Method for manufacturing three-dimensional object and three-dimensional printing device

Abstract

To suppress prolongation of a molding time due to a waiting time until preparation of molding data is completed.SOLUTION: A method for manufacturing a three-dimensional molded object by molding the three-dimensional molded object by discharging a molding material from a discharge part and laminating a plurality of layers, according to molding data generated based on shape data for molding the three-dimensional molded object layer by layer, includes: a first lamination step of laminating an n-th layer when n is an arbitrary integer of 2 or more; a measurement step of measuring a physical quantity of an (n-1)-th layer; a data processing step of preparing molding data for (n+1)-th or higher layers; and a second lamination step of laminating the (n+1)-th or higher layers according to the prepared molding data. In the data processing step, any one of a correction step of preparing the molding data for the (n+1)-th or higher layers by correcting the pre-generated molding data based on the physical quantity, and a generation step of generating the molding data for the (n+1)-th or higher layers based on the physical quantity and the shape data is executed.SELECTED DRAWING: Figure 5

Description

[Technical Field]

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

[0002] Regarding the manufacture of three-dimensional objects, Patent Document 1 discloses a technology for correcting the modeling data of the nth layer to be modeled following the (n-1)th layer, based on the planar shape data of the (n-1)th layer measured by a measuring means and the amount of displacement of the shape of the (n-1)th layer predicted by a predicting means. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-217729 Summary of the Invention [Problem to be solved by the invention]

[0004] The technology of Patent Document 1 corrects the modeling data based on the planar shape of the modeled layer, so that a three-dimensional object can be precisely modeled even if the surrounding environment, etc. changes during modeling. However, because the modeling data of the layer that is modeled immediately after the layer whose planar shape has been measured is corrected, there are cases where the modeling time is prolonged due to the waiting time that occurs until the correction of the modeling data is completed. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object, which comprises stacking multiple layers by discharging a modeling material from a discharging unit provided in a three-dimensional printing device in accordance with modeling data for forming the three-dimensional object layer by layer, the modeling data being generated based on shape data representing the shape of the three-dimensional object. The method for manufacturing a three-dimensional object includes: a first stacking step of stacking an n-th layer, where n is an integer equal to or greater than 2; a measuring step of measuring physical quantities of the n-1th layer; a data processing step of preparing modeling data for the n+1th and subsequent layers; and a second stacking step of stacking the n+1th and subsequent layers in accordance with the modeling data prepared in the data processing step. The data processing step includes one of a correction step of preparing modeling data for the n+1th and subsequent layers by correcting previously generated modeling data based on the physical quantities; and a generation step of generating modeling data for the n+1th and subsequent layers based on the physical quantities and the shape data.

[0006] According to a second aspect of the present disclosure, there is provided a three-dimensional printing apparatus including a stage, a discharge unit that discharges a printing material toward the stage, a position change unit that changes the relative position of the discharge unit and the stage, a control unit that controls the discharge unit and the position change unit to discharge the printing material from the discharge unit in accordance with printing data for printing the three-dimensional object layer by layer, the printing data being generated based on shape data representing the shape of the three-dimensional object, thereby printing the three-dimensional object on the stage, and a measurement unit that measures physical quantities of the layers stacked on the stage. The control unit executes the following steps: a first stacking step of stacking an n-th layer, where n is an integer equal to or greater than 2; a measurement step of measuring the physical quantities of an n-1-th layer using the measurement unit; a data processing step of preparing printing data for n+1 or later layers; and a second stacking step of stacking the n+1 or later layers in accordance with the printing data prepared in the data processing step. In the data processing step, the control unit executes either a correction step of preparing modeling data for the (n+1)th or higher layers by correcting previously generated modeling data based on the physical quantities, or a generation step of generating modeling data for the (n+1)th or higher layers based on the physical quantities and the shape data. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus. [Figure 2] FIG. 2 is a perspective view showing a schematic configuration of the underside of the screw. [Figure 3] FIG. 2 is a schematic plan view showing the upper surface side of the barrel. [Figure 4] FIG. 1 is a schematic diagram illustrating how a three-dimensional object is formed. [Figure 5] 4 is a flowchart of a three-dimensional modeling process according to the first embodiment. [Figure 6] 10 is a flowchart of a three-dimensional modeling process according to a second embodiment. [Figure 7] 10 is a flowchart of a three-dimensional modeling process according to a third embodiment. [Figure 8] 10 is an example of a flowchart of a three-dimensional printing process for printing a second object. [Figure 9] 10 is an example of a flowchart of a three-dimensional modeling process according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] A. First embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing apparatus 100 according to a first embodiment. FIG. 1 shows arrows along the mutually orthogonal X, Y, and Z directions. The X, Y, and Z directions are directions along three mutually orthogonal spatial axes, the X axis, the Y axis, and the Z axis, and each direction includes both a direction on one side of the X axis, the Y axis, and the Z axis, and the opposite direction. The X axis and the Y axis are axes along a horizontal plane, and the Z axis is an axis along a vertical line. Arrows along the X, Y, and Z directions are also shown in other figures as appropriate. The X, Y, and Z directions in FIG. 1 and the X, Y, and Z directions in other figures represent the same directions. Hereinafter, the +Z direction will also be referred to as "up" and the -Z direction will also be referred to as "down."

[0009] The three-dimensional modeling device 100 includes a control unit 500 that controls the three-dimensional modeling device 100, a discharge unit 200 that generates and discharges modeling material, a modeling stage 300 that serves as a base for the three-dimensional object, and a position change unit 400 that controls the discharge position of the modeling material.

[0010] Under the control of the control unit 500, the discharging unit 200 melts a solid material to form a paste-like modeling material and discharges it onto the stage 300. The discharging unit 200 includes a material supply unit 20 that is a supply source of the material before it is converted into the modeling material, a plasticizing unit 30 that plasticizes the material to generate the modeling material, and a nozzle 61 that discharges the generated modeling material.

[0011] The material supply unit 20 contains material in the form of pellets, powder, or the like. In this embodiment, a resin formed into pellets is used as the material. The material supply unit 20 in this embodiment is configured as a hopper. A supply path 22 is provided below the material supply unit 20, connecting the material supply unit 20 and the plasticizing unit 30. The material supply unit 20 supplies the material to the plasticizing unit 30 via the supply path 22.

[0012] The plasticizing unit 30 includes a screw case 31, a drive motor 32, a screw 40, and a barrel 50. The plasticizing unit 30 plasticizes at least a portion of the material supplied from the material supply unit 20 to generate a fluid, paste-like modeling material, which is supplied to the nozzle 61. "Plasticization" is a concept that includes melting and refers to changing a material from a solid to a fluid state. Specifically, for materials that undergo glass transition, plasticization refers to raising the temperature of the material above the glass transition point. For materials that do not undergo glass transition, plasticization refers to raising the temperature of the material above the melting point. The screw 40 in this embodiment is sometimes called a flat screw or a scroll.

[0013] Fig. 2 is a perspective view showing a schematic configuration of the screw lower surface 48 side, which is the lower surface of the screw 40. Fig. 3 is a schematic plan view showing the barrel upper surface 52 side, which is the upper surface of the barrel 50. The screw 40 has a roughly cylindrical shape whose height in the axial direction, which is the direction along its central axis RX, is smaller than its diameter. The screw 40 is positioned so that the central axis RX, which is the center of rotation, is parallel to the Z direction.

[0014] As shown in Fig. 1, the screw 40 is housed in a screw case 31. An upper surface 47 of the screw 40 is connected to a drive motor 32, and the screw 40 rotates in the screw case 31 by the rotational driving force generated by the drive motor 32. The drive motor 32 is driven under the control of a control unit 500. The screw 40 may be driven by the drive motor 32 via a reducer.

[0015] As shown in FIG. 2, a spiral groove 42 is formed on the screw lower surface 48. The supply path 22 of the material supply unit 20 described above communicates with the groove 42 from the side surface of the screw 40. The groove 42 continues to a material inlet 44 formed on the side surface of the screw 40. This material inlet 44 is a portion that receives the material supplied via the supply path 22 of the material supply unit 20. As shown in FIG. 2, in this embodiment, three grooves 42 are formed, separated by ridges 43. The number of grooves 42 is not limited to three, and may be one, two, or more. The groove 42 is not limited to a spiral shape, but may also be a spiral shape or an involute curve shape, or may have a shape that extends in an arc from a center portion 46 to the outer periphery.

[0016] As shown in FIG. 1 , the barrel 50 is disposed below the screw 40. The barrel upper surface 52 faces the screw lower surface 48, and a space is formed between the groove 42 of the screw lower surface 48 and the barrel upper surface 52. The barrel 50 has a communication hole 56 formed on the central axis RX of the screw 40, the communication hole 56 communicating with a flow path 65 of a nozzle 61 (described later). The barrel 50 has a built-in heater 58 at a position facing the groove 42 of the screw 40. The temperature of the heater 58 is controlled by a control unit 500.

[0017] The material supplied into the groove 42 of the screw 40 is melted in the groove 42, flows along the groove 42 due to the rotation of the screw 40, and is guided to the center 46 of the screw 40 as a modeling material. The paste-like modeling material that has flowed into the center 46 and exhibits fluidity is supplied to the nozzle 61 through the communication hole 56. Note that it is not necessary for all types of substances constituting the modeling material to be melted. It is sufficient for the modeling material to be converted into a fluid state as a whole by melting at least some of the types of substances constituting the modeling material.

[0018] As shown in FIG. 1, the nozzle 61 includes a flow path 65, a tip surface 63 provided with a nozzle opening 62, and a discharge rate adjustment unit 70. The flow path 65 is a flow path for the modeling material formed within the nozzle 61 and is connected to the communication hole 56 of the barrel 50 described above. The tip surface 63 is a surface that constitutes the tip portion of the nozzle 61 that protrudes in the -Z direction toward the modeling surface 311. The nozzle opening 62 is a portion of the flow path 65 with a reduced cross section, provided at the end of the flow path 65 that communicates with the atmosphere. The modeling material generated by the plasticization unit 30 is supplied to the nozzle 61 through the communication hole 56 and discharged from the nozzle opening 62 via the flow path 65.

[0019] The discharge rate adjustment unit 70 adjusts the flow rate of the modeling material discharged from the nozzle opening 62. The flow rate of the modeling material discharged from the nozzle opening 62 to the outside is sometimes referred to as the discharge rate. In this embodiment, the discharge rate adjustment unit 70 is configured as a butterfly valve that rotates within the flow path 65 to change the opening of the flow path 65, and is provided midway along the flow path 65. The discharge rate adjustment unit 70 is driven by a drive unit 74 configured by a stepping motor or the like under the control of the control unit 500. The control unit 500 adjusts the opening of the flow path 65 by using the drive unit 74 to control the rotation angle of the butterfly valve. This allows the control unit 500 to adjust the flow rate of the modeling material flowing from the plasticizing unit 30 to the nozzle 61 and thereby adjust the discharge rate. The discharge rate adjustment unit 70 can also set the discharge rate to zero by setting the opening of the flow path 65 to zero. In other words, the discharge rate adjustment unit 70 adjusts the discharge rate and also controls the on / off control of the delivery of the modeling material.

[0020] In this embodiment, the nozzle 61 is provided with a nozzle heater 69. The nozzle heater 69 in this embodiment is provided around the flow path 65 and heats the modeling material in the flow path 65 under the control of the control unit 500. The control unit 500 can adjust the fluidity of the modeling material in the flow path 65 by controlling the output of the nozzle heater 69.

[0021] The stage 300 is disposed at a position facing the nozzle 61. As will be described later, the three-dimensional modeling device 100 forms a three-dimensional object by ejecting a modeling material from the nozzle 61 toward a modeling surface 311 of the stage 300 and stacking layers.

[0022] The position changer 400 changes the relative position of the nozzle 61 and the stage 300. In this embodiment, the position changer 400 moves the stage 300 relative to the nozzle 61. Note that a change in the relative position of the nozzle 61 relative to the stage 300 may simply be referred to as movement of the nozzle 61. In this embodiment, for example, moving the stage 300 in the +X direction can also be rephrased as moving the nozzle 61 in the -X direction. The position changer 400 in this embodiment is configured with a three-axis positioner that moves the stage 300 in three axial directions, that is, the X, Y, and Z directions, using the driving forces of three motors. Each motor is driven under the control of the control unit 500. Note that the position changer 400 may not be configured to move the stage 300, but may be configured to move the nozzle 61 without moving the stage 300. Alternatively, the position changer 400 may be configured to move both the stage 300 and the nozzle 61.

[0023] The measurement unit 550 measures physical quantities of the layer stacked on the build surface 311 of the stage 300. In this embodiment, the measurement unit 550 includes an infrared camera 560, two cameras 570, and a measurement control unit 580 that controls the infrared camera 560 and the camera 570. The measurement control unit 580 in this embodiment is a functional unit realized by the control unit 500 executing a program. In this embodiment, the measurement control unit 580 measures the layer temperature and the dimensions and position of each part of the layer as physical quantities of the layer. More specifically, the measurement control unit 580 measures the layer temperature based on thermography by the infrared camera 560 and measures the dimensions and position of each part of the layer based on the parallax between the two cameras 570. In other embodiments, the measurement unit 550 may include, for example, a laser rangefinder in addition to or instead of the camera 570 as a sensor for measuring the dimensions and position of the layer. For example, the measuring unit 550 may not include the camera 570, and may use thermography by the infrared camera 560 to measure the dimensions and positions of the layers. The measuring unit 550 may distinguish the layer that was just laminated from other layers, for example, based on the image by the camera 570 and the thermography by the infrared camera 560. Furthermore, the measuring unit 550 may measure the physical quantities over the entire layer, or may measure the physical quantities in a portion of the layer.

[0024] The control unit 500 is a control device that controls the overall operation of the 3D printing apparatus 100. The control unit 500 is configured by a computer having one or more processors, a main memory device, and an input / output interface that inputs and outputs signals to and from the outside. The control unit 500 performs various functions, such as the function of the measurement control unit 580 described above and the function of executing the 3D printing process described below, by the processor executing programs and instructions loaded into the main memory device. Note that the control unit 500 may be configured by combining multiple circuits that realize at least some of the functions, instead of being configured by a computer.

[0025] The three-dimensional printing process refers to a process for printing a three-dimensional object. The three-dimensional printing process is executed by the control unit 500 when a user performs a predetermined start operation on an operation panel provided in the three-dimensional printing device 100 or on a computer connected to the three-dimensional printing device 100. The three-dimensional printing process is sometimes simply referred to as the printing process.

[0026] FIG. 4 is a schematic diagram illustrating how a three-dimensional object OB is formed by the three-dimensional modeling process. In the modeling process, the control unit 500 appropriately controls the discharge unit 200 and the position change unit 400 in accordance with modeling data (described later) to discharge the modeling material from the nozzle 61 of the discharge unit 200 toward the stage 300, and stacks layers of the modeling material in the Z direction on the modeling surface 311, thereby forming the three-dimensional model OB. Specifically, as shown in FIG. 4, the control unit 500 discharges the modeling material from the nozzle 61 while moving the nozzle 61 in a direction along the modeling surface 311. The modeling material discharged from the nozzle 61 is continuously deposited in the movement direction of the nozzle 61. This forms a linear part along the movement path of the nozzle 61. Furthermore, the control unit 500 forms layers of the modeling material by discharging additional modeling material on the already discharged modeling material. In the modeling process, the control unit 500 discharges the modeling material from the nozzle 61 while maintaining the distance between the nozzle 61 and the discharge target. The discharge target is the modeling surface 311 when the modeling material is discharged onto the modeling surface 311, and is the upper surface of the already discharged modeling material when the modeling material is discharged onto an already discharged modeling material. The distance between the nozzle 61 and the discharge target is sometimes referred to as the gap Gp.

[0027] The modeling data is data for modeling a three-dimensional object layer by layer, and includes path data and discharge amount information. The path data refers to data that represents the path along which the discharging unit 200 moves while discharging the modeling material, using multiple partial paths. The discharge amount information refers to information that represents the amount of modeling material discharged on each partial path. The modeling data is generated based on shape data of the three-dimensional object. The shape data refers to data that represents the shape of the three-dimensional object, such as three-dimensional CAD data.

[0028] In this embodiment, the path data specifies linear partial paths that represent the path along which the nozzle 61 moves while discharging the modeling material. The discharge amount information specifies the layer pitch and line width for each partial path. The layer pitch refers to the thickness of the modeling material discharged along each partial path. The line width refers to the width of the modeling material discharged along each partial path. The layer pitch and line width are determined by the size of the gap Gp described above and the amount of modeling material discharged from the nozzle 61 per unit movement distance. For example, when the gap Gp is small, the modeling material discharged from the nozzle 61 is pressed more firmly against the discharge target by the nozzle 61 than when the gap Gp is large, resulting in a smaller layer pitch and a larger line width. The amount of modeling material discharged from the nozzle 61 per unit movement distance is determined by, for example, the movement speed of the nozzle 61 and the amount of modeling material discharged from the nozzle 61 per unit time. The amount of modeling material discharged from the nozzle 61 per unit time is determined by, for example, the opening diameter of the nozzle opening 62, the flow rate of the modeling material flowing through the nozzle 61, and the like.

[0029] 5 is a flowchart of a three-dimensional printing process that realizes a method for manufacturing a three-dimensional object in this embodiment. In step S110, the control unit 500 acquires printing data for all layers. In step S110, the control unit 500 acquires the printing data, for example, by communication with an external computer.

[0030] In step S120, the control unit 500 executes a determination step of determining whether the modeling data is compatible with the 3D modeling apparatus 100. As shown in FIG. 5 , the determination step in step S120 is executed prior to step S130 (described later) and the first lamination steps of steps S150 to S170. In this embodiment, in step S120, the control unit 500 analyzes, for example, the number of nozzles and the modeling method required to model a 3D model in accordance with the modeling data acquired in step S110, and determines that the modeling data is compatible with the 3D modeling apparatus 100 if the number of nozzles and the modeling method match the number of nozzles 61 and the modeling method of the 3D modeling apparatus 100. In another embodiment, the control unit 500 may determine that the modeling data is compatible with the 3D modeling apparatus 100 if, for example, a header section of the modeling data contains specific identification information.

[0031] If it is determined in step S120 that the modeling data is not suitable for the 3D modeling device 100, the control unit 500 proceeds to step S125, where it displays an error on a notification unit (not shown) configured by a speaker, LCD monitor, or the like, to notify the user that the modeling data is not suitable for the 3D modeling device 100. The control unit 500 then terminates the 3D modeling process. In other embodiments, if it is determined in step S120 that the modeling data is not suitable for the 3D modeling device 100, the control unit 500 may return the process to step S110, for example, and acquire modeling data different from the previously acquired modeling data.

[0032] In step S130, the control unit 500 stacks the bottom layer of the three-dimensional object. In step S130, the control unit 500 stacks the bottom layer by controlling the discharging unit 200 and the position changing unit 400 in accordance with the modeling data for forming the first layer, which is included in the modeling data acquired in step S110.

[0033] After step S140, the control unit 500 repeatedly executes steps S140 to S170 as one cycle, thereby stacking layers of the three-dimensional object from the second layer to the layer immediately below the top layer. In this embodiment, the control unit 500 stacks one layer of the three-dimensional object in one cycle. Hereinafter, when n is an integer equal to or greater than 2, a cycle for stacking the nth layer of the three-dimensional object may be referred to as the nth cycle. That is, in the nth cycle, the control unit 500 stacks the nth layer as the current layer. For example, when step S140 is executed for the first time since the start of the three-dimensional printing process, the second cycle is started in step S140, and the second layer is stacked as the current layer. Hereinafter, the nth layer may be simply referred to as the "nth layer."

[0034] In step S140, control unit 500 controls measurement unit 550 to measure the physical quantities of the (n-1)th layer that was modeled prior to the nth layer. That is, in step S140, control unit 500 measures the physical quantities of the layer immediately preceding the current layer. For example, in step S140 in the second cycle, the physical quantities of the first layer are measured. Similarly, in step S140 in the third cycle, the physical quantities of the second layer are measured. Hereinafter, the step of measuring the physical quantities of the (n-1)th layer, such as in step S140, may also be referred to as the measurement step.

[0035] In step S150, the control unit 500 starts stacking the nth layer, which is the current layer. After step S150, the control unit 500 stacks the nth layer by controlling the discharging unit 200 and the position changing unit 400 in accordance with the modeling data for modeling the nth layer until the stacking of the nth layer is completed in step S170, which will be described later. Hereinafter, the modeling data for stacking the nth layer may simply be referred to as the "modeling data for the nth layer." Similarly, the modeling data for stacking the first layer may also be referred to as the "modeling data for the first layer," and the modeling data for stacking the top layer may also be referred to as the "modeling data for the top layer." Furthermore, the process of stacking the nth layer, such as steps S150 to S170 in the nth cycle, may also be referred to as the first stacking process.

[0036] In steps S150 to S170 of the second cycle, the control unit 500 models the second layer in accordance with the modeling data of the second layer included in the modeling data acquired in step S110. On the other hand, in steps S150 to S170 of the third cycle and subsequent cycles, the control unit 500 models the nth layer in accordance with the modeling data prepared in step S160 of the (n-1)th cycle, which will be described later. For example, in the third cycle, the control unit 500 models the third layer in accordance with the modeling data prepared in the second cycle.

[0037] In step S160, the control unit 500 executes a data processing step. The data processing step refers to a step of preparing modeling data for the (n+1)th or higher layer, which is a layer subsequent to the current layer. In this embodiment, the control unit 500 executes a correction step in the data processing step of step S160. The correction step refers to a step of preparing modeling data for the (n+1)th or higher layer by correcting previously generated modeling data based on measured values of physical quantities. In this embodiment, the control unit 500 prepares modeling data for only one layer in the data processing step.

[0038] More specifically, in this embodiment, in step S160, the control unit 500 prepares the modeling data for the (n+1)-th layer by correcting the modeling data for the (n+1)-th layer acquired in step S110 based on the measured values of the physical quantities of the (n-1)-th layer measured in step S140. For example, in step S160 of the second cycle, the control unit 500 prepares the modeling data for the third layer by correcting the modeling data for the third layer acquired in step S110 based on the measured values of the physical quantities of the first layer that was laminated in accordance with the modeling data acquired in step S110. In addition, in step S160 of the fourth cycle, the control unit 500 prepares the modeling data for the fifth layer by correcting the modeling data for modeling the fifth layer based on the measured values of the physical quantities of the third layer that was laminated in accordance with the modeling data prepared in step S160 of the second cycle.

[0039] In this embodiment, in the second and third cycles, the control unit 500 corrects the modeling data of the (n+1)th layer acquired in step S110 based on the difference between the measured shape and the predicted shape of the (n-1)th layer in the correction process of step S160. The measured shape refers to the shape of a layer calculated based on measured values of physical quantities. The predicted shape refers to the shape of a layer predicted based on modeling data. In this embodiment, the predicted shape is predicted based on the modeling data acquired in step S110. The measured shape and the predicted shape may be shapes of corresponding parts, and each may be the shape of a part of a layer. For example, if the dimensions of the contour of the (n-1)th layer calculated based on the measured values of physical quantities are larger than the predicted dimensions of the contour of the (n-1)th layer in step S160, the control unit 500 corrects the modeling data of the (n+1)th layer so that the contour of the (n+1)th layer modeled in accordance with the corrected modeling data is smaller than the contour of the (n+1)th layer modeled in accordance with the uncorrected modeling data. In this case, the control unit 500 corrects the modeling data, for example, by multiplying the length of the partial path and the discharge amount contained in the modeling data of the n+1th layer before correction by a correction coefficient calculated based on the difference between the actual shape and the predicted shape of the n-1th layer.

[0040] In the fourth cycle and thereafter, in step S160, the control unit 500 corrects the shaping data of the (n+1)th layer based on the difference between the measured shape and the predicted shape of the (n-1)th layer and the difference between the corrected shaping data of the (n-1)th layer and the uncorrected shaping data of the (n-1)th layer. For example, the corrected shaping data of the fifth layer is shaping data obtained by correcting the uncorrected shaping data of the fifth layer acquired in step S110 based on the difference between the measured shape and the predicted shape of the third layer and the difference between the corrected shaping data of the third layer and the uncorrected shaping data of the third layer. As described above, the corrected shaping data of the third layer is shaping data obtained by correcting the uncorrected shaping data of the third layer based on the difference between the measured shape and the predicted shape of the first layer. Therefore, it can be said that the shaping data of the fifth layer is corrected based on the difference between the measured shape and the predicted shape of the third layer and the difference between the measured shape and the predicted shape of the first layer.

[0041] The difference between the measured shape and the predicted shape described above occurs due to changes in the actual amount, position, temperature, etc. of the modeling material being discharged, caused by changes in the modeling environment, such as temperature and humidity, or deterioration over time of the discharging unit 200. By performing the correction process in step S160, the possibility of accurately manufacturing a three-dimensional model increases even when there is a change in the modeling environment or deterioration over time of the discharging unit 200.

[0042] The modeling data for the (n+1)th or higher layers prepared in the data processing step of step S160 is used to model the (n+1)th or higher layers in the nth cycle and subsequent cycles. In this embodiment, the modeling data for the (n+1)th layer prepared in step S160 of the nth cycle is used to model the (n+1)th layer in steps S150 to S170 of the (n+1)th cycle. This process of stacking the (n+1)th or higher layers in accordance with the modeling data prepared in the data processing step is sometimes referred to as the second stacking process. In this embodiment, for example, if the current cycle is the second cycle, steps S150 to S170 of the second cycle are the first stacking process, and steps S150 to S170 of the third cycle are the second stacking process. Similarly, if the current cycle is the third cycle, steps S150 to S170 of the third cycle are the first lamination step, and steps S150 to S170 of the fourth cycle are the second lamination step.

[0043] In step S170, the control unit 500 completes the modeling of the nth layer. That is, in this embodiment, the control unit 500 completes the data processing step of step S160 described above while the first lamination step is being performed, that is, between the start and completion of lamination of the nth layer, which is the current layer.

[0044] In step S180, the control unit 500 determines whether the layer to be modeled next is the uppermost layer. If the control unit 500 determines in step S180 that the layer to be modeled next is not the uppermost layer, the control unit 500 returns the process to step S140 and starts the next cycle.

[0045] If it is determined in step S180 that the next layer to be modeled is the top layer, the control unit 500 models the top layer in step S190. In step S190, the control unit 500 models the top layer in accordance with the modeling data for modeling the top layer prepared in the immediately preceding step S160. For example, if the top layer is the tenth layer, the control unit 500 models the tenth layer in accordance with the modeling data corrected in step S160 of the ninth cycle.

[0046] The manufacturing method of a three-dimensional object according to the present embodiment described above includes a first lamination step of laminating an nth layer, a measurement step of measuring physical quantities of the n-1th layer, a data processing step of preparing modeling data for the n+1th and subsequent layers, and a second lamination step of laminating the n+1th and subsequent layers in accordance with the modeling data prepared in the data processing step. The data processing step includes a correction step of preparing modeling data for the n+1th and subsequent layers by correcting predetermined modeling data based on measured physical quantities. This allows the nth layer to be modeled while preparing the modeling data for the n+1th and subsequent layers. This reduces the waiting time required for the modeling data to be prepared, compared to preparing the modeling data for the nth layer based on measured physical quantities. This increases the likelihood of accurately modeling a three-dimensional object and minimizes the time required for modeling.

[0047] In addition, in this embodiment, the data processing step is completed while the first lamination step is being performed, which makes it possible to further reduce the waiting time until the preparation of the modeling data is completed, and further prevent the modeling time from being prolonged.

[0048] Furthermore, in this embodiment, before the first lamination step is performed, a determination step is provided in which it is determined whether or not the modeling data is compatible with the three-dimensional modeling device 100. Therefore, a three-dimensional model can be formed using modeling data that is compatible with the three-dimensional modeling device 100.

[0049] In this embodiment, the modeling data for one layer is prepared as the modeling data for the (n+1)th or higher layer in one data processing step, which reduces the waiting time until the modeling data preparation is completed compared to when the modeling data for multiple layers is prepared in one data processing step.

[0050] B. Second embodiment: FIG. 6 is a flowchart of a three-dimensional printing process that realizes a manufacturing method of a three-dimensional object in the second embodiment. In this embodiment, the control unit 500 prepares printing data for the (n+1)th or higher layer by executing a generation process rather than a correction process in the data processing process. The generation process refers to a process of generating printing data for the (n+1)th or higher layer based on measured values of the physical quantities of the (n-1)th layer and shape data of the three-dimensional object. Parts of the configuration of the three-dimensional printing apparatus 100 in this embodiment that are not particularly described are the same as those in the first embodiment.

[0051] In step S205, the control unit 500 acquires shape data of the three-dimensional object. Hereinafter, the shape data acquired in step S205 may also be referred to as "initial shape data."

[0052] In step S210, the control unit 500 generates layer data in which the shape of the three-dimensional object represented by the shape data is sliced into layers, based on the shape data acquired in step S205. In this embodiment, in step S210, the control unit 500 generates layer data for all layers of the three-dimensional object, from the bottom layer to the top layer, so that the shapes represented by each layer data have the same thickness. The layer pitch specified in the discharge amount information of the modeling data is determined by the thickness represented by the layer data. Hereinafter, the layer data representing the shape of the portion corresponding to the nth layer of the three-dimensional object may be simply referred to as the "layer data of the nth layer." Similarly, the layer data representing the shape of the first layer or the top layer may be simply referred to as the "layer data of the first layer" or the "layer data of the top layer."

[0053] In step S215, the control unit 500 generates modeling data for the bottom layer and modeling data for the second layer. In step S215, the control unit 500 determines, from the layer data generated in step S210, path data and discharge amount data for modeling the shape represented in the layer data for the first layer, and path data and discharge amount data for modeling the shape represented in the layer data for the second layer, thereby generating each modeling data.

[0054] In this embodiment, the path data and discharge amount data included in each modeling data are determined based on the layer data of each layer and the modeling conditions of the 3D model. The modeling conditions in this embodiment include the set temperature of the nozzle heater 69 and the internal filling rate of each layer of the 3D model. For example, the higher the set temperature of the nozzle heater 69, the greater the fluidity of the modeling material discharged from the nozzle 61, resulting in a larger amount of modeling material being discharged per unit time. Therefore, the control unit 500 determines the discharge amount data so that, for example, the higher the set temperature of the nozzle heater 69, the smaller the amount of modeling material discharged per partial path. Furthermore, the control unit 500 determines the path data so that the longer and the larger the number of partial paths required to fill the interior of the outer shell of each layer, the higher the internal filling rate. In other embodiments, the modeling conditions may include other conditions. For example, the modeling conditions may include a cooling time, which refers to the waiting time required for the stacked layers to cool, or, if the 3D modeling apparatus 100 is equipped with a cooling mechanism, such as a cooling fan, for cooling the stacked layers. The modeling conditions may also include the set value of the cooling mechanism's output.

[0055] In step S220, the control unit 500 models the bottom layer in accordance with the modeling data for modeling the bottom layer generated in step S215.

[0056] After step S225, the control unit 500 repeatedly executes steps S225 to S250 as one cycle, in the same way as in the first embodiment where steps S140 to S170 in FIG. 5 are repeatedly executed as one cycle, thereby forming the second layer of the three-dimensional object through the layer immediately below the top layer.

[0057] Step S225 is the same as step S140 in FIG. 5. In step S230, the control unit 500 starts laminating the n-th layer as the current layer. Hereinafter, steps S230 to S250 in the n-th cycle may be referred to as the first lamination process, similar to steps S150 to S170 in the n-th cycle in FIG. 5 described in the first embodiment. In steps S230 to S250 in the second cycle, the control unit 500 models the second layer in accordance with the modeling data for modeling the second layer generated in step S215. On the other hand, in the lamination processes from the third cycle onwards, the control unit 500 models the n-th layer in accordance with the modeling data prepared in the (n-1)th cycle, which will be described later.

[0058] Steps S235 to S245 in this embodiment correspond to the generation step of the data processing step described above. Hereinafter, steps S235 to S245 may be simply referred to as the data processing step or the generation step. In this embodiment, as in the first embodiment, in the nth cycle of the data processing step, the control unit 500 prepares only the modeling data for the (n+1)th layer as the modeling data.

[0059] In step S235, the control unit 500 corrects the initial shape data acquired in step S205 based on the measured values of the physical quantities of the (n-1)th layer measured in step S225. In this embodiment, as will be described later, the shape data corrected in step S235 of the nth cycle is used to generate modeling data for the (n+1)th layer. In step S235 of the second and third cycles, the control unit 500 corrects the entire shape data acquired in step S205 based on the difference between the measured shape of the (n-1)th layer and the shape in the data. In this embodiment, the shape in the data refers to the shape represented in the layer data generated in step S210. As with the predicted shape described in the first embodiment, the shape in the data may be the shape of a portion corresponding to the measured shape, or may be the shape of a portion of the layer. For example, in step S235, if the dimensions of the contour of the (n-1)th layer calculated based on the measured physical quantities are larger than the dimensions of the contour of the shape of the (n-1)th layer represented in the layer data, the control unit 500 corrects the initial shape data so that the shape represented in the corrected shape data is smaller than the shape represented in the initial shape data. In this case, the control unit 500 corrects the initial shape data, for example, by multiplying the initial shape data by a correction coefficient calculated based on the difference between the measured shape and the shape in the data. The difference between the measured shape and the shape in the data occurs, for example, due to changes in the modeling environment or aging deterioration of the discharge unit 200, similar to the difference between the measured shape and the predicted shape described in the first embodiment.

[0060] In step S235 of the fourth cycle and thereafter, the control unit 500 corrects the initial shape data based on not only the difference between the measured shape of the n-1th layer and the shape in the data, but also the difference between the shape data used to generate the modeling data of the n-1th layer and the initial shape data, i.e., the difference between the shape data corrected in step S235 of the n-2th cycle and the initial shape data. For example, in step S235 of the fourth cycle, the control unit 500 corrects the initial shape data based on the difference between the measured shape of the third layer and the shape in the data, and the difference between the shape data corrected in step S235 of the second cycle and the initial shape data, in order to generate modeling data of the fifth layer in step S245, which will be described later. As described above, the shape data corrected in step S235 of the second cycle is shape data corrected based on the difference between the measured shape of the first layer and the shape in the data. Therefore, in step S235 of the fourth cycle, the initial shape data is corrected based on the difference between the measured shape of the third layer and the shape in the data, and the difference between the measured shape of the first layer and the shape in the data.

[0061] In other embodiments, the shape in the data described above may not be the shape represented in the layer data, but may be, for example, the shape of a portion of the shape represented in the initial shape data that corresponds to the measured shape. In this case, the control unit 500 may not generate layer data for all layers in step S210, but may generate, for example, layer data for only the first layer and the second layer.

[0062] In step S240, the control unit 500 generates layer data for the (n+1)th and higher layers based on the shape data corrected in step S235. In this embodiment, the control unit 500 generates only layer data for the (n+1)th layer in step S240. In step S240, the control unit 500 generates layer data for the (n+1)th layer based on the corrected shape data, in the same way as it generated layer data based on the uncorrected shape data in step S210.

[0063] In this embodiment, in step S240, the control unit 500 determines the thickness represented by the layer data generated in step S240 based on the measured values of the physical quantities measured in step S225. In this embodiment, the control unit 500 determines the thickness represented by the layer data of the (n+1)th layer in accordance with a change in the dimension in the Z direction represented by the shape data due to the correction performed in step S235. For example, if the control unit 500 corrects the shape data in step S235 so that the dimension in the Z direction of the shape represented by the shape data is increased, in step S240, the control unit 500 makes the thickness represented by the layer data of the (n+1)th layer larger than the thickness represented by the layer data of each layer generated in step S210.

[0064] In step S245, the control unit 500 generates modeling data for the (n+1)th or higher layer based on the layer data generated in step S240. In this embodiment, in step S245, the control unit 500 generates modeling data for the (n+1)th layer by determining path data and discharge amount data for modeling the shape represented in the layer data of the (n+1)th layer based on the layer data of the (n+1)th layer generated in step S240.

[0065] Steps S250 and S255 are similar to steps S170 and S180 in Fig. 5. If the control unit 500 determines in step S255 that the layer to be modeled next is not the uppermost layer, the control unit 500 returns the process to step S225 and starts the next cycle.

[0066] The method for manufacturing a three-dimensional object according to the present embodiment described above also allows the nth layer to be modeled while the modeling data for the (n+1)th or later layer is being prepared. This reduces the waiting time until the modeling data preparation is complete, compared to when modeling data for the nth layer is prepared based on measured values of the physical quantities of the (n-1)th layer. This increases the likelihood of accurately modeling a three-dimensional object and reduces the length of the modeling time. In particular, in the present embodiment, the data processing step generates modeling data for the (n+1)th or later layer based on measured values of the physical quantities and shape data of the three-dimensional object. This allows new modeling data for the (n+1)th or later layer to be generated based on measured values of the physical quantities. This increases the likelihood of preparing modeling data capable of modeling a three-dimensional object having a desired shape, compared to when modeling data for the (n+1)th or later layer is prepared by correcting the modeling data.

[0067] In this embodiment, the shape data is corrected based on the measured values of the physical quantities, layer data is generated based on the corrected shape data, and modeling data for the (n+1)th or higher layers is generated based on the generated layer data. This corrects the shape data based on the measured values of the physical quantities, which further increases the possibility of preparing modeling data capable of modeling a three-dimensional object having a desired shape.

[0068] Furthermore, in the generation process of this embodiment, the thickness of the shape represented by the layer data is determined based on the measured values of the physical quantities, which can further improve the modeling accuracy of the three-dimensional object in the Z direction.

[0069] C. Third embodiment: FIG. 7 is a flowchart of a three-dimensional printing process that realizes a manufacturing method of a three-dimensional object according to the third embodiment. In this embodiment, unlike the second embodiment, the control unit 500 determines printing conditions for the (n+1)th and subsequent layers based on the measured values of the physical quantities of the (n-1)th layer in the generation process, and generates printing data for the (n+1)th and subsequent layers based on the shape data and the determined printing conditions. In FIG. 7, the same steps as in FIG. 6 are denoted by the same reference numerals as in FIG. 6. Portions of the configuration of the three-dimensional printing apparatus 100 according to this embodiment that are not specifically described are the same as those in the second embodiment.

[0070] In step S243, the control unit 500 determines the modeling conditions for the (n+1)th or higher layers based on the measured values of the physical quantities of the (n-1)th layer. In this embodiment, the control unit 500 determines the modeling conditions for the (n+1)th layer based on the physical quantities of the (n-1)th layer measured in step S225. For example, if the measured value of the temperature of the (n-1)th layer measured in step S225 is lower than the predicted value, the control unit 500 sets the set temperature of the nozzle heater 69 for modeling the (n+1)th layer higher than the set temperature of the nozzle heater 69 for modeling the (n-1)th layer based on the difference between the measured value and the predicted value. Furthermore, for example, if deformation of the (n-1)th layer is detected in step S225, the control unit 500 determines the internal filling rate for modeling the (n+1)th layer so as to suppress deformation of the (n+1)th layer. For example, if deflection of the (n-1)th layer is detected in step S225, the internal filling rate when forming the (n+1)th layer is set higher than the internal filling rate when forming the (n-1)th layer, based on the degree of deflection. The degree of deflection is calculated based on, for example, the dimensions of the (n-1)th layer, the position of the edge portion, etc., measured as physical quantities of the (n-1)th layer by the measurement unit 550. In another embodiment, the control unit 500 may determine a pattern of partial paths for forming the internal shape of the (n-1)th layer so as to suppress, for example, deformation of the (n+1)th layer. Furthermore, as described in the second embodiment, if the forming conditions include a cooling time and an output value of the cooling mechanism, the control unit 500 may determine, in step S243, the cooling time and the output value of the cooling mechanism based on the temperature of the (n-1)th layer measured in step S225.

[0071] In step S245b, the control unit 500 generates modeling data for the (n+1)th or higher layer. In this embodiment, in step S245b, the control unit 500 determines path data and discharge amount information in the modeling data for the (n+1)th layer based on the modeling conditions determined in step S243, and generates modeling data for the (n+1)th layer. For example, in step S245b, the control unit 500 determines a partial path for modeling the (n+1)th layer based on the internal filling rate determined in step S243, and determines path data. In addition, in step S245b, the control unit 500 determines the discharge amount in the modeling data for the (n+1)th layer based on the set temperature of the nozzle heater 69 determined in step S243. For example, if the set temperature of the nozzle heater 69 when modeling the (n+1)th layer is increased in step S243, the control unit 500 reduces the rotation speed or set pressure of the screw 40 in the modeling data for the (n+1)th layer based on the set temperature.

[0072] Then, in steps S230 to S250 of the n+1th cycle, the control unit 500 forms the n+1th layer under the forming conditions determined in step S243 of the nth cycle described above and in accordance with the forming data generated in S245b of the nth cycle.

[0073] According to the manufacturing method of the three-dimensional object in this embodiment described above, the modeling conditions for the (n+1)th and subsequent layers are determined based on the measured values of the physical quantities of the (n-1)th layer, and modeling data for the (n+1)th and subsequent layers is generated based on the shape data of the three-dimensional object and the determined modeling conditions. Therefore, it is possible to change the modeling conditions based on the measured values of the physical quantities, and to accurately model a three-dimensional object under the changed modeling conditions.

[0074] In another embodiment, the control unit 500 may not correct the shape data in the generation process. In this case, the control unit 500 may determine the modeling conditions based on the measurement values of the physical quantities of the (n-1)th layer without correcting the shape data in the generation process, and generate the modeling data of the (n+1)th or later layers based on the uncorrected shape data and the determined modeling conditions.

[0075] D. Fourth embodiment: FIG. 8 is an example of a flowchart of a three-dimensional printing process for forming a second object in the fourth embodiment. In the fourth embodiment, the control unit 500 executes the three-dimensional printing process twice in succession to manufacture a first object and a second object having a shape corresponding to that of the first object, as three-dimensional objects. The second object is formed after the first object is formed. In this embodiment, the first object and the second object have the same dimensions and shapes in each part. Portions of the configuration of the three-dimensional printing device 100 in this embodiment that are not particularly described are the same as those in the first embodiment.

[0076] In this embodiment, the modeling data used in manufacturing the first object is used in manufacturing the second object. For example, the control unit 500 first executes the 3D modeling process of FIG. 5 to model and manufacture the first object while executing the first layering process, the second layering process, the measurement process, and the data processing process. After completing the modeling of the first object, the control unit 500 executes the 3D modeling process of FIG. 8 and acquires the modeling data actually used in manufacturing the first object in step S310. More specifically, in step S310, the control unit 500 acquires uncorrected modeling data for the first and second layers of the first object, and modeling data for the third and subsequent layers of the first object that have been corrected based on the measured values of the physical quantities. Next, in step S320, the control unit 500 layers a modeling material on the modeling surface 311 of the stage 300 in accordance with the modeling data acquired in step S310, thereby manufacturing the second object. That is, in this embodiment, the control unit 500 uses the modeling data used in manufacturing the first object as is, without correcting it, in manufacturing the second object.

[0077] According to the method for manufacturing a three-dimensional object in this embodiment described above, the modeling data used to manufacture a first object is used to manufacture a second object having a shape corresponding to that of the first object. This increases the possibility of manufacturing the second object with high accuracy compared to manufacturing the second object without using the modeling data of the first object. In particular, in this embodiment, the modeling data used to manufacture the first object is used directly to manufacture the second object without correction, allowing the second object to be manufactured efficiently.

[0078] In other embodiments, when manufacturing a second object using the printing data used in manufacturing the first object, the three-dimensional printing process of Fig. 5 may be executed, for example. In this case, by acquiring the printing data used in manufacturing the first object in step S110 of Fig. 5, the printing data can be further corrected while manufacturing the second object, thereby increasing the possibility of manufacturing the second object with higher accuracy. Furthermore, when manufacturing the first object, the three-dimensional printing process of Fig. 6 or 7 may be executed instead of the three-dimensional printing process of Fig. 5.

[0079] In other embodiments, the first and second objects do not have to have the same shape. For example, the first and second objects may be similar objects, or the second object may be an object obtained by enlarging or reducing the first object by a certain factor in the X, Y, or Z directions. In this case, the control unit 500 may, for example, correct the modeling data used to manufacture the first object based on the dimensional ratio between the first and second objects, and use the corrected modeling data based on the dimensional ratio to manufacture the second object.

[0080] FIG. 9 is an example flowchart of a three-dimensional printing process for printing a first object according to another embodiment. As shown in FIG. 9, in another embodiment, the printing data used in manufacturing the first object may not be used in manufacturing the second object. Instead, the printing data for the second object may be corrected based on the measured physical quantities of each layer measured when manufacturing the first object. Note that in FIG. 9, the same steps as in FIG. 5 are denoted by the same reference numerals as in FIG. 5. In the example of FIG. 9, in step S110b, the control unit 500 acquires printing data for printing the first object and printing data for printing the second object. In step S110b, the acquired printing data may be, for example, one type of printing data common to both objects. Then, after completing the stacking of the first object up to the layer just below the top layer, the control unit 500 measures the physical quantities of the layer just below the top layer of the first object in step S185. Furthermore, after stacking the top layer of the first object in step S190, the control unit 500 measures the physical quantities of the top layer of the first object in step S192. That is, in this embodiment, the control unit 500 measures the physical quantities of all layers of the first object from the bottom layer to the top layer.

[0081] In step S194, the control unit 500 corrects the printing data for printing the second object acquired in step S110b, based on the measured physical quantities of the first object. In this embodiment, the control unit 500 corrects the printing data for a layer of the second object corresponding to the layer, based on the measured physical quantities of the layer. For example, the control unit 500 corrects the printing data for the first layer of the second object based on the difference between the measured and predicted shapes of the first layer of the first object, just as the control unit 500 corrects the printing data for the third layer of the second object based on the difference between the measured and predicted shapes of the first layer when printing the first object. Similarly, the control unit 500 corrects the printing data for the third layer of the second object based on the difference between the measured and predicted shapes of the third layer of the first object, for example, and based on the difference between the measured and predicted shapes of the third layer of the first object and the difference between the corrected printing data for the third layer of the first object and the uncorrected printing data for the third layer of the first object. The same applies to the correction of the top layer of the second object and the object immediately below the top layer.

[0082] When forming the second object, the control unit 500 executes, for example, the three-dimensional printing process of Fig. 8, and acquires the corrected printing data as described above, instead of the printing data of the first object, in step S310. Alternatively, the control unit 500 may form the second object by executing, for example, the three-dimensional printing process of Fig. 5 or 9. This allows the control unit 500 to correct the printing data of the layers corresponding to each layer of the second object based on the measured values of the physical quantities of each layer of the first object, thereby increasing the possibility that the second object can be formed more accurately than the first object.

[0083] E. Other Embodiments: (E-1) In the above embodiment, the control unit 500 prepares modeling data for the (n+1)th layer, which is the layer immediately following the nth layer, based on the measured values of the physical quantities of the (n-1)th layer in the data processing step. In contrast, the control unit 500 may prepare modeling data for two or more layers following the nth layer in the data processing step. For example, the control unit 500 may prepare modeling data for the (n+2)th layer based on the modeling data of the (n-1)th layer. Furthermore, the control unit 500 may prepare modeling data for two or more layers, rather than one layer, in the data processing step. For example, the control unit 500 may prepare modeling data for the (n+1)th layer and the (n+2)th layer based on the measured values of the physical quantities of the (n-1)th layer in the data processing step.

[0084] (E-2) In the above embodiment, the physical quantities acquired in the measurement process include the dimensions, position, and temperature of the layer. In contrast, the physical quantities may include only one or two of the dimensions, position, and temperature of the layer, or may include, for example, other physical quantities. Even if the physical quantities include only temperature, for example, the control unit 500 can correct the modeling data or shape data of layers subsequent to the current layer in the correction process or generation process of the data processing process based on the relationship between the temperature and the shape or dimensions of the layer calculated in advance by experiments or the like.

[0085] (E-3) In the above embodiment, the control unit 500 completes the data processing step while the stacking step is being performed. In contrast, the control unit 500 does not have to complete the data processing step while the stacking step is being performed. Even in this case, it is possible to reduce the waiting time until the preparation of the modeling data is completed.

[0086] (E-4) In the above embodiment, the control unit 500 executes the measurement process after completion of modeling of the (n-1)th layer and before start of modeling of the nth layer. In contrast, the control unit 500 may execute the measurement process during modeling of the (n-1)th layer, or may execute the measurement process after start of modeling of the nth layer and before completion of modeling of the nth layer.

[0087] (E-5) In the above embodiment, when the control unit 500 executes the correction step in the data processing step, it acquires the modeling data for all layers before starting to lay the first layer. In contrast, the control unit 500 does not have to acquire the modeling data for all layers before starting to lay the first layer. For example, the control unit 500 may acquire the modeling data for the first and second layers before starting to lay each layer, and acquire the modeling data for the third and subsequent layers before correcting each data in the correction step of the data processing step. For example, the control unit 500 may acquire the modeling data for the first and second layers in step S110 of FIG. 5 , and then acquire the modeling data for the (n+1)th layer before executing step S160 in each cycle from the third cycle onward. In this case, the control unit 500 may execute a determination process each time it acquires modeling data to determine whether the layer is compatible with the 3D printing device 100 before modeling the layer. Furthermore, the control unit 500 may, for example, in the judgment process of step S120, determine whether the modeling data of the first or second layer acquired in step S110 is compatible with the three-dimensional printing device 100, and if the modeling data of the first or second layer is compatible with the three-dimensional printing device 100, may also consider the modeling data of the other layers to be compatible with the three-dimensional printing device 100.

[0088] (E-6) In the second and third embodiments described above, the control unit 500 corrects the entire shape data based on the measured values of the physical quantities of the (n-1)th layer in the generation step of the data processing step. In contrast, the control unit 500 may correct, in the generation step, not the entire shape data, but only a portion of the shape data representing the shape of a portion corresponding to the (n+1)th layer or higher, based on the measured values of the physical quantities of the (n-1)th layer. For example, in step S235 of FIG. 6, the control unit 500 may correct, in the shape data acquired in step S205, a portion representing the shape of a portion corresponding to the (n+1)th layer, based on the measured values of the physical quantities of the (n-1)th layer. Similarly, the control unit 500 may correct the layer data of the (n+1)th layer or higher, rather than the shape data, based on the measured values of the physical quantities of the (n-1)th layer.

[0089] (E-7) In the above embodiment, the control unit 500 executes the data processing step. However, the data processing step may be executed by a computer or the like external to the 3D printing apparatus 100. In this case, the control unit 500 may execute the 3D printing process while communicating with the external computer. For example, the control unit 500 may transmit the measured values of the physical quantities of the (n-1)th layer measured in the measurement step to the external computer, and then receive printing data for the (n+1)th or later layer prepared by the external computer executing the data processing step, and print the layer in accordance with the received printing data.

[0090] (E-8) In the above embodiment, the control unit 500 executes the determination step when the correction step is executed in the data processing step. Alternatively, the control unit 500 may execute the determination step when the generation step is executed in the data processing step. For example, when a three-dimensional object is formed while communicating with an external computer in the three-dimensional printing process, the control unit 500 may determine whether the printing data generated by the generation step executed by the external computer is compatible with the three-dimensional printing device 100 before executing the stacking step.

[0091] (E-9) In the above embodiment, the plasticizing unit 30 of the discharge unit 200 plasticizes the material using a flat screw to generate the modeling material. Alternatively, the plasticizing unit 30 may generate the modeling material by, for example, rotating an in-line screw. The discharge unit 200 may also be configured as a head that plasticizes and discharges a filament-like material.

[0092] (E-10) In the above embodiment, a resin material formed into pellets is used as the raw material supplied to the material supply unit 20. In contrast, the 3D printing apparatus 100 can print a 3D object using various materials as the main material, such as a thermoplastic material, a metal material, or a ceramic material. Here, the term "main material" refers to the material that forms the core of the shape of the 3D object, and refers to a material that accounts for 50% or more by weight of the 3D object. The above-mentioned printing materials include those main materials that are melted alone, and those that are made into a paste by melting some of the components contained together with the main material.

[0093] When a thermoplastic material is used as the main material, the modeling material is generated by plasticizing the material in the plasticizing unit 30. "Plasticizing" means that heat is applied to the thermoplastic material to melt it.

[0094] As the material having thermoplasticity, for example, the following thermoplastic resin materials can be used. <Examples of thermoplastic resin materials> General-purpose 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), polyether ether ketone (PEEK), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate; and engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyether ether ketone.

[0095] The thermoplastic material may contain pigments, metals, ceramics, and other additives such as wax, flame retardants, antioxidants, and thermal stabilizers. The thermoplastic material is plasticized and converted into a molten state in the plasticizing section 30 by the rotation of the screw 40 and the heat of the heater 58. The modeling material produced by melting the thermoplastic material is discharged from the nozzle 61 and then hardens as the temperature drops.

[0096] It is desirable that the thermoplastic material be heated to or above its glass transition point and in a completely melted state before being injected from the nozzle 61. For example, ABS resin has a glass transition point of approximately 120°C, and it is desirable that the temperature be approximately 200°C when injected from the nozzle 61.

[0097] In the three-dimensional modeling apparatus 100, for example, the following metal materials may be used as the main material instead of the thermoplastic materials described above. In this case, it is desirable that the powder material made by powdering the following metal materials be mixed with a component that melts when generating the modeling material, and then be introduced into the plasticizing unit 30 as a raw material. <Examples of metal materials> A single metal, or an alloy containing one or more of the following metals: magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), or nickel (Ni). <Examples of the alloy> Maraging steel, stainless steel, cobalt chrome molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chrome alloy.

[0098] In the three-dimensional modeling apparatus 100, a ceramic material can be used as the main material instead of the above-mentioned metal materials. Examples of ceramic materials that can be used include oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, and zirconium oxide, and non-oxide ceramics such as aluminum nitride. When using the above-mentioned metal or ceramic materials as the main material, the modeling material placed on the stage 300 may be hardened by sintering using laser irradiation, hot air, or the like.

[0099] The powder material of a metal or ceramic material fed as a raw material to the material supply unit 20 may be a mixed material obtained by mixing multiple types of powder of a single metal, alloy powder, or ceramic material. The powder material of a metal or ceramic material may also be coated with, for example, the thermoplastic resin exemplified above or a different thermoplastic resin. In this case, the thermoplastic resin may be melted in the plasticizing unit 30 to exhibit fluidity.

[0100] For example, the following solvents can be added to the powdered metal or ceramic material fed as raw material to the material supply unit 20. The solvent can be one or a combination of two or more selected from the following: <Examples of solvents> 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-based solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and 2,6-lutidine; tetraalkylammonium acetates (for example, tetrabutylammonium acetate); and ionic liquids such as butyl carbitol acetate.

[0101] In addition, the powder material of the metal material or ceramic material fed into the material supply unit 20 as a raw material may also contain, for example, the following binders. <Example of a binder> Acrylic resin, epoxy resin, silicone resin, cellulose-based resin or other synthetic resin, or PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone) or other thermoplastic resin.

[0102] F. Other Forms: The present disclosure is not limited to the above-described embodiments and can be realized in various forms without departing from the spirit thereof. For example, the present disclosure can also be realized in the following forms. The technical features in the above embodiments corresponding to the technical features in each form described below can be appropriately replaced or combined to solve some or all of the problems of the present disclosure or to achieve some or all of the effects of the present disclosure. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0103] (1) According to a first aspect of the present disclosure, there is provided a method for manufacturing a three-dimensional object, which comprises stacking multiple layers by discharging a modeling material from a discharging unit provided in a three-dimensional printing device in accordance with modeling data for forming the three-dimensional object layer by layer, the modeling data being generated based on shape data representing the shape of the three-dimensional object. This method for manufacturing a three-dimensional object includes: a first stacking step of stacking an nth layer, where n is an integer equal to or greater than 2; a measurement step of measuring physical quantities of the n-1th layer; a data processing step of preparing modeling data for the n+1th and subsequent layers; and a second stacking step of stacking the n+1th and subsequent layers in accordance with the modeling data prepared in the data processing step. The data processing step includes one of a correction step of preparing modeling data for the n+1th and subsequent layers by correcting previously generated modeling data based on the physical quantities; and a generation step of generating modeling data for the n+1th and subsequent layers based on the physical quantities and the shape data. According to this embodiment, the n-th layer can be modeled while the modeling data of the (n+1)-th or higher layers is being prepared, and therefore the waiting time until the modeling data preparation is completed can be reduced compared to when the modeling data of the n-th layer is prepared based on the measured values of the physical quantities of the (n-1)-th layer. As a result, it is possible to increase the possibility of accurately modeling a three-dimensional object and prevent the modeling time from becoming longer.

[0104] (2) In the above-described embodiment, the physical quantity may include at least one of a dimension, a position, and a temperature of a layer. According to this embodiment, modeling data for the (n+1)th or higher layer can be prepared based on at least one of the dimension, the position, and the temperature of the (n-1)th layer.

[0105] (3) In the above-described embodiment, the data processing step may be completed while the first lamination step is being performed. According to this embodiment, the waiting time until the preparation of the modeling data is completed can be further reduced, and the modeling time can be further reduced.

[0106] (4) In the above-described embodiment, the data processing step may include executing the generating step, which corrects the shape data based on the physical quantities, generates layer data representing a shape obtained by slicing the shape of the three-dimensional object into layers based on the corrected shape data, and generates modeling data for the (n+1)th or higher layer based on the generated layer data. According to this embodiment, the shape data is corrected based on the measured values of the physical quantities, which further increases the possibility of preparing modeling data capable of modeling a three-dimensional object having a desired shape.

[0107] (5) In the above-described embodiment, the generating step may determine a thickness of the shape represented by the layer data based on the physical quantity. This embodiment can further improve the modeling accuracy in the direction in which the layers of the three-dimensional object are stacked.

[0108] (6) In the above-described aspect, the data processing step may include executing the generating step, in which modeling conditions for the (n+1)th or higher layers are determined based on the physical quantities, and modeling data for the (n+1)th or higher layers are generated based on the determined modeling conditions and the shape data. According to this aspect, the modeling conditions can be changed based on the measured values of the physical quantities, and a three-dimensional object can be accurately modeled under the changed modeling conditions.

[0109] (7) In the above aspect, a step of determining whether or not the modeling data is compatible with the three-dimensional modeling device may be provided before the first lamination step is performed. According to this aspect, a three-dimensional object can be modeled using modeling data that is compatible with the three-dimensional modeling device.

[0110] (8) In the above-described embodiment, in the data processing step, modeling data for one layer may be prepared as the modeling data for the (n+1)th or higher layer. According to this embodiment, the waiting time until the modeling data preparation is completed can be further reduced compared to when modeling data for multiple layers is prepared in a single data processing step.

[0111] (9) In the above-described embodiment, a first object and a second object having a shape corresponding to that of the first object and manufactured after the manufacturing of the first object are manufactured as the three-dimensional objects, and the modeling data used in manufacturing the first object may be used in manufacturing the second object. This embodiment increases the possibility of manufacturing the second object with high accuracy compared to manufacturing the second object without using the modeling data of the first object.

[0112] (10) According to a second aspect of the present disclosure, there is provided a three-dimensional printing apparatus including a stage, a discharge unit that discharges a printing material toward the stage, a position change unit that changes the relative position of the discharge unit and the stage, a control unit that controls the discharge unit and the position change unit to discharge the printing material from the discharge unit in accordance with printing data for printing the three-dimensional object layer by layer, the printing data being generated based on shape data representing the shape of the three-dimensional object, thereby printing the three-dimensional object on the stage, and a measurement unit that measures physical quantities of the layers stacked on the stage. The control unit executes the following steps: a first stacking step of stacking an n-th layer, where n is an integer equal to or greater than 2; a measurement step of measuring the physical quantities of an n-1-th layer using the measurement unit; a data processing step of preparing printing data for n+1 or more layers; and a second stacking step of stacking the n+1 or more layers in accordance with the printing data prepared in the data processing step. In the data processing step, the control unit executes either a correction step of preparing modeling data for the (n+1)th or later layers by correcting previously generated modeling data based on the physical quantities, or a generation step of generating modeling data for the (n+1)th or later layers based on the physical quantities and the shape data. According to this embodiment, the nth layer can be modeled while the modeling data for the (n+1)th or later layers is being prepared. Therefore, the waiting time until the modeling data preparation is completed can be reduced compared to when the modeling data for the nth layer is prepared based on measured values of the physical quantities of the (n-1)th layer. Therefore, it is possible to increase the possibility of accurately modeling a three-dimensional object and prevent the modeling time from being prolonged. [Explanation of symbols]

[0113] 20...material supply section, 22...supply path, 30...plasticization section, 31...screw case, 32...drive motor, 40...screw, 42...groove section, 43...ridge section, 44...material inlet, 46...center section, 47...upper surface, 48...screw lower surface, 50...barrel, 52...barrel upper surface, 56...communicating hole, 58...heater, 61...nozzle, 62...nozzle opening, 63...tip surface, 65...flow path, 69...nozzle heater, 70...discharge amount adjustment section, 74...drive section, 100...three-dimensional modeling device, 200...discharge section, 300...stage, 311...modeling surface, 400...position change section, 500...control section, 550...measurement section, 560...infrared camera, 570...camera, 580...measurement control section

Claims

1. A manufacturing method of a three-dimensional object, comprising: discharging a modeling material from a discharging unit provided in a three-dimensional modeling device to stack a plurality of layers in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data representing a shape of the three-dimensional object; When n is an arbitrary integer of 2 or more, a first lamination step of laminating an n-th layer; a measuring step of measuring a physical quantity of the (n-1)th layer; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th layer or more in accordance with the modeling data prepared in the data processing step, In the data processing step, a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data; Do one of the following: In the data processing step, the generating step is executed, In the producing step, correcting the shape data based on the physical quantity; generating layer data representing a shape obtained by slicing the shape of the three-dimensional object into layers based on the corrected shape data; generating modeling data for the n+1th or greater layer based on the generated layer data; A method for manufacturing three-dimensional objects.

2. A method for manufacturing a three-dimensional object, comprising stacking a plurality of layers by ejecting a modeling material from an ejection unit provided in a three-dimensional modeling device in accordance with modeling data for forming the three-dimensional object layer by layer, the modeling data being generated based on shape data representing the shape of the three-dimensional object, When n is an arbitrary integer of 2 or more, a first lamination step of laminating an n-th layer; a measuring step of measuring a physical quantity of the (n-1)th layer; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th layer or more in accordance with the modeling data prepared in the data processing step, In the data processing step, a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data; Do one of the following: The method for manufacturing a three-dimensional object, wherein the data processing step is completed while the first stacking step is being performed.

3. A method for manufacturing a three-dimensional object, comprising stacking a plurality of layers by ejecting a printing material from an ejection unit provided in a three-dimensional printing device in accordance with printing data for printing the three-dimensional object layer by layer, the printing data being generated based on shape data representing the shape of the three-dimensional object, When n is an arbitrary integer of 2 or more, a first lamination step of laminating an n-th layer; a measuring step of measuring a physical quantity of the (n-1)th layer; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th layer or more in accordance with the modeling data prepared in the data processing step, In the data processing step, a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data; Do one of the following: A method for manufacturing a three-dimensional object, comprising: a step of determining whether or not modeling data is compatible with the three-dimensional modeling device before performing the first lamination step.

4. A method for manufacturing a three-dimensional object, comprising stacking a plurality of layers by ejecting a printing material from an ejection unit provided in a three-dimensional printing device in accordance with printing data for printing the three-dimensional object layer by layer, the printing data being generated based on shape data representing the shape of the three-dimensional object, When n is an arbitrary integer of 2 or more, a first lamination step of laminating an n-th layer; a measuring step of measuring a physical quantity of the (n-1)th layer; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th layer or more in accordance with the modeling data prepared in the data processing step, In the data processing step, a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data; Do one of the following: manufacturing, as the three-dimensional object, a first object and a second object having a shape corresponding to that of the first object and manufactured after the manufacturing of the first object is completed; A method for manufacturing a three-dimensional object, wherein modeling data used in manufacturing the first object is used in manufacturing the second object.

5. The method for manufacturing a three-dimensional structure according to any one of claims 2 to 4, comprising: In the data processing step, the generating step is executed, In the producing step, correcting the shape data based on the physical quantity; generating layer data representing a shape obtained by slicing the shape of the three-dimensional object into layers based on the corrected shape data; generating modeling data for the n+1th or greater layer based on the generated layer data; A method for manufacturing three-dimensional objects.

6. The method for manufacturing a three-dimensional object according to claim 1 or 5, In the generating step, a thickness of the shape represented by the layer data is determined based on the physical quantity.

7. A method for manufacturing a three-dimensional structure according to any one of claims 1 to 6, comprising: The method for manufacturing a three-dimensional object, wherein the physical quantity includes at least one of a dimension, a position, and a temperature of a layer.

8. A method for manufacturing a three-dimensional structure according to any one of claims 1 to 7, comprising: In the data processing step, the generating step is executed, In the producing step, determining modeling conditions for the n+1th or greater layer based on the physical quantity; generating modeling data for the (n+1)th or greater layer based on the determined modeling conditions and the shape data; A method for manufacturing three-dimensional objects.

9. A method for manufacturing a three-dimensional structure according to any one of claims 1 to 8, comprising: In the data processing step, modeling data for one layer is prepared as the modeling data for the (n+1)th or greater layer.

10. The stage and a discharge unit that discharges a modeling material toward the stage; a position change unit that changes the relative position between the discharge unit and the stage; a control unit that controls the discharging unit and the position changing unit in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data that represents a shape of the three-dimensional object, and that causes the discharging unit to discharge the modeling material to stack a plurality of layers, thereby modeling the three-dimensional object on the stage; a measurement unit for measuring a physical quantity of the layer stacked on the stage, When n is an arbitrary integer of 2 or more, the control unit a first lamination step of laminating an n-th layer; a measuring step of measuring the physical quantity of the (n-1)th layer by the measuring unit; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th or greater layer in accordance with the modeling data prepared in the data processing step; In the data processing step, the control unit a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data, In the data processing step, the generating step is executed, In the producing step, correcting the shape data based on the physical quantity; generating layer data representing a shape obtained by slicing the shape of the three-dimensional object into layers based on the corrected shape data; generating modeling data for the n+1th or greater layer based on the generated layer data; Three-dimensional printing equipment.

11. A stage; a discharge unit that discharges a modeling material toward the stage; a position change unit that changes the relative position between the discharge unit and the stage; a control unit that controls the discharging unit and the position changing unit in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data that represents a shape of the three-dimensional object, and that causes the discharging unit to discharge the modeling material to stack a plurality of layers, thereby modeling the three-dimensional object on the stage; a measurement unit for measuring a physical quantity of the layer stacked on the stage, When n is an arbitrary integer of 2 or more, the control unit a first lamination step of laminating an n-th layer; a measuring step of measuring the physical quantity of the (n-1)th layer by the measuring unit; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th or greater layer in accordance with the modeling data prepared in the data processing step; In the data processing step, the control unit a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data, completing the data processing step while the first stacking step is being performed; Three-dimensional printing equipment.

12. A three-dimensional modeling apparatus, The stage and a discharge unit that discharges a modeling material toward the stage; a position change unit that changes the relative position between the discharge unit and the stage; a control unit that controls the discharging unit and the position changing unit in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data that represents a shape of the three-dimensional object, and that causes the discharging unit to discharge the modeling material to stack a plurality of layers, thereby modeling the three-dimensional object on the stage; a measurement unit for measuring a physical quantity of the layer stacked on the stage, When n is an arbitrary integer of 2 or more, the control unit a first lamination step of laminating an n-th layer; a measuring step of measuring the physical quantity of the (n-1)th layer by the measuring unit; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th or greater layer in accordance with the modeling data prepared in the data processing step; In the data processing step, the control unit a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data, determining whether or not the modeling data is compatible with the three-dimensional modeling device before performing the first lamination step; Three-dimensional printing equipment.

13. A stage; a discharge unit that discharges a modeling material toward the stage; a position change unit that changes the relative position between the discharge unit and the stage; a control unit that controls the discharging unit and the position changing unit in accordance with modeling data for modeling the three-dimensional object layer by layer, the modeling data being generated based on shape data that represents a shape of the three-dimensional object, and that causes the discharging unit to discharge the modeling material to stack a plurality of layers, thereby modeling the three-dimensional object on the stage; a measurement unit for measuring a physical quantity of the layer stacked on the stage, When n is an arbitrary integer of 2 or more, the control unit a first lamination step of laminating an n-th layer; a measuring step of measuring the physical quantity of the (n-1)th layer by the measuring unit; a data processing step of preparing modeling data for the (n+1)th or greater layer; a second lamination step of laminating the (n+1)th or greater layer in accordance with the modeling data prepared in the data processing step; In the data processing step, the control unit a correcting step of correcting previously generated modeling data based on the physical quantity to prepare modeling data for the (n+1)th or greater layer; a generating step of generating modeling data of the (n+1)th or greater layer based on the physical quantity and the shape data, manufacturing, as the three-dimensional object, a first object and a second object having a shape corresponding to that of the first object and manufactured after the manufacturing of the first object is completed; using the modeling data used in manufacturing the first object in manufacturing the second object; Three-dimensional printing equipment.

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