams showing yet another object produced by further connecting the yet another object shown in FIG. 18, where (a) is a plan view seen from the Z-axis direction, (b) is a side view seen from the X-axis direction, and (c) is a perspective view. [Figure 22] 21A and 21B are diagrams showing yet another object produced by further connecting the yet another object shown in FIG. 20, where (a) is a plan view seen from the Z-axis direction, (b) is a side view seen from the X-axis direction, and (c) is a perspective view. [Figure 23] 21A and 21B are diagrams showing yet another object produced by further connecting the yet another object shown in FIG. 20, where (a) is a plan view seen from the Z-axis direction, (b) is a side view seen from the X-axis direction, and (c) is a perspective view. [Figure 24] 21A and 21B are diagrams showing yet another object produced by further connecting the yet another object shown in FIG. 20, where (a) is a plan view seen from the Z-axis direction, (b) is a side view seen from the X-axis direction, and (c) is a perspective view. [Diagram 25]24 is a photograph showing a manufacturing example of the shaped object shown in FIG. 23. [Figure 26] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 27] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 28] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Figure 29] 1A and 1B are diagrams showing an example of a torus knot that determines the loop shape of the shaped portion of the above-mentioned object, in which (a) is a plan view shown from the Z-axis direction, (b) is a side view shown from the X-axis direction, (c) is a side view shown from the -Y-axis direction, (d) is a perspective view shown from one direction, and (e) is a perspective view shown from another direction. [Diagram 30] 1A and 1B are diagrams showing another example of a torus knot that determines the loop shape of the shaped portion of the same object, in which (a) is a plan view shown from the Z-axis direction, (b) is a side view shown from the X-axis direction, (c) is a side view shown from the -Y-axis direction, (d) is an oblique view shown from one direction, and (e) is an oblique view shown from another direction. [Diagram 31] FIG. 11 shows yet another object produced using the same 3D printer, where (a) is a plan view from the Z-axis direction, (b) is a side view from the X-axis direction, (c) is a side view from the -Y-axis direction, (d) is an oblique view from one direction, and (e) is an oblique view from another direction. [Diagram 32] 27(a) is a photograph showing an example of the state of the shaped object shown in FIG. 26 after it has been deformed, and (b) is a photograph showing an example of the state of (a) after it has been restored to its original deformation. [Diagram 33]13 is a cross-sectional view showing a reference example of the rise angle from the modeling table of an object that can be support-less modeled by the 3D printer. FIG. [Diagram 34] 34 is a photograph showing a manufacturing example of the reference example of FIG. 33. [Diagram 35] 7 is a photograph showing a manufacturing example of the shaped object shown in FIG. 6. [Diagram 36] 15 is a photograph showing a production example of the shaped object shown in FIG. 14. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] An embodiment of the present invention will be described with reference to the drawings.

[0020] In FIG. 1, reference numeral 1 denotes a fused deposition model 3D printer, which is a device for manufacturing objects. This fused deposition model 3D printer (hereinafter sometimes simply referred to as "3D printer 1") is a modeling machine that produces a three-dimensional object W by sequentially layering resin, which is a modeling material that has been melted (dissolved) by heat, one layer at a time based on 3D modeling data.

[0021] The resin used as the modeling material in the 3D printer 1 is, for example, a thermoplastic resin, such as general-purpose plastic, engineering plastic, super engineering plastic, reinforced resin, recycled plastic, biomass plastic, biodegradable plastic, etc. More specifically, for example, PVC, POM, PBAT, AAS, PS, PLA, PLA with plant fiber, ABS, ABS with glass fiber, ABS with carbon fiber, PP, PP with glass fiber, PP with carbon fiber, PC, PC·ABS, ASA, TPE, TPU, cellulose acetate, PA, PETG, etc. The modeling material may be in any shape, such as pellets or filaments. In addition, the 3D printer 1 is, for example, a single nozzle head type, and only one type of resin is required for modeling, and a resin dedicated to support (such as a water-soluble resin) is not required. In addition, the modeling material is not limited to resin, and may be metal, ceramic, silicone, etc. In addition, these molding materials may have one or more of the following properties: flexibility, antibacterial properties, chemical resistance, heat resistance, stain resistance, and weather resistance, or may have these properties added to them using desired additives.

[0022] The 3D printer 1 includes, for example, a box-shaped main body 3 having a modeling chamber 2 inside, a modeling head 4 that is movable in the X-axis direction (horizontal, i.e., left-right direction) and the Z-axis direction (up-down, i.e., height direction) within the modeling chamber 2, and a modeling table 5 that is movable in the Y-axis direction (horizontal, i.e., front-back direction) within the modeling chamber 2.

[0023] Since the modeling head 4 can move in the X-axis and Z-axis directions and the modeling table 5 can move in the Y-axis direction, the modeling head 4 moves in three dimensions relative to the modeling table 5 (as will be described later, the 3D printer 1 is not limited to the configuration shown in Figure 1, and it is sufficient that the modeling head 4 moves in at least three dimensions relative to the modeling table 5).

[0024] The 3D printer 1 also includes a first drive unit 6 that moves the modeling head 4 in the X-axis direction and Z-axis direction within the modeling chamber 2, a second drive unit 7 that moves the modeling table 5 in the Y-axis direction within the modeling chamber 2, and a control unit 8 that controls both drive units 6, 7, etc. based on 3D modeling data such as STL data.

[0025] Then, based on the control by the control unit 8, the modeling head 4 moves three-dimensionally relative to the modeling table 5, while resin (molten resin) is ejected from the nozzle 11 of the moving modeling head 4, and as the ejected resin hardens and solidifies, the resin is layered on the modeling table 5, thereby forming a three-dimensional object W of the desired shape.

[0026] Here, the modeling head 4 of the single-nozzle head fused deposition modeling 3D printer 1 is, for example, of a molten resin extrusion type, and has a single nozzle 11 that ejects melted resin from an outlet using heat from a heating means (not shown) within the modeling head 4.

[0027] That is, the resin that has been heated and melted by a heating means such as a heater (not shown) is extruded by an extrusion means (not shown) such as a gear inside the modeling head 4, and is discharged (exhausted) from the outlet of one nozzle 11 for discharging the modeling material in the direction of the central axis of the outlet, for example, downward. Note that the heating means and the extrusion means may be provided outside the modeling head 4, rather than inside the modeling head 4.

[0028] The object W produced by the 3D printer 1 of this embodiment has a shaped portion W1 having a loop shape defined based on the torus knot, and constitutes at least a part of the porous structure.

[0029] Here, as shown in Figure 2, a torus knot K is defined as a knot that wraps around the surface of a virtual torus T. This torus knot K is defined by the following equation (hereinafter collectively referred to as equation (1)) using a parameter t.

[0030] Xt=(a·cos(d·t)+e)·cos(f·t) Yt=(b·cos(d·t)+e)·sin(f·t) Zt = c sin(d t)

[0031] The X-axis, Y-axis, and Z-axis directions correspond to the X-axis, Y-axis, and Z-axis directions in the 3D printer 1 (shown in FIG. 1). a to f are coefficients that are not 0. The parameter t is 0 to 2π [rad], and the coefficients a, b, and c are coefficients that set the magnification ratio of the torus T in the X-axis, Y-axis, and Z-axis directions with respect to the unit torus, respectively. The coefficient e is a coefficient that sets the so-called "diameter" of the torus T, and together with the coefficients a and b, is a coefficient that sets the magnification ratio of the diameter in the X-axis and Y-axis directions with respect to the unit torus. The coefficient d is a coefficient whose absolute value sets the number of loops in the meridian direction M of the torus knot K, and the coefficient f is a coefficient whose absolute value sets the number of loops in the latitude direction L of the torus knot K. The coefficients d and f basically have absolute values ​​of 1 or more, and preferably at least one of them has an absolute value of 2 or more. Any value may be used as long as a loop shape is formed, but it is preferable to select the coefficients so that the torus knot K forms a closed loop shape, and as an example, they are integer values. In addition, the coefficients d and f are preferably set to a value whose greatest common denominator of their absolute values ​​is 1, that is, an integer value in which one absolute value is 1 and the other absolute value is 2 or more, or a value whose absolute value ratio is equal to the ratio of integers that are relatively prime. In addition, the coefficients a, b, c, and e are used to define the size of the loop shape and are not limited to integer values. Preferably, the coefficients a, b, c, and e are set so that the loop shape does not self-intersect, but self-intersections may occur. As is self-evident from formula (1), a congruent torus knot K is formed even when the values ​​of Xt, Yt, and Zt are mutually interchanged. However, in order to facilitate modeling by the 3D printer 1 shown in FIG. 1, it is preferable to fix the axis direction of the torus T (shown in FIG. 2) to the Z axis direction and only allow the values ​​of Xt and Yt to be interchanged.

[0032] In this embodiment, the 3D modeling data of the modeling unit W1 is designed by a computer or the like using the formula (1), and the 3D printer 1 is driven to manufacture the model W based on the designed modeling data.

[0033] Next, a method for designing the object W will be described.

[0034] When the formula (1) is used, the shaping data for manufacturing the shaped object W can be designed by roughly two methods.

[0035] The first design method is to create modeling data by adding thickness to a surface formed by connecting two adjacent torus knots with a line.

[0036] The second design method is a method of forming modeling data by sweeping a predetermined cross-sectional shape along a torus knot. Note that sweeping refers to continuously moving a predetermined cross-sectional shape along a trajectory, in this case, the torus knot.

[0037] The first design method will be described with reference to the drawings.

[0038] FIG. 3 shows an example of a modeling portion W1 (modeled object W) defined based on a torus knot having a closed loop shape of |a|=|b|=|c|, d=1, and f=2 in formula (1). As shown in FIG. 4(a), two adjacent torus knots K1 and K2 of approximately similar shape, which differ only in the value (position) of the coefficient e in formula (1), are used, and a surface 16 is formed by connecting these torus knots K1 and K2 with a line 15, for example, a straight line. A non-self-intersecting line is preferable as the line 15. Then, the surface 16 is made three-dimensional (solidified) by adding thickness in the normal direction as shown in FIG. 4(b), and modeling data D is formed. The width of the formed portion W1 can be controlled by changing the difference in the coefficient e in equation (1) that describes the two torus knots K1 and K2, and for example, the example shown in Fig. 5 is a formed portion W1 (object W) formed using printing data in which the difference in the coefficient e in equation (1) that describes the two torus knots is smaller than in the example shown in Fig. 3. In addition, by fixing the coefficients d and f in equation (1) and taking large absolute values ​​for the coefficients a, b, c, and e, it becomes possible to expand the formed portion W1 (object W) in the X-axis, Y-axis, and Z-axis directions without changing the number of loops.

[0039] The shape of the shaped portion W1 (shaped object W) in the examples shown in Figures 3 and 5 varies greatly depending on the viewing angle, and can be a circle with a small loop inside a large loop, or, as shown in particular in Figure 5(b), a figure-eight shape in which the large loop and small loop extend in opposite directions.

[0040] Similarly, Figure 6 shows an example of a portion W1 (object W) defined based on a torus knot in the form of a closed loop in formula (1) where |a| ≠ |b| << |c| (|a| << |b| << |c|), d = 1, and f = 2. In this example, the absolute value of coefficient a is set small compared to coefficients b and c, so that portion W1 is thin in the X-axis direction and has a nearly flat Möbius ring shape. The twisted structure of the surface itself is reflected in portion W1 as a twisted structure, as shown in Figure 6 (f).

[0041] The thickness of the surface may be set so that there is no self-intersection, or so that some of the surface intersects with itself. The self-intersections can be regarded as intersections in a lattice structure. The self-intersections can be made thicker at any point to improve impact resistance. To increase the thickness of the self-intersections, it is possible to increase the amount of modeling material dispensed by the 3D printer 1, or perform other operations.

[0042] The lines used in the first design method are not limited to straight lines, and may be any curved lines. For example, Fig. 7 shows an example of a modeling part W1 (modeled object W) defined based on a torus knot having a closed loop shape of |a|=|b|=|c|, d=1, and f=2 in formula (1), and as shown in Fig. 8(a), a surface 16 is formed by connecting two torus knots K1 and K2 having different coefficients e in formula (1) with a sine curve as a line 15. The modeling data D is formed by adding thickness to the surface 16 as shown in Fig. 8(b) to make it three-dimensional.

[0043] The second design method will be described with reference to the drawings.

[0044] FIG. 9 shows an example of a modeled portion W1 (modeled object W) defined based on a torus knot having a closed loop shape of |a|=|b|=|c|, d=1, and f=2 in formula (1). As shown in FIG. 10(a), a sweep line 20 is set by a torus knot, and the center or center of gravity of a predetermined cross-sectional shape 21 shown in FIG. 10(b) is moved (circulated) along the sweep line 20 as shown in FIG. 10(c) to form a three-dimensional shape, thereby forming the modeling data D. For example, the cross-sectional shape 21 is a hexagon, particularly a regular hexagon. In this example, the cross-sectional shape 21 passes through virtual lines 20a and 20b, which are torus knots obtained by increasing or decreasing a coefficient e, which is equal to the width of the cross-sectional shape 21 in formula (1), with respect to the torus knot that is the closed loop sweep line 20.

[0045] Preferably, as shown in FIG. 10(d), the cross-sectional shape 21 has a side edge 22 extending along the modeling table 5. That is, the side edge 22 is a portion that does not substantially have a Z-axis direction component. The shape of the side edge 22 is preferably, for example, a straight line, but is not limited thereto. For example, the shape may be a curved line approximating a straight line (with a large radius of curvature), or a shape having a straight line or a curved line approximating a straight line extending along the modeling table 5 at the tip as a tangent or envelope, such as a wave shape, a zigzag shape, or a sawtooth shape. In this way, the cross-sectional shape 21 of the modeling part W1 has the side edge 22 extending along the modeling table 5 of the 3D printer 1, so that the modeling part W1 can be manufactured by the 3D printer 1 using the side edge 22 as a support part for the modeling table surface (or a raft surface on the modeling table surface), and therefore the modeling part W1 (modeled object W) can be manufactured without support.

[0046] FIG. 11 shows an example of a shaped portion W1 (shaped object W) defined based on a torus knot in the form of a closed loop in formula (1) where |a|=|b|<<|c|, d=1, and f=2.

[0047] The cross-sectional shape 21 is not limited to a hexagon, but may be a triangle, particularly an equilateral triangle, as shown in FIG. 12, or a polygon, such as a quadrangle, particularly a square, as shown in FIG. 13, or may be a circle, as shown in FIG. 14. In addition, the cross-sectional shape may be a hollow shape, an oval shape such as an ellipse or an oval shape, or may be any shape, such as a concave polygon, as well as a convex polygon. By utilizing the difference in the section modulus to form any cross-sectional shape, a shaped portion W1 (shaped object W) having a desired strength can be manufactured. In addition, the size of the cross-sectional shape 21 is preferably set so that no self-intersecting portion is formed in the shaped portion W1, but may be set so that a self-intersecting portion is formed in a part of the shaped portion W1. The self-intersecting portion becomes an intersection in a lattice structure.

[0048] In the examples of FIGS. 11 to 14, the shaped portion W1 (shaped object W) takes on various shapes, such as a circle with overlapping large and small loops, a figure eight (Möbius ring) shape, or a trefoil knot, depending on the viewing angle.

[0049] The shaping portion W1 may form the shaped object W alone as shown in FIGS. 3 to 14, or may form the shaped object W by connecting a plurality of the shaping portions W1 together.

[0050] When a plurality of shaping portions W1 are connected to form a shaped object W, there are roughly two methods.

[0051] The first connecting method is a method of connecting the shaping parts W1 so that the loop shapes intersect. The second connecting method is a method of connecting the shaping parts W1 in a so-called chain shape or torus link shape so that the closed loop shapes do not intersect when at least a part of the shaping parts W1 has a closed loop shape.

[0052] The first connection method will be described with reference to the drawings.

[0053] FIG. 15 shows an example of a shaped object W in which two shaped parts W1a and W1b are connected, the shaped parts being defined based on a torus knot having a closed loop shape of |a|=|b|<|c|, d=1, and f=2 in Equation (1). In this example, the shaped parts W1a and W1b are different in size and have substantially similar shapes with the same number of loops. In this example, the above-mentioned first design method is used, for example, and as shown in FIG. 16(a), first, two torus knots K1a and K2a having different values ​​of coefficient e (different orders) in Equation (1) and other two torus knots K1b and K2b having different values ​​of coefficient e (different orders) in Equation (1) are used. In this case, coefficients are selected so that the torus knots K1a and K2a and the torus knots K1b and K2b have one or more intersections with each other. In this example, the coefficients a through d and f in formula (1) are all set equal, and the coefficient e is selected so that the torus knots K1a and K1b intersect at one point, and the torus knots K2a and K2b intersect at another point. In addition, by setting the difference in coefficient e in formula (1) representing the torus knots K1a and K2a and the difference in coefficient e in formula (1) representing the torus knots K1b and K2b equal, the widths of the connected modeling portions W1a and W1b can be made equal to each other.

[0054] Next, a surface 16a is formed by connecting the torus knots K1a and K2a with a line 15a, for example, a straight line, and a surface 16b is formed by connecting the torus knots K1b and K2b with a line 15b, for example, a straight line. Then, the Boolean sum of the shapes of the surfaces 16a and 16b, which are three-dimensionalized (solidified) by adding thickness in the normal direction as shown in FIG. 16(b), is taken to form the printing data D. Note that the lines 15a and 15b are not limited to straight lines and may be curved lines. Also, the lines 15a and 15b do not need to be the same type of line.

[0055] The width of the shaping portion W1 can be controlled by changing the difference in the coefficient e in the formula (1) representing the torus knots K1a and K2a and the difference in the coefficient e in the formula (1) representing the torus knots K1b and K2b.

[0056] In this way, when a plurality of shaped portions W1 of substantially similar shapes but different sizes are connected, it is possible to easily manufacture an attractive shaped object W that has a self-similar appearance or an appearance similar thereto.

[0057] When designing the modeling data D in the first linking method, the above-mentioned second design method may be used.

[0058] 17 and 18 show an example of a model W in which two modeling portions W1a and W1b are connected, and the two modeling portions W1a and W1b are defined based on a torus knot that forms a closed loop shape in equation (1) where |a|=|b|<<|c|, d=1, and f=2. In this example, the modeling portions W1a and W1b have mirror-symmetric shapes, and in equation (1), the absolute values ​​of each coefficient are equal, with only the positive and negative values ​​of Xt differing.

[0059] The printing data D for forming these printing portions W1a and W1b is formed by taking the Boolean sum of shapes that are three-dimensionalized by moving (circling) the center or center of gravity of a predetermined cross-sectional shape 21 along each sweep line, with torus knots that are mirror images of each other, as sweep lines. For example, as the cross-sectional shape 21, an example of a hexagon, particularly a regular hexagon, is shown in Fig. 17, and an example of a circle is shown in Fig. 18, but the shape is not limited to these and any shape may be used.

[0060] In this manner, in the first connecting method, by connecting the loop shapes of the multiple shaped portions W1 so that they intersect with each other, it is possible to easily manufacture an integrally connected rigid shaped object W.

[0061] For example, when viewed from the angles shown in Figures 17(f) and 18(f), the object W has an eight-knot shape, and when viewed from the angles shown in Figures 17(g) and 18(g), it has an epitrochoidal knot shape.

[0062] The second connecting method is the opposite of the first connecting method, and can be realized by manufacturing a shaped part W1 defined based on a plurality of torus knots in which the coefficients in formula (1) are selected so that no intersections occur. This second connecting method makes it easy to manufacture a chain-like shaped object W that can easily deform at the connecting parts between the shaped parts.

[0063] The number of connected shaping portions W1 is not limited to two, but may be any number of three or more.

[0064] For example, FIG. 19 shows an example of a modeled object W in which four modeled portions W1a, W1b, W1c, and W1d are connected, which are defined based on a torus knot in the form of a closed loop of |a|=|b|<<|c|, d=1, and f=2 in Equation (1). In this example, the modeled portions W1a and W1b are mirror-symmetrical to each other, and in Equation (1), the absolute values ​​of each coefficient are equal, and only the positive and negative of Xt are different. In addition, the modeled portions W1a and W1c are such that Xt and Yt in Equation (1) are interchanged, and similarly, the modeled portions W1b and W1d are such that Xt and Yt in Equation (1) are interchanged. That is, the modeled portions W1c and W1d are such that the modeled portions W1a and W1b are rotated by π / 2 [rad] around the Z axis, respectively. Therefore, the shaping portions W1c and W1d have mirror-symmetric shapes, and in formula (1), the absolute values ​​of the coefficients are equal, and only the positive and negative values ​​of Yt differ.

[0065] When the modeling data for forming these modeling portions W1a, W1b, W1c, and W1d is designed by the above-mentioned first design method, two sets of two torus knots with similar shapes having different coefficients e in formula (1) are set, and the two torus knots of the sets are connected by a line to form a surface, and a thickness is added to the surface to obtain a three-dimensional shape, and a Boolean sum is taken. When the modeling data is designed by the second design method, each torus knot is set as a sweep line, and the center or center of gravity of a predetermined cross-sectional shape is moved along each sweep line to obtain a three-dimensional shape, and a Boolean sum is taken. For example, the cross-sectional shape 21 is shown in FIG. 19 as a quadrangle, particularly a rectangle, but is not limited to this, and may be any shape, such as a circle as shown in FIG. 20.

[0066] Furthermore, a plurality of connected shaping portions W1 may be treated as a mesh (unit shape, unit cell) and connected together to form a shaped object W. It is also possible to form a single larger shaped object W by arranging the above-mentioned shaped objects W as unit shapes in the left-right direction or stacking them up-down.

[0067] For example, FIG. 21 shows an example of a molded object W in which meshes formed by a combination of the molded portions W1a and W1b shown in FIG. 18 are arranged in a circular shape, and FIG. 22 and FIG. 23 show an example of a molded object W in which meshes formed by a combination of the molded portions W1a to W1d shown in FIG. 20 are arranged in a circular shape. In these examples, the molded object W is configured by arranging and connecting a row of meshes at equal angles in the Z-axis direction on the Z-axis and / or on multiple concentric circles centered on the Z-axis. Moreover, the molded object W shown in FIG. 23 includes an X-shaped or cross-shaped connecting portion 25 that connects the meshes at the center, in comparison with the molded object W shown in FIG. 22. In other words, when a large number of molded portions W1 are connected to each other to form the molded object W, not only parts of the molded portions W1 may be used as connecting portions, but also other connecting portions may be used. Moreover, the arrangement of the molded portions W1 does not have to be at equal angles or at equal intervals.

[0068] FIG. 24 shows an example of a model W in which meshes each made up of a combination of the model portions W1a to W1d shown in FIG. 20 are connected in a rectangular parallelepiped shape in the X-axis direction, the Y-axis direction, and the Z-axis direction.

[0069] In these examples, the meshes are connected by the first connecting method at positions where the loop shapes intersect to form a single overall shaped object W, but this is not limiting, and they may be connected by applying the second connecting method at positions where the closed loop shapes do not intersect. In other words, when a shaped object W is formed by connecting multiple shaped parts W1, specific parts of the shaped parts W1 do not act as connecting parts, but any position of the loop shape or closed loop shape acts as a connecting part.

[0070] In this way, by connecting multiple modeling parts W1 having the same shape or mirror-symmetric shapes, it is possible to easily manufacture an attractive model W that has an appearance with symmetry and regularity. A model W that has symmetry and regularity can be manufactured without support, for example, by a 3D printer 1 using the fused deposition modeling method or the DLP method (FIG. 25 shows a photograph of an example of the model W shown in FIG. 23 manufactured by a 3D printer 1 using the DLP method).

[0071] In addition, a shaped object W formed by connecting a number of shaped parts W1 together as a mesh is preferably used as at least a part of, for example, a filter, net, cushion (cushion material), equipment, rainwater storage tank, plant growth medium, filter material for water treatment, and especially a filter bed for water purification, but is not limited to these examples. The shaped object W (shaped part W1) may be used as any porous article. In particular, as shown in Figs. 21 to 24, by regularly arranging shaped parts W1 each having a different shape when viewed from each direction to form the shaped object W, it is possible to bias the ease of passage of fluids such as air and water, so that the shaped object W can be effectively used as a filter or filter material by selecting an arrangement pattern according to the shape of each shaped part W1. In addition, by biasing the connection structure of the shaped parts W1, the elasticity, rigidity, etc. of the shaped object W can be arbitrarily manipulated. Furthermore, by connecting the forming part W1 in any arrangement pattern in accordance with bioscan data, for example data calculated by a pressure sensor or the like along the shape of the biosimilar, it is possible to form cushions, orthotics, etc. that are suitable for the shape of each individual biosimilar.

[0072] By changing the connection structure of the forming part W1 (modeled object W), the properties can be changed even with the same material. For example, although not shown, cushioned chairs and the like can be formed with the same material, and in this case, there is no need to separate them when disposing of them, which saves the trouble of separating them and makes them easier to recycle, which is also environmentally friendly. In addition, by forming items such as cushions and plant growth media, which are often used with urethane mats, with the forming part W1 (modeled object W), it is possible to form items that are flexible and elastic, while eliminating the need for incineration and landfill processing, as with urethane, when disposing of them. This is expected to reduce disposal costs and environmental impact.

[0073] In addition, since the forming part W1 (forming part W) has a loop shape, it can be used as a gripping part or a hook part for a jig, and therefore can be easily replaced when formed as a mesh.

[0074] By making the connecting portions W1 (molded object W) denser, the strength is improved.

[0075] In the above embodiment, an example was given of a shaped portion W1 or shaped object W defined by a torus knot in equation (1) that satisfies |d|<|f| and has a trivial (unravellable) closed loop shape that is mathematically homeomorphic to a circle, but the present invention is not limited to this and the coefficients d and f may be selected to any value.

[0076] For example, as an example where |d| or |f| is 3 or more, FIG. 26 shows an example of a shaped portion W1 defined based on a torus knot in equation (1) that has a closed loop shape with |a|=|b|=|c|, d=5, and f=6.

[0077] As an example of |d|>|f|, Fig. 27 shows an example of a shaping part W1 defined based on a torus knot that forms a closed loop shape of |a|=|b|=|c|, d=-7, and f=4 in formula (1), and Fig. 28 shows an example of a shaping part W1 defined based on a torus knot that forms a closed loop shape of |a|=|b|=|c|, d=3, and f=2 in formula (1). Fig. 29 shows an example of another torus knot K that forms a closed loop shape of d=3 and f=2 in formula (1) similar to the torus knot that defines the loop shape of the shaping part W1 shown in Fig. 28, but since the absolute values ​​of the coefficients c and e are larger than those of the shaping part W1 shown in Fig. 28, the torus knot K shown in Fig. 29 shows a three-dimensional cloverleaf shape that stands up in the Z-axis direction, as shown in Fig. 29(e) in particular. In this way, even if the absolute values ​​or ratios of the coefficients d and f are equal, by selecting the other coefficients a to c and e, it is possible to easily impart shape variation to the shaping portion W1.

[0078] 30 shows an example of a torus knot K that has a closed loop shape with |a|=|b|<<|c|, d=6, and f=5. The shaped portion W1 having a closed loop shape defined by this torus knot K will have an appearance similar to a Lissajous figure. In the example shown in FIGS. 29 and 30, the shaped portion W1 is inscribed in a cube, which makes it easier to handle as a unit shape when connecting the shaped portions to form the shaped object W.

[0079] Furthermore, the torus knot for defining the loop shape of the shaping portion W1 may itself have a self-intersection, and Fig. 31 shows an example of the shaping portion W1 defined based on a torus knot that forms a closed loop shape of |a|=|b|=|c|, d=2, e=1, and f=5 in formula (1). In this example, the torus knot itself is in close proximity or self-intersecting near the center, i.e., the Z-axis, so that the shaping portion W1 whose loop shape is defined by this torus knot also has a self-intersection. Even such an example is included in the shaping portion W1 of this embodiment.

[0080] Additionally, the torus knot may self-intersect at a position other than near the Z axis.

[0081] In this way, in the case of the molded part W1 (molded object W) in which the absolute values ​​of the coefficients d and f in formula (1) are set large, the loop shape of the molded part W1 is determined by a torus knot that forms a closed loop shape that is not mathematically obvious (cannot be untied). In this case, the molded part W1 (molded object W) is formed so that many loop shapes are intertwined, which gives it a soft feel, and when the material is a soft material (elastic material), the molded object W can be elastically deformed in the Z-axis direction like a spring. In the above example, the molded object W shown in FIG. 26 has particularly excellent elastic deformation performance, and can be molded as a particularly elastic cushion even without connecting multiple molded parts W1 (molded object W). Moreover, in the example of a molded object W that does not have self-intersecting parts in the molded portion W1, since it is mathematically homeomorphic to a circle, it can be deformed in various directions compared to a configuration that has self-intersecting parts, and since it has a unicursal structure that is mathematically homeomorphic to a circle, even if it is pulled in the radial expansion direction, the relative positions of the loop shapes only change and it can easily return to its original shape when the external force is released (see, for example, Figures 32(a) and 32(b)). Similarly, even if it is pushed in the radial contraction direction, it can easily return to its original shape when the external force is released. In other words, even if the molded portion W1 (molded object W) is made of a hard molding material, it is structurally capable of shrinking, expanding, and deforming, and can have flexibility, elastic deformation performance, and impact resistance, so that it can be molded using, for example, less plasticizer or no plasticizer at all, which also leads to consideration of the environment.

[0082] For example, when the object W is pushed into a pipeline or the like having a cross-sectional shape smaller than the outer shape of the object W, it returns to its original shape due to its deformation performance and is pressed against the inner surface of the pipeline, so that it can be easily attached to the pipeline in a manner similar to a tension rod. In addition, since the outer periphery of the object W is formed in a curved (curved) shape, even if the object W1 has a self-intersecting portion, it can be easily attached to the pipeline. When fixing the object W to the pipeline, for example, by applying an adhesive to the outer portion and then pushing the object into the pipeline, it can be easily fixed without the need for a support member or the like. In addition, in places where the water flow is weak, it can be attached to the pipeline just by pushing the object into the pipeline without the need for adhesive. In that case, the object W can be slid to any position by hand or a tool to move the installation position, and the labor and cost can be saved by not using adhesive.

[0083] As an example, the shaped object W can be used as a mesh or filter material for separating impurities in a cultivation tank by forming the shaped object W using a material that is resistant to dirt (has dirt resistance) and is placed in the piping of a plant factory where water is circulated and the nutrient solution is reused. In particular, the shaped object W of this embodiment can be easily formed into a shape that has symmetry (no directionality), so that it can be easily attached without making a mistake in the installation direction. Furthermore, if the shaped object W is formed with dimensions that match the existing piping, it can be easily applied to plant factories where the piping cannot be easily changed (the flow of water cannot be easily stopped), and if it is formed to the desired size, it can be easily attached horizontally to the piping. Furthermore, since the loop shape of the shaped part W1 can be used as a hook part or a grip part, it is easy to attach and replace even when it is installed deep inside the piping, so it can be easily used as a filter material that requires frequent replacement and maintenance.

[0084] Furthermore, although an example of integer coefficients has been shown for equation (1), the present invention is not limited to this, and examples in which coefficients d to f are not integers are also included in the present embodiment.

[0085] Thus, according to this embodiment, by having the shaped portion W1 (shaped object W) having a curved structure with a loop shape defined based on a torus knot, it is possible to support weight with a compressive force, and it is flexible and elastic, and it is possible to freely connect the shaped portion W1, thereby further improving the degree of freedom in shaping. In addition, because it has a curved structure, it is easier to grip than a linear structure, and because there are no corners, it is also safer.

[0086] By utilizing equation (1), which is a continuous function, and appropriately selecting the coefficients a to f, it becomes possible to manufacture the shaped portion W1, i.e., the object W, into any shape, which has a complex shape and whose shape varies greatly depending on the viewing angle, and it is also possible to easily increase the shape variations of the shaped portion W1, i.e., the object W.

[0087] Furthermore, compared to a structure in which linear lattice structures are regularly connected, when multiple shaped parts W1 are connected by crossing each other in a loop shape, the connection positions can be set arbitrarily, and by providing connecting parts with various properties by appropriately selecting the shaping material, it is possible to set the performance of the shaped object W. For example, by providing thickness to the connecting parts at arbitrary points, it is possible to provide a shaped object W with excellent impact resistance.

[0088] The above-mentioned forming part W1 (model W) has a loop shape defined based on a torus knot K (an example of which is shown in FIG. 2), which is a smooth curve that wraps around the surface of a virtual torus T (shown in FIG. 2), and therefore has a shape that does not include overhanging parts that require support materials or bridge parts that extend in a direction horizontal to the modeling table surface, and can be manufactured without supports using the 3D printer 1. Furthermore, when a model W is constructed by connecting multiple forming parts W1, it becomes possible to manufacture a more complex shape without supports.

[0089] For example, as a condition for forming the forming portion W1 (object W) without support in three-axis modeling as in the 3D printer 1 of this embodiment, when the angle between the central axis of the nozzle 11 and the modeling table 5 is 90°, it is desirable that the rising angle of the forming portion W1 (object W) is 45°, but this is not limited thereto, and it was confirmed that the forming is possible if the rising angle is at least 6.5° with respect to the modeling table 5 (FIG. 33 shows a reference example, and FIG. 34 shows a photograph of a manufacturing example). Also, in the case of the 3D printer 1 for six-axis modeling, it was confirmed that all of the forming portions W1 and objects W described above can be formed without support (FIGS. 35 and 36 show photographs of manufacturing examples).

[0090] In addition, the fused deposition model 3D printer, which is an object manufacturing device for producing (shaping) the various objects (models) described above, may be a large pellet-type 3D printer with a nozzle diameter φ of 10 mm or more, for example. In this large 3D printer, it is possible to use general pellet-type thermoplastic resin (which may be recycled pellet material, etc.) that is inexpensively obtainable as the modeling material, rather than a dedicated filament resin.

[0091] Furthermore, the object manufacturing device is not limited to a fused deposition model 3D printer, but may be, for example, a stereolithography (DLP or SLA) 3D printer.

[0092] Furthermore, the object manufacturing device is not limited to a configuration in which a modeling head (discharging means) having a nozzle for discharging the modeling material can move in the X-axis direction and the Z-axis direction and the modeling table can move in the Y-axis direction, but may be configured so that the modeling head can move at least three-dimensionally relative to the modeling table. For example, the modeling head may be configured so that the modeling table can move in the Z-axis direction, or the modeling head may be provided at the tip of a robot arm (preferably a robot arm of a six-axis robot) and can move in any direction including the three directions of the X-axis direction, the Y-axis direction, and the Z-axis direction. Since support-less modeling is possible with a three-axis modeling or six-axis modeling 3D printer, the lack of support leads to a reduction in modeling time (improvement in modeling speed of the object W). For example, if the object manufacturing device is a six-axis modeling device, when the nozzle 11 does not interfere with the modeling unit W1 (object W), it is possible to trace a torus knot, which is a continuous function, in one stroke, and therefore the modeling speed of the object W is improved. [Explanation of symbols]

[0093] 1. Fused deposition modeling 3D printer, a machine for manufacturing objects 5. Modeling table 15 lines 16 Surface 21 Cross-sectional shape 22 Side edge D Modeling data K-torus knot W sculpture W1 Modeling Department

Claims

1. A shaped object manufactured by a shaped object manufacturing apparatus, comprising: A shaped portion having a loop shape defined based on a torus knot, The shaping portion forms at least a part of a unit shape of the shaped object, and is configured by connecting a plurality of the shaping portions. A structure characterized by the above.

2. The multiple shaped portions are connected so that the loop shapes intersect with each other.

2. The object according to claim 1 .

3. The multiple shaped portions are connected so that the closed loop shapes do not intersect with each other.

2. The object according to claim 1 .

4. The multiple shaping portions are of the same shape or mirror image shape.

2. The object according to claim 1 .

5. The multiple molded parts have different sizes and shapes.

2. The object according to claim 1 .

6. A method for designing a shaped object according to claim 1, comprising the steps of: The modeling data for the modeling part is formed by setting a thickness to the surface that is connected by a line between two adjacent torus knots. A method for designing a molded object comprising the steps of:

7. A method for designing a shaped object according to claim 1, comprising the steps of: The modeling data for the modeling part is formed by sweeping a predetermined cross-sectional shape along a loop-shaped torus knot. A method for designing a molded object comprising the steps of:

8. A model is manufactured by a model manufacturing device based on modeling data formed by the model design method of claim 6 or 7. A method for manufacturing a shaped object, comprising:

9. The modeling device is a 3D modeling device using the fused deposition modeling method or the photolithography method.

9. The method for producing a shaped object according to claim 8.

Images