3D modeling device

Abstract

To provide a three-dimensional molding apparatus capable of maintaining positional relationship between a molded object formed on a molding surface and a stage.SOLUTION: A three-dimensional molding apparatus 1 includes: a stage 2 having a first groove 29 and a second groove 31 extending in a first direction 28 on a molding surface 2a; a discharge part 13 for supplying a molding material 3 to the molding surface 2a; a moving mechanism 7 for relatively moving the stage 2 and the discharge part 13; and a control part 4 for controlling the discharge part 13 and the moving mechanism 7. The control part 4: forms a first girder layer 44 by supplying the molding material 3 to a first groove 29 while moving the discharge part 13 relative to the stage 2 in a first direction 28; forms a second girder layer 45 by supplying the molding material 3 to a second groove 31 while moving the discharge part 13 relative to the stage 2 in the first direction 28; and controls the moving mechanism 7 and the discharge part 13 so as to form a first floor layer 46 connecting the first girder layer 44 and the second girder layer 45 by supplying the molding material 3 to the molding surface 2a while moving the discharge part 13 relative to the stage 2.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a three-dimensional modeling apparatus. [Background technology]

[0002] Various 3D modeling devices have been proposed that form 3D objects using the fused deposition modeling method, which deposits modeling material on the modeling surface of a stage. Hereinafter, the 3D object will be referred to as the model. When the modeling surface is flat, there is a risk that the model will move on the modeling surface, so a means for fixing the model to the surface is required. Patent Document 1 discloses a method of making the model difficult to move on the modeling surface by making the model uneven.

[0003] For example, a stage with recesses arranged in a grid pattern on the modeling surface has been introduced. A discharge unit dispenses modeling material into the grid-like recesses. The resin that enters the recesses becomes protrusions. The protrusions and recesses interlock, detachably joining the model and the stage. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2020-29019 Summary of the Invention [Problem to be solved by the invention]

[0005] However, when the molding material is a material with a large resin shrinkage rate, such as polypropylene, a gap forms between the recess and the protruding portion of the resin that has entered the recess. The 3D printing device disclosed in Patent Document 1 has the possibility of the protruding portion becoming dislodged from the recess. In this case, it is difficult for the object formed on the printing surface to maintain its positional relationship with the stage. Therefore, there has been a demand for a 3D printing device that can maintain the positional relationship of the object formed on the printing surface with the stage even when the resin shrinkage rate of the molding material is large. [Means for solving the problem]

[0006] The three-dimensional modeling device comprises a stage having a modeling surface with a first groove extending in a first direction and a second groove extending in the first direction, a discharge unit that supplies modeling material to the modeling surface, a movement mechanism that moves the stage and the discharge unit relatively, and a control unit that controls the discharge unit and the movement mechanism, and the control unit controls the movement mechanism and the discharge unit so that, while moving the discharge unit relative to the stage in the first direction, the modeling material is supplied to the first groove to form a first digit layer, while moving the discharge unit relative to the stage in the first direction, the modeling material is supplied to the second groove to form a second digit layer, and while moving the discharge unit relative to the stage, the modeling material is supplied to the modeling surface to form a first bed layer connecting the first digit layer and the second digit layer. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic diagram showing the configuration of a three-dimensional modeling apparatus according to a first embodiment. [Figure 2] FIG. 2 is a schematic plan view showing the configuration of a stage. [Figure 3] FIG. [Figure 4] FIG. [Figure 5] 10 is a flowchart for generating a modeled object. [Figure 6] Schematic diagrams for explaining a method for generating a shaped object. [Figure 7] Schematic diagrams for explaining a method for generating a shaped object. [Figure 8] Schematic diagrams for explaining a method for generating a shaped object. [Figure 9] Schematic diagrams for explaining a method for generating a shaped object. [Figure 10] Schematic diagrams for explaining a method for generating a shaped object. [Figure 11] Schematic diagrams for explaining a method for generating a shaped object. [Figure 12] Schematic diagrams for explaining a method for generating a shaped object. [Figure 13] Schematic diagrams for explaining a method for generating a shaped object. [Figure 14] Schematic diagrams for explaining a method for generating a shaped object. [Figure 15] FIG. 10 is a schematic cross-sectional side view of a main part of a stage according to a second embodiment. [Figure 16] FIG. 11 is a schematic cross-sectional side view of a main part of a stage according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] First embodiment In this embodiment, a characteristic example of a three-dimensional printing apparatus will be described. Arrows indicating mutually orthogonal X, Y, and Z directions are shown in Fig. 1. For example, the X and Y directions are parallel to a horizontal plane, and the positive Z direction is opposite to the vertical direction. The vertical direction is the direction of gravity.

[0009] The 3D printing apparatus 1 forms a model 20 by depositing a modeling material 3 on a modeling surface 2a of a stage 2. In addition to the stage 2, the 3D printing apparatus 1 includes a control unit 4 that controls the 3D printing apparatus 1, a modeling unit 5 that generates the modeling material 3 and deposits it on the stage 2, a base 6 that supports the stage 2, and a movement mechanism 7 that moves the base 6. The control unit 4 controls the deposition position of the modeling material 3.

[0010] The control unit 4 controls the overall operation of the 3D printing apparatus 1. The control unit 4 is configured by a computer equipped with a processor and a main memory device. The processor executes programs and instructions loaded onto the main memory device, allowing the control unit 4 to perform various functions.

[0011] The control unit 4 controls the modeling unit 5 and the moving mechanism 7 according to modeling data that defines the modeled object 20. The control unit 4 executes a modeling process to deposit the modeling material 3 on the modeling surface 2a of the stage 2 and form the modeled object 20. The control unit 4 controls the temperature control unit 8 to adjust the temperature of the stage 2.

[0012] Under the control of the control unit 4, the modeling unit 5 generates a molten paste-like modeling material 3. The modeling unit 5 deposits the modeling material 3 at a target position on the modeling surface 2a. The modeling unit 5 includes a material supply unit 11 that is a supply source of raw materials 9, a generation unit 12 that converts the raw materials 9 into the modeling material 3, and a discharge unit 13 that discharges the modeling material 3.

[0013] The material supply unit 11 supplies raw materials 9 to the generation unit 12. The raw materials 9 are materials for generating the modeling material 3. The material supply unit 11 is composed of a hopper 14 that stores the raw materials 9, a connecting passage 15, etc. The hopper 14 has a discharge outlet in the negative Z direction. The discharge outlet is connected to the generation unit 12 via the connecting passage 15. The raw materials 9 are fed into the hopper 14 in the form of pellets, powder, etc.

[0014] The generating unit 12 melts the raw materials 9 supplied from the material supply unit 11 to generate a paste-like modeling material 3 that exhibits fluidity. The generating unit 12 supplies the modeling material 3 to the discharging unit 13. The generating unit 12 has a screw case 16, a drive motor 17, a flat screw 18, and a screw facing unit 22.

[0015] The flat screw 18 has a generally cylindrical shape with a height in the axial direction, which is the direction along its central axis, that is smaller than its diameter. The flat screw 18 is arranged so that its axial direction is parallel to the Z direction. The central axis of the flat screw 18 coincides with the rotation axis 18a. The flat screw 18 rotates around the rotation axis 18a.

[0016] The flat screw 18 is housed in a screw case 16. The flat screw 18 is connected to the rotary shaft of a drive motor 17. The flat screw 18 is rotated by the rotary driving force generated by the drive motor 17. The drive motor 17 is driven under the control of the control unit 4.

[0017] The flat screw 18 has a groove forming surface 18b that intersects with the rotation axis 18a. A spiral scroll groove 19 is formed on the groove forming surface 18b. The groove forming surface 18b is arranged in the negative Z direction of the flat screw 18. The scroll groove 19 is connected to a material inlet 21. The material inlet 21 opens on the outer peripheral side surface of the flat screw 18. The scroll groove 19 extends in a spiral shape from the material inlet 21 toward a central portion 18c. The rotation axis 18a of the flat screw 18 passes through the central portion 18c.

[0018] The groove forming surface 18b of the flat screw 18 faces the upper surface 22a of the screw facing portion 22. A space is formed between the scroll groove 19 of the groove forming surface 18b and the upper surface 22a of the screw facing portion 22. At the material inlet 21, the communicating passage 15 of the material supply portion 11 and the scroll groove 19 are connected via a gap. Raw material 9 is supplied from the communicating passage 15 of the material supply portion 11 to the scroll groove 19.

[0019] A heater 23 is embedded in the screw facing portion 22. The heater 23 heats the raw material 9 supplied into the scroll groove 19 of the rotating flat screw 18. Within the scroll groove 19, the raw material 9 is melted to become the molding material 3. The molding material 3 develops fluidity and becomes paste-like. As the flat screw 18 rotates, the molding material 3 flows along the scroll groove 19. The molding material 3 is guided to the central portion 18c of the flat screw 18. The molding material 3 that flows into the central portion 18c is supplied to the discharge portion 13 via the communicating hole 22c. The communicating hole 22c is provided in the center of the screw facing portion 22.

[0020] The discharge unit 13 includes a nozzle 24 and a flow path 25. The nozzle 24 is connected to the communication hole 22c of the screw facing portion 22 through the flow path 25. The flow path 25 guides the modeling material 3 generated in the generation unit 12 to the nozzle 24. The flow path 25 extends along the Z direction, and the flow path 25 and the nozzle 24 are arranged along the Z direction. The nozzle 24 discharges the modeling material 3 from the discharge port 24a at its tip toward the stage 2 on the base 6. The discharge unit 13 supplies the modeling material 3 to the modeling surface 2a. The discharge unit 13 includes a nozzle 24 that discharges the modeling material 3.

[0021] The base 6 and stage 2 are disposed in the negative Z direction of the nozzle 24. The stage 2 is placed on the base 6. The modeling surface 2a of the stage 2 faces the discharge port 24a of the nozzle 24. The modeling surface 2a is approximately horizontal.

[0022] Under the control of the control unit 4, the movement mechanism 7 changes the relative positional relationship between the stage 2, the modeling surface 2a, and the nozzle 24. The movement mechanism 7 is equipped with a three-axis positioner that moves the base 6 in three directions, the X, Y, and Z directions, using the driving forces of three motors. The movement mechanism 7 moves the stage 2 and the discharge unit 13 relative to each other. The control unit 4 controls the discharge unit 13 and the movement mechanism 7.

[0023] The 3D printing apparatus 1 is installed in a chamber 26, which is a processing chamber where printing is performed. The 3D printing apparatus 1 forms a sacrificial layer 10 and a modeled object 20 in the chamber 26. The sacrificial layer 10 is installed so that the modeled object 20 does not come off the stage 2. The sacrificial layer 10 is formed to form the modeled object 20. After the sacrificial layer 10 and the modeled object 20 are formed, the modeled object 20 is separated from the sacrificial layer 10. The separated sacrificial layer 10 is discarded. Using the temperature control unit 8, the control unit 4 adjusts the temperature in the chamber 26 and controls the temperature of the stage 2.

[0024] In parallel with the ejection of the modeling material 3 from the nozzle 24, the movement mechanism 7 moves the modeling surface 2a. The first layer of modeling material 3 is placed. Next, the movement mechanism 7 moves the modeling surface 2a in the negative Z direction. Next, the second layer of modeling material 3 is placed on top of the first layer of modeling material 3. Furthermore, the movement of the modeling surface 2a in the negative Z direction and the placement of modeling material 3 are repeated. As a result, the third and subsequent layers of modeling material 3 are placed on top of each other. This method of layering the molten modeling material 3 to form a model 20 is called the fused deposition modeling method. The layering direction 27 in which the modeling material 3 is layered is the Z direction.

[0025] The main component of the stage material that is the material of the stage 2 is glass or aluminum. According to this configuration, the main component of the stage material is glass or aluminum. Glass and aluminum maintain their rigidity even at the temperature when the modeling material 3 is supplied. Therefore, even when the modeling material 3 is discharged onto the modeling surface 2a, the stage 2 can maintain its rigidity, thereby preventing a decrease in the modeling accuracy of the modeled object 20.

[0026] 2, the Y positive direction and the Y negative direction are defined as a first direction 28. The stage 2 has a first groove 29, a second groove 31, a third groove 32, a fourth groove 33, a fifth groove 34, a sixth groove 35, a seventh groove 36, an eighth groove 37, a ninth groove 38, and a tenth groove 39 on the printing surface 2a. The first groove 29 to the tenth groove 39 extend in the first direction 28.

[0027] The stage 2 has a first side surface 2b that intersects with the printing surface 2a in the Y-negative direction, which is one side of the first direction 28. One end of the first groove 29 opens to the first side surface 2b. One end of the second groove 31 opens to the first side surface 2b. One ends of the third groove 32 to the tenth groove 39 each open to the first side surface 2b. The stage 2 has a second side surface 2c that intersects with the printing surface 2a in the Y-positive direction, which is one side of the first direction 28. The other ends of the first grooves 29 to the tenth grooves 39 do not open to the second side surface 2c.

[0028] As shown in Fig. 3, the cross-sectional shapes of the first groove 29 and the second groove 31 are trapezoidal. The cross-sectional shapes of the third groove 32 to the tenth groove 39 are also trapezoidal. A first angle 29b, which is the angle between the first sidewall 29a of the first groove 29, which is the sidewall on the second groove 31 side, and the modeling surface 2a, is equal to or greater than 70 degrees and less than 90 degrees. A third angle 29d, which is the angle between the third sidewall 29c of the first groove 29, which faces the first sidewall 29a, and the modeling surface 2a, is preferably larger than the first angle 29b. This can suppress warping of the sacrificial layer 10.

[0029] In the second groove 31, the second sidewall 31a, which is the sidewall on the first groove 29 side, forms a second angle 31b that is equal to or greater than 70 degrees and less than 90 degrees with the modeling surface 2a. In the second groove 31, the fourth angle 31d, which is the angle between the modeling surface 2a and the fourth sidewall 31c that faces the second sidewall 31a, is preferably larger than the second angle 31b. This can suppress warping of the sacrificial layer 10.

[0030] The groove width 41, which is the width of the first groove 29 or the width of the second groove 31, is wider than the nozzle outer diameter 24b, which is the outer diameter of the nozzle 24. With this configuration, the groove width 41 of the first groove 29 and the second groove 31 is wider than the nozzle outer diameter 24b of the nozzle 24. Therefore, the modeling material 3 discharged from the nozzle 24 can be easily injected into the first groove 29 and the second groove 31. The groove width 41 is not particularly limited, but is 0.1 mm to 0.5 mm. The groove width 41 of the first groove 29 is the distance between the intersection line of the modeling surface 2a and the first side wall 29a and the intersection line of the modeling surface 2a and the third side wall 29c.

[0031] Fig. 4 is a cross-sectional view taken along line AA in Fig. 2. Fig. 4 also serves as a cross-sectional view taken along line BB in Fig. 2. As shown in Fig. 4, the cross-sectional shape of the first groove 29 is the same as the cross-sectional shape of the second groove 31. The first groove 29 has a first shallow groove portion 29e and a first deep groove portion 29f. The second groove 31 has a second shallow groove portion 31e and a second deep groove portion 31f.

[0032] Most of the first groove 29 is the first shallow groove portion 29e. The depth of the first groove 29 indicates the depth of the first shallow groove portion 29e. Most of the second groove 31 is the second shallow groove portion 31e. The depth of the second groove 31 indicates the depth of the second shallow groove portion 31e.

[0033] Shallow groove depth 42, which is the depth of first shallow groove portion 29e indicating the depth of first groove 29 and the depth of second shallow groove portion 31e indicating the depth of second groove 31, is 0.2 mm or more and 1 mm or less. Deep groove depth 43, which is the depth of first deep groove portion 29f and second deep groove portion 31f relative to first shallow groove portion 29e and second shallow groove portion 31e, is 0.5 mm. The lengths of first deep groove portion 29f and second deep groove portion 31f in the Y direction are not particularly limited, but are preferably 0.2 mm or more and 2 mm or less.

[0034] The cross-sectional shapes of the third groove 32, fifth groove 34, seventh groove 36, and ninth groove 38 when viewed from the Y-negative direction are the same as that of the first groove 29. The cross-sectional shapes of the fourth groove 33, sixth groove 35, eighth groove 37, and tenth groove 39 when viewed from the Y-negative direction are the same as that of the second groove 31. The first groove 29 and the second groove 31 are mirror images of each other.

[0035] Next, a method for manufacturing a model 20 using the 3D printing apparatus 1 will be described. In the flowchart of FIG. 5, step S1 is an alignment step. In step S1, the stage 2 and the nozzle 24 are aligned. The stage 2 is equipped with a height detection sensor, and the movement mechanism 7 moves the stage 2 relative to the nozzle 24. The height detection sensor is positioned directly below the nozzle 24. The movement mechanism 7 reduces the distance in the Z direction between the nozzle 24 and the stage 2. The position where the height detection sensor detects contact with the discharge part 13 is set as the reference point of the stage 2 in the Z direction.

[0036] The movement mechanism 7 is equipped with an X side sensor that detects the side surface of the stage 2 on the negative X direction side. Furthermore, the movement mechanism 7 is equipped with a Y side sensor that detects the side surface of the stage 2 on the negative Y direction side. The side surface of the stage 2 on the negative X direction side and the side surface of the negative Y direction are precisely formed so that the perpendicularity between them is high. The side surfaces of the stage 2 on the negative X direction side and the negative Y direction side serve as reference surfaces. The X side sensor and the Y side sensor detect the corner where the side surface of the negative X direction and the side surface of the negative Y direction intersect, and use this as a reference point in the planar direction. The X side sensor and the Y side sensor detect any rotational deviation of the stage 2 around the Z direction as an axis. The control unit 4 calculates the position of the stage 2 relative to the base 6. The first to tenth grooves 29 to 39 on the stage 2 are precisely positioned relative to the reference surfaces and reference points on the side surfaces.

[0037] The relative positional relationship between the base 6 and the nozzle 24 is measured in advance. Based on the reference point of the stage 2, the control unit 4 calculates the coordinates of the first groove 29 to the tenth groove 39, the sacrificial layer 10, and the model 20. Next, the control unit 4 generates data on the movement path of the nozzle 24. Next, the process proceeds to step S2.

[0038] Step S2 is the digit layer formation process. In step S2, the 3D modeling apparatus 1 forms a first digit layer 44 in the first groove 29 and a second digit layer 45 in the second groove 31. The movement mechanism 7 moves the nozzle 24 along the Y direction based on the movement path. The nozzle 24 supplies the modeling material 3 to the first groove 29 and the second groove 31 to form the first digit layer 44 and the second digit layer 45. While the first digit layer 44 and the second digit layer 45 are being formed, there is a predetermined distance between the nozzle 24 and the modeling surface 2a. The surfaces of the formed first digit layer 44 and second digit layer 45 protrude from the modeling surface 2a in the positive Z direction. When the nozzle 24 ejects the modeling material 3, contact between the tip of the nozzle 24 and the stage 2 can be prevented. Next, the process proceeds to step S3.

[0039] Step S3 is a sacrificial layer formation process. In step S3, the 3D modeling apparatus 1 forms a sacrificial layer 10. The movement mechanism 7 moves the nozzle 24 along the X direction based on the movement path. At this time, the nozzle 24 supplies the modeling material 3 to the modeling surface 2a to form the sacrificial layer 10. The sacrificial layer 10 is composed of a first bed layer to a fourth bed layer. The first bed layer, which is formed directly above the first digit layer 44 and the second digit layer 45, is formed while being pressed by the nozzle 24. This improves the adhesion between the first bed layer 44 and the second digit layer 45 and the first bed layer. The surface of the first bed layer on the positive Z direction side is flat.

[0040] The movement path of the nozzle 24 when forming the first bed layer only needs to intersect with the Y direction in the XY plane, and is preferably formed along the X direction perpendicular to the Y direction. In this case, the effective area of the sacrificial layer 10 on which the model 20 can be formed can be increased. The modeling material 3 supplied from the nozzle 24 onto the modeling surface 2a is a linear portion.

[0041] The linear portions shrink when cooled. The first floor layer has a high thermal shrinkage rate in the direction in which the linear portions are formed. The first girder layer 44 in the first groove 29 and the second girder layer 45 in the second groove 31 are biased in a direction to approach the first floor layer. This allows the girder layer to improve adhesion with the first groove 29 and the second groove 31.

[0042] The second, third, and fourth floor layers are stacked on top of the first floor layer. The movement path of the nozzle 24 when forming each floor layer should intersect with the Y direction in the XY plane. Next, proceed to step S4.

[0043] Step S4 is a modeling layer formation process. In step S4, the 3D modeling device 1 stacks modeling layers to form the model 20. The movement mechanism 7 moves the nozzle 24 based on the set movement path. The nozzle 24 supplies the modeling material 3 in layers to stack the modeling layers. Next, the process proceeds to step S5.

[0044] Step S5 is a process of removing the object. After the 3D printing apparatus 1 has finished forming the object 20, the operator moves the sacrificial layer 10 along the first direction 28. Because the first groove 29 and the second groove 31 are open in the first direction 28, the sacrificial layer 10 is removed from the stage 2. This allows the sacrificial layer 10 to be separated from the stage 2 without applying a large force to the object 20.

[0045] The stage 2 may be equipped with a heater. After the 3D printing apparatus 1 has finished forming the model 20, the control unit 4 and the temperature control unit 8 cause the heater to heat the first to fourth bed layers. The heated first to fourth bed layers thermally expand, which can temporarily weaken the adhesion between the first girder layer 44 and the first groove 29 and between the second girder layer 45 and the second groove 31.

[0046] Secondary processing such as milling is performed on the sacrificial layer 10. The shaped object 20 and the sacrificial layer 10 are separated, and the shaped object 20 is completed.

[0047] Next, a method for manufacturing the shaped object 20 will be described in detail in accordance with the steps shown in FIG. 6 to 8 are diagrams corresponding to the digit layer forming process of step S2. As shown in FIG. 6, in step S2, the control unit 4 supplies the modeling material 3 to the first groove 29 while moving the nozzle 24 of the discharge unit 13 relative to the stage 2 in the first direction 28, thereby forming the first digit layer 44. Next, the control unit 4 supplies the modeling material 3 to the second groove 31 while moving the nozzle 24 of the discharge unit 13 relative to the stage 2 in the first direction 28, thereby forming the second digit layer 45. The order in which the first digit layer 44 and the second digit layer 45 are formed is not limited. The first direction 28 in which the nozzle 24 is moved is not limited to the Y-positive direction and the Y-negative direction. In this embodiment, for example, the direction in which the nozzle 24 moves when supplying the modeling material 3 is the Y-positive direction.

[0048] The first digit layer 44 is formed on the second groove 31 side of the first groove 29. The second digit layer 45 is formed on the first groove 29 side of the second groove 31. The height by which the first digit layer 44 and the second digit layer 45 protrude from the molding surface 2a is not particularly limited, but in this embodiment, the height is, for example, 0.2 mm.

[0049] As shown in FIG. 7, the molding material 3 in the first deep groove portion 29f and the second deep groove portion 31f hangs down in the negative Z direction compared to the molding material 3 in the first shallow groove portion 29e and the second shallow groove portion 31e. In the first groove 29, the molding material 3 catches on the first step side surface 29g, which prevents the molding material 3 from moving in the positive Y direction. In the second groove 31, the molding material 3 catches on the second step side surface 31g, which prevents the molding material 3 from moving in the positive Y direction. In the first deep groove portion 29f, the molding material 3 hanging down in the negative Z direction becomes the first protrusion 44a. In the second deep groove portion 31f, the molding material 3 hanging down in the negative Z direction becomes the second protrusion 45a.

[0050] As shown in FIG. 8, the molding material 3 is supplied to the first groove 29 and the second groove 31. In FIG. 8, the areas where the molding material 3 is supplied are hatched. At this time, a sacrificial layer 10 is formed from the first groove 29 to the second groove 31. In addition, when forming the sacrificial layer 10 from the third groove 32 to the fourth groove 33, the molding material 3 is supplied to the third groove 32 and the fourth groove 33. In addition, when forming the sacrificial layer 10 from the fifth groove 34 to the sixth groove 35, the molding material 3 is supplied to the fifth groove 34 and the sixth groove 35. In addition, when forming the sacrificial layer 10 from the seventh groove 36 to the eighth groove 37, the molding material 3 is supplied to the seventh groove 36 and the eighth groove 37. In addition, when forming the sacrificial layer 10 from the ninth groove 38 to the tenth groove 39, the molding material 3 is supplied to the ninth groove 38 and the tenth groove 39.

[0051] With this configuration, the depth of the first groove 29 is 0.2 mm or more, which prevents the first digit layer 44 from coming off the first groove 29. The depth of the second groove 31 is also 0.2 mm or more, which prevents the second digit layer 45 from coming off the second groove 31. The depths of the first groove 29 and the second groove 31 are 1 mm or less, which allows the thickness of the stage 2 to be thin. This is effective when the conditions of the first angle 29b, the second angle 31b, and the shallow groove depth 42 are all within the above ranges.

[0052] 9 to 12 are views corresponding to the sacrificial layer formation process in step S3. As shown in Fig. 9, in step S3, the control unit 4 controls the movement mechanism 7 and the discharge unit 13 to supply the modeling material 3 to the modeling surface 2a while moving the nozzle 24 of the discharge unit 13 relative to the stage 2, thereby forming a first bed layer 46 that connects the first digit layer 44 and the second digit layer 45.

[0053] It is preferable that the molding material 3 supplied in step S2 and the molding material 3 supplied in step S3 are made of the same material. This can increase the adhesion between the first and second girder layers 44, 45, and the first floor layer 46. There are no particular restrictions on the type of molding material 3, but in this embodiment, for example, ABS resin is used as the molding material 3. Resins with a high shrinkage rate, such as polyethylene, can also be used.

[0054] According to this configuration, the modeling material 3 is supplied to the modeling surface 2a. The modeling material 3 contracts as it cools. The first digit layer 44 contracts relative to the first groove 29. The second digit layer 45 also contracts relative to the second groove 31. At this time, the first base layer 46 connecting the first digit layer 44 and the second digit layer 45 contracts. The first base layer 46 biases the first digit layer 44 and the second digit layer 45 so that they approach each other. The first digit layer 44 then presses the first groove 29 toward the second groove 31. The second digit layer 45 presses the second groove 31 toward the first groove 29. Therefore, even if the modeling material 3 contracts, the model 20 formed on the modeling surface 2a can maintain its positional relationship with the stage 2.

[0055] As shown in Figure 10, the first digit layer 44 and the second digit layer 45 extend in the first direction 28. The first bed layer 46 is formed by supplying the modeling material 3 onto the stage 2 while the control unit 4 reciprocates the nozzle 24 of the discharge unit 13 in a second direction 47 that intersects with the first direction 28. The second direction 47 is not limited to a direction perpendicular to the first direction 28. The second direction 47 is preferably a direction perpendicular to the first direction 28. This allows the area of the sacrificial layer 10 to be increased in a planar view from the Z direction.

[0056] There is no particular limitation on the route along which the nozzle 24 moves when forming the first bed layer 46. In this embodiment, for example, the nozzle 24 advances alternately in the X-positive direction and the X-negative direction in the second direction 47. In the first direction 28, the first bed layer 46 is formed sequentially from the Y-positive direction toward the Y-negative direction.

[0057] There are no particular limitations on the molding conditions when forming the first bed layer 46. In this embodiment, for example, the area occupied by the molding material 3 per unit area of the first bed layer 46 is 5%. The area occupied by the molding material 3 per unit area is also referred to as the infill rate.

[0058] According to this configuration, to form the first bed layer 46, the nozzle 24 of the discharge unit 13 supplies the modeling material 3 to the modeling surface 2a while moving in a second direction 47 intersecting the first direction 28. At this time, the first bed layer 46, in which the supplied modeling material 3 has solidified, has a property of being strong in the second direction 47, which is the movement direction of the discharge unit 13. When the discharge unit 13 repeatedly moves back and forth to expand the width of the first bed layer 46, the first bed layer 46 has weak strength in the first direction 28, which is perpendicular to the movement direction of the discharge unit 13. The movement direction of the discharge unit 13 is from the first digit layer 44 to the second digit layer 45, and from the second digit layer 45 to the first digit layer 44. When the modeling material 3 cools and shrinks, tension acts in the direction from the first digit layer 44 to the second digit layer 45 and in the direction from the second digit layer 45 to the first digit layer 44. Therefore, tension acts on the first bed layer 46 in the direction of movement of the discharge portion 13, so that cracking of the first bed layer 46 can be suppressed even when the modeling material 3 contracts.

[0059] With this configuration, the first girder layer 44 is formed on the second groove 31 side within the first groove 29. When the first bed layer 46 shrinks due to cooling, the first girder layer 44 is pressed against the second groove 31 side within the first groove 29. Therefore, the frictional force between the first groove 29 and the first girder layer 44 can be increased. Similarly, the second girder layer 45 is formed on the first groove 29 side within the second groove 31. When the first bed layer 46 shrinks due to cooling, the second girder layer 45 is pressed against the first groove 29 side within the second groove 31. Therefore, the frictional force between the second groove 31 and the second girder layer 45 can be increased.

[0060] According to this configuration, the angle formed between the first side wall 29a and the printing surface 2a is less than 90 degrees. Therefore, when the first girder layer 44 is pulled toward the second groove 31, the first girder layer 44 is pressed against the bottom surface of the first groove 29. Similarly, the angle formed between the second side wall 31a and the printing surface 2a is less than 90 degrees. Therefore, when the second girder layer 45 is pulled toward the first groove 29, the second girder layer 45 is pressed against the bottom surface of the second groove 31. Therefore, it is possible to make it difficult for the first layer 46 to separate from the printing surface 2a.

[0061] The first angle 29b formed between the first side wall 29a and the building surface 2a is 70 degrees or more. Therefore, the first girder layer 44 can be manually separated from the first groove 29. The second angle 31b formed between the second side wall 31a and the building surface 2a is also 70 degrees or more. Therefore, the second girder layer 45 can be manually separated from the second groove 31. Therefore, the first bed layer 46 can be manually separated from the building surface 2a.

[0062] 11, the nozzle 24 of the discharge unit 13 is moved back and forth in a second direction 47 intersecting the first direction 28, while supplying the modeling material 3 onto the first bed layer 46 to form a second bed layer 48. The area occupied by the modeling material 3 per unit area of the second bed layer 48 is larger than the area occupied by the modeling material 3 per unit area of the first bed layer 46.

[0063] According to this configuration, the second bed layer 48 is laminated on the first bed layer 46. The second bed layer 48 has a larger area occupied by the modeling material 3 per unit area than the first bed layer 46, and therefore has a surface with less unevenness. Therefore, the surface roughness can be reduced compared to the first bed layer 46.

[0064] For example, in this embodiment, the area occupied by the building material 3 per unit area of the first bed layer 46 is 5%, and the area occupied by the building material 3 per unit area of the second bed layer 48 is 75%.

[0065] While the nozzle 24 is moved back and forth in the second direction 47, the modeling material 3 is supplied onto the second bed layer 48 to form a third bed layer 49. Furthermore, while the nozzle 24 is moved back and forth in the second direction 47, the modeling material 3 is supplied onto the third bed layer 49 to form a fourth bed layer 51.

[0066] For example, in this embodiment, the area occupied by the molding material 3 per unit area of the third bed layer 49 and the fourth bed layer 51 is 85%. The area occupied by the molding material 3 per unit area of the third bed layer 49 and the fourth bed layer 51 is larger than that of the second bed layer 48. Therefore, the surface roughness of the fourth bed layer 51 is smaller than that of the second bed layer 48. In this way, it is preferable that the area occupied by the molding material 3 per unit area of the upper layer is larger than the area occupied by the molding material 3 per unit area of the lower layer. The surface roughness of the upper layer can be reduced.

[0067] 12, in the second direction 47, the first bed layer 46, the second bed layer 48, the third bed layer 49, and the fourth bed layer 51 are arranged between the first girder layer 44 and the second girder layer 45. In step S2, when the groove for supplying the modeling material 3 is changed, the first bed layer 46, the second bed layer 48, the third bed layer 49, and the fourth bed layer 51 are arranged between the two grooves into which the modeling material 3 was supplied. In step S3, the sacrificial layer 10 is completed.

[0068] There are no particular limitations on the shaping conditions when forming the sacrificial layer 10. In this embodiment, for example, the shaping speed is 100 mm / s, and the layer pitch is, for example, 0.1 mm to 0.2 mm.

[0069] Fig. 13 is a diagram corresponding to the modeling layer formation step of step S4. As shown in Fig. 13, in step S4, a modeling material 3 is supplied onto the sacrificial layer 10 to form a modeling layer 52. A plurality of modeling layers 52 are stacked to form a modeled object 20.

[0070] Figure 14 is a diagram corresponding to the object removal step in step S5. As shown in Figure 14, in step S5, the operator moves the object 20 in the negative Y direction. The first digit layer 44 moves along the first groove 29. The second digit layer 45 moves along the second groove 31. The sacrificial layer 10 can be easily moved by heating a heater installed on the stage 2. Because the first groove 29 and the second groove 31 are open on the first side surface 2b side, the first digit layer 44 and the second digit layer 45 can be pulled out in the negative Y direction.

[0071] When the first digit layer 44 is about 80% out of the first groove 29, the operator rotates the sacrificial layer 10 around the X-axis. The sacrificial layer 10 on the Y-positive side is lifted in the Z-positive direction, and the first digit layer 44 and the second digit layer 45 are removed from the first groove 29 and the second groove 31, respectively. In this way, the model 20 is removed from the stage 2. Next, the model 20 is separated from the sacrificial layer 10, and the model 20 is completed.

[0072] Second embodiment This embodiment differs from the first embodiment in that the first groove 29 shown in Fig. 4 does not have the first deep groove portion 29f, and the first groove 29 is formed by the first shallow groove portion 29e. Note that the same components as those in the first embodiment are denoted by the same reference numerals, and redundant explanations will be omitted.

[0073] As shown in Figure 15, the stage 55 has a first groove 56 and a second groove 57 on its printing surface 55a. The stage 55 has a first side surface 55b on the Y negative direction side that intersects with the printing surface 55a. One end of the first groove 56 opens to the first side surface 55b. One end of the second groove 57 opens to the first side surface 55b. The first side surface 55b is one surface of the stage 55 in the first direction 28.

[0074] According to this configuration, when the modeling material 3 is supplied to the first groove 56 beyond one end thereof, a portion of the modeling material 3 flows in the direction of gravity and hangs down. The first girder layer 58 hangs down along the first side surface 55b. Similarly, when the modeling material 3 is supplied to the second groove 57, a portion of the modeling material 3 flows down along the first side surface 55b and hangs down. The second girder layer 59 hangs down along the first side surface 55b. Therefore, the first bed layer 46 can be further prevented from moving to the side opposite the first side surface 55b of the stage 55.

[0075] Since the first side surface 55b of the first groove 56 and the second groove 57 is open, the first digit layer 58 and the second digit layer 59 can be moved in the negative Y direction in the object removal process of step S5. Therefore, the sacrificial layer 10 can be easily removed from the stage 55.

[0076] Third embodiment This embodiment differs from the first embodiment in that the first groove 29 and the second groove 31 shown in Fig. 4 do not open on the first side surface 2b. Note that the same components as those in the first embodiment are denoted by the same reference numerals, and redundant explanations will be omitted.

[0077] 16, the stage 65 has a first groove 66 and a second groove 67 on a printing surface 65a. The stage 65 has a first side surface 65b on the Y negative direction side that intersects with the printing surface 65a. The first groove 66 and the second groove 67 do not open to the first side surface 65b.

[0078] The first groove 66 has a first shallow groove portion 66e and a first deep groove portion 66f. The first deep groove portion 66f is deeper than the first shallow groove portion 66e. The second groove 67 has a second shallow groove portion 67e and a second deep groove portion 67f. The second deep groove portion 67f is deeper than the second shallow groove portion 67e.

[0079] In the girder layer forming process of step S2, the molding material 3 is supplied to the first groove 66 to form the first girder layer 68. The molding material 3 is supplied to the second groove 67 to form the second girder layer 69. The first protrusions 68a are formed in the first deep groove portions 66f. The second protrusions 69a are formed in the second deep groove portions 67f.

[0080] Compared to the molding material 3 in the first shallow groove portion 66e and the second shallow groove portion 67e, the molding material 3 in the first deep groove portion 66f and the second deep groove portion 67f hangs down in the Z negative direction. In the first groove 66, the molding material 3 is caught on the first step side surface 66g, which prevents the molding material 3 from moving in the Y positive direction. In the second groove 67, the molding material 3 is caught on the second step side surface 67g, which prevents the molding material 3 from moving in the Y positive direction.

[0081] Fourth embodiment In the first embodiment, the relative positional relationship between the nozzle 24 and the first and second grooves 29 and 31 is set by calibration before modeling. The 3D modeling apparatus 1 may have a means for detecting the positions of the first grooves 29 and the second grooves 31. For example, an imaging device, a laser measurement device, or the like can be used as the means for detecting the positions of the first grooves 29 and the second grooves 31.

[0082] Fifth embodiment In the first embodiment, two digit layers, a first digit layer 44 and a second digit layer 45, were formed in the digit layer formation process of step S2. The number of digit layers may be three or more. Furthermore, the sacrificial layer 10 and the stage 2 can be firmly connected. [Explanation of symbols]

[0083] 1...3D printing device, 2,55,65...stage, 2a,55a,65a...printing surface, 2b...first side, 3...printing material, 4...control unit, 7...movement mechanism, 13...discharge unit, 24...nozzle, 28...first direction, 29,56,66...first groove, 29a...first side wall, 31a...second side wall, 31,57,67...second groove, 44,58,68...first digit layer, 45,59,69...second digit layer, 46...first floor layer, 48...second floor layer.

Claims

1. A stay having a first groove extending in a first direction and a second groove extending in the first direction on a shaping surface. Ji and, a discharge unit that supplies a modeling material to the modeling surface to form a model; a movement mechanism that moves the stage and the discharge unit relatively; a control unit that controls the discharge unit and the movement mechanism, The control unit The discharge unit is moved relative to the stage in the first direction, and the discharge unit is applying the build material to form a first digit layer; The discharge unit is moved relative to the stage in the first direction, and the discharge unit is applying the build material to form a second spar layer; The modeling material is supplied to the modeling surface while the discharge unit is moved relative to the stage. the moving mechanism to feed the first floor layer connecting the first girder layer and the second girder layer. and controlling the discharge unit, The first bed layer is located between the object and the stage in the stacking direction of the object. To be shaped, 3D modeling device.

2. The three-dimensional modeling apparatus according to claim 1, The depth of the first groove and the depth of the second groove are 0.2 mm or more and 1 mm or less. This is a three-dimensional modeling device.

3. The three-dimensional modeling apparatus according to claim 1 or 2, The angle formed between the first side wall of the first groove, which is the side wall on the second groove side, and the modeling surface is 7. is equal to or greater than 0 degrees and less than 90 degrees, The angle formed between the second side wall of the second groove, which is the side wall on the first groove side, and the modeling surface is 7. A three-dimensional modeling device characterized in that the angle is greater than or equal to 0 degrees and less than 90 degrees.

4. The three-dimensional modeling apparatus according to claim 1 or 2, the stage has a first side surface that intersects with the build surface; One end of the first groove opens to the first side surface, The three-dimensional modeling apparatus is characterized in that one end of the second groove opens to the first side surface.

5. The three-dimensional modeling apparatus according to claim 1 or 2, The first bed layer is configured such that the control unit reciprocates the discharge unit in a direction intersecting the first direction. a three-dimensional object to be formed by supplying the modeling material onto the stage while Modeling equipment.

6. The three-dimensional modeling apparatus according to claim 5, The discharge unit is reciprocated in a direction intersecting the first direction, and the discharge unit is then discharged forward onto the first bed layer. supplying the build material to form a second bed layer; The area occupied by the building material per unit area of the second bed layer is: a three-dimensional modeling apparatus having a surface area larger than the area occupied by the modeling material per unit area.

7. A three-dimensional printing apparatus according to claim 6, The second bed layer is a layer between the object and the stage when viewed from the stacking direction of the object. A 3D modeling device that creates shapes between the parts.

8. The three-dimensional modeling apparatus according to claim 1 or 2, the first girders are formed on the second groove side in the first groove, the second girders are formed on the first groove side of the second groove, Device.

9. The three-dimensional modeling apparatus according to claim 1 or 2, The main component of the stage material is glass or aluminum. A three-dimensional modeling device.

10. The three-dimensional modeling apparatus according to claim 1 or 2, the discharging unit includes a nozzle that discharges the modeling material, The width of the first groove and the second groove on the modeling surface is wider than the outer diameter of the nozzle. A three-dimensional modeling apparatus characterized by:

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