Three-dimensional object manufacturing apparatus

Abstract

To provide a three-dimensional molded article production device for producing a three-dimensional molded article by discharging liquid from a head to a powder layer, in which failure of liquid discharge is reduced.SOLUTION: A device 1 for producing a three-dimensional molded article has a molding table 9, layer forming parts 2 and 6 that form a powder layer 500, a head 3 that discharges liquid containing binder to a three-dimensional molded article molding region P, a liquid supply system 40 that supplies the liquid to the head 3, and movement systems 8 and 10 that move the head 3 relative to the molding table 9. The head 3 has a nozzle N that discharges the liquid, a pressure chamber 36 in communication with the nozzle N, supply channels 31, 37 and 45a in communication with the pressure chamber 36 at an upstream side in the liquid supply direction, and circulation channels 32, 38 and 45b in communication with the pressure chamber 36 at a downstream side in the supply direction. The circulation channels include a first filter F1, and a pore diameter of the first filter F1 is larger than a particle diameter of powder forming the powder layer.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing a three-dimensional object.

Background Art

[0002] Conventionally, various types of apparatuses for manufacturing three-dimensional objects have been used. Among these, there is an apparatus for manufacturing a three-dimensional object that forms a powder layer and discharges a liquid from a nozzle of a head onto a shaping region of the three-dimensional object in the powder layer to manufacture the three-dimensional object. For example, Patent Document 1 discloses a three-dimensional shaping apparatus that forms a layer of a powder material and discharges a curing liquid onto the layer from a nozzle of a line head to manufacture a three-dimensional object.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in an apparatus for manufacturing a three-dimensional object that discharges a liquid from a head onto a powder layer to manufacture the three-dimensional object, such as the three-dimensional shaping apparatus described in Patent Document 1, the powder for forming the powder layer may enter the head from the nozzle. When such powder enters the head, the liquid may thicken, which may cause poor discharge of the liquid.

Means for Solving the Problems

[0005] The manufacturing apparatus for a three-dimensional object of the present invention for solving the above problems includes a shaping table, a layer forming unit that forms a powder layer on the shaping table, a head that discharges a liquid containing a binder into a shaping region of the three-dimensional object in the powder layer, a liquid supply system that supplies the liquid to the head, and a movement system that relatively moves the head with respect to the shaping table. The head includes a nozzle that discharges the liquid, a pressure chamber that communicates with the nozzle, a supply flow path that communicates with the pressure chamber on the upstream side in the supply direction of the liquid, and a circulation flow path that communicates with the pressure chamber on the downstream side in the supply direction. The circulation flow path includes a first filter, and the pore diameter of the first filter is larger than the particle diameter of the powder forming the powder layer.

Brief Description of the Drawings

[0006]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0007] First, the present invention will be briefly described. The manufacturing apparatus for a three-dimensional shaped object according to the first aspect of the present invention for solving the above problems includes a shaping table, a layer forming unit that forms a powder layer on the shaping table, a head that discharges a liquid containing a binder into a shaping region of the three-dimensional shaped object in the powder layer, a liquid supply system that supplies the liquid to the head, and a movement system that relatively moves the head with respect to the shaping table. The head includes a nozzle that discharges the liquid, a pressure chamber that communicates with the nozzle, a supply flow path that communicates with the pressure chamber on the upstream side in the supply direction of the liquid, and a circulation flow path that communicates with the pressure chamber on the downstream side in the supply direction. The circulation flow path includes a first filter, and the pore diameter of the first filter is larger than the particle diameter of the powder forming the powder layer.

[0008] During the manufacturing of the head or the like, foreign matters generated during the manufacturing of the head may flow back from the circulation flow path into the pressure chamber, which may cause a decrease in the performance of the head. However, by providing the first filter in the circulation flow path as in this aspect, it is possible to suppress the backflow of foreign matters generated during the manufacturing of the head from the circulation flow path into the pressure chamber. Further, according to this aspect, the pore diameter of the first filter is larger than the particle diameter of the powder forming the powder layer. For this reason, it is possible to suppress the powder that has entered the head from the nozzle from passing through the first filter and continuously staying in the head, causing the liquid between the nozzle and the first filter to thicken continuously. Therefore, it is possible to suppress the thickening of the liquid in the head and suppress the poor discharge of the liquid.

[0009] The manufacturing apparatus for a three-dimensional shaped object according to the second aspect of the present invention is characterized in that, in the first aspect, the inner diameter of the nozzle is larger than the pore diameter of the first filter.

[0010] According to this aspect, the inner diameter of the nozzle is larger than the pore diameter of the first filter. For this reason, even if powder enters the head from the nozzle, it becomes possible to discharge the powder again through the nozzle.

[0011] The manufacturing apparatus of the three-dimensional object according to the third aspect of the present invention is characterized in that, in the first or second aspect, a second filter is provided at a position downstream of the first filter in the supply direction.

[0012] According to this aspect, a second filter is provided at a position downstream of the first filter in the supply direction. Therefore, the capturing performance of foreign matters contained in the liquid returning from the circulation flow path to the supply flow path can be enhanced.

[0013] The manufacturing apparatus of the three-dimensional object according to the fourth aspect of the present invention is characterized in that, in the third aspect, the pore diameter of the second filter is smaller than the particle diameter of the powder forming the powder layer.

[0014] According to this aspect, the pore diameter of the second filter is smaller than the particle diameter of the powder forming the powder layer. Therefore, the powder that has entered the head from the nozzle and passed through the first filter can be captured by the second filter.

[0015] The manufacturing apparatus of the three-dimensional object according to the fifth aspect of the present invention is characterized in that, in the third or fourth aspect, the second filter is replaceable.

[0016] According to this aspect, the second filter is replaceable. Therefore, when the performance of the second filter deteriorates due to clogging or the like, it can be easily restored to its original state.

[0017] The manufacturing apparatus of the three-dimensional object according to the sixth aspect of the present invention is characterized in that, in the fifth aspect, a flow rate sensor for the liquid is provided at a position downstream of the second filter in the supply direction in the circulation flow path, and when the flow rate sensor detects that the flow rate of the liquid is a flow rate equal to or lower than a threshold value, exchange information of the second filter is output.

[0018] According to this aspect, a liquid flow sensor is provided, and when the liquid flow rate is detected by the flow sensor to be equal to or less than a threshold value, exchange information of the second filter is output. Therefore, the user can easily recognize the proper replacement timing of the second filter.

[0019] The manufacturing apparatus of the three-dimensional object according to the seventh aspect of the present invention is characterized in that, in any one of the first to sixth aspects, a third filter having a pore diameter smaller than the particle diameter of the powder forming the powder layer is provided in the supply flow path.

[0020] According to this aspect, a third filter having a pore diameter smaller than the particle diameter of the powder forming the powder layer is provided in the supply flow path. Therefore, it is possible to suppress the powder that has entered the head from the nozzle from flowing backward in the supply flow path.

[0021] The manufacturing apparatus of the three-dimensional object according to the eighth aspect of the present invention is characterized in that, in any one of the first to seventh aspects, the bottom surface of the region adjacent to the pressure chamber in the circulation flow path is arranged at a position lower in the gravitational direction than the bottom surface of the region adjacent to the pressure chamber in the supply flow path.

[0022] According to this aspect, the bottom surface of the region adjacent to the pressure chamber in the circulation flow path is arranged at a position lower in the gravitational direction than the bottom surface of the region adjacent to the pressure chamber in the supply flow path. Since the powder that has entered the head from the nozzle tends to flow downward due to the influence of gravity, the powder is more likely to flow to the circulation flow path side than to flow backward to the supply flow path side. Therefore, it is possible to suppress the powder that has entered the head from the nozzle from flowing backward in the supply flow path.

[0023] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. [Example 1] First, the outline of the manufacturing apparatus 1 for the three-dimensional object of Example 1 will be described with reference to FIG. 1. Here, in FIG. 1 and each of the figures described later, the X direction in the figure is the horizontal direction and corresponds to the reciprocating movement direction of the supply unit 8. Among these, the X1 direction corresponds to the forward direction, and the X2 direction corresponds to the return direction. Further, the Y direction is the horizontal direction and is a direction orthogonal to the X direction, and corresponds to the direction in which the rotation axis of the roller 6 extends. Further, the Z direction is the vertical direction and corresponds to the stacking direction of the layer 500.

[0024] Note that the "three-dimensional modeling" in this specification indicates forming a so-called three-dimensional object, and includes, for example, forming a shape having a thickness even if it is a flat plate shape, a so-called two-dimensional shape.

[0025] The manufacturing apparatus 1 for the three-dimensional object of this example is a manufacturing apparatus for manufacturing a three-dimensional object by stacking the layer 500 composed of the layers 501, 502, 503, ···, 50n. And, as shown in FIG. 1, the manufacturing apparatus 1 for the three-dimensional object of this example includes a table unit 10 having a modeling table 9, a supply unit 8 for supplying the modeling material of the three-dimensional object to the modeling table 9, and a control unit 12 for controlling the operations of the table unit 10 and the supply unit 8. Note that the manufacturing apparatus 1 for the three-dimensional object is electrically connected to an external device 20 such as a personal computer, and is configured to be able to receive an instruction from a user via the external device 20.

[0026] The modeling table 9 is configured to be movable in the Z direction under the control of the control unit 12. The modeling surface 9a of the modeling table 9 is disposed at a position lower by a predetermined distance in the Z direction with respect to the upper surface portion 10a of the table unit 10, and the modeling material of the three-dimensional object is supplied from the supply unit 8 to the modeling surface 9a to form one layer of the layer 500. Then, the layer 500 is stacked by repeating the downward movement of the modeling table 9 by a predetermined distance and the supply of the modeling material of the three-dimensional object from the supply unit 8. FIG. 1 shows a state in which the formation of four layers, namely, the layers 501, 502, 503, and 504, is repeated to form the structure S of the three-dimensional object on the modeling surface 9a.

[0027] The supply unit 8 is configured to be movable in the X direction along the guide bar 11. The supply unit 8 is also provided with a shaping material supply unit 2 that supplies a shaping material containing powder such as metal, ceramics, or resin to the shaping table 9. Note that the shaping material supply unit 2 includes a shaping material supply unit 2A formed at the leading end side in the X1 direction and a shaping material supply unit 2B formed at the leading end side in the X2 direction.

[0028] The supply unit 8 is also provided with a roller 6 capable of compressing and leveling the shaping material supplied to the shaping table 9. Note that the roller 6 includes a roller 6A formed adjacent to the shaping material supply unit 2A in the X direction and a roller 6B formed adjacent to the shaping material supply unit 2B in the X direction. Here, the shaping material supply unit 2 and the roller 6 constitute a layer forming unit that forms a layer 500, which is a powder layer, on the shaping table 9. Note that the supply unit 8 may be provided with a squeegee capable of leveling the shaping material supplied to the shaping table 9 instead of the roller 6.

[0029] The supply unit 8 is also provided with a head 3 that discharges a liquid containing a binder that binds the powder contained in the shaping material supplied from the shaping material supply unit 2 into the shaping region P of the three-dimensional shaped object. Note that the head 3 includes a head 3A formed adjacent to the roller 6A in the X direction and a head 3B formed adjacent to the roller 6B in the X direction. Details of the detailed configuration of the head 3 and the configuration of the liquid supply system 40 represented in FIG. 2 for supplying liquid to the head 3 will be described later. Note that the liquid discharged from the head 3 does not necessarily have to contain a binder, and the shaping material supplied from the shaping material supply unit 2 may be configured to contain a binder.

[0030] Here, the liquids discharged from the heads 3A and 3B are the same liquid, and both are liquids containing an ultraviolet curable resin as a binder. However, it is not limited to such a liquid, and a liquid containing a thermosetting resin as a binder, a liquid in a state where a solid resin as a binder is dissolved in a volatile solvent, etc. may be used. Further, in the supply unit 8, temperature sensors 7 for detecting the temperature of the nozzles of the head 3 are provided corresponding to the heads 3A and 3B.

[0031] And, between the heads 3A and 3B in the X direction, an ultraviolet irradiation unit 4 for irradiating ultraviolet rays capable of curing the ultraviolet curable resin is provided. Note that the supply unit 8 of the present embodiment has a configuration including one ultraviolet irradiation unit 4, but depending on the configuration including two or more ultraviolet irradiation units 4, the type of liquid used, etc., a configuration not including the ultraviolet irradiation unit 4, a configuration including a heater for curing a thermosetting resin or volatilizing a solvent instead of the ultraviolet irradiation unit 4, etc. may be used.

[0032] As shown in FIG. 1, the supply unit 8 of the present embodiment has a symmetric shape of the constituent members in the X direction. For this reason, the three-dimensional modeling apparatus 1 of the present embodiment can execute the modeling operation of the three-dimensional model while moving the supply unit 8 in the X1 direction, and can execute the modeling operation of the three-dimensional model while moving the supply unit 8 in the X2 direction.

[0033] Further, as shown in FIG. 1, in the three-dimensional modeling apparatus 1 of the present embodiment, a liquid receiving portion 5 is provided in the table unit 10, and it is possible to execute a flushing operation by discharging a liquid from the head 3 at a position facing the liquid receiving portion 5. That is, the position facing the liquid receiving portion 5 is the flushing position, and for this reason, naturally, the flushing position is a position different from the modeling region P of the three-dimensional model. Note that the liquid receiving portion 5 includes a liquid receiving portion 5A and a liquid receiving portion 5B.

[0034] As described above, the manufacturing apparatus 1 for the three-dimensional object of the present embodiment includes a shaping table 9, a shaping material supply unit 2 and a roller 6 as a layer forming unit that forms a layer 500 which is a powder layer on the shaping table 9, a head 3 that discharges a liquid containing a binder from a nozzle to a shaping region P of the three-dimensional object in the layer 500, a supply unit 8 and a table unit 10 as a moving system that relatively moves the head 3 with respect to the shaping table 9, a control unit 12 that controls the movement of the head 3 with respect to the shaping table 9 and the driving of the head 3 by applying a voltage. Further, a liquid supply system 40 that supplies liquid to the head 3 is provided.

[0035] Hereinafter, the liquid supply system 40 will be described in detail with reference to FIG. 2. The liquid supply system 40 shown in FIG. 2 is composed of a circulation unit 41 including a supply flow path 45a for supplying liquid to the head 3, and a replenishment unit 42 including a liquid replenishment flow path 45d for replenishing liquid to the circulation unit 41.

[0036] The circulation unit 41 has the head 3, a liquid tank 43a for pressure control, a liquid tank 43b for vacuum control, a pump 44a for pressure control, a pump 44b for vacuum control, a pump 44c for flow, and a solenoid valve V1. Further, the circulation unit 41 has a supply flow path 45a connecting the liquid tank 43a for pressure control and the head 3, a first circulation flow path 45b connecting the head 3 and the liquid tank 43b for vacuum control, and a second circulation flow path 45c connecting the liquid tank 43a for pressure control and the liquid tank 43b for vacuum control. Here, a filter F2 and a flow rate sensor 46 for detecting the flow rate of the liquid flowing in the first circulation flow path 45b are provided in the first circulation flow path 45b.

[0037] Differential pressure control is performed by the liquid tank 43a for pressure control, the pump 44a for pressure control, the liquid tank 43b for vacuum control, and the pump 44b for vacuum control so that a slightly negative pressure is applied to the nozzle N of the head 3 represented in FIG. 6 from the atmospheric pressure.

[0038] In the second circulation passage 45c for flowing a liquid from the decompression control liquid tank 43b, which is a decompression tank, to the pressurization control liquid tank 43a, which is a pressurization tank, a flow pump 44c and a solenoid valve V1 are installed. When the liquid discharge operation of the head 3 is executed, when supplying liquid to the head 3, the solenoid valve V1 is opened and the flow pump 44c is operated to circulate the liquid in the supply passage 45a, the first circulation passage 45b, and the second circulation passage 45c.

[0039] The replenishment unit 42 includes an exchangeable liquid cartridge 43c containing a liquid, a flow pump 44d, and a solenoid valve V2. The replenishment unit 42 also has a liquid replenishment passage 45d connecting the pressurization control liquid tank 43a and the liquid cartridge 43c. When replenishing the liquid from the liquid cartridge 43c to the pressurization control liquid tank 43a, the solenoid valve V2 is opened and the flow pump 44d is operated to flow the liquid in the liquid replenishment passage 45d.

[0040] Here, in the three-dimensional object manufacturing apparatus 1 of the present embodiment, a configuration is adopted in which one liquid supply system 40 is provided for each of the heads 3A and 3B. However, for example, the head 3A may be connected to the first circulation passage 45b via the head 3B, so that one liquid supply system may also serve as the liquid supply systems for both the heads 3A and 3B. That is, one liquid supply system may be configured to correspond to a plurality of heads. At this time, the supply port 33 of the head 3B described later is connected to the discharge port 34 of the head 3A described later. In such a configuration, it is possible to suppress the powder that has entered the head from the nozzle of the head 3A from entering the head 3B.

[0041] Next, specific examples of the modeling material that constitutes the powder layer 500, which can be used in the three-dimensional object manufacturing apparatus 1 of this embodiment, will be described. As the metal powder that can be contained in the modeling material, for example, simple powders of magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or alloys containing one or more of these metals (maraging steel, stainless steel (SUS), cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy) powders, or mixed powders thereof can be used.

[0042] In addition, as the ceramic powder that can be contained in the modeling material, for example, silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, silicon nitride, etc. can be preferably used.

[0043] In addition, as the resin powder that can be contained in the modeling material, or as the binder contained in the liquid ejected from the head 3, for example, PMMA (acrylic), ABS (acrylonitrile-butadiene-acrylic ester), ASA (acrylonitrile-styrene-acrylic ester), PLA (polylactic acid), PEI (polyetherimide), PC (polycarbonate), PP (polypropylene), PE (polyethylene), PA (polyamide), EP (epoxy), PPS (polyphenylene sulfide), PS (polystyrene), paraffin wax, PVA (polyvinyl alcohol), carboxymethyl cellulose, polyoxymethylene, polymethyl methacrylate, etc. can be preferably used. Also, for example, acrylic resins, epoxy resins, silicone resins, cellulose-based resins, or other synthetic resins, etc. can be used alone or in combination. Furthermore, thermoplastic resins, and ultraviolet curable resins of the type using radical polymerization of unsaturated double bonds such as acrylic, or the type using cationic polymerization such as epoxy can also be used.

[0044] In addition, examples of the solvent contained in the liquid discharged from the head 3 include water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetic acid esters such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and isobutyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine solvents such as pyridine, γ-picoline, and 2,6-lutidine; ionic liquids such as tetraalkylammonium acetate (for example, tetrabutylammonium acetate, etc.). One or more selected from these can be used in combination.

[0045] Next, an example of a method for manufacturing a three-dimensional object that can be executed using the three-dimensional object manufacturing apparatus 1 will be described with reference to FIG. 3 and using the flowchart of FIG. 4. The method for manufacturing a three-dimensional object of the present embodiment represented by the flowchart of FIG. 4 is performed by the control unit 12 controlling each component of the three-dimensional object manufacturing apparatus 1 such as the supply unit 8 and the shaping table 9. Note that FIG. 3 shows an example when forming the layer 502 in the layer 500.

[0046] In the method for manufacturing a three-dimensional object of the present embodiment, as shown in FIG. 4, first, in the shaping data input step of step S110, the shaping data of the three-dimensional object to be manufactured is input. There is no particular limitation on the input source of the shaping data of the three-dimensional object, but the shaping data can be input into the three-dimensional object manufacturing apparatus 1 using the external device 20.

[0047] Next, in the pre-shaping flushing process of step S120, pre-shaping flushing of the head 3 is performed. Here, when moving the supply unit 8 in the X1 direction to form the layer 500, pre-shaping flushing of the head 3A is performed at a position facing the liquid receiving portion 5B. On the other hand, when moving the supply unit 8 in the X2 direction to form the layer 500, pre-shaping flushing of the head 3B is performed at a position facing the liquid receiving portion 5A. Note that the pre-shaping flushing process of this step S120 may be omitted.

[0048] Next, in the layer formation process of step S130, the shaping material is supplied from the shaping material supply unit 2 to the shaping surface 9a of the shaping table 9, and the layer 500 is formed by compressing and leveling the shaping material with the roller 6. The top state in FIG. 3 represents the state where the supply unit 8 is moved in the X1 direction to form the layer 502. Here, when moving the supply unit 8 in the X1 direction to form the layer 500, the shaping material is supplied from the shaping material supply unit 2A, and the layer 500 is formed by compressing and leveling the shaping material with the roller 6A. On the other hand, when moving the supply unit 8 in the X2 direction to form the layer 500, the shaping material is supplied from the shaping material supply unit 2B, and the layer 500 is formed by compressing and leveling the shaping material with the roller 6B.

[0049] Next, in the liquid discharge process of step S140, a liquid containing a binder is discharged from the nozzle N of the head 3 to the shaping region P of the three-dimensional shaped object in the layer 500. The second state from the top in FIG. 3 represents the state where the liquid is being discharged from the nozzle N of the head 3 to the shaping region P of the layer 502 while moving the supply unit 8 in the X1 direction. Here, when moving the supply unit 8 in the X1 direction to form the layer 500, the liquid is discharged from the head 3A. On the other hand, when moving the supply unit 8 in the X2 direction to form the layer 500, the liquid is discharged from the head 3B.

[0050] Next, in the ultraviolet irradiation step of step S150, ultraviolet rays are irradiated from the ultraviolet irradiation unit 4 toward the shaping region P of the three-dimensional object in layer 500. The bottom state in FIG. 3 represents a state where ultraviolet rays are being irradiated from the ultraviolet irradiation unit 4 toward the shaping region P of the three-dimensional object in layer 502 while moving the supply unit 8 in the X1 direction.

[0051] Next, in the flushing step of step S160, the head 3 is flushed. Here, when moving the supply unit 8 in the X1 direction to form layer 500, the head 3A is flushed at a position facing the liquid receiving portion 5A. On the other hand, when moving the supply unit 8 in the X2 direction to form layer 500, the head 3B is flushed at a position facing the liquid receiving portion 5B.

[0052] Then, in the step of determining whether the shaping data is finished in step S170, in the control unit 12 of the three-dimensional object manufacturing apparatus 1, it is determined whether the formation of layer 500 based on the shaping data input in step S110 has all been completed. If it is determined that the formation of layer 500 has not all been completed, the process returns to the pre-shaping flushing step of step S120 to form the next layer 500. On the other hand, if it is determined that the formation of layer 500 has all been completed, the process proceeds to the degreasing step of step S180.

[0053] In the degreasing step of step S180, the resin component of the structure S manufactured by repeating the pre-shaping flushing step of step S120 to the step of determining whether the shaping data is finished in step S170, such as a binder, is degreased using an external device or the like. Note that the degreasing method includes a method of volatilizing the resin component by heating, a method of immersing the structure S in a solvent to dissolve the resin component, etc., but there is no particular limitation. Note that, depending on the type of the three-dimensional object to be manufactured, such as when manufacturing a resin three-dimensional object, the degreasing step of this step S180 may be omitted.

[0054] Then, in the sintering step of step S190, the structure S that has been degreased in the degreasing step of step S180 is heated using an external device or the like to sinter the shaping material. Even if a resin component such as a binder of the structure S remains after the degreasing step of step S180, the resin component is removed with the execution of the sintering step of this step S190. Then, with the completion of the sintering step of this step S190, the method for manufacturing the three-dimensional shaped object of this embodiment is terminated. Note that, similar to the degreasing step of step S180, depending on the type of the three-dimensional shaped object to be manufactured, etc., the sintering step of this step S190 may be omitted.

[0055] Next, a detailed configuration of the head 3 will be described with reference to FIGS. 5 to 7. Here, the head 3A and the head 3B have the same structure. Therefore, the following description applies to both the head 3A and the head 3B. Note that the solid arrows in FIG. 7 represent the direction in which the liquid flows inside the head 3.

[0056] As shown in FIG. 5, the head 3 is connected to a supply flow path 45a and a first circulation flow path 45b. The supply flow path 45a as a supply flow path for supplying liquid inside the head 3, and the first circulation flow path 45b as a circulation flow path for once discharging the liquid inside the head 3 to the outside and circulating it, can be regarded as constituting a part of the head 3. In other words, the head 3 includes the supply flow path 45a and the first circulation flow path 45b. The supply flow path 45a is connected to the supply port 33, and the first circulation flow path 45b is connected to the discharge port 34.

[0057] As shown in FIGS. 5 to 7, the head 3 has a supply liquid chamber 31 having a supply port 33, and the liquid is sent from the supply flow path 45a to the supply liquid chamber 31 through the supply port 33. Also, as shown in FIGS. 6 and 7, the head 3 has an individual supply flow path 37 communicating with the supply liquid chamber 31 via a filter F3, and the liquid supplied to the supply liquid chamber 31 is sent to the individual supply flow path 37.

[0058] As shown in FIGS. 5 and 7, the head 3 has a piezoelectric element 35 that deforms along the Z direction by applying a voltage. The piezoelectric element 35 is disposed in a space on the side opposite to the pressure chamber 36 with the diaphragm D interposed therebetween in the Z direction. As shown in FIGS. 6 and 7, the pressure chamber 36 communicates with the individual supply flow path 37, and the liquid is sent from the individual supply flow path 37 to the pressure chamber 36. Further, a nozzle N communicates with the pressure chamber 36. When the piezoelectric element 35 deforms, the volume of the pressure chamber 36 contracts, and the liquid in the pressure chamber 36 is pressurized, so that the liquid is discharged from the nozzle N. Note that the lower side in FIG. 7 is the vertically downward direction, and the discharge direction of the liquid from the nozzle N is the vertically downward direction corresponding to the gravitational direction.

[0059] As described above, the three-dimensional object manufacturing apparatus 1 of the present embodiment includes the liquid supply system 40 shown in FIG. 2, and circulates and supplies the liquid to be supplied to the head 3. Therefore, in order to circulate the liquid once sent to the pressure chamber 36, the pressure chamber 36 also communicates with an individual circulation flow path 38 in addition to the individual supply flow path 37. The individual circulation flow path 38 communicates with the circulation liquid chamber 32 having a discharge port 34 via a filter F1. The three-dimensional object manufacturing apparatus 1 of the present embodiment circulates the liquid by flowing the liquid through the supply flow path 45a, the supply liquid chamber 31, the individual supply flow path 37, the pressure chamber 36, the individual circulation flow path 38, the circulation liquid chamber 32, and the first circulation flow path 45b inside the head 3.

[0060] As described above, the head 3 includes a nozzle N that discharges liquid, a pressure chamber 36 that communicates with the nozzle N, a supply channel 45a as a supply channel that communicates with the pressure chamber 36 on the upstream side in the liquid supply direction, a supply liquid chamber 31 and an individual supply channel 37, an individual circulation channel 38 as a circulation channel that communicates with the pressure chamber 36 on the downstream side in the liquid supply direction, a circulation liquid chamber 32 and a first circulation channel 45b. Further, a filter F1 as a first filter is provided in the circulation channel, and a filter having a pore diameter larger than the particle diameter of the powder forming the powder layer is used as the filter F1. Note that the "liquid supply direction" includes the direction in which the liquid flows from the supply channel 45a side to the pressure chamber 36 side, and also the direction in which the liquid flows from the pressure chamber 36 side to the first circulation channel 45b side. That is, the liquid supply direction corresponds to the liquid circulation direction in the circulation unit 41. Also, the "pore diameter" can be, for example, the maximum diameter of the pores, and catalog values of the filter can be adopted. Further, the "particle diameter" can be, for example, the maximum particle diameter of the powder, and values measured by laser diffraction or scattering methods can be adopted. In addition, values measured by observing the powder with an electron microscope can also be adopted.

[0061] When manufacturing the head 3, foreign matter generated during the manufacturing process of the head 3 may flow backward from the circulation channel into the pressure chamber 36, which may cause a decline in the performance of the head 3. However, by providing the filter F1 in the circulation channel as in the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment, it is possible to suppress the backward flow of foreign matter generated during the manufacturing of the head 3 from the circulation channel into the pressure chamber 36. Further, as in the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment, in a configuration where a powder layer is formed and liquid is discharged from the nozzle N of the head 3 onto the powder layer, the powder for forming the powder layer may enter the inside of the head 3 from the nozzle N. When powder enters the inside of the head 3, thickening of the liquid may occur, which may cause poor discharge of the liquid. However, the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment is provided with the filter F1 in the circulation channel, and the pore diameter of the filter F1 is larger than the particle diameter of the powder for forming the powder layer. Therefore, in the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment, it is possible to suppress the powder that has entered the head 3 from the nozzle N from passing through the filter F1 and continuously staying in the head 3, causing the liquid to continuously thicken between the nozzle N and the filter F1. Therefore, the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment can suppress the thickening of the liquid in the head 3 and suppress poor discharge of the liquid.

[0062] Here, the inner diameter of the nozzle N is larger than the pore diameter of the filter F1. Therefore, even if powder enters the head 3 from the nozzle N in the manufacturing apparatus 1 of the three-dimensional molded object of the present embodiment, the powder can be discharged again through the nozzle N in the pre-molding flushing process, the liquid discharge process, the flushing process, etc.

[0063] Further, as shown in FIG. 2, the three-dimensional object manufacturing apparatus 1 of the present embodiment includes a filter F2 in the first circulation channel 45b. In other words, the three-dimensional object manufacturing apparatus 1 of the present embodiment includes a filter F2 as a second filter at a position downstream of the filter F1 in the liquid supply direction. Therefore, the foreign matter capturing performance of the liquid returning from the circulation channel to the supply channel is enhanced. As described above, in the three-dimensional object manufacturing apparatus 1 of the present embodiment, the first circulation channel 45b is provided with a filter F2 at a position downstream of the filter F1 in the liquid supply direction in the circulation channel. However, the present invention is not limited to such a configuration. For example, the second circulation channel 45c, the liquid tank 43a for pressure control, or the liquid tank 43b for decompression control may be provided with the filter F2.

[0064] Here, the pore diameter of the filter F2 is smaller than the particle diameter of the powder forming the powder layer. Therefore, the three-dimensional object manufacturing apparatus 1 of the present embodiment is configured to be able to capture the powder that has entered the head 3 from the nozzle N and passed through the filter F1 with the filter F2.

[0065] The filter F2 can be removed from the first circulation channel 45b, and the user can easily replace it with a new filter F2. Therefore, when the filter F2 becomes clogged and its performance as a filter deteriorates, the user can easily restore it to its original state.

[0066] Here, as shown in FIG. 2, the three-dimensional object manufacturing apparatus 1 of the present embodiment includes a flow rate sensor 46 in the first circulation channel 45b. Specifically, the flow rate sensor 46 is provided at a position downstream of the filter F2 in the liquid supply direction in the first circulation channel 45b. When the control unit 12 detects that the flow rate of the liquid is equal to or lower than a preset threshold value by the flow rate sensor 46, the control unit 12 outputs the replacement information of the filter F2 to a PC or the like as an external device 20. Therefore, the user using the three-dimensional object manufacturing apparatus 1 of the present embodiment can easily recognize the appropriate replacement timing of the filter F2.

[0067] Further, as shown in FIG. 7, the three-dimensional object manufacturing apparatus 1 of the present embodiment includes a filter F3 as a third filter at a position between a supply liquid chamber 31 and an individual supply channel 37 that together form a supply channel. Here, the pore diameter of the filter F3 is smaller than the particle diameter of the powder forming the powder layer. In this way, since the three-dimensional object manufacturing apparatus 1 of the present embodiment includes the filter F3 having a pore diameter smaller than the particle diameter of the powder forming the powder layer in the supply channel, it is possible to suppress the powder that has entered the head 3 from the nozzle N from flowing back through the supply channel.

[0068] [Embodiment 2] Hereinafter, the three-dimensional object manufacturing apparatus 1 of Embodiment 2 will be described with reference to FIG. 8. Note that FIG. 8 is a diagram corresponding to FIG. 7 in the three-dimensional object manufacturing apparatus 1 of Embodiment 1, and the solid arrows in FIG. 8 represent the direction in which the liquid flows inside the head 3. In FIG. 8, the constituent members common to the above-described Embodiment 1 are denoted by the same reference numerals, and detailed descriptions thereof are omitted.

[0069] Here, in the three-dimensional object manufacturing apparatus 1 of the present embodiment, the configuration other than the head 3 is the same as that of the three-dimensional object manufacturing apparatus 1 of the embodiment. Further, the head 3 of the present embodiment has a supply liquid chamber 31 having a supply port 33, similar to the head 3 of Embodiment 1, and the liquid is sent from the supply channel 45a to the supply liquid chamber 31 through the supply port 33. And the head 3 of the present embodiment has an individual supply channel 37 communicating with the supply liquid chamber 31 via the filter F3, similar to the head 3 of Embodiment 1, and the liquid supplied to the supply liquid chamber 31 is sent to the individual supply channel 37.

[0070] The head 3 of this embodiment, similar to the head 3 of Embodiment 1, as shown in FIG. 8, has a piezoelectric element 35 that deforms along the Z direction by applying a voltage. A pressure chamber 36 is formed at a position facing the piezoelectric element 35 in the Z direction via a diaphragm D. As shown in FIG. 8, the pressure chamber 36 communicates with an individual supply flow path 37, and the liquid is sent from the individual supply flow path 37 to the pressure chamber 36. Further, a nozzle N communicates with the pressure chamber 36. When the piezoelectric element 35 deforms, the pressure chamber 36 is vibrated by the diaphragm D, and the liquid in the pressure chamber 36 is pushed and pressurized, so that the liquid is discharged from the nozzle N. Note that the lower side in FIG. 8 is the vertically downward direction, and the discharge direction of the liquid from the nozzle N is the vertically downward direction corresponding to the gravitational direction.

[0071] Similar to the three-dimensional object manufacturing apparatus 1 of Embodiment 1, the three-dimensional object manufacturing apparatus 1 of this embodiment includes a liquid supply system 40 shown in FIG. 2, and circulates and supplies the liquid to be supplied to the head 3. Therefore, in order to circulate the liquid once sent to the pressure chamber 36, the pressure chamber 36 communicates with an individual circulation flow path 38 in addition to the individual supply flow path 37. The individual circulation flow path 38 communicates with a circulation liquid chamber 32 having a discharge port 34 via a filter F1. That is, similar to the three-dimensional object manufacturing apparatus 1 of Embodiment 1, the three-dimensional object manufacturing apparatus 1 of this embodiment circulates the liquid by flowing the liquid through a supply flow path 45a, a supply liquid chamber 31, an individual supply flow path 37, a pressure chamber 36, an individual circulation flow path 38, a circulation liquid chamber 32, and a first circulation flow path 45b inside the head 3.

[0072] As shown in FIG. 7, in the head 3 of Embodiment 1, the position of the bottom surface 37b of the individual supply flow path 37 and the position of the bottom surface 38b of the individual circulation flow path 38 in the Z direction were substantially the same. On the other hand, as shown in FIG. 8, in the head 3 of this embodiment, the position of the bottom surface 38b of the individual circulation flow path 38 in the Z direction is lower than the position of the bottom surface 37b of the individual supply flow path 37 in the Z direction.

[0073] In other words, in the manufacturing apparatus 1 for a three-dimensional object of the present embodiment, the bottom surface 38b of the individual circulation channel 38, which is a region adjacent to the pressure chamber 36 in the circulation channel, is arranged at a lower position in the gravitational direction than the bottom surface 37b of the individual supply channel 37, which is a region adjacent to the pressure chamber 36 in the supply channel. Here, the powder that has entered the head 3 from the nozzle N tends to flow downward due to the influence of gravity. Therefore, with such a configuration, the powder that has entered the head 3 from the nozzle N is more likely to flow toward the circulation channel side than to flow backward toward the supply channel side. Thus, the manufacturing apparatus 1 for a three-dimensional object of the present embodiment can suppress the powder that has entered the head 3 from the nozzle N from flowing backward through the supply channel.

[0074] The present invention is not limited to the above-described embodiments, and can be realized in various configurations without departing from the gist thereof. For example, the technical features in the embodiments corresponding to the technical features in each form described in the summary of the invention can be appropriately replaced or combined in order to solve some or all of the above-described problems, or to achieve some or all of the above-described effects. Further, if the technical feature is not described as essential in this specification, it can be appropriately deleted.

Explanation of Reference Numerals

[0075] 1... Manufacturing apparatus for three-dimensional object, 2... Modeling material supply unit (layer forming unit), 2A... Modeling material supply unit (layer forming unit), 2B... Modeling material supply unit (layer forming unit), 3... Head, 3A... Head, 3B... Head, 4... Ultraviolet irradiation unit, 5... Liquid receiving part, 5A... Liquid receiving part, 5B... Liquid receiving part, 6... Roller (layer forming unit), 6A... Roller (layer forming unit), 6B... Roller (layer forming unit), 7... Temperature sensor, 8... Supply unit (moving system), 9... Modeling table, 9a... Modeling surface, 10... Table unit (moving system), 10a... Upper surface part, 11... Guide bar, 12… Control unit, 20… External device, 31… Supply liquid chamber (supply flow path), 32… Circulation liquid chamber (circulation flow path), 33… Supply port, 34… Drain port, 35… Piezoelectric element, 36… Pressure chamber, 37… Individual supply flow path (supply flow path), 37a… Bottom surface, 38… Individual circulation flow path (circulation flow path), 38b… Bottom surface, 40… Liquid supply system, 41… Circulation section, 42… Supplementary section, 43a… Liquid tank for pressure control, 43b… Liquid tank for vacuum control, 43c… Liquid cartridge, 44a… Pump for pressure control, 44b… Pump for vacuum control, 44c… Pump for flow, 44d… Pump for flow, 45a… Supply flow path, 45b… First circulation flow path (common circulation flow path), 45c… Second circulation flow path, 45d… Liquid replenishment flow path, 46… Flow sensor, 500… Layer (powder layer), 501, 502, 503, ··· 50n… Layers, D… Diaphragm, F1… Filter (first filter), F2… Filter (second filter), F3… Filter (third filter), N… Nozzle, P… Modeling area, S… Structure, V1… Solenoid valve, V2… Solenoid valve

Claims

1. A modeling table and a layer forming unit for forming a powder layer on the modeling table; a head that ejects a liquid containing a binder onto a modeling region of a three-dimensional object in the powder layer; a liquid supply system for supplying the liquid to the head; a movement system that moves the head relative to the modeling table; Equipped with the head includes a nozzle that ejects the liquid, a pressure chamber that communicates with the nozzle, a supply flow path that communicates with the pressure chamber on an upstream side in a supply direction of the liquid, and a circulation flow path that communicates with the pressure chamber on a downstream side in the supply direction, The supply flow path includes a filter; The apparatus for manufacturing a three-dimensional object, wherein the pore size of the filter of the supply flow path is smaller than the particle size of the powder that forms the powder layer.

2. The apparatus for manufacturing a three-dimensional object according to claim 1, An apparatus for manufacturing a three-dimensional object, wherein an inner diameter of the nozzle is larger than a particle diameter of the powder that forms the powder layer.

3. The apparatus for manufacturing a three-dimensional object according to claim 1 or 2, The apparatus for manufacturing a three-dimensional object, further comprising a filter provided in the circulation flow path.

4. The apparatus for manufacturing a three-dimensional object according to claim 3, The apparatus for manufacturing a three-dimensional object, wherein the pore size of a filter in the circulation flow path is smaller than the particle size of the powder that forms the powder layer.

5. The apparatus for manufacturing a three-dimensional object according to claim 3 or 4, The apparatus for manufacturing a three-dimensional object, wherein the filter of the circulation flow path is replaceable.

6. The apparatus for manufacturing a three-dimensional object according to claim 5, a flow rate sensor for the liquid is provided at a position downstream of a filter in the circulation flow path in the supply direction; The device for manufacturing a three-dimensional object, characterized in that, when the flow rate sensor detects that the flow rate of the liquid is equal to or lower than a threshold value, the device outputs information to replace a filter in the circulation flow path.

7. The apparatus for manufacturing a three-dimensional object according to any one of claims 1 to 6, a bottom surface of an area adjacent to the pressure chamber in the circulation flow path is positioned lower in the direction of gravity than a bottom surface of an area adjacent to the pressure chamber in the supply flow path.

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