Support member and method for manufacturing a shaped object

Abstract

To provide a support member for supporting a support necessary part of a model in shaping.SOLUTION: A support member is a recyclable support S1 obtained by being separated from a model as a grease trap body having a box shape whose upper surface is opened. The recyclable support S1 has a bottom part 126 formed in a shape corresponding to a swollen part of the grease trap body supported by the support S1, and a plurality of cylindrical parts 127 erected on the upper face of the bottom part 126.SELECTED DRAWING: Figure 28

Description

Technical Field

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

Background Art

[0002] In recent years, as a manufacturing apparatus for manufacturing a three-dimensional object, for example, a 3D printer using a fused deposition modeling method is widely known (see, for example, Patent Document 1).

[0003] And when manufacturing a three-dimensional object having a desired shape using the fused deposition modeling method 3D printer, depending on the shape of the target object, a support (support material) for supporting the support required part (overhang part) of the model to be the object may be required.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, since the support for supporting the support required part of the model during modeling is unnecessary after modeling, it is necessary to separate the two and remove the support, but the removal is often difficult.

[0006] Therefore, one of the problems of the present invention is to provide a method for manufacturing an object that can easily remove the support.

Means for Solving the Problems

[0007] The support member according to an embodiment of the present invention is a support member that supports a portion of a model that needs to be supported when manufacturing a shaped object using a shaped object manufacturing apparatus, and is a reusable support obtained by being separated from the model when the shaped object is manufactured. The model that is shaped using the shaped object manufacturing apparatus with the support is a housing.

[0008] Also, the support member according to an embodiment of the present invention is a support member that supports a portion of a model that needs to be supported when manufacturing a shaped object using a shaped object manufacturing apparatus, and is a reusable support obtained by being separated from the model when the shaped object is manufactured. The model that is shaped using the shaped object manufacturing apparatus with the support is a grease trap body having a box shape with an upper surface opening.

[0009] Furthermore, the support member according to an embodiment of the present invention is a support member that supports a portion of a model that needs to be supported when manufacturing a shaped object using a shaped object manufacturing apparatus, and is a reusable support obtained by being separated from the model when the shaped object is manufactured. The model that is shaped using the shaped object manufacturing apparatus with the support is a grease trap body having a box shape with an upper surface opening. The support supports a bulging portion for attaching an oil-water separation member, which is formed in a bulging shape upward, to the bottom plate of the bottomed cylindrical tubular portion of the grease trap body.

[0010] Also, the support member according to an embodiment of the present invention is a support member that supports a portion of a model that needs to be supported when manufacturing a shaped object using a shaped object manufacturing apparatus, and is a reusable support obtained by being separated from the model when the shaped object is manufactured. The model that is shaped using the shaped object manufacturing apparatus with the support is a grease trap body having a box shape with an upper surface opening. The support supports a flange portion protruding from the outer peripheral surface of the upper end portion of the bottomed cylindrical tubular portion of the grease trap body.

[0011] Furthermore, when manufacturing a shaped object using a shaped object manufacturing apparatus, the support member according to an embodiment of the present invention is a support member that supports a portion of a model that requires support. It is a reusable support obtained by being separated from the model when the shaped object is manufactured. The model that is shaped using the support by the shaped object manufacturing apparatus is a member having a box shape with an upper surface opening. The support supports a bulging portion formed in a bulging shape upward on the bottom plate of the bottomed cylindrical tubular portion among the members.

[0012] Moreover, a shaped object manufacturing method according to an embodiment of the present invention is a shaped object manufacturing method for manufacturing a shaped object using a shaped object manufacturing apparatus with the above support member. It includes a step of performing a shaping operation without installing the support member, a step of temporarily stopping the shaping operation immediately before the portion of the model that requires support is shaped and installing the support member, and a step of restarting the shaping operation with the support member installed and shaping the portion of the model that requires support on the support member.

[0013] Furthermore, a shaped object manufacturing method according to an embodiment of the present invention is a shaped object manufacturing method for manufacturing a housing, which is a shaped object, using a shaped object manufacturing apparatus with a support member that supports a portion of a model that requires support. The support member is a reusable support obtained by being separated from the housing, which is its model, when the housing is manufactured using the shaped object manufacturing apparatus.

[0014] Moreover, a shaped object manufacturing method according to an embodiment of the present invention is a shaped object manufacturing method for manufacturing a grease trap body, which is a shaped object with a box shape having an upper surface opening, using a shaped object manufacturing apparatus with at least one support member that supports a portion of a model that requires support. The grease trap body has a bottomed cylindrical tubular portion, a bulging portion for attaching an oil-water separation member formed in a bulging shape upward on the bottom plate of the tubular portion, and a flange portion protruding from the outer peripheral surface of the upper end portion of the tubular portion. The at least one support member is a reusable support obtained by being separated from the bulging portion for attaching an oil-water separation member of the grease trap body, which is its model, when the grease trap body is manufactured using the shaped object manufacturing apparatus. [Effect of the Invention]

[0015] According to the embodiment of the present invention, the support can be easily removed. [Brief Description of the Drawings]

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Figure 24

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30

Figure 31

Figure 32

DETAILED DESCRIPTION OF THE INVENTION

[0017] One embodiment of the present invention will be described with reference to the drawings.

[0018] In FIG. 1, reference numeral 1 denotes a 3D printer of the hot-melt lamination type, which is a shaping device for manufacturing a shaped object. This hot-melt lamination type 3D printer (hereinafter sometimes simply referred to as "3D printer 1") is a shaping machine for manufacturing a three-dimensional shaped object W by sequentially laminating layers of resin, which is a shaping material melted (fused) by heat, based on 3D shaping data.

[0019] Note that the resin, which is the shaping material used in the 3D printer 1, is, for example, a thermoplastic resin (such as a filament), and more specifically, for example, PLA, PLA with plant fibers, ABS, ABS with glass fibers, ABS with carbon fibers, PP, PP with glass fibers, PP with carbon fibers, PC, PC·ABS, ASA, TPE, TPU, cellulose acetate, PA, PETG, etc. Further, the 3D printer 1 is, for example, of a single nozzle head specification, and only one type of resin used for shaping is sufficient, and a support - dedicated resin (such as a water - soluble resin) is not required.

[0020] As shown in FIGS. 1(a) and (b), the 3D printer 1 includes, for example, a box - shaped main body 3 having a shaping chamber 2 inside, a shaping head 4 movable in the X - axis direction (left - right direction, which is the horizontal direction) and the Z - axis direction (up - down direction, which is the height direction) within the shaping chamber 2, and a shaping table 5 movable in the Y - axis direction (front - back direction, which is the horizontal direction) within the shaping chamber 2.

[0021] Note that since the shaping head 4 is movable in the X - axis direction and the Z - axis direction and the shaping table 5 is movable in the Y - axis direction in this way, the shaping head 4 moves three - dimensionally relative to the shaping table 5. (As will be described later, the 3D printer 1 is not limited to the configuration shown in FIG. 1, and any configuration in which the shaping head 4 moves at least three - dimensionally relative to the shaping table 5 is acceptable.)

[0022] The 3D printer 1 also includes a first drive unit 6 that moves the shaping head 4 in the X - axis direction and the Z - axis direction within the shaping chamber 2, a second drive unit 7 that moves the shaping table 5 in the Y - axis direction within the shaping chamber 2, and a control unit 8 that controls both drive units 6, 7, etc. based on 3D shaping data such as STL data.

[0023] Then, based on the control by the control unit 8, while the shaping head 4 moves three - dimensionally relative to the shaping table 5, resin (melted resin) is discharged from the nozzle 11 of the moving shaping head 4, and the discharged resin hardens and solidifies, so that the resin is laminated on the shaping table 5 and a three - dimensional shaped object W of a desired shape is shaped.

[0024] However, depending on the shape of the target shaped object W, as will be described later, a support (support material) S for supporting the support required part (overhang part) MO of the model M that finally becomes the target shaped object W may be necessary. In this case, a rough shaped object W1 composed of the model M and the support S is shaped.

[0025] That is, when the support S is required, after once shaping the rough shaped object W1 composed of the model M and the support S, the support S is removed from the rough shaped object W1 to obtain the target shaped object W.

[0026] Here, the shaping head 4 of the 3D printer 1 of the thermal melting lamination method with a single nozzle head specification is, for example, of the molten resin extrusion type, and has a single nozzle 11 that discharges the resin melted by the heat from a heating means (not shown) in the shaping head 4 from the discharge port 10.

[0027] That is, the resin melted by being heated by a heating means such as a heater (not shown) is extruded by an extrusion means (not shown) such as a gear in the shaping head 4, and is discharged (ejected) downward from the discharge port 10 of one nozzle 11 for discharging the shaping material. Note that the heating means and the extrusion means may be provided outside the shaping head 4 instead of inside the shaping head 4.

[0028] And the opening diameter (the opening diameter of the nozzle 11) φ of the discharge port 10 having a circular shape that opens downward is, for example, 0.2 mm to 1.0 mm, and in this embodiment, it is, for example, 0.4 mm (φ = 0.4 mm).

[0029] Next, a method for manufacturing a shaped object for manufacturing a three-dimensional shaped object W shown in, for example, FIG. 2 using the above-described 3D printer 1 of the thermal melting lamination method will be described.

[0030] The shaped object W shown in FIG. 2 is, for example, a cap-shaped lid body, and includes a cylindrical portion 16 and a disk-shaped portion 17 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 16.

[0031] And the disk-shaped part 17 that constitutes a part of the shaped object (model M) W is a part that requires support by the support S so as not to collapse under its own weight during shaping (during the shaping process) by the 3D printer 1, that is, a part that needs support MO, that is, a so-called overhang part (the part of the model M that floats in the air) (see FIG. 3).

[0032] Moreover, FIG. 3 is a diagram schematically showing a shaped object manufacturing method (an example of the manufacturing method according to the present embodiment) for manufacturing the shaped object W shown in FIG. 2. (a) to (c) are diagrams of the shaping process, and (d) is a diagram of the removing process.

[0033] In the shaping process, which is the first step, as shown in FIGS. 3(a) to (c), while discharging resin (molten resin made of one type of shaping material) from the discharge port 10 of the nozzle 11 of the shaping head 4 that moves three-dimensionally relative to the shaping table 5, it is laminated on the shaping table 5. Thus, a three-dimensional rough-shaped object W1 having the model M that finally becomes the target shaped object W and the support S that supports the part that needs support MO of the model M from below during shaping is shaped (formed) on the shaping table 5.

[0034] In the removing process, which is the second step, as shown in FIG. 3(d), after the shaping process, the support S is removed from the rough-shaped object W1 by separating the model M and the support S from each other to obtain the target shaped object W.

[0035] And in the shaped object manufacturing method according to the present embodiment, in the above-described shaping process, while temporarily forming a predetermined gap 20 between the support S and the part that needs support MO of the model M (while leaving a gap), the shaping of the part that needs support MO is performed.

[0036] More specifically, as shown in Fig. 4(a), during the shaping process, a predetermined gap (constant gap) 20 in the height direction is temporarily formed between the upper surface 21 of the already shaped support S and the lower surface (the lower surface of the linear molten resin immediately after being discharged from the discharge port 10 of the nozzle 11 during horizontal movement) 22 of the support-required part MO of the model M being shaped, and the shaping of the layer (one layer that becomes the lower surface of the support-required part MO which is the disk-shaped part 17) of the lower surface of the support-required part MO is carried out.

[0037] In addition, for the shaping object manufacturing method according to the present embodiment, when the dimension (gap height dimension) of the predetermined gap 20 in the shaping process is H and the opening diameter (nozzle diameter) of the nozzle 11 in the 3D printer 1 using the thermal melting lamination method is φ, it satisfies φ / 2 ≦ H ≦ φ.

[0038] Therefore, for example, when φ is 0.4 mm as in the present embodiment, H is a dimension within the range of 0.2 mm to 0.4 mm. In other words, the dimension H of the predetermined gap 20 in the shaping process is a dimension that is not less than half of the opening diameter φ of the nozzle 11 that discharges the shaping material (molten resin) and is within the range of being the same as or less than the opening diameter φ.

[0039] Here, as shown in Figs. 4(b) and 5, the gap 20 temporarily formed in the shaping process is substantially filled by the resin sag because the resin deforms (sags) downward due to its own weight. Note that Fig. 3 is a diagram in which the resin sag is omitted (the same applies to Fig. 12).

[0040] That is, if the molten resin discharged from the discharge port 10 of the nozzle 11 moving in the horizontal direction cools and hardens simultaneously with the discharge, no sag occurs. However, since it takes a certain amount of time for the discharged molten resin to be cooled by the air in the shaping chamber 2 and hardened, basically, sag occurs due to its own weight as shown in Fig. 4(b).

[0041] As a result, the resin discharged from the discharge port 10 of the nozzle 11 moving in the horizontal direction sags due to its own weight by the amount of the gap 20, and its lower surface 22 comes into contact with the upper surface (the upper surface of the hardened layer which is the hardened part) 21 of the support S and is supported by the upper surface 21.

[0042] However, even if the contact portion of the resin supported on the upper surface 21 (the lower surface of the resin sag) hardens and solidifies, it does not firmly integrate (adhere) with the upper surface 21 of the support S. Therefore, the removal of the support S in the removal process after the shaping process becomes easy.

[0043] That is, in this shaping process, the easily removable support S that is not firmly integrated with the model M at the end of shaping is shaped together with the model M from the same material.

[0044] Also, the dimension H of the predetermined gap 20 for not firmly integrating (adhering) the model M and the support S in this way preferably satisfies φ / 2 ≤ H ≤ φ in relation to the opening diameter φ of the nozzle 11. This is because, for example, when H is smaller than φ / 2, the model M and the support S are relatively firmly integrated. On the other hand, for example, when H is larger than φ, the support S is meaningless and at least a part of the support-required part MO of the model M collapses.

[0045] In short, when the relationship of φ / 2 ≤ H ≤ φ is satisfied, while preventing the collapse of the model M, the resin sag can be minimized, and the model M and the support S are not firmly integrated (adhered).

[0046] Therefore, the separation of the model M and the support S in the removal process is easy. For example, as shown in FIG. 3(d), on the shaping table 5, without using any tools (tool-less), the operator can simply lift the model M upward by hand, and the model M can be easily separated from the support S (the support laminated and shaped in a state of directly contacting the upper surface of the shaping table 5) on the shaping table 5. That is, the support S can be extremely easily removed from the model M with just one action of lifting the model M, and the removal of the support S from the rough-shaped object W1 is easy.

[0047] In addition to the above-described gap 20, as shown in FIGS. 4 and 5, in the shaping process, a predetermined horizontal gap (constant gap) 25 is formed over the entire circumference between the outer peripheral surface (outer peripheral surface of the outer cylindrical portion 32) 26 of the support S and the inner peripheral surface (inner peripheral surface of the cylindrical portion 16) 27 of the model M.

[0048] The dimension D of this gap 25 is, for example, the same as the opening diameter φ of the nozzle 11 and is, for example, 0.4 mm. However, it is not necessarily the case that D = φ. For example, the dimension D of the gap 25 may be, for example, 0.5 mm.

[0049] Further, in the shaping object manufacturing method according to the present embodiment, as shown in FIGS. 6 and 7, the support S of the rough shaping object W1 shaped in the shaping process is an inner cylindrical portion 31 that is annular in plan view, that is, a cylindrical portion that is, for example, annular in plan view, and an outer cylindrical portion 32 that is located at a predetermined distance away from the inner cylindrical portion 31 on the outer side of the inner cylindrical portion 31 and is close to the inner peripheral surface 27 of the model M and has a shape corresponding to the inner peripheral surface 27 of the model M, that is, annular in plan view, for example, annular in plan view centered on the center point P of the inner cylindrical portion 31, and a connecting portion (connecting plate-like portion) 33 that is a plurality of planar linear and plate-like extending portions that extend radially outward from the inner cylindrical portion 31 around the center point P of the inner cylindrical portion 31 and integrally connect the inner cylindrical portion 31 and the outer cylindrical portion 32.

[0050] Further, this support S is formed to have a smaller diameter than the inner cylindrical portion 31 and has a plurality of, for example, two reduced-diameter cylindrical portions 36, 37 that are annular in plan view and are located inside the inner cylindrical portion 31, that is, annular in plan view centered on the center point P of the inner cylindrical portion 31. That is, the planar shape (support pattern) of this support S is not restricted to being drawn in one stroke, and the reduced-diameter cylindrical portions 36, 37 on the central side are not connected to the inner cylindrical portion 31.

[0051] Then, these small-diameter cylindrical portions 36 and 37, the inner cylindrical portion 31, and the outer cylindrical portion 32 are concentric and are all formed in a cylindrical shape (a cylindrical shape with upper and lower surfaces open in the axial direction in the vertical direction) centered on a central axis L extending in the vertical direction (Z-axis direction) passing through the same center point P (see Fig. 5).

[0052] Also, each of the short cylindrical portions 31, 32, 36, and 37 with upper and lower surfaces open forms a single closed curve that is a closed curve in a plan view (the same applies to the cylindrical portions and the like described later). A single closed curve (Jordan closed curve) is a closed curve that does not intersect itself. To explain further, it is a curve where the starting point and the ending point coincide and does not contact or intersect itself from the starting point to the ending point. Single closed curves include circles and ellipses. Also, single closed curves include polygons such as triangles and quadrilaterals, as well as cardioids (heart shapes), etc. Furthermore, a closed curve is a curve where the starting point and the ending point coincide (e.g., a lemniscate, etc.), and since a lemniscate divides the region into three parts, it is not a single closed curve.

[0053] As shown in Fig. 6, the angle θ formed by both connecting portions (extending portions) 33 adjacent to each other in the circumferential direction is, for example, 10°. Although all the angles θ are equal in the illustrated example, they do not necessarily have to be all equal. The thickness (plate thickness dimension) t of the plate-shaped connecting portion 33 is the same as the opening diameter φ of the nozzle 11 and is, for example, 0.4 mm. The interval dimension between both small-diameter cylindrical portions 36 and 37 is the same as the interval dimension between the small-diameter cylindrical portion 36 and the inner cylindrical portion 31 and is, for example, 0.8 mm. In this illustrated example, the number of small-diameter cylindrical portions 36 and 37 located inside the inner cylindrical portion 31 (inner circumferential side) is two, but it may be one or three or more, for example.

[0054] Then, the support S after removal removed in the removal process has exactly the same shape as before removal, as shown in Fig. 8(a), and has the inner cylindrical portion 31, the outer cylindrical portion 32, the connecting portion 33, and the small-diameter cylindrical portions 36 and 37.

[0055] Therefore, after removal, the support S can be reused as a support member (a piece to be placed) that supports the support-required part MO of the model M during shaping when manufacturing the same shaped object W (a three-dimensional shaped object with the same shape) W as the shaped object W formed when shaping the support S together with the model M.

[0056] That is, when repeatedly manufacturing (shaping) the shaped object (model M) W shown in FIG. 2 by reusing the removed support S shown in FIG. 8(a) as a piece to be placed, as shown in FIG. 8(b), immediately before the support-required part MO of the model M is shaped, the shaping operation is temporarily stopped, the support S as a piece to be placed (a base for supporting the support-required part MO) is placed on the shaping table 5, and then the shaping operation is resumed to shape the support-required part MO of the model M on the piece to be placed.

[0057] And by reusing the support S as a piece to be placed in this way, without performing support shaping, also in the shaping process of support reuse where only the model M is shaped, similar to the above-mentioned shaping process, while temporarily forming a predetermined gap 20 between the removed support (piece to be placed) S and the support-required part MO of the model M, the support-required part MO is shaped.

[0058] As a result, also in this case, the model M and the support (piece to be placed) S are not firmly integrated (adhered), and therefore, even when reusing the support S as a piece to be placed, the separation between the model M and the support (piece to be placed) S in the removal process becomes easy. And the removed support S can be repeatedly used any number of times.

[0059] According to the method for manufacturing a shaped object according to the above-described embodiment, a shaping step of shaping a rough shaped object W1 having a model M that becomes the shaped object W and a support S that supports a support-required portion MO of the model M, and a removal step of removing the support S from the rough shaped object W1 by separating the model M and the support S after the shaping step are provided. In the shaping step, in order to shape the support-required portion MO while forming a slight predetermined gap 20 between the support S and the support-required portion MO of the model M, the separation between the model M and the support (support structure) S in the removal step becomes easy, and the support S can be easily removed from the rough shaped object W1. Therefore, the productivity of manufacturing the shaped object W can be improved.

[0060] Moreover, support marks are less likely to remain on the support-required portion MO of the shaped object (model M) W, and the quality of the shaped object W can also be improved.

[0061] Also, when the dimension of the predetermined gap 20 in the shaping step is H and the opening diameter of the nozzle 11 in the 3D printer 1 using the fused deposition modeling method is φ, by satisfying φ / 2 ≦ H ≦ φ, not only can the collapse of the model M in the shaping step be appropriately prevented, but also the separation between the model M and the support S in the removal step becomes easy, and the support S can be easily and appropriately removed from the rough shaped object W1.

[0062] Furthermore, the support S of the rough shaped object W1 in the shaping step has a cylindrical inner cylindrical portion 31 having an annular shape in plan view, a cylindrical outer cylindrical portion 32 having an annular shape in plan view that is located outside the inner cylindrical portion 31 and has a shape corresponding to the cylindrical inner peripheral surface of the model M, and a plurality of flat plate-shaped connecting portions (extending portions) 33 having a linear shape in plan view that extend radially outward from the inner cylindrical portion 31 and connect the inner cylindrical portion 31 and the outer cylindrical portion 32. Therefore, the separation between the model M and the support S in the removal step becomes even easier, and the support S can be removed even more easily from the rough shaped object W1.

[0063] In recent years, modeling software has evolved, and in some cases, it is possible to select a support structure that is relatively easy to remove. However, since it is easy to remove, problems such as the support being prone to collapse during modeling may occur. In the manufacturing method of this embodiment, by using the support S of a predetermined shape, such problems do not occur.

[0064] Furthermore, in the manufacturing method of this embodiment, without being restricted by modeling software, a modeling machine, etc., it is possible to easily obtain a support S that can be removed in the removal process. That is, for example, since support generation does not depend on modeling software, a desired support shape (support material) corresponding to the model shape (model material) can be modeled and embedded in the 3D modeling data, it can be applied to any thermal melting lamination type modeling machine.

[0065] In addition, since there is no problem with the model M and the support S being made of the same modeling material, there is no restriction on the number of nozzles, and there is no problem with the single head specification 3D printer 1.

[0066] Here, FIGS. 9(a) and (b) are photographs of a prototype of the modeled object W (satisfying φ / 2 ≦ H ≦ φ), and FIGS. 10(a) to (c) are photographs of a prototype of the modeled object W (not satisfying φ / 2 ≦ H ≦ φ).

[0067] Note that the lid of the modeled object (model M) W has a diameter of 53 mm, a height of 10 mm, and a thickness of 1.5 mm. Also, the nozzle diameter φ of the 3D printer 1 is 0.4 mm.

[0068] And the prototype shown in FIG. 9(a) is the case where H = 0.2 mm and D = 0.4 mm. In this case, with almost no resistance, by simply lifting the model M by hand on the modeling table 5, the model M could be easily separated from the support S on the modeling table 5. Also, on the support required part MO of the model M, some support marks can be seen, but there are no irregularities, there is no problem with the quality of the modeled object W, and there is no lamination abnormality (collapse). Furthermore, the separated support S can be reused as a spare piece.

[0069] In addition, the prototype shown in Fig. 9(b) is the case where H = 0.4 mm and D = 0.4 mm. In this case, the model M could be easily separated from the support S on the shaping table 5 just by lifting the model M by hand on the shaping table 5 without any resistance. Also, although there were slight signs of resin sagging in the necessary support part MO of the model M, there was no problem with the quality of the shaped object W, and there was no lamination abnormality (collapse). Furthermore, the separated support S could be reused as a spare piece.

[0070] On the other hand, the prototype shown in Fig. 10(a) is the case where H = 0.1 mm and D = 0.4 mm. In this case, the model M could not be separated just by lifting it by hand. After removing the rough shaped object W1 from the shaping table 5, the model M and the support S were separated using a radio pliers as a tool, but there was some resistance at that time. Also, there were traces of deformation on the support S when it was pinched by the radio pliers, and this support S could not be reused as a spare piece.

[0071] In addition, the prototype shown in Fig. 10(b) is the case where H = 0.5 mm and D = 0.4 mm. In this case, the model M could be easily separated from the support S on the shaping table 5 just by lifting the model M by hand without any resistance. However, partial lamination abnormality (collapse) occurred in the necessary support part MO of the model M.

[0072] Furthermore, the prototype shown in Fig. 10(c) is the case without a support. In this case, lamination abnormality (collapse) occurred in the necessary support part MO of the model M.

[0073] Therefore, it was confirmed from these prototypes that it is preferable to satisfy φ / 2 ≦ H ≦ φ.

[0074] In the above embodiment, the case of manufacturing the shaped object W shown in Fig. 2 has been described, but it is not limited to this. For example, the shaped object W shown in Fig. 11 can also be manufactured by the same method, and in this case, the support S can be easily removed, etc., and the same operational effects can be achieved.

[0075] That is, the shaped object W shown in FIG. 11 is, for example, a stepped, obliquely capped lid, and includes a lower cylindrical portion 41, an upper cylindrical portion 42 that is integrally provided on the inner peripheral surface of the upper end portion of the lower cylindrical portion 41 and is formed to have a smaller diameter than the lower cylindrical portion 41, and an inclined disk-shaped portion 43 that is integrally provided on the inner peripheral surface of the upper end portion of the upper cylindrical portion 42.

[0076] The upper cylindrical portion 42 and the disk-shaped portion 43 that form part of the shaped object (model M) W are support-required portions (overhang portions) MO that need to be supported by the support S so as not to collapse under their own weight during shaping (during the shaping process) by the 3D printer 1 (see FIG. 12).

[0077] FIG. 12 is a diagram schematically showing a shaped object manufacturing method (an example of the manufacturing method according to the present embodiment) for manufacturing the shaped object W shown in FIG. 11, where (a) to (e) are diagrams of the shaping process, and (f) is a diagram of the removal process.

[0078] Similar to the case of manufacturing the shaped object W shown in FIG. 2 described above, in the shaping process shown in FIG. 12, while temporarily forming a predetermined gap 20 between the support S and the support-required portion MO of the model M so as to satisfy φ / 2 ≦ H ≦ φ, the support-required portion MO is shaped. Note that the predetermined gap 20 is substantially filled by resin sag due to its own weight (see FIG. 13).

[0079] Also, the support S laminated and shaped in the shaping process shown in FIG. 12 also has an inner cylindrical portion 31, an outer cylindrical portion 32, a connecting portion 33, and smaller-diameter cylindrical portions 36, 37, as shown in FIGS. 13 to 15, similar to the case of manufacturing the shaped object W shown in FIG. 2 described above. The outer cylindrical portion 32 having a shape corresponding to the inner peripheral surface 27 of the model M is composed of a cylindrical lower cylindrical portion 32a corresponding to the lower cylindrical portion 41 and a cylindrical upper cylindrical portion 32b corresponding to the upper cylindrical portion 42.

[0080] Furthermore, the support (spare part) S after removal shown in FIG. 15 is also reusable as a spare part for supporting the support-required portion MO of the model M when manufacturing the same shaped object W, similar to the support S shown in FIG. 8.

[0081] Note that the support S according to this embodiment is not limited to those shown in FIGS. 8 and 15. For example, as shown in FIG. 16, it may have a plate-shaped spiral portion (spiral plate-shaped portion) 51 having a spiral shape (e.g., an Archimedean spiral shape, etc.) in plan view.

[0082] That is, the support S shown in FIG. 16 is composed of only one continuous plate-shaped spiral portion 51 and has a cross-sectional shape formed of a figure that can be drawn in one stroke. That is, this support S is formed by a seamless nozzle operation (continuous movement of the nozzle 11) that traces a curve (the same applies to the spiral portion and the like described later). Note that the thickness (plate thickness dimension) of the spiral portion 51 is the same as the opening diameter φ of the nozzle 11 and is, for example, 0.4 mm.

[0083] In addition, such a spiral (volute-shaped) support (support pattern) S can be designed by applying, for example, an Archimedean spiral, and the continuous function that forms the basis of its design is as follows in parametric representation.

[0084] X t =t·cos(t) Y t =t·sin(t)

[0085] And even for the support S shown in FIG. 16, a cap-shaped shaped object W as shown in FIG. 2 can be manufactured in the same manner, and in this case, the support S can be easily removed, and the same effects can be obtained.

[0086] In addition, since such a spiral support pattern is created by a continuous function, support design can be performed in a short time, and the operation of the nozzle 11 during shaping becomes smooth, and the shaping time can be shortened.

[0087] Note that the model M (a shaped object that is an object such as a product) and the support S (a reusable support member, a chess piece) according to the manufacturing method of the present embodiment are not limited to the above-described shapes, and various shapes are conceivable. For example, they may be those shown in FIGS. 17 to 32. In any case, the same effects can be achieved, such as the support S can be easily removed.

[0088] First, the model M shown in FIGS. 17(a) and 17(b) is, for example, a lid having an elliptical shape, and includes an elliptical cylindrical portion 61 and an elliptical disk-shaped portion 62 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 61. The continuous function that forms the basis of the design of the support S when forming the model M having such an elliptical shape is as follows in parametric representation. However, a ≠ b in the following.

[0089] X t =at·cos(t) Y t =bt·sin(t)

[0090] And the disk-shaped portion (upper plate portion) 62 that constitutes a part of the model M is a support-required portion MO that requires support by the support S shown in FIGS. 17(c) and 17(d) so as not to collapse due to its own weight during shaping by the 3D printer 1 (during shaping).

[0091] The support S shown in FIGS. 17(c) and 17(d) is different from the plate-shaped spiral portion 51 having a perfect circular shape shown in FIG. 16 above, and is composed of a plate-shaped spiral portion 63 having an elliptical shape.

[0092] Next, the model M shown in FIGS. 18(a) and 18(b) is, for example, a lid having a hexagonal star shape (it may also be a pentagonal star shape, an octagonal star shape, etc.), and includes a hexagonal star-shaped cylindrical portion 66 and a hexagonal star-shaped plate-shaped portion 67 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 66.

[0093] And the plate-shaped part (upper plate part) 67 that constitutes a part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 18(c) and (d) so as not to collapse under its own weight during the shaping by the 3D printer 1 (during shaping).

[0094] The support S shown in FIGS. 18(c) and (d) has a plate-shaped spiral part 68 having a perfect circular shape and a hexagonal outer peripheral plate part 69 integrally provided on the outer peripheral side of the spiral part 68. Triangular through-holes 70 are formed through the upper and lower surfaces of this outer peripheral plate part.

[0095] Next, the model M shown in FIGS. 19(a) and (b) is a lid body having a structure using, for example, a three-dimensional Archimedes spiral shape, and includes a cylindrical part 71 and a hole-forming part 73 integrally provided on the inner peripheral side of the cylindrical part 71 and having a spiral hole (spiral hole) 72 formed inside and opening downward.

[0096] And the hole-forming part 73 that constitutes a part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 19(c) and (d) so as not to collapse under its own weight during the shaping by the 3D printer 1 (during shaping).

[0097] The support S shown in FIGS. 19(c) and (d) is composed of a plate-shaped spiral part 75 whose width dimension (vertical dimension) gradually increases from the outer peripheral side toward the center side. As is clear from FIG. 19(c), this spiral part 75 has a perfect circular shape in plan view, but is not limited to this, and may have other shapes such as an elliptical shape.

[0098] Note that such a support (support pattern) S can be designed by applying, for example, the Archimedes spiral. The continuous function that is the basis of the design is as follows in parametric representation, and the specific design method is as shown in FIG. 20, for example.

[0099] X t =t·cos(t) Y t=t·sin(t) Z t =t

[0100] Next, the model M shown in FIGS. 21(a) and (b) is, for example, a lid having a perfect circular shape, and like the one shown in FIG. 2, includes a cylindrical portion 76 and a disk-shaped portion 77 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 81.

[0101] And, the disk-shaped portion 77 that constitutes a part of this model M is a support-required portion MO that needs to be supported by the support S shown in FIGS. 21(c) and (d) and FIG. 22 so as not to collapse under its own weight during shaping (during printing) by the 3D printer 1.

[0102] The support S shown in FIGS. 21(c) and (d) and FIG. 22, like the one shown in FIG. 6 etc., has an inner cylindrical portion (cylindrical portion) 81, an outermost outer cylindrical portion 82, and a plurality of plate-shaped connecting portions (extending portions) 83 that extend radially outward from the inner cylindrical portion 81 to connect the two cylindrical portions 81, 82.

[0103] Also, this support S has a plurality of, for example, two reduced-diameter cylindrical portions 86, 87 that are located inside the inner cylindrical portion 81, and these cylindrical portions 86, 87 are connected to the inner cylindrical portion 81 via a connecting portion 88 that forms a cross shape in plan view.

[0104] Furthermore, this support S has a plurality of, for example, three intermediate cylindrical portions 91, 92, 93 that are located between the inner cylindrical portion 81 and the outer cylindrical portion 82 so as to intersect the respective connecting portions 83. Note that each of the cylindrical portions 81, 82, 86, 87, 91, 92, 93 of this support S is cylindrical, but the cylindrical portion is not limited to this shape as will be described later.

[0105] Next, the model M shown in FIGS. 23(a) and (b) is, for example, a lid having a square shape, and includes a four-corner cylindrical cylindrical portion 96 and a square plate-shaped portion 97 integrally provided on the inner peripheral surface of the upper end portion of the cylindrical portion 96.

[0106] The plate-like part 97 that constitutes a part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 23(c) and (d) and FIG. 24 so as not to collapse under its own weight during the shaping (during the shaping) by the 3D printer 1.

[0107] The support S shown in FIGS. 23(c) and (d) and FIG. 24 has, similar to those shown in FIG. 6 and the like, an inner cylindrical part (cylindrical part) 101, an outermost outer cylindrical part 102, and a plurality of plate-like connecting parts (extending parts) 103 that extend radially outward from the inner cylindrical part 101 to connect the two cylindrical parts 101 and 102.

[0108] Also, this support S has a plurality, that is, for example, two additional cylindrical parts 104 and 105, located inside the inner cylindrical part 101. The additional cylindrical part 104 is connected to the inner cylindrical part 101 via a plurality of radially located connecting parts 108. On the other hand, the additional cylindrical part 105 is not connected to the additional cylindrical part 104 and is arranged separately inside the additional cylindrical part 104.

[0109] Furthermore, this support S has a plurality, for example, two intermediate cylindrical parts 106 and 107, located between the inner cylindrical part 101 and the outer cylindrical part 102 so as to intersect with each connecting part 103. In this support S, the additional cylindrical parts 104 and 105 are triangular cylindrical, the inner cylindrical part 101 is cylindrical, and the outer cylindrical part 102 and the intermediate cylindrical parts 106 and 107 are quadrangular cylindrical, but here it is not limited to the illustrated shape and any cylindrical shape is acceptable.

[0110] Next, the model M shown in FIGS. 25(a) and (b) is, for example, a lid having a circular shape, and includes a short cylindrical columnar part 111 and an annular plate-like part 112 provided integrally on the outer peripheral surface of the upper end part of this columnar part 111.

[0111] The plate-like part (flange part) 112 that constitutes a part of this model M is a support-required part MO that needs to be supported by the support S shown in FIGS. 25(c) and (d) and FIG. 26 so as not to collapse under its own weight during the shaping (during the shaping) by the 3D printer 1.

[0112] The support S shown in FIGS. 25(c) and (d) and FIG. 26 has, similar to that shown in FIG. 6 etc., an inner cylindrical portion (cylindrical portion) 116, an outermost outer cylindrical portion 117, and a plurality of plate-like connecting portions (extending portions) 118 that extend radially outward from the inner cylindrical portion 116 to connect the two cylindrical portions 116, 117.

[0113] Further, this support S has one additional cylindrical portion 119 located inside the inner cylindrical portion 116, but this additional cylindrical portion 119 is not connected to the inner cylindrical portion 116 and is separate from the inner cylindrical portion 116. And the inner peripheral surface of this additional cylindrical portion 119 is formed in a shape corresponding to the outer peripheral surface of the columnar portion 111 of the model M.

[0114] Furthermore, this support S has one intermediate cylindrical portion 120 located between the inner cylindrical portion 116 and the outer cylindrical portion 117 so as to intersect each connecting portion 118. In this support S, each of the cylindrical portions 116, 117, 119, 120 is cylindrical.

[0115] Next, the model M shown in FIGS. 27(a) and (b) is, for example, a grease trap body having a box shape with an upper surface opening, and includes a bottomed cylindrical cylindrical portion 121 having a quadrangular shape, and a quadrangular annular plate-like portion (flange portion) 122 integrally provided on the outer peripheral surface of the upper end portion of the cylindrical portion 121. Further, on the bottom plate 123 of the cylindrical portion 121, a substantially cross-shaped bulging portion 124 is formed to bulge upward, and the lower end portion of an oil-water separation member 125, which is a mounting member, is attached to this bulging portion 124 by fitting.

[0116] And the bulging portion 124 and the plate-like portion (flange portion) 122 that constitute a part of this model M are support-required portions MO that need to be supported by two separate supports S (S1, S2) shown in FIGS. 27 and 28 so as not to collapse due to their own weight during the shaping (during shaping) by the 3D printer 1.

[0117] Further, the support S1 has a plate-shaped bottom (base) 126 having a shape corresponding to the bulging portion 124 of the model M, and a plurality (for example, 10 or more) of cylindrical portions 127 erected on the upper surface of the bottom 126. Further, the support S2 has a quadrangular annular and plate-shaped bottom (base) 128 having a shape corresponding to the plate-shaped portion (flange portion) 122 of the model M, and a plurality (for example, 5 or more) of cylindrical portions 129 erected on the upper surface of the bottom 128. That is, each of the supports S1 and S2 has a support shape that does not have a radial element (extending portion) extending radially from the cylindrical portion.

[0118] Next, the model M shown in FIGS. 29(a) and (b) is a member (statue, pet tomb, etc.) imitating an animal such as a seal, and includes a cylindrical portion 131 and a dome-shaped plate-shaped portion 132 integrally provided on the upper end side of the cylindrical portion 131.

[0119] And, the plate-shaped portion 132 constituting a part of this model M is a support-required portion MO that needs to be supported by the support S shown in FIGS. 29(c) to (e) and FIG. 30 so as not to collapse under its own weight during shaping (during shaping) by the 3D printer 1. Note that FIG. 31 shows a rough-shaped object W1 composed of these model M and support S.

[0120] This support S has an inner cylindrical portion (cylindrical portion) 136, an outermost outer cylindrical portion 137, and a plurality of plate-shaped connecting portions (extending portions) 138 that extend radially outward from the inner cylindrical portion 136 and connect the two cylindrical portions 136 and 137, similar to those shown in FIG. 6 and the like.

[0121] Further, this support S has an additional cylindrical portion 139 located inside the inner cylindrical portion 136, and a rod-shaped portion (for example, a cylindrical portion or a square cylindrical portion having a cylindrical shape) 140 that is a round bar-shaped central axis portion located inside the additional cylindrical portion 139. In this support S, each of the cylindrical portions 136, 137, and 139 is cylindrical. Also, the shape of the upper surface portion of this support S is a dome shape corresponding to the plate-shaped portion 132 of the model M.

[0122] Next, the model M shown in FIG. 32 has an undercut shape, and the portion MO that needs to be supported of this model M is supported by the support S and shaped. And even in such a case, according to the shaping method of the shaped article according to the present embodiment, the support S can be easily removed from the roughly shaped article W1 after shaping, but it is necessary to destroy a part of the support S during this removal. Therefore, the support S after its removal, unlike the one described above, cannot be reused as a spare part.

[0123] Note that the 3D printer of the thermal melting lamination method, which is a shaped article manufacturing apparatus for manufacturing (shaping) the various shaped articles (models) described above, may be, for example, a large-sized pellet type 3D printer with a nozzle diameter φ of 10 mm or more. In this large-sized 3D printer, instead of a dedicated filament resin, a general pellet-shaped thermoplastic resin (which may be a recycled pellet material or the like) that can be obtained at low cost can be used as a shaping material.

[0124] Also, the shaped article manufacturing apparatus is not limited to a 3D printer of the thermal melting lamination method, and may be, for example, a 3D printer of the stereolithography method (DLP method or SLA method) or the like.

[0125] Furthermore, the three-dimensional shaped article shaped using the shaped article manufacturing apparatus is not limited to the one described above, and may be, for example, a housing, a joint, a box, etc. The type, shape, size, etc. of the shaped article are arbitrary.

[0126] Also, the shaped article manufacturing apparatus is not limited to a configuration in which a shaping head (discharging means) having a nozzle for discharging a shaping material is movable in the X-axis direction and the Z-axis direction and a shaping table is movable in the Y-axis direction. Any configuration in which the shaping head is movable relative to the shaping table in at least three dimensions is acceptable. For example, a configuration in which the shaping head is movable in the X-axis direction and the Y-axis direction and the shaping table is movable in the Z-axis direction, or a configuration in which the shaping head is provided at the tip of a robot arm (for example, a robot arm of a 6-axis robot is preferable) and is movable in any direction including three directions of the X-axis direction, the Y-axis direction, and the Z-axis direction may also be acceptable.

[0127] In addition, the dimension of a predetermined gap in the shaping process may be a clearance (a slight gap height dimension) such that the resin sag (sag of the shaping material) based on its own weight is minimized and the lower surface of the portion of the model that needs to be supported and the upper surface of the support that supports the portion that needs to be supported do not firmly integrate (adhere) to each other.

[0128] Furthermore, the support for the rough-formed object in the shaping process may have a configuration without an outer cylindrical portion, a configuration without an additional cylindrical portion, a configuration without a radially extending portion, etc.

[0129] In addition, the additional cylindrical portion located inside the inner cylindrical portion of the support may have either a configuration connected to the inner cylindrical portion (an integrated configuration) or a configuration not connected (a separate configuration), and the number, shape, etc. of the additional cylindrical portion are also arbitrary.

Explanation of Reference Numerals

[0130] 1 A 3D printer of the heat-melting lamination method, which is a shaping object manufacturing apparatus 11 Nozzle 20 Predetermined gap 31, 81, 101, 116, 136 Inner cylindrical portion, which is a cylindrical portion 32, 82, 102, 117, 137 Outer cylindrical portion 33, 83, 103, 118, 138 Connecting portion, which is an extending portion 36, 37, 86, 87, 104, 105, 119, 139 Additional cylindrical portion 51, 63, 68, 75 Spiral portion 126, 128 Bottom 127, 129 Cylindrical portion H Dimension of the predetermined gap (gap height dimension) φ Opening diameter of the nozzle (nozzle diameter) W Shaping object W1 Rough-formed object M Model MO Portion that needs to be supported (overhang portion) S Support

Claims

1. A method for manufacturing a shaped article, which uses at least one support member for supporting a portion that requires support of a model to manufacture a grease trap body having an upper surface opening and a box shape, which is a shaped article, using a shaping apparatus, wherein the grease trap body includes: a bottomed cylindrical tubular portion; a substantially cross-shaped bulge portion for attaching an oil-water separation member, which is formed in a bulging shape upward on the bottom plate of the tubular portion and to which the lower end portion of the oil-water separation member is attached by fitting; and a flange portion protruding from the outer peripheral surface of the upper end portion of the tubular portion, wherein the at least one support member is a reusable support obtained by separating from the bulge portion, which is a portion that requires support and constitutes a part of the grease trap body as a model thereof, when manufacturing the grease trap body using the shaping apparatus, wherein the support includes: a plate-shaped bottom portion having a shape corresponding to the bulge portion, which is a portion that requires support and is supported by the support; and a plurality of cylindrical portions erected on the upper surface of the bottom portion. A method for manufacturing a shaped article, characterized by the above.

2. A method for manufacturing a shaped article, which uses at least one support member for supporting a portion that requires support of a model to manufacture a grease trap body having an upper surface opening and a box shape, which is a shaped article, using a shaping apparatus, wherein the grease trap body includes: a bottomed cylindrical tubular portion; a substantially cross-shaped bulge portion for attaching an oil-water separation member, which is formed in a bulging shape upward on the bottom plate of the tubular portion and to which the lower end portion of the oil-water separation member is attached by fitting; and a flange portion protruding from the outer peripheral surface of the upper end portion of the tubular portion, wherein the at least one support member is a reusable support obtained by separating from the bulge portion, which is a portion that requires support and constitutes a part of the grease trap body as a model thereof, when manufacturing the grease trap body using the shaping apparatus, wherein the support includes: a plate-shaped spiral portion having a circular spiral shape in a plan view; and an outer peripheral plate portion integrally provided on the outer peripheral side of the spiral portion. A method for manufacturing a shaped article, characterized by the above.

3. A method for manufacturing a shaped article, which uses at least one support member for supporting a portion that requires support of a model to manufacture a grease trap body having an upper surface opening and a box shape, which is a shaped article, using a thermally melted shaping material discharging nozzle from a discharge port of a thermally melted lamination type shaping apparatus, wherein the grease trap body includes: a bottomed cylindrical tubular portion; A bulging portion for attaching an oil-water separation member, which is formed in a bulging shape upward on the bottom plate of the cylindrical portion and to which the lower end portion of the oil-water separation member is attached by fitting, and a flange portion protruding from the outer peripheral surface of the upper end portion of the cylindrical portion, wherein the at least one support member is a reusable support obtained by separating from the bulging portion, which is a support-required portion constituting a part of the grease trap body as a model thereof, when the grease trap body is manufactured using the modeling apparatus, the support comprising: a plate-shaped spiral portion having a circular spiral shape in plan view, and an outer peripheral plate portion integrally provided on the outer peripheral side of the spiral portion, wherein the spiral portion is formed by continuous movement of the nozzle and has an Archimedean spiral shape in plan view. A method for manufacturing a shaped article, characterized by the above.

Images