Method for manufacturing a three-dimensional object and three-dimensional shaping apparatus

Abstract

To improve user convenience in a method for manufacturing a three-dimensional molded object in which a discharge port is cleaned.SOLUTION: A method for manufacturing a three-dimensional molded object includes: a first step of accepting a selection of a molding mode of the three-dimensional molded object; a second step, in which a molding material is discharged from a nozzle based on a molding data for molding the three-dimensional molded object, and the three-dimensional molded object is molded; and a third steps that controls nozzle cleaning according to the molding mode received in the first step.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a three-dimensional object and a three-dimensional shaping apparatus.

Background Art

[0002] Patent Document 1 discloses a three-dimensional shaping apparatus that blows air onto a nozzle of a shaping head to remove foreign matter adhering to the nozzle by the force of the air.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By cleaning the nozzle as described above, a three-dimensional object can be shaped with high precision. However, the accuracy required for three-dimensional objects varies, and if the nozzle is frequently cleaned during the shaping of a three-dimensional object that does not require such high accuracy, the shaping time may be prolonged, which may impair the convenience for the user.

Means for Solving the Problems

[0005] According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object. The manufacturing method includes a first step of receiving a designation of a shaping mode of the three-dimensional object, a second step of discharging a shaping material from a nozzle to shape the three-dimensional object based on shaping data for shaping the three-dimensional object, and a third step of controlling cleaning of the nozzle according to the shaping mode received in the first step.

[0006] According to a second aspect of the present disclosure, a three-dimensional modeling apparatus is provided. The three-dimensional modeling apparatus includes a modeling processing unit that discharges a modeling material from a nozzle to model the three-dimensional object based on modeling data for modeling the three-dimensional object, and a cleaning control unit that controls cleaning of the nozzle according to a specified modeling mode.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0008] A. First Embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling system 5 according to the first embodiment. The three-dimensional modeling system 5 includes a three-dimensional modeling apparatus 10 and an information processing apparatus 11. In FIG. 1, arrows along the X, Y, and Z directions orthogonal to each other are shown. The X, Y, and Z directions are directions along the X-axis, Y-axis, and Z-axis, which are three mutually orthogonal spatial axes, and each includes both the direction on one side along the X-axis, Y-axis, and Z-axis and the opposite direction. The X-axis and the Y-axis are axes along the horizontal plane, and the Z-axis is an axis along the vertical line. The -Z direction is the vertical direction, and the +Z direction is the direction opposite to the vertical direction. The -Z direction is also referred to as "down", and the +Z direction is also referred to as "up". The X, Y, and Z directions in FIG. 1 represent the same directions as the X, Y, and Z directions in other figures.

[0009] The information processing apparatus 11 is a computer including a CPU 12 as a control unit, a memory 13, and a storage device 14. The storage device 14 stores modeling data. The modeling data is data for modeling a three-dimensional object. The modeling data includes movement path information representing the movement path of a nozzle 60 provided in the three-dimensional modeling apparatus 10 and discharge amount information representing the discharge amount of the modeling material in the movement path. These pieces of information are described as various commands in the modeling data. The information processing apparatus 11 supplies the modeling data to the three-dimensional modeling apparatus 10, and the three-dimensional modeling apparatus 10 models a three-dimensional object based on the modeling data supplied from the information processing apparatus 11.

[0010] The CPU 12 provided in the information processing apparatus 11 functions as a reception unit 15 by reading and executing a predetermined program from the storage device 14 onto the memory 13. The reception unit 15 receives a designation of a modeling mode from a user via an input device provided in the information processing apparatus 11. The CPU 12 notifies the three-dimensional modeling apparatus 10 by adding the designated modeling mode to the modeling data.

[0011] The three-dimensional modeling apparatus 10 includes a discharge unit 100, a material storage unit 20, a housing 110, a drive unit 210, a stage 220, a cleaning mechanism 250, and a control unit 300.

[0012] The discharging unit 100 includes a plasticizing mechanism 30 that plasticizes at least a part of the raw material supplied from the material storage unit 20 to generate a modeling material, and a nozzle 60. The discharging unit 100 discharges the modeling material plasticized by the plasticizing mechanism 30 from the nozzle 60 toward the stage 220.

[0013] The three-dimensional modeling apparatus 10 of the present embodiment is provided with two discharging units 100. From the nozzle 60 of one discharging unit 100, a modeling material for modeling a three-dimensional model is discharged, and from the nozzle 60 of the other discharging unit 100, a support material for supporting an overhang portion of the three-dimensional model is discharged. The former nozzle 60 is hereinafter also referred to as the main nozzle, and the latter nozzle 60 is hereinafter also referred to as the support nozzle. Note that only one discharging unit 100 may be provided, or three or more discharging units 100 may be provided.

[0014] The housing 110 has a modeling space 111 inside. In the modeling space 111, a stage 220 on which a modeling material is laminated is disposed. The housing 110 may be provided with, for example, an opening that communicates the modeling space 111 with the outside, a door that opens and closes the opening, and the like. The user can take out the model modeled on the stage 220 through the opening by opening the door to open the opening.

[0015] The driving unit 210 changes the relative position between the ejection unit 100 and the stage 220. In the present embodiment, the driving unit 210 includes a first driving unit 211 that moves the stage 220 along the Z direction, and a second driving unit 212 that moves the ejection unit 100 along the X and Y directions. The first driving unit 211 is configured as a lifting device and includes a motor for moving the stage 220 in the Z direction. The second driving unit 212 is configured as a horizontal transfer device and includes a motor for sliding the ejection unit 100 along the X direction and a motor for sliding the ejection unit 100 along the Y direction. Each motor is driven under the control of the control unit 300. In other embodiments, the driving unit 210 may be configured to move the stage 220 or the ejection unit 100 in three directions of X, Y, and Z, or may be configured to move the stage 220 along the X and Y directions and move the ejection unit 100 in the Z direction.

[0016] The cleaning mechanism 250 has a brush 251 and a blade 252 for cleaning the nozzle 60. The cleaning mechanism 250 is arranged in a region different from the stage 220 in the horizontal direction. In the vertical direction, the cleaning mechanism 250 is arranged at a height where the brush 251 and the blade 252 can contact the nozzle 60. A purge waste container 260 is provided below the cleaning mechanism 250. Resin dust removed by the cleaning mechanism 250 drops into and is collected in the purge waste container 260. Note that the blade 252 is also called a flapper plate. The cleaning mechanism 250 is also called a chip wipe assembly. FIG. 1 shows an example in which a cleaning mechanism 250 and a purge waste container 260 are provided for each of the two ejection units 100, but the cleaning mechanism 250 and the purge waste container 260 may be provided in common for the two ejection units 100.

[0017] The control unit 300 is composed of a computer including a CPU 310 and a memory 320. The CPU 310 provided in the control unit 300 functions as a shaping processing unit 311 and a cleaning control unit 312 by executing a predetermined program on the memory 320. The shaping processing unit 311 controls the ejection unit 100 and the drive unit 210 based on the shaping data supplied from the information processing device 11, ejects the shaping material from the nozzle 60, and shapes a three-dimensional object. The cleaning control unit 312 controls the cleaning of the nozzle 60 using the cleaning mechanism 250 according to the shaping mode added to the shaping data. Note that the control unit 300 may be composed of a combination of a plurality of circuits instead of a computer.

[0018] FIG. 2 is a diagram showing a schematic configuration of the ejection unit 100. The ejection unit 100 includes a plasticizing mechanism 30, a nozzle 60, and a flow rate adjusting unit 70. The plasticizing mechanism 30 has a material conveying mechanism 40 and a heating block 90. The material accommodated in the material accommodating unit 20 is supplied to the ejection unit 100. The ejection unit 100 plasticizes at least a part of the material supplied from the material accommodating unit 20 by the plasticizing mechanism 30 to generate a shaping material under the control of the control unit 300, and injects and laminates the generated shaping material onto the stage 220 from the nozzle 60. In the present embodiment, "plasticization" is a concept including melting, and is to change from a solid state to a state having fluidity. Specifically, in the case of a material in which glass transition occurs, plasticization is to raise the temperature of the material above the glass transition point. In the case of a material in which glass transition does not occur, plasticization is to raise the temperature of the material above the melting point.

[0019] In the material accommodating unit 20 of the present embodiment, materials in the form of pellets, powders, etc. are accommodated. In the present embodiment, the material accommodated in the material accommodating unit 20 is pellet-shaped ABS resin. The material accommodating unit 20 of the present embodiment is composed of a hopper. The material accommodated in the material accommodating unit 20 is supplied to the material conveying mechanism 40 of the plasticizing mechanism 30 through a supply path 22 provided below the material accommodating unit 20 so as to connect the material accommodating unit 20 and the ejection unit 100.

[0020] The heating block 90 has a heater 58. The heater 58 is controlled by the control unit 300 and heated to a plasticizing temperature for plasticizing the material. The plasticizing temperature varies depending on the type of material used, and is, for example, the glass transition point or melting point of the material. If the material is an ABS resin, the plasticizing temperature is set to about 110°C, which is, for example, the glass transition point of the ABS resin. The heating block 90 is provided with a through hole 80. The through hole 80 is configured to be detachable from the nozzle 60. The material conveying mechanism 40 conveys the modeling material toward the nozzle flow path 61 of the nozzle 60 attached to the through hole 80 of the heating block 90. The plasticizing mechanism 30 plasticizes the material supplied from the material storage unit 20 to the material conveying mechanism 40 while conveying it toward the nozzle flow path 61 of the nozzle 60 by the material conveying mechanism 40 and heating it with the heat of the heating block 90.

[0021] The material conveying mechanism 40 of the present embodiment includes a screw case 31, a screw 41 accommodated in the screw case 31, and a drive motor 32 that drives the screw 41. The heating block 90 of the present embodiment includes a case portion 91 having an opening 94 and a barrel 50 disposed in the case portion 91. The barrel 50 is provided with a communication hole 56. The through hole 80 of the present embodiment is formed by the communication between the opening 94 and the communication hole 56. Further, the above-described heater 58 is built in the barrel 50. Note that the screw 41 of the present embodiment is a so-called flat screw and is sometimes referred to as a "scroll".

[0022] The screw 41 has a substantially cylindrical shape in which the height in the direction along its central axis RX is smaller than the diameter. The screw 41 has a groove forming surface 42 on the surface facing the barrel 50, and a screw groove 45 is formed on the groove forming surface 42. The groove forming surface 42 faces the screw facing surface 52 of the barrel 50 described later. Note that the central axis RX of the present embodiment coincides with the rotation axis of the screw 41. Details of the configuration of the screw 41 will be described later.

[0023] The drive motor 32 is connected to the surface of the screw 41 opposite to the groove forming surface 42. The drive motor 32 is driven under the control of the control unit 300. The screw 41 rotates about the central axis RX by the torque generated by the rotation of the drive motor 32. Note that the drive motor 32 may not be directly connected to the screw 41, and may be connected via a speed reducer, for example.

[0024] The barrel 50 has a screw facing surface 52 facing the groove forming surface 42 of the screw 41. The case portion 91 is disposed so as to cover the surface of the barrel 50 opposite to the screw facing surface 52, that is, the lower surface of the barrel 50. The above-described communication hole 56 and the opening 94 are provided at positions overlapping the central axis RX of the screw 41. That is, the through hole 80 is located at a position overlapping the central axis RX.

[0025] As described above, the nozzle 60 is detachably attached to the through hole 80 of the heating block 90. The nozzle 60 is also called a nozzle tip. The nozzle 60 is provided with the above-described nozzle flow path 61. The nozzle flow path 61 has a nozzle opening 63 at the tip of the nozzle 60 and an inlet 65 at the rear end of the nozzle 60. The nozzle opening 63 is located at the -Z direction position of the inlet 65. The nozzle 60 of the present embodiment discharges the material that has flowed into the nozzle flow path 61 through the communication hole 56 and the inlet 65 from the nozzle opening 63 toward the stage 220.

[0026] The flow rate adjustment unit 70 changes the opening degree of the nozzle flow path 61 by rotating within the nozzle flow path 61. In the present embodiment, the flow rate adjustment unit 70 is constituted by a butterfly valve. The flow rate adjustment unit 70 is driven by a valve drive unit 74 under the control of the control unit 300. The valve drive unit 74 is constituted by, for example, a stepping motor. The control unit 300 can adjust the flow rate of the modeling material flowing from the material conveyance mechanism 40 to the nozzle 60, that is, the flow rate of the modeling material discharged from the nozzle 60, by controlling the rotation angle of the butterfly valve using the valve drive unit 74. The flow rate adjustment unit 70 adjusts the flow rate of the modeling material and controls the on / off of the outflow of the modeling material.

[0027] FIG. 3 is a schematic perspective view showing the configuration on the groove formation surface 42 side of the screw 41. In FIG. 3, the position of the central axis RX of the screw 41 is indicated by a dashed line. As described above, screw grooves 45 are provided on the groove formation surface 42. The screw central portion 47, which is the central portion of the groove formation surface 42 of the screw 41, is configured as a depression to which one end of the screw groove 45 is connected. The screw central portion 47 faces the communication hole 56 of the barrel 50. The screw central portion 47 intersects the central axis RX.

[0028] The screw grooves 45 of the screw 41 constitute so-called scroll grooves. The screw grooves 45 extend spirally from the screw central portion 47 in an arc shape toward the outer periphery of the screw 41. The screw grooves 45 may be configured to extend in an involute curve shape or a spiral shape. On the groove formation surface 42, ridge portions 46 are provided that constitute the side wall portions of the screw grooves 45 and extend along each screw groove 45. The screw grooves 45 are continuous up to the material introduction port 44 formed on the side surface 43 of the screw 41. The material introduction port 44 is a portion that receives the material supplied through the supply path 22 of the material storage unit 20.

[0029] FIG. 3 shows an example of a screw 41 having three screw grooves 45 and three rib portions 46. The number of screw grooves 45 and rib portions 46 provided on the screw 41 is not limited to three, and only one screw groove 45 may be provided, or a plurality of two or more screw grooves 45 may be provided. Further, FIG. 3 shows an example of a screw 41 in which material inlets 44 are formed at three locations. The number of material inlets 44 provided on the screw 41 is not limited to three, and it may be provided at only one location, or may be provided at two or more locations.

[0030] FIG. 4 is a top view showing the configuration on the screw facing surface 52 side of the barrel 50. As described above, a communication hole 56 is formed at the center of the screw facing surface 52. A plurality of guide grooves 54 are formed around the communication hole 56 on the screw facing surface 52. Each guide groove 54 has one end connected to the communication hole 56 and extends in a spiral shape from the communication hole 56 toward the outer periphery of the screw facing surface 52. Each guide groove 54 has a function of guiding the modeling material to the communication hole 56. Note that one end of the guide groove 54 may not be connected to the communication hole 56. Further, the guide groove 54 may not be formed in the barrel 50.

[0031] FIG. 5 is an explanatory view showing a schematic configuration of the cleaning mechanism 250. As described above, the cleaning mechanism 250 has a brush 251 and a blade 252. The brush 251 is configured by arranging a plurality of tufts of hair along the Y direction. The blade 252 is a flat plate member along the Z direction and the Y direction. The tip of the brush 251 and the tip of the blade 252 face in the +Z direction. The tip of the blade 252 is disposed below the tip of the brush 251. As described above, the brush 251 and the blade 252 are disposed at a height at which they can contact the nozzle 60. In the present embodiment, the brush 251 and the blade 252 are integrated by a fixture 258 and can be replaced simultaneously when worn out. Note that the brush 251 and the blade 252 may be replaceable individually.

[0032] The cleaning mechanism 250 further includes a purge unit 253, which is also called a purge ledge. In this embodiment, the purge unit 253, the blade 252, and the brush 251 are arranged horizontally in this order. That is, the blade 252 is disposed between the purge unit 253 and the brush 251. The tip of the purge unit 253 in the +Z direction is lower than the tip of the blade 252. On the purge unit 253, the modeling material as waste material ejected from the nozzle 60 falls and is gathered into a spherical shape on the purge unit 253, and then falls into the purge waste container 260. The upper surface of the purge unit 253 is configured as an inclined surface to facilitate the fall of the waste material. More specifically, the purge unit 253 has a first inclined surface 254, a second inclined surface 255, and a third inclined surface 256 in the order from far away from the blade 252 and in the order of lower position in the vertical direction. In this embodiment, the inclination angles of the second inclined surface 255 and the third inclined surface 256 from the horizontal plane are larger than the inclination angle of the first inclined surface 254 from the horizontal plane.

[0033] Note that the cleaning mechanism 250 in this embodiment includes the brush 251, the blade 252, and the purge unit 253. However, for example, a configuration in which the purge unit 253 is omitted may also be used. Further, for example, the cleaning mechanism 250 may be configured to include only the brush 251 or only the blade 252.

[0034] FIG. 6 is an explanatory diagram schematically showing how a three-dimensional object is being formed in the three-dimensional forming apparatus 10. In the three-dimensional forming apparatus 10, as described above, in the discharge unit 100, the raw material in a solid state supplied to the screw groove 45 of the rotating screw 41 is melted to generate the forming material MM. The control unit 300 controls the drive unit 210 while maintaining the distance between the forming surface 221 on the stage 220 and the nozzle 60, and discharges the forming material MM from the nozzle 60 while changing the position of the nozzle 60 relative to the stage 220 in the direction along the forming surface 221 of the stage 220. The forming material MM discharged from the nozzle 60 is continuously deposited in the moving direction of the nozzle 60 to form a layer ML. After forming one layer ML, the control unit 300 lowers the stage 220 to move the position of the nozzle 60 relative to the stage 220 in the +Z direction. Then, a three-dimensional object is formed by stacking further layers ML on top of the layer ML formed so far.

[0035] The control unit 300 may, for example, move the nozzle 60 in the Z direction when one layer of the layer ML is completed, or may temporarily interrupt the discharge of the forming material from the nozzle 60 when there are a plurality of independent forming regions in each layer. In this case, the control unit 300 closes the nozzle flow path 61 by the flow rate adjustment unit 70 to stop the discharge of the forming material MM from the nozzle opening 63. After changing the position of the nozzle 60, the control unit 300 opens the nozzle flow path 61 by the flow rate adjustment unit 70 to resume the deposition of the forming material MM from the changed position of the nozzle 60.

[0036] FIG. 7 is a flowchart of a three-dimensional forming process representing a method for manufacturing a three-dimensional object. In step S100, the reception unit 15 of the information processing apparatus 11 receives a designation of a forming mode. Step S100 is also referred to as the first step. For example, the information processing apparatus 11 displays a plurality of forming modes on a display device connected to the information processing apparatus 11, and the user selects and designates a desired forming mode from among them using an input device such as a mouse.

[0037] In step S110, the information processing apparatus 11 adds the specified modeling mode to the modeling data stored in the storage device 14, and supplies the modeling data to the three-dimensional modeling apparatus 10. Adding the modeling mode specifically means adding an identifier representing the modeling mode to the modeling data.

[0038] In step S120, the modeling processing unit 311 of the three-dimensional modeling apparatus 10 executes modeling processing. In this modeling processing, the modeling processing unit 311 moves the nozzle 60 while discharging the modeling material from the nozzle 60 according to the modeling data supplied from the information processing apparatus 11, and laminates a plurality of layers to form a three-dimensional object. Step S120 is also referred to as the second step.

[0039] During the modeling process of step S120, the cleaning control unit 312 executes cleaning processing as step S125 according to the modeling mode represented by the identifier added to the modeling data. Step S125 is also referred to as the third step. In step S125, the cleaning control unit 312 performs nozzle cleaning based on the cleaning processing content pre-associated with the modeling mode.

[0040] FIG. 8 is a diagram showing the correspondence between the modeling mode and the cleaning processing content. In the present embodiment, the user can select a modeling mode from a plurality of modes including a mode related to the modeling accuracy of the three-dimensional object and a mode related to the modeling time of the three-dimensional object. FIG. 8 shows three modes: the high-definition mode, the standard mode, and the high-speed mode. The high-definition mode is a mode related to the modeling accuracy, and the high-speed mode is a mode related to the modeling time. The high-precision mode is a mode for modeling a three-dimensional object with higher accuracy than the high-speed mode and the standard mode. The high-speed mode is a mode for modeling a three-dimensional object at a higher speed than the high-precision mode and the standard mode. The user selects and specifies a desired mode from these three modes in step S100 above.

[0041] As the cleaning process details in each mode, the first cleaning timing, the second cleaning timing, the nozzles to be cleaned, the cleaning time, and the number of cleaning times are defined.

[0042] When the high-precision mode is specified as the shaping mode, the cleaning control unit 312 performs the cleaning process at the first cleaning timing every time the shaping time elapses by 5 minutes and every time the nozzle 60 to be used is switched once. Also, as the second cleaning timing, the cleaning process is performed both before and after the use of the nozzle 60 when the nozzle 60 is switched. And the nozzles to be cleaned are both nozzles 60 of the main nozzle and the support nozzle. Further, the cleaning time is set to 15 seconds and the number of cleaning times is set to 3 times. The cleaning time refers to the time spent on a series of cleaning steps in the cleaning process, and the number of cleaning times refers to the number of times a series of cleaning steps are performed. A series of cleaning steps is, for example, a process in which after discharging a predetermined amount of shaping material from the nozzle 60 onto the purge unit 253, the tip of the nozzle 60 is passed over the blade 252 so that it contacts the blade 252, and the tip of the nozzle 60 is reciprocated a predetermined number of times on the brush 251 while contacting the brush 251. In this embodiment, increasing the cleaning time is realized by increasing the time for discharging the shaping material from the nozzle 60 among these series of steps. In this embodiment, the number of cleaning times represents the intensity of cleaning. That is, the higher the number of cleaning times, the stronger the cleaning will be. Note that the intensity of cleaning may be represented by, for example, the rotation speed of the screw or the discharge pressure when discharging the shaping material onto the purge unit 253.

[0043] When the standard mode is specified as the shaping mode, the cleaning control unit 312 performs a cleaning process each time the nozzle 60 to be used is switched once as the first cleaning timing, and performs a cleaning process only before using the nozzle 60 at the time of switching the nozzle 60 as the second cleaning timing. Then, the nozzle to be cleaned is only the main nozzle, and further, the cleaning time is set to 10 seconds and the cleaning frequency is set to 2 times.

[0044] When the high-speed mode is specified as the shaping mode, the cleaning control unit 312 performs a cleaning process each time the nozzle 60 to be used is switched twice as the first cleaning timing, and performs a cleaning process only before using the nozzle 60 at the time of switching the nozzle 60 as the second cleaning timing. Then, the nozzle to be cleaned is only the main nozzle. Further, the cleaning time is set to 5 seconds and the cleaning frequency is set to 1 time.

[0045] As described above, in the high-precision mode, compared with the standard mode and the high-speed mode, the number of times the cleaning process is executed in one three-dimensional shaping process increases. Therefore, a three-dimensional shaped object can be shaped with high precision. Also, in the high-speed mode, compared with the standard mode and the high-precision mode, the number of times the cleaning process is executed in one three-dimensional shaping process decreases. Therefore, a three-dimensional shaped object can be shaped at high speed.

[0046] Prior to the above-described step S110, the information processing apparatus 11 may execute a modeling data generation process for generating modeling data. In this modeling data generation process, the information processing apparatus 11 acquires shape data such as three-dimensional CAD data representing the shape of a three-dimensional object, analyzes the shape data, and slices the shape of the three-dimensional object into a plurality of layers along the XY plane. Then, the information processing apparatus 11 generates movement path information representing the movement path of the nozzle 60 for filling the outer shell and the internal region of each layer. The movement path information includes data representing a plurality of linear movement paths. Each movement path included in the movement path information includes discharge amount information representing the discharge amount of the modeling material discharged in that movement path. The information processing apparatus 11 generates modeling data by generating movement path information and discharge amount information for all layers. The modeling data is represented by, for example, G code.

[0047] According to the first embodiment described above, since the cleaning of the nozzle 60 is controlled according to the modeling mode selected by the user, for example, a situation where cleaning is frequently performed during the modeling of a three-dimensional object that does not require high precision does not occur. Therefore, the modeling time does not inadvertently become long, and the convenience of the user can be improved.

[0048] Also, in the present embodiment, when the high-precision mode is selected as the modeling mode, at least one of the number of cleaning times, cleaning time, cleaning intensity, and cleaning target nozzles is made different in the cleaning process compared to when the standard mode is selected as the modeling mode. Specifically, when the high-precision mode is selected, compared to when the standard mode is selected as the modeling mode, at least one of (A) increasing the number of cleaning times, (B) lengthening the cleaning time, (C) increasing the cleaning intensity, and (D) increasing the cleaning target nozzles is performed. Therefore, in the high-precision mode, the cleanliness of the nozzle 60 can be increased, and a three-dimensional object can be modeled with high precision.

[0049] In addition, in this embodiment, increasing the cleaning time is achieved by increasing the time for discharging the modeling material from the nozzle 60. Therefore, the cleaning time can be easily increased. In other embodiments, the cleaning time may be increased by increasing the number of reciprocating movements of the nozzle 60 on the brush 251, that is, the number of times the nozzle 60 is brushed. By doing so, the cleaning time can also be easily increased.

[0050] In this embodiment, as shown in FIG. 8, the cleaning process content in each mode is determined by five items: the first cleaning timing, the second cleaning timing, the cleaning target nozzle, the cleaning time, and the number of cleaning times. On the other hand, not all of these items need to be defined. In each mode, at least one of these items may be defined.

[0051] In this embodiment, in the standard mode, only the main nozzle is set as the cleaning target nozzle. However, in the standard mode, both the main nozzle and the support nozzle may be set as the cleaning target nozzles. In this case, when the high-speed mode is selected as the modeling mode, compared with the case where the standard mode is selected as the modeling mode, the number of cleaning times of the support nozzle is reduced in the cleaning process. The accuracy of the modeling by the support material has little influence on the accuracy of the three-dimensional model. Therefore, by reducing the number of cleaning times of the support nozzle, high-speed modeling can be performed while suppressing the influence on the modeling accuracy of the three-dimensional model.

[0052] In this embodiment, in the high-precision mode, the number of cleaning processes is larger and the modeling time is longer than in other modes. Therefore, the high-precision mode can also be called the low-speed mode. In the high-speed mode, the number of cleaning processes is smaller and the modeling accuracy is lower than in other modes. Therefore, the high-speed mode can also be called the low-accuracy mode.

[0053] B. Second Embodiment: FIG. 9 is a flowchart of the three-dimensional modeling process in the second embodiment. The three-dimensional modeling process of the first embodiment differs from that of the second embodiment in that a cleaning command is added to the modeling data after receiving the modeling mode.

[0054] Similar to step S100 in the first embodiment, in step S200 of the second embodiment, the reception unit 15 of the information processing apparatus 11 receives the designation of the modeling mode.

[0055] In the second embodiment, in the subsequent step S205, the CPU 12 of the information processing apparatus 11 executes a cleaning command addition process. This cleaning command addition process is a process of adding a cleaning command corresponding to the modeling mode received in step S200 to the modeling data. Specifically, in this cleaning command addition process, the CPU 12 adds a command for realizing the cleaning process content shown in FIG. 8 to the modeling data according to the modeling mode received in step S200. For example, when the high-precision mode is specified, a cleaning command is added to the modeling data so that the nozzle 60 is cleaned every 5 minutes, and further, a cleaning command is added before and after each nozzle switching command so that cleaning is executed before and after the nozzle 60 is switched. In this way, by adding a cleaning command, for example, when the high-precision mode or the low-speed mode is specified as the modeling mode, compared with the case where the standard mode is specified as the modeling mode, the number of cleaning commands added to the modeling data increases, or a cleaning command with a stronger intensity than the cleaning command added in the standard mode to the modeling data is added.

[0056] In step S210, the information processing apparatus 11 supplies the modeling data with the cleaning command added thereto to the three-dimensional modeling apparatus 10.

[0057] In step S220, the shaping processing unit 311 of the three-dimensional shaping apparatus 10 executes a shaping process. In this shaping process, a three-dimensional shaped object is shaped according to the shaping data. While the three-dimensional shaped object is being shaped, the cleaning control unit 312 interprets the cleaning commands added to the shaping data, and controls the cleaning process in step S225 according to the operations represented by the cleaning commands.

[0058] According to the second embodiment described above, in the information processing apparatus 11, since a cleaning command corresponding to the shaping mode is added to the shaping data, the three-dimensional shaping apparatus 10 can perform cleaning corresponding to the shaping mode only by operating the nozzle 60 according to the cleaning command. Therefore, the burden of the cleaning process in the three-dimensional shaping apparatus 10 is reduced.

[0059] In the second embodiment described above, the CPU 12 of the information processing apparatus 11 executes a process of adding a cleaning command corresponding to the shaping mode to the shaping data. In contrast, according to the shaping mode specified by the user, shaping data including a cleaning command corresponding to the shaping mode may be generated. It is not necessary to add a cleaning command corresponding to the shaping mode later, and shaping data including a cleaning command corresponding to the shaping mode can be generated quickly.

[0060] C. Other Embodiments: (C1) In the first embodiment described above, the information processing apparatus 11 accepts a specification of the shaping mode. In contrast, the specification of the shaping mode may be accepted by the three-dimensional shaping apparatus 10 through a predetermined operation button provided in the three-dimensional shaping apparatus 10. In this case, in step S100 shown in FIG. 7, it is the three-dimensional shaping apparatus 10, not the information processing apparatus 11, that accepts the specification of the shaping mode, and in step S110, the addition of the shaping mode to the shaping data is not performed. By doing so, the convenience of the user can be improved as in the first embodiment.

[0061] (C2) In the above-described embodiment, the CPU 12 of the information processing apparatus 11 may generate modeling data according to the modeling mode specified by the user. For example, when the high-precision mode is specified, the CPU 12 reduces the lamination pitch and the line width of the modeling material to be discharged as compared with the standard mode. By doing so, not only the content of the cleaning process but also the lamination pitch and the line width can be changed according to the modeling mode, so that the convenience for the user can be further improved.

[0062] (C3) In the above-described embodiment, the plasticizing mechanism 30 includes a flat screw as the screw 41. In contrast, the plasticizing mechanism 30 may include an in-line screw. Further, the discharge unit 100 only needs to be able to discharge the modeling material while relatively moving the nozzle 60 with respect to the stage 220. For example, various types of discharge units such as the FDM method, the binder jet method, and the inkjet method can be adopted.

[0063] (C4) In the above embodiment, pellet-shaped ABS resin is used as the raw material of the modeling material. In contrast, the three-dimensional modeling apparatus 10 can model a three-dimensional object using various materials such as a material having thermoplasticity, a metal material, and a ceramic material as the main material. Here, the "main material" means the material that forms the center of the shape of the three-dimensional object and means the material that occupies a content rate of 50% by weight or more in the three-dimensional object. The above-described modeling materials include those in which these main materials are melted alone and those in which some components contained together with the main material are melted into a paste shape.

[0064] When a material having thermoplasticity is used as the main material, in the plasticizing mechanism 30, the modeling material is generated by plasticizing the material. As the material having thermoplasticity, for example, the following thermoplastic resin materials can be used. <Examples of thermoplastic resin materials> General engineering plastics such as polypropylene resin (PP), polyethylene resin (PE), polyacetal resin (POM), polyvinyl chloride resin (PVC), polyamide resin (PA), acrylonitrile-butadiene-styrene resin (ABS), polylactic acid resin (PLA), polyphenylene sulfide resin (PPS), polyetheretherketone (PEEK), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, polyethylene terephthalate, etc., and engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, polyetheretherketone, etc.

[0065] In the material having thermoplasticity, additives such as pigments, metals, ceramics, and in addition, waxes, flame retardants, antioxidants, heat stabilizers, etc. may be mixed. The material having thermoplasticity is plasticized and converted into a molten state by the rotation of the screw 41 and the heating of the heater 58 in the plasticizing mechanism 30. The shaped material generated by the melting of the material having thermoplasticity is discharged from the nozzle 60 and then cured by the temperature drop.

[0066] It is desirable that the material having thermoplasticity be heated above its glass transition point and injected from the nozzle 60 in a completely molten state. For example, the ABS resin has a glass transition point of about 110°C and it is desirable to be about 200°C at the time of injection from the nozzle 60.

[0067] In the three-dimensional shaping apparatus 10, instead of the above-described material having thermoplasticity, for example, the following metal materials may be used as the main material. In this case, it is desirable that a component that melts during the generation of the shaped material be mixed with the powder material obtained by pulverizing the following metal materials, and the mixture be introduced into the plasticizing mechanism 30 as a raw material. <Examples of metal materials> A single metal such as magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or an alloy containing one or more of these metals. <Examples of the alloy> Maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy.

[0068] In the three-dimensional shaping apparatus 10, instead of the above metal materials, a ceramic material can be used as the main material. As the ceramic material, for example, oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, and non-oxide ceramics such as aluminum nitride can be used. When using a metal material or a ceramic material as described above as the main material, the shaping material disposed on the stage 220 may be cured by sintering by laser irradiation or hot air.

[0069] The powder materials of the metal materials and ceramic materials input as raw materials into the material storage unit 20 may be a mixed material in which powders of a single metal, alloy powders, or ceramic material powders are mixed in a plurality of types. Further, the powder materials of the metal materials and ceramic materials may be coated with, for example, the thermoplastic resin exemplified above or other thermoplastic resins. In this case, in the plasticizing mechanism 30, the thermoplastic resin may be melted and fluidity may be exhibited.

[0070] For example, the following solvents can be added to the powder materials of the metal materials and ceramic materials input as raw materials into the material storage unit 20. The solvents can be used by selecting one or a combination of two or more from the following. <Examples of the solvent> Water; (Poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetate esters such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and 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; tetraalkylammonium acetate (for example, tetrabutylammonium acetate, etc.); ionic liquids such as butyl carbitol acetate, etc.

[0071] In addition, for the powder materials of metal materials and ceramic materials input as raw materials into the material storage unit 20, for example, the following binders can also be added. <Examples of Binders> Acrylic resin, epoxy resin, silicone resin, cellulose-based resin, or other synthetic resins, or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), or other thermoplastic resins.

[0072] D. Other Forms: The present disclosure 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 of the embodiments corresponding to the technical features in each of the forms described below 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. Also, if the technical features are not described as essential in this specification, they can be appropriately deleted.

[0073] (1) According to the first aspect of the present disclosure, a method for manufacturing a three-dimensional object is provided. This manufacturing method includes a first step of receiving a specification of a shaping mode of the three-dimensional object, a second step of shaping the three-dimensional object by discharging a shaping material from a nozzle based on shaping data for shaping the three-dimensional object, and a third step of controlling the cleaning of the nozzle according to the shaping mode received in the first step. According to such an aspect, since the cleaning of the nozzle is controlled according to the shaping mode selected by the user, the convenience for the user can be improved.

[0074] (2) In the above aspect, in the first step, the shaping mode may be specified from a plurality of modes including a mode related to the shaping accuracy of the three-dimensional object and a mode related to the shaping time of the three-dimensional object. In such an aspect, a shaping mode corresponding to the shaping accuracy and shaping time can be selected.

[0075] (3) In the above aspect, when the high-precision mode for shaping the three-dimensional object with high precision or the low-speed mode for shaping the three-dimensional object at a low speed is specified as the shaping mode, compared with the case where the standard mode is specified as the shaping mode, in the third step, at least one of the cleaning frequency, cleaning time, cleaning intensity, and cleaning target nozzles may be made different.

[0076] (4) In the above aspect, when the high-precision mode or the low-speed mode is specified as the shaping mode, compared with the case where the standard mode is specified as the shaping mode, at least one of (A) increasing the cleaning frequency, (B) lengthening the cleaning time, (C) increasing the cleaning intensity, and (D) increasing the cleaning target nozzles may be performed. In such an aspect, the cleanliness of the nozzle can be increased in the high-precision mode and the low-speed mode.

[0077] (5) In the above-described embodiment, increasing the cleaning time (B) may be achieved by increasing the time for discharging the modeling material from the nozzle or by increasing the number of times of brushing the nozzle. In such a case, the cleaning time can be easily increased.

[0078] (6) In the above-described embodiment, when a low-precision mode for forming a three-dimensional object with low precision or a high-speed mode for forming a three-dimensional object at high speed is specified as the modeling mode, the number of cleaning times of the nozzle for discharging the support material in the third step may be less than when the standard mode is specified as the modeling mode. The accuracy of the modeling by the support material has little influence on the accuracy of the three-dimensional object. Therefore, high-speed modeling can be performed by reducing the number of cleaning times of the nozzle for discharging the support material.

[0079] (7) In the above-described embodiment, a cleaning command may be added to the modeling data according to the modeling mode received in the first step, and in the third step, cleaning may be controlled according to the cleaning command in the modeling data.

[0080] (8) In the above-described embodiment, when a high-precision mode for forming a three-dimensional object with high precision or a low-speed mode for forming a three-dimensional object at low speed is specified as the modeling mode, the number of cleaning commands added to the modeling data may increase compared to when the standard mode is specified as the modeling mode, or a cleaning command with a stronger intensity than the cleaning command added in the standard mode may be added to the modeling data.

[0081] (9) According to the second aspect of the present disclosure, a three-dimensional modeling apparatus is provided. This three-dimensional modeling apparatus includes a modeling processing unit that discharges a modeling material from a nozzle to model the three-dimensional object based on modeling data for modeling the three-dimensional object, and a cleaning control unit that controls the cleaning of the nozzle according to a specified modeling mode.

[0082] (10) According to a third aspect of the present disclosure, an information processing apparatus is provided. The information processing apparatus includes a reception unit that receives a selection of a modeling mode of a three-dimensional object, and a control unit that adds the modeling mode to modeling data for modeling the three-dimensional object, or adds a cleaning command according to the modeling mode to the modeling data, and supplies the modeling data to a three-dimensional modeling apparatus that controls nozzle cleaning according to the modeling mode.

Explanation of Signs

[0083] 5... Three-dimensional modeling system, 10... Three-dimensional modeling apparatus, 11... Information processing apparatus, 12... CPU, 13... Memory, 14... Storage device, 15... Reception unit, 20... Material storage unit, 22... Supply path, 30... Plasticizing mechanism, 31... Screw case, 32... Drive motor, 40... Material conveyance mechanism, 41... Screw, 42... Groove formation surface, 43... Side surface, 44... Material inlet, 45... Screw groove, 46... Ridge portion, 47... Screw central portion, 50... Barrel, 52... Screw opposing surface, 54... Guide groove, 56... Communication hole, 58... Heater, 60... Nozzle, 61... Nozzle flow path, 63... Nozzle opening, 65... Inlet, 70... Flow rate adjustment unit, 74... Valve drive unit, 80... Through hole, 90... Heating block, 91... Case portion, 94... Opening, 100... Discharge portion, 110... Housing, 111... Modeling space, 210... Drive unit, 211... First drive unit, 212... Second drive unit, 220... Stage, 221... Modeling surface, 250... Cleaning mechanism, 251... Brush, 252... Blade, 253... Purge portion, 254... First inclined surface, 255... Second inclined surface, 256... Third inclined surface, 258... Fixture, 260... Purge waste material container, 300... Control unit, 310... CPU, 311... Modeling processing unit, 312... Cleaning control unit, 320... Memory

Claims

1. A first step of designating a shaping mode from a plurality of modes including a mode related to the shaping accuracy of a three-dimensional shaped object and a mode related to the shaping time of the three-dimensional shaped object; A second step of discharging a shaping material from a nozzle based on shaping data for shaping the three-dimensional shaped object to shape the three-dimensional shaped object; A third step of controlling cleaning of the nozzle according to the shaping mode received in the first step, the method for manufacturing a three-dimensional shaped object, comprising: In the third step, when the high-precision mode or the low-speed mode is designated as the shaping mode, compared with the case where the standard mode is designated as the shaping mode, (1) increasing the number of cleaning times, (2) lengthening the cleaning time, (3) increasing the cleaning strength, and (4) increasing the nozzles to be cleaned, at least one of which is performed.

2. A first step of designating a shaping mode from a plurality of modes including a mode related to the shaping accuracy of a three-dimensional shaped object and a mode related to the shaping time of the three-dimensional shaped object; A second step of discharging a shaping material from a nozzle based on shaping data for shaping the three-dimensional shaped object to shape the three-dimensional shaped object; A third step of controlling cleaning of the nozzle according to the shaping mode received in the first step, the method for manufacturing a three-dimensional shaped object, comprising: In the third step, when the low-precision mode for shaping a three-dimensional shaped object with low accuracy or the high-speed mode for shaping a three-dimensional shaped object at high speed is designated as the shaping mode, compared with the case where the standard mode is designated as the shaping mode, in the third step, the number of cleaning times of the nozzle for discharging the support material is small.

3. A first step of designating a shaping mode from a plurality of modes including a mode related to the shaping accuracy of a three-dimensional shaped object and a mode related to the shaping time of the three-dimensional shaped object; A second step of discharging a shaping material from a nozzle based on shaping data for shaping the three-dimensional shaped object to shape the three-dimensional shaped object; A third step of controlling cleaning of the nozzle according to the shaping mode received in the first step, the method for manufacturing a three-dimensional shaped object, comprising: Adding a cleaning command to the shaping data according to the shaping mode received in the first step; In the third step, cleaning is performed according to the cleaning command in the shaping data. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ A method for manufacturing a three-dimensional object that controls G.

4. A method for manufacturing a three-dimensional object according to any one of Claims 1 and 3, wherein lengthening the cleaning time in (2) is achieved by lengthening the time for discharging the modeling material from the nozzle, or by increasing the number of times of brushing the nozzle. A method for manufacturing a three-dimensional object.

5. A method for manufacturing a three-dimensional object according to Claim 3, wherein when the high-precision mode for shaping a three-dimensional object with high precision or the low-speed mode for shaping a three-dimensional object at a low speed is specified as the shaping mode, compared with the case where the standard mode is specified as the shaping mode, the number of cleaning commands added to the shaping data increases, or a cleaning command with a stronger intensity than the cleaning command added in the standard mode is added to the shaping data. A method for manufacturing a three-dimensional object

6. Based on shaping data for shaping a three-dimensional object, a shaping processing unit that discharges a shaping material from a nozzle to shape the three-dimensional object, and a cleaning control unit that controls cleaning of the nozzle according to a specified shaping mode selected from a plurality of modes including a mode related to the shaping accuracy of the three-dimensional object and a mode related to the shaping time of the three-dimensional object. 。 The control unit, when the high-precision mode or the low-speed mode is specified as the shaping mode, compared with the case where the standard mode is specified as the shaping mode, (1) increases the number of cleaning times, (2) lengthens the cleaning time, (3) increases the cleaning intensity, (4) increases the number of nozzles to be cleaned. A three-dimensional shaping apparatus that performs at least any one of these. ​ ​ ​ ​ ​ ​ ​ ​ ​

Images