FORMED OBJECT, FORMED OBJECT DESIGN METHOD, AND FORMED OBJECT MANUFACTURING METHOD

Abstract

To provide a shaped object that can further improve the degree of freedom in shaping. [Solution] A shaped object W is manufactured by a 3D printer and has a shaped portion W1 having a shape defined based on a square curve.

Description

[Technical Field]

[0001] The present invention relates to a three-dimensional object, a method for designing an object, and a method for manufacturing an object. [Background technology]

[0002] BACKGROUND ART In recent years, fused deposition modeling 3D printers, for example, have become widely known as model manufacturing devices for manufacturing three-dimensional models (see, for example, Patent Document 1).

[0003] When it comes to objects manufactured using 3D printers, there is more freedom in design than with conventional methods, and they can handle complex shapes; however, the more complex the shape, the more support is required to support the parts of the model that need support during printing, and it is often difficult to remove support that is no longer needed after printing.

[0004] Furthermore, when manufacturing objects using a 3D printer, lattice structures such as lattice structures have traditionally been used (see, for example, Patent Document 2). A lattice structure is a structure in which branched lattices are periodically arranged, allowing the interior of the object to be hollow, making it easy to reduce its weight. However, because each element (edge) of this lattice structure is linear, it lacks flexibility (elasticity), and it has been necessary to combine multiple unit cells to create a curved surface (curve). In addition, because the lattice structure is configured by connecting the ends of the branched lattices, the connection direction (angle) is limited. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Special Publication No. 2000-500709 [Patent Document 2] Japanese Patent Application Laid-Open No. 2015-93461 Summary of the Invention [Problem to be solved by the invention]

[0006] Therefore, one object of the present invention is to provide a shaped object, a shaped object design method, and a shaped object manufacturing method that can further improve the degree of freedom in shaping. [Means for solving the problem]

[0007] A shaped object according to an embodiment of the present invention is a shaped object manufactured by a shaped object manufacturing apparatus, and has a shaped portion having a shape defined based on a square lobe curve.

[0008] In the above-described shaped object, the shaped portion may have a loop shape defined based on a square lobe curve.

[0009] The object may be a solid object having an outer edge defined by a square lobe curve.

[0010] The above-described shaped object may be configured by connecting a plurality of shaped portions.

[0011] In the above-described shaped object, the plurality of shaped portions may have the same shape or mirror-symmetric shapes.

[0012] In the above-described shaped object, the plurality of shaped portions may have shapes that are different in size from one another.

[0013] In the above-described object, the cross-sectional shape of the shaping portion may have a side edge portion that extends along the shaping table of the shaping object manufacturing apparatus.

[0014] In the above-described shaped object, the cross-sectional shape of the shaped portion may be a Reuleaux polygon.

[0015] In the above-described shaped object, the cross-sectional shape of the shaped portion may be an intersection of two circles.

[0016] The shaped article may form at least a part of a porous structure.

[0017] The shaped object may be at least a part of a mesh.

[0018] The outer surface of the shaped article may form at least a part of the filter medium.

[0019] The shaped object may be a connecting part that connects a plurality of structural parts.

[0020] Furthermore, the method for designing a shaped object according to the present invention forms shaping data for a shaped part by setting a thickness to a surface formed by connecting adjacent square curves with a line.

[0021] In the above-described method for designing a shaped object, the shaping data of the shaped portion may be formed by sweeping a predetermined cross-sectional shape along a square lobe curve.

[0022] In the above-described method for designing a shaped object, the shaping data of the shaped portion may be formed by connecting cross-sectional shapes at different positions along a square lobe curve.

[0023] In the above-described method for designing a shaped object, the shaping data of the shaping part may be formed by setting a thickness on a surface surrounded by a square lobe curve.

[0024] A method for manufacturing a shaped object according to the present invention is a method for manufacturing a shaped object by using a shaped object manufacturing apparatus, based on the modeling data formed by the above-described method for designing a shaped object. [Effects of the Invention]

[0025] According to the embodiment of the present invention, it is possible to further improve the degree of freedom in shaping. [Brief explanation of the drawings]

[0026] [Figure 1] 1 is a front view schematically illustrating a fused deposition modeling 3D printer, which is an apparatus for manufacturing a molded object according to an embodiment of the present invention. [Figure 2] FIG. 10 is an explanatory diagram showing an example of a square curve for forming a shaped object or shaped portion manufactured using the same 3D printer. [Figure 3]10A and 10B are perspective views showing a first design method for the modeling data of the same object in order. [Figure 4] 10A and 10B are perspective views showing a second design method for the modeling data of the same object in order. [Figure 5] These are figures showing an object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view from one direction, and (e) is a perspective view from another direction. [Figure 6] 10A and 10B are diagrams showing other objects manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, (d) is a perspective view from one direction, and (e) is a perspective view from another direction. [Figure 7] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, and (c) is a side view from the +Y axis direction. [Figure 8] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 9] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 10] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 11] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 12]10A and 10B show still another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view, and (e) is a front view showing an example of the cross-sectional shape. [Figure 13] 11 is a photograph showing a manufacturing example of the shaped object shown in FIG. 10. [Figure 14] 10A and 10B show still another object produced using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view from one direction, and (e) is a perspective view from another direction. [Figure 15] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 16] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 17] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 18] FIG. 17 is a perspective view showing an application example of the shaped object shown in FIG. 16. [Figure 19] FIG. 10A is a perspective view showing an example of a square lobe curve, and FIG. 10B is a perspective view showing a shaped object formed by connecting a plurality of shaped portions manufactured based on the square lobe curve of FIG. [Figure 20] 1A and 1B are diagrams showing an example of modeling data for the same object, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 21]10A and 10B are diagrams showing other examples of the modeling data of the same object, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 22] 10A and 10B are diagrams showing yet another example of the modeling data of the same object, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 23] 10A and 10B are diagrams showing yet another example of the modeling data of the same object, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 24] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 25] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 26] 25(a) is a perspective view showing the mesh of the shaped object shown in FIG. 24, and FIG. 25(b) is a perspective view showing an example of use of (a). [Figure 27] FIG. 26 is a perspective view showing another example of use of the shaped object shown in FIG. 25. [Figure 28] 26A and 26B are photographs showing an example of manufacturing the shaped object shown in FIG. 25, where (a) shows the normal state and (b) shows the state when a pulling force is applied. [Figure 29] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 30] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 31] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 32] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 33] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 34] 33 is a photograph showing a manufacturing example of the shaped object shown in FIG. 32. [Figure 35] 33A and 33B are explanatory diagrams showing application examples of the shaped object shown in FIG. 32, in which (a) shows an example in which the shaped object is inserted and placed inside, and (b) shows an example in which the shaped object is hung and placed outside. [Figure 36] 10A and 10B show still another object produced using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view from one direction, and (e) is a perspective view from another direction. [Figure 37] 10A and 10B show still another object produced using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view from one direction, and (e) is a perspective view from another direction. [Figure 38] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 39]10A and 10B show still another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is a perspective view, and (e) is a front view showing an example of the cross-sectional shape. [Figure 40] FIG. 10 is an explanatory diagram schematically illustrating an example in which the above-mentioned shaped object is used as a connecting portion between structural portions. [Figure 41] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, and (c) is a side view from the +Y axis direction. [Figure 42] 10A and 10B show yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, and (c) is a perspective view. [Figure 43] 10A to 10C are explanatory diagrams showing a third design method for the modeling data of the same object. [Figure 44] 44A and 44B show a model manufactured based on the modeling data designed in FIG. 43, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 45] 10A to 10F are explanatory diagrams showing a fourth design method for the modeling data of the same object in the order of (a) to (f). [Figure 46] 46A and 46B show a model manufactured based on the modeling data designed in FIG. 45, where (a) is a plan view from the +Z-axis direction, (b) is a side view from the +X-axis direction, (c) is a side view from the +Y-axis direction, and (d) is a perspective view. [Figure 47] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, (d) is an oblique view, and (e) is a plan view from the -Z axis direction. [Figure 48]Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 49] Figures showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is a side view from the +Y axis direction, and (d) is a perspective view. [Figure 50] Figures showing yet another object produced using the same 3D printer, where (a) is a plan view from the +Z axis direction, (b) is a side view from the +X axis direction, (c) is an oblique view from one direction, (d) is an oblique view from the other direction, and (e) is a photograph from the -Z axis direction. [Figure 51] 51A and 51B are perspective views showing application examples of the object shown in FIG. 50, where (a) shows an example using a single object, and (b) shows an example using a pair of objects. [Figure 52] 10A to 10C are explanatory views showing another example of the fourth design method for the modeling data of the same modeled object in the order of (a) to (c). [Figure 53] 10A and 10B are diagrams showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, and (b) is a plan view from the +X-axis direction. [Figure 54] 10A and 10B are diagrams showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, and (b) is a plan view from the +X-axis direction. [Figure 55] FIG. 55 is an explanatory diagram showing an application example of the shaped object shown in FIG. 54. [Figure 56] 10A and 10B are diagrams showing yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, and (b) is a plan view from the +X-axis direction. [Figure 57] 10A and 10B show yet another object manufactured using the same 3D printer, where (a) is a plan view from the +Z-axis direction, (b) is a plan view from the +X-axis direction, and (c) is a perspective view. [Figure 58] 31 is a photograph showing a manufacturing example of the shaped object shown in FIG. 30. [Figure 59] 1A and 1B show the main body of a foam generating means as an application example of a molded object manufactured using the same 3D printer, where (a) is a perspective view and (b) is a cross-sectional view. [Figure 60] 59. (a) is a photograph showing an example of foam generated by the foam generating means shown in FIG. 59, and (b) is a photograph showing an example of foam in a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0027] An embodiment of the present invention will be described with reference to the drawings.

[0028] In Figure 1, 1 is a fused deposition modeling 3D printer, which is a device for manufacturing objects. This fused deposition modeling 3D printer (hereinafter sometimes simply referred to as "3D printer 1") is a modeling machine that produces a three-dimensional object W by sequentially layering resin, which is a modeling material that has been melted (dissolved) by heat, one layer at a time based on 3D modeling data.

[0029] The resin used as the modeling material in the 3D printer 1 is, for example, a thermoplastic resin, such as general-purpose plastic, engineering plastic, super engineering plastic, reinforced resin, recycled plastic, biomass plastic, or biodegradable plastic. More specifically, examples include PVC, POM, PBAT, AAS, PS, PLA, PBS, PE, plant fiber-filled PLA, plant fiber-filled PBS, ABS, glass fiber-filled ABS, carbon fiber-filled ABS, PP, glass fiber-filled PP, basalt fiber-filled PLA, basalt fiber-filled ABS, basalt fiber-filled PP, basalt fiber-filled PC, basalt fiber-filled PE, basalt fiber-filled PVC, carbon fiber-filled PP, PC, glass fiber-filled PC, PC-ABS, ASA, TPE, TPU, cellulose acetate, PA, and PETG. The modeling material may be in any shape, such as pellets or filaments. Furthermore, the 3D printer 1 may be, for example, a single-nozzle-head model, and only one type of resin may be used for modeling; a resin specifically for support (such as a water-soluble resin) is not required. The modeling material is not limited to resin; it may also be metal, ceramic, silicone, or the like. These modeling materials may also have one or more of the following properties: flexibility, antibacterial properties, chemical resistance, heat resistance, stain resistance, and weather resistance, or may have these properties added to them using desired additives.

[0030] The 3D printer 1 includes, for example, a box-shaped main body 3 having a modeling chamber 2 inside, a modeling head 4 that can move in the X-axis direction (horizontal, i.e., left-right direction) and Z-axis direction (up-down, i.e., height direction) within the modeling chamber 2, and a modeling table 5 that can move in the Y-axis direction (horizontal, i.e., front-to-back direction) within the modeling chamber 2.

[0031] Since the modeling head 4 can move in the X-axis direction and the Z-axis direction and the modeling table 5 can move in the Y-axis direction, the modeling head 4 moves three-dimensionally relative to the modeling table 5 (as will be described later, the 3D printer 1 is not limited to the configuration shown in Figure 1, and may be configured in any way so long as the modeling head 4 moves at least three-dimensionally relative to the modeling table 5).

[0032] The 3D printer 1 also includes a first drive unit 6 that moves the modeling head 4 in the X-axis direction and Z-axis direction within the modeling chamber 2, a second drive unit 7 that moves the modeling table 5 in the Y-axis direction within the modeling chamber 2, and a control unit 8 that controls both drive units 6, 7, etc. based on 3D modeling data such as STL data.

[0033] Then, based on the control by the control unit 8, the modeling head 4 moves three-dimensionally relative to the modeling table 5, and resin (molten resin) is ejected from the nozzle 11 of the moving modeling head 4.As the ejected resin hardens and solidifies, the resin is layered on the modeling table 5, and a three-dimensional object W of the desired shape is formed.

[0034] Here, the modeling head 4 of the fused deposition modeling 3D printer 1 with a single nozzle head is, for example, a molten resin extrusion type, and has a single nozzle 11 that ejects melted resin from an outlet using heat from a heating means (not shown) within the modeling head 4.

[0035] That is, the resin that has been heated and melted by a heating means such as a heater (not shown) is extruded by an extrusion means (not shown) such as a gear inside the model-forming head 4, and is discharged (exhausted) from the outlet of one nozzle 11 for discharging the model-forming material in the direction of the central axis of the outlet, for example, downward. Note that the heating means and the extrusion means may be provided outside the model-forming head 4, rather than inside the model-forming head 4.

[0036] The object manufactured by the 3D printer 1 of this embodiment has a shaped portion having a shape defined based on the square lobe curve R, an example of which is shown in Figure 2. The shaped portion may be a linear body or a continuation thereof having a loop shape defined based on the square lobe curve R, or may be a solid shape having an outer edge shape defined based on the square lobe curve R.

[0037] Here, the regular lobe curve R is also called a rose curve, and is defined by the following equation (hereinafter collectively referred to as equation (1)) using a parameter t.

[0038] Xt=a·(b+r(t))·cos(c+d·t) Yt=e·(f+r(t))·sin(c+d·t) Zt=any

[0039] The X-axis, Y-axis, and Z-axis directions correspond to the X-axis, Y-axis, and Z-axis directions of the 3D printer 1 (shown in FIG. 1). The coefficients a and e are coefficients that set the magnification ratios of the "petal" shape in the X-axis and Y-axis directions, and are each non-zero. The coefficients b and f are arbitrary coefficients for setting the radial width of the "petal." The number c is a coefficient that sets the start angle of rotation in the X-axis and Y-axis directions, and is an arbitrary coefficient that can add variation to the shape of the regular lobe curve. The coefficient d is a non-zero rational number. Preferably, a = e and b = f to make the regular lobe curve R symmetrical. Furthermore, r(t) is calculated by the following equation: g is an arbitrary positive number (preferably an integer greater than or equal to 1), h is an arbitrary coefficient, and r is a positive rational number, preferably greater than or equal to 1, and is expressed as sin g (h+r·t) or cos g The formula is (h + r·t). g is a coefficient for setting the width of the "petal" shape; the larger g is, the thinner the "petal" shape. The shape of the "petal" is preferably set appropriately depending on the cross-sectional shape of the object to be formed. The sin and cos in the above r(t) may be replaced by a finite Fourier series. Using a finite Fourier series makes the outer shape of the "petal" jagged, not only improving the appearance but also sharpening the tip, making it suitable for applications such as cutting tools. h is a coefficient for setting the start and / or end points of the regular lobe curve R, and r is a coefficient for setting the number of "petal" shapes. The parameter t is, for example, 0 to 2π [rad], but may be arbitrarily changed depending on the size of r, etc., as long as the desired shape can be obtained. Furthermore, Zt may be 0 or a function using t as a parameter. As an example of Zt, taking into consideration the ease of forming the forming part W1 (object W), for example, Zt=k, Zt=k·t, Zt=k·sin g (h+r·t), Zt=k·cos g(h + r t), or any combination thereof, or a constant, is preferably used. Furthermore, a finite Fourier series may be used for Zt instead of sin or cos. However, it is preferable to select the coefficients b, f, h, rational numbers r, Zt, etc. so that the orthotropic curve R does not trivially become a circle or a torus knot. By selecting these coefficients, it is possible to form a Reuleaux polygonal hole in the center of the shaping portion W1 (shaping object W). When using the shaping portion W1 (shaping object W) as a mesh, it is not desirable to have a hole in the center. However, in this case, it is possible to design and install another torus, or orthotropic curve, or an inscribed object, embedded within the mesh. Furthermore, the relationship between XT or YT and ZT may be separately defined using a parameter T different from parameter t, so as to draw an arbitrary curve in the XZ or YZ plane. For example, the orthotropic curve R shown in Figure 2 is on the XY plane set at Zt = 0, and shows an example of a = e, b = c = f = h = 0, r = 3 / 2, d = g = 1, and t = 0 to 4π [rad]. Depending on the range of the parameter t, the orthotropic curve R generally has a closed loop shape.

[0040] As is clear from equation (1), a congruent square lobe curve R is formed even when the values ​​of Xt, Yt, and Zt are interchanged. Furthermore, the square lobe curve R of this embodiment also includes a curve obtained by arbitrarily rotating equation (1) in three-dimensional directions. Furthermore, as is clear from equation (1), an arbitrary constant may be added to any of Xt, Yt, and Zt, and a modeling portion W1 (modeled object W) may be modeled at any position on the modeling table 5 of the 3D printer 1.

[0041] In this embodiment, 3D modeling data of the modeling unit is designed using a computer or the like using equation (1), and a model is manufactured by driving the 3D printer 1 based on the designed modeling data.

[0042] Next, a method for designing the object W will be described.

[0043] When the formula (1) is used, the modeling data for manufacturing the model W can be designed in four main ways.

[0044] The first design method is a method of forming modeling data by adding thickness to a surface formed by connecting two adjacent square curves with a line.

[0045] The second design method is a method of creating modeling data by sweeping a predetermined cross-sectional shape along a square lobe curve. Sweeping refers to continuously moving a predetermined cross-sectional shape along a locus, in this case a square lobe curve.

[0046] The third design method is a method in which cross-sectional shapes at different positions are connected along a square lobe curve to form the modeling data of the modeling part.

[0047] The fourth design method is a method of forming modeling data by adding thickness to the surface surrounded by the square curve.

[0048] The first to third design methods are primarily used to design modeling data for manufacturing a linear modeling portion W1 (modeled object W), examples of which are shown in Figures 5 to 44. In contrast, the fourth design method is used to design modeling data for manufacturing a solid modeling portion W1 (modeled object W), examples of which are shown in Figures 45 to 57.

[0049] First, the first design method will be described with reference to the drawings.

[0050] As shown in Figure 3(a), two adjacent orthogonal curves R1 and R2 of approximately similar shape are used, and a line 15, for example a straight line, is used to connect them to form a surface 16. A non-self-intersecting line is preferable as the line 15. Then, as shown in Figure 3(b), this surface 16 is made three-dimensional (solidified) by adding thickness in the normal direction, thereby forming the modeling data D.

[0051] The thickness of the surface may be set so that there are no self-intersections, or so that some of the surfaces are self-intersecting. Note that the self-intersections can be considered as intersections in a lattice structure. For example, by adding thickness to any location of the self-intersections, impact resistance can be improved. To increase the thickness of the self-intersections, it is possible to perform operations such as increasing the amount of modeling material dispensed by the 3D printer 1.

[0052] The lines used in the first design method are not limited to straight lines, but may be any curve, such as a sine curve. Preferably, the square lobe curve R1 and the square lobe curve R2 do not intersect with each other. Furthermore, the square lobe curve R1 and the square lobe curve R2 do not need to have exactly the same Zt value; for example, one Zt may be set to be gradually larger than the other Zt depending on the magnitude of t.

[0053] Next, the second design method will be described with reference to the drawings.

[0054] As shown in FIG. 4(a), the center or center of gravity of a predetermined cross-sectional shape 21 is moved along a sweep line 20 set by a square lobe curve, thereby creating a three-dimensional shape as shown in FIG. 4(b), thereby forming the printing data D. The size of the cross-sectional shape 21 may be set so that no self-intersections are formed in the printing portion W1, or may be set so that self-intersections are formed in part of the printing portion W1. The self-intersections become intersections in a lattice structure.

[0055] Preferably, the cross-sectional shape 21 has side edges 22 extending along the modeling table 5. In other words, the side edges 22 are portions that do not substantially have a Z-axis component. The shape of the side edges 22 is preferably, for example, a straight line, but is not limited thereto. For example, the shape may be a curve approximating a straight line (with a large radius of curvature), or a shape having a straight line or a curve approximating a straight line extending along the modeling table 5 at its tip as a tangent or envelope, such as a wave shape, zigzag shape, or sawtooth shape. In this way, the cross-sectional shape 21 of the modeling part W1 has side edges 22 extending along the modeling table 5 of the 3D printer 1. This allows the modeling part W1 to be manufactured by the 3D printer 1 using the side edges 22 as supports for the modeling table surface (or a raft surface on the modeling table surface). This allows the modeling part W1 (modeled object W) to be manufactured without supports.

[0056] For example, while the cross-sectional shape 21 is shown as a hexagon, particularly a regular hexagon, it may be any other polygonal shape, such as a triangle or a square, a fan shape, a kamaboko shape, an oval shape such as a circle or an ellipse, or a Reuleaux polygon. For example, using a Reuleaux polygonal cross-sectional shape 21, particularly a Reuleaux triangle, can suppress sagging of the molding material when layer by layer is stacked, at least in the case of triaxial molding. The shape also provides resistance to bending stress, enhancing fatigue resistance during repeated use of the molded part W1 (molded object W). In the case of a Reuleaux polygonal cross-sectional shape 21, for example, by changing the "petal" shape to a pointed shape such as a rugby ball or jagged edge, it is suitable for use as a rotating cleaning brush, etc., as it can easily reach corners of a room. Generally, when the rise angle of the cross section of the forming part W1 (formed object W) (the angle between the forming table 5 and the forming part W1 (formed object W)) is 45 degrees or less (for example, in the case of a dome-shaped ceiling part such as a circular cross section with a curved surface where the tangent to the forming table 5 is an obtuse angle), the layers often collapse. In the case of a forming part W1 (formed object W) that has a twisted, spiral, or loop shape, if the cross section shape is, for example, a Reuleaux polygon or the intersection of circles (Boolean product), in other words, a rugby ball shape, it becomes easier to form it without supports, and by further reducing the layer pitch, support-less forming becomes even easier, making it possible to reduce the effort required to remove supports after forming, as well as the forming time and forming materials.

[0057] Furthermore, the cross-sectional shape 21 is not limited to a planar shape, but may be a hollow shape such as a frame. By using a frame-shaped cross-sectional shape 21 and selecting the appropriate molding material, the hollow molded portion W1 (molded object W) can be made lighter and more elastic. Furthermore, by molding the molded portion W1 (molded object W) with a frame-shaped cross-sectional shape 21 and both ends so that fluid can pass through the interior between the ends, and by attaching or integrally molding a turbulence-generating portion such as a filter (filtering material) or a spiral molded portion W1 (e.g., the molded portion W1 in Figures 7 to 10 and 17 to 19 described below) within the hollow interior, the overall curved structure can ensure the fluid flow distance in a small space, resulting in a compact filtration mechanism. In this case, the periodic structure of the molded portion W1 (molded object W) stabilizes the fluid flow and prevents stagnation.

[0058] Furthermore, the cross-sectional shape 21 may be swept while remaining perpendicular to the square lobe curve, or if it connects to another surface at the end of the square lobe curve, it may be extended or deformed so as to be aligned flush with and connect to that surface.

[0059] Examples of the shaping portion W1 (shaped object W) manufactured based on the shaping data D designed by the first and second design methods are shown in Figures 5 to 42. These shaping portions W1 (shaped objects W) constitute at least a part of the porous structure.

[0060] 5(a) to 5(e) show an example of a part W1 (object W) to be formed based on a square lobe curve where Zt=k·cos(r·t)·sin(d·t) in equation (1) and a=e=k, r=3 / 4, d=g=1, and t=0 to 8π [rad]. In this example, the part W1 has a rectangular cross-sectional shape, and the forming data can be designed using either the first or second design method.

[0061] In addition, the examples shown in Figures 6(a) to 6(e) have cross-sectional shapes different from those of the examples shown in Figures 5(a) to 5(e), and the modeling data was designed using the second design method with the cross-sectional shape being, for example, a circular shape for the sweep line formed by the same equation (1).

[0062] These examples of the shaped portion W1 (shaped object W) have a particularly good aesthetic appearance, forming a rotationally symmetric square leaf curve when viewed from the X-axis direction and the Z-axis direction, and each has a spring-like shape, resulting in a shaped portion W1 (shaped object W) with excellent cushioning and springiness. Therefore, even if the shaped portion W1 (shaped object W) is made of a hard shaped material, it is structurally capable of stretching and deforming, and can have flexibility, elastic deformation performance, and impact resistance. Therefore, for example, it can be shaped using less plasticizer or no plasticizer at all, which is also environmentally friendly.

[0063] Furthermore, the examples shown in Figures 7(a) to 7(c) are of a part W1 (object W) formed based on a square lobe curve set as Zt=k(h+r·t) in equation (1) with a=e=k, r=1 / 2, d=g=1, and t=0 to 5π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0064] This example of the shaped portion W1 (shaped object W) has a rotationally symmetrical square lobe curve when viewed along the Z-axis, and a spring-like or spiral shape, resulting in a shaped portion W1 (shaped object W) with excellent cushioning and springiness. Furthermore, by making the cross-sectional shape a frame shape, such as a double circle, it can also be used as a pipe-shaped turbulent flow generator that randomly disrupts the flow pattern of a fluid passing through it to generate turbulence. Compared to a pipe with a fixed diameter, turbulence can be generated at a lower fluid velocity. Because flow resistance is proportional to the square of the fluid velocity, generating turbulence at a low fluid velocity can be expected to save energy. Because turbulence can be easily generated in a fluid passing through it, the turbulent flow generates bubbles, making it suitable as a microbial cultivation device that can efficiently cultivate microorganisms such as aerobic bacteria on its inner surface. Furthermore, the spiral shape allows for a compact configuration of a long flow path. Furthermore, by making it possible to insert and remove a hollow structure W that can be expanded and contracted so as to be pressed against the inner surface of a pipeline through which a fluid passes, it can be effectively used as a microbial carrier or microbial cultivation device that can easily collect microorganisms that have grown inside (for example, plankton, which is food for seafood).In addition, the number of turns and length of the spiral can be easily adjusted by changing the range of t in equation (1), and the winding direction of the spiral can also be easily changed by changing the sign of the coefficient in equation (1), making it easy to design.

[0065] 5 to 7, the unit cell of the shaped portion W1 (shaped object W) can be inscribed in a rectangular parallelepiped. Also, if the coefficients Xt and Zt in formula (1) are the same, the unit cell can be inscribed in a square, and therefore, depending on the shape, it can also be inscribed in a cube.

[0066] Furthermore, by changing Zt and the coefficient r in Equation (1), the shape of the formed portion W1 (formed object W) can be significantly changed. The examples shown in Figures 8(a) to 8(d) are set as Zt = k cos(r t) in Equation (1), and the examples shown in Figures 9(a) to 9(d) are set as Zt = k cos(r t) sin(r t) in Equation (1), and are formed based on a square lobe curve with a = e = k, r = 1 / 20, d = g = 1, and t = 0 to 10π [rad]. The forming data was designed using the second design method with a circular cross-sectional shape.

[0067] The shape of the formed portion W1 (object W) can also be changed by setting the range of the parameter t. For example, the examples shown in Figures 10(a) to 10(d) are formed based on the square lobe curve of t = 0 to 15π [rad] in the examples shown in Figures 9(a) to 9(d), and have a shape that bulges out near the center in the Z-axis direction.

[0068] Furthermore, the example of the formed portion W1 (formed object W) shown in Figures 11(a) to 11(d) is the same as the example shown in Figures 10(a) to 10(d), except that the parameter t in Equation (1) is set to a range of 5π to 15π. In this way, the shape can be significantly changed by setting the range of the parameter t. In this example, the shape is substantially symmetrical in the Z-axis direction, so there is no directionality in the Z-axis direction, and it is less likely to cause mistakes in the installation direction during use, for example.

[0069] Furthermore, even when the same coefficients and ranges of the closed-form factor are used in Equation (1), the shape can be changed by changing the cross-sectional shape in the second design method. For example, the example of the shaped portion W1 (shaped object W) shown in FIGS. 12(a) to 12(e) is the same as the example shown in FIGS. 8(a) to 8(d), except that the cross-sectional shape 21 is a sector shape. While this example shows a sector with a central angle of π / 2 rad, the central angle may be any angle less than 2π rad, preferably less than π rad. In this case, by making the linear portion 21a of the sector shape 21 a side edge extending along the shaping table 5, support-less shaping becomes easier. Furthermore, in the case of a cross-sectional shape 21 having a curved surface (curve), a uniformly tapered curved surface can be created, which has the advantage of facilitating insertion and removal, for example, into a pipeline.

[0070] The examples of the shaped portion W1 (shaped object W) shown in Figures 8 to 12 form a rotationally symmetric square leaf curve when viewed from the Z-axis direction, and each has a spring-like or spiral shape. They are stretchable in the X-axis, Y-axis, and Z-axis directions, providing excellent cushioning and springiness, and are suitable for use as containers, etc. For example, in the examples shown in Figures 8 to 12, even if the shaping material is hard, the shaped portion W1 (shaped object W) is structurally stretchable and deformable, and has a gradually expanding spiral shape. Therefore, it can be used as a container that can be folded into a bucket-like shape by compressing it in the Z-axis direction to save space, or as a support for a linear, columnar, or cylindrical object, such as a filter or candle holder. For example, the manufacturing example shown in Figure 13 was shaped using acrylic shaping material, but elasticity, etc., can be imparted regardless of the physical properties of the material. Therefore, unlike, for example, metal springs, it can be imparted with unique elasticity and is resistant to rust. In addition, by selecting the coefficients Xt and Yt in formula (1) to create an elliptical shape when viewed from the Z-axis direction, it can be used as a mesh member that is placed at the entrance of a pipeline and is less likely to fall into the pipeline. Furthermore, by making it larger, it can also be used as the framework of a folding tent.

[0071] In addition, the examples shown in Figures 8 to 12 have a spiral spring shape like a bowl or dome that gradually expands from one end, which has the advantage that it is less likely to come loose in the expanding direction, especially in cases where the cross-sectional shape is a polygon, such as a simple triangle.

[0072] Furthermore, by changing the range of the coefficient r and the parameter t accordingly, it is possible to manufacture a shaped portion W1 (shaped object W) with a more complex shape.

[0073] In the examples shown in FIGS. 14 and 15, Equation (1) is set as Zt = k cos(r t). The examples shown in FIGS. 14(a) to 14(e) are for a portion W1 (object W) to be formed based on a square lobe curve with a = e = k, r = 2, d = g = 1, and t = 0 to 2π [rad]. The examples are for designing the forming data using the first design method with lines assumed to be sinusoidal curves. In these examples, the portion W1 (object W) does not have a front or back. The examples shown in FIGS. 15(a) to 15(d) are for a portion W1 (object W) to be formed based on a square lobe curve with a = e = k, r = 5 / 2, d = g = 1, and t = 0 to 4π [rad]. The examples are for designing the forming data using the second design method with a circular cross-sectional shape.

[0074] Furthermore, the forming portion W1 may be a mesh (unit shape, unit cell), and a plurality of forming portions W1 may be combined to form a formed object W. For example, the examples shown in Figures 16(a) to 16(d) are formed by connecting a forming portion W1a formed based on the square lobe curve with h = 0 in Equation (1) of the example shown in Figure 14 and a forming portion W1b formed based on the square lobe curve with h = π / 2 so that their loop shapes interfere with each other, and the forming data for each portion is designed using a circular cross-sectional shape in the second design method, for example.

[0075] Similarly, the example shown in Figures 17(a) to 17(d) is a molded object W that combines a molded portion W1a molded based on the square lobe curve of h=0 in equation (1) of the example shown in Figure 14, a molded portion W1c molded based on the square lobe curve of h=π / 4, a molded portion W1d molded based on the square lobe curve of h=2π / 4, and a molded portion W1e molded based on the square lobe curve of h=3π / 4, and the molding data is designed by, for example, replacing the line in the first design method with a sine curve.

[0076] In the examples shown in FIGS. 16 and 17, the modeling data may be designed by, for example, rotating and duplicating the mesh multiple times or mirror-duplicating the mesh.

[0077] In this way, by connecting a plurality of forming portions W1 to form a shaped object W, it is possible to manufacture a shaped object W having a more complex shape.

[0078] 14 to 17, the shaped portion W1 (shaped object W) forms a rotationally symmetrical square lobe curve when viewed from the Z-axis direction and has a hollow spherical shape. The outer surface of the shaped portion W1 is porous and can be used as a filter, net, cushion, buffer material for dispersing pressure caused by changes in shape between the wearer's skin and an orthosis (such as a prosthetic limb or an artificial joint), rainwater storage tank, plant growth medium, water treatment filter, and particularly at least a part of a filter bed for water purification. For example, when used as a buffer material between the wearer's skin and an orthosis, rubber is too elastic and irritating to the human body. Therefore, a material that takes time to recover its elasticity, such as a thermoplastic elastomer or soft urethane foam, is suitable. However, thermoplastic elastomers have poor durability and strength. Therefore, by selecting an appropriate molding material and molding using a 3D printer 1, it is possible to provide an orthosis that fits the shape of the wearer. The porous nature of the shaped portion W1 (shaped object W) allows for proper pressure distribution, prevents stuffiness when wearing the prosthesis, and is easy to wash and dry, which can lead to, for example, fewer skin problems for the wearer. Furthermore, by using curved, particularly sinusoidal, curved lines in the first design method, or by using a cross-sectional shape other than circular in the second design method, the surface area of ​​the outer surface of the shaped portion W1 (shaped object W) can be increased compared to a circular cross-sectional shape, allowing this outer surface to function more effectively as a microbial carrier or filter material. Furthermore, because the shaped portion W1 (shaped object W) has a spherical appearance and defines a space within it, it can also function as a holder for, for example, a separate sponge-like (e.g., urethane) filter member or any other desired member in the space.

[0079] Furthermore, this molded portion W1 (molded object W) has an internal space, allowing it to contain more air and be suitably used as a laundry ball that produces good foam. Also, by intentionally creating strings (air cuts) between the molded portions W1 while molding, it is possible to obtain better foaming due to the strings. Therefore, it is also suitable for use in dishwashers, etc.

[0080] Furthermore, in the example of the shaped portion W1 (shaped object W) shown in FIGS. 14 to 17, the unit cell can be inscribed in a cube.

[0081] Furthermore, because this forming portion W1 (formed object W) has a different shape when viewed from each direction, it is possible to impart bias to the ease with which fluids such as air and water pass through it, and therefore by selecting an arrangement pattern according to the shape of each forming portion W1, it is possible to make the outer surface of the formed object W effectively function as a filter. Also, by imparting bias to the connecting structure of the forming portion W1, it is possible to arbitrarily manipulate the elasticity, rigidity, etc. of the formed object W.

[0082] 18 shows an example in which a shaped object W is attached to a duct portion 25 such as a pipe through which a fluid, preferably a liquid, passes. The shaped object W, which has an outer edge based on a square lobe curve, has a shape in which the outer periphery is symmetrically inscribed in a predetermined circle when viewed in the Z-axis direction, for example. Therefore, when the shaped object W is inserted into an opening 26, such as an inlet or outlet, which has a circular cross section in the duct portion 25, by slightly compressing it toward the center, it is held in pressure contact with the inside of the opening 26 due to its recovery deformation, allowing for easy and stable attachment.

[0083] When attaching this object W to the duct portion 25, adhesive may be used, but adhesive may not be necessary if the water flow is weak, for example. In that case, the object W can be slid to any position by hand or with a jig, and the attachment position can be moved, and by not using adhesive, effort and cost can be saved.

[0084] As an example, by using a stain-resistant (fouling-resistant) material, the object W can be placed in the piping of a plant factory where water is circulated and the nutrient solution is reused, and used as a mesh or filter to separate impurities from the cultivation tank. Furthermore, because the object W is made of resin, it can be reused by washing with water, etc. In particular, the object W of this embodiment can be easily shaped into a symmetrical shape, making it difficult to install it in the wrong direction. Furthermore, if the object W is sized to fit the existing piping, it can be easily applied to plant factories where the piping cannot be easily changed (the water flow cannot be easily stopped). Furthermore, if the object W is shaped to the desired size, it can be easily installed horizontally relative to the piping. Furthermore, since the loop shape of the shaped portion W1 can be used as a hook or grip, installation and replacement are easy, even when the object is installed deep inside the piping. Therefore, it can be used as a filter that requires frequent replacement and maintenance. For example, sound-insulating or shock-absorbing materials such as urethane may be attached to the object W during actual use. It can also be suitably used as furniture, soundproof structures, dirt adsorbents and microorganism carriers.

[0085] Furthermore, if the shaped object W is attached to the air intake of a range hood or ventilation fan through which gas flows instead of water, the air passage can be narrowed, leading to improved suction power.

[0086] Furthermore, because these objects W are spherical, they can be suitably used as lampshades by placing a lamp (light source) inside. In other words, a lighting device such as indirect lighting can be configured by combining the object W and a light source. For example, the object W can be suspended from a ceiling or other installation surface using a hanging material such as a rope, or can be placed on any base (e.g., the object W shown in FIG. 19 , described later). In particular, as shown in FIG. 17 , if the object W is shaped as a sine curve instead of the line in the first design method, the diffuse reflection and shadows created by the shaped portion W1 can be utilized to achieve a wide variety of light distribution designs. In this case, using a heat-resistant material, for example, can withstand the heat dissipation of the lamp. Furthermore, by appropriately selecting the refractive index and transparency, or by incorporating a reflective or glossy material such as glitter, light distribution with excellent design properties can be achieved. Furthermore, for example, by adjusting the thickness of the nozzle 11 (shown in Figure 1) of the 3D printer 1 and the modeling speed, it is possible to intentionally create strings (air cuts) while modeling, thereby creating a fantastic light effect with random shadows caused by the strings. If strings are generated so as to connect each vertex (selecting any vertex) in a so-called thread mandala shape, the model W will have a rotationally symmetrical shape, which is aesthetically pleasing and can function as a porous structure such as a microorganism carrier or filter with a wide variety of shapes, or as a lampshade.

[0087] In the examples shown in Figures 14 to 17, by actually adding k to each Zt, it becomes possible to form the intersections of the forming parts W1 so that they are positioned on the forming table 5, thereby further improving the formability.

[0088] Furthermore, if the 3D printer 1 is a six-axis printer, it can print by tracing the contours shown not only on the XY plane but also on the YZ plane. Because the movement is composed of curves based on continuous functions, the lack of corners makes the movement seamless, resulting in faster printing speeds. This effect can also be achieved when a rotation axis or a running axis is added to the six-axis 3D printer 1 to perform more multi-axis printing, such as seven or eight axes.

[0089] 19(a) and 19(b) show an example of a shaped object W (FIG. 19(b)) manufactured by arranging and connecting multiple shaped portions W1 at equal angles around the Z axis, where the shaped portion W1 is formed based on a square lobe curve R (FIG. 19(a)) where Zt=k·cos(r·t) in Equation (1) and a=e=-k, b=g, h=π / 2, r=3, d=g=1, and t=0 to π / 2 [rad], using the shaping data designed for the second design method, with the cross-sectional shape being a circle. In this example, the shaped object W is rotationally symmetric when viewed from the Z axis direction and has a pedestal-like appearance, making it suitable for use as a vessel or the like.

[0090] 20(a) to 20(d) show examples of modeling data D based on a regular lobe curve set by Zt=k·t in equation (1), with a=e=k, b=g, r=3 / 2, d=g=1, and t=0 to 10π [rad], where Zt of the two regular lobe curves used in the first design method, for example, is matched over the entire range of the parameter t to maintain a flat state. In the example shown in FIG. 20, the line 15 used in the first design method is a sine curve, but the line 15 may be any line, such as a straight line.

[0091] In addition, the examples shown in Figures 21(a) to 21(d) and Figures 22(a) to 22(d) use the same square lobe curves as the example shown in Figure 20, but in the examples shown in Figures 21(a) to 21(d), the difference in Zt between the two square lobe curves used in the first design method increases as the parameter t increases, while in the examples shown in Figures 22(a) to 22(d), the difference in Zt between the two square lobe curves used in the first design method decreases as the parameter t increases. In these examples, the line 15 used in the first design method is, for example, a straight line.

[0092] 20 to 22, the example of the modeling data D can be formed to have a rotationally symmetric square lobe curve when viewed from the Z-axis direction, and a spring-like shape that is stretchable in the Z-axis direction, resulting in a modeled portion W1 (modeled object W) with excellent springiness and cushioning properties. Therefore, even if the modeling material is hard, the modeled portion W1 (modeled object W) is structurally stretchable and deformable, and has flexibility, elastic deformation performance, and impact resistance.

[0093] Furthermore, in each of the above examples, the formed part W1 (formed object W) can be placed inside a pipeline through which a liquid such as water passes or inside a container that stores a liquid such as water, and rotated using an appropriate rotating device, thereby stirring the liquid and allowing microorganisms to attach and grow, and the device can also be suitably used as a microbial carrier or microbial cultivation device that can efficiently produce plankton and other fish and shellfish food.

[0094] 23(a) to 23(d) show examples in which the cross-sectional shape used in the second design method is a fan shape based on the same square lobe curve as the example shown in Fig. 20. In this example, the cross-sectional shape is a fan shape, and by making the straight portions of the fan shape side edges extending along the modeling table 5, support-less modeling becomes easier.

[0095] In addition, based on the same square lobe curve as the example shown in Figure 20, the cross-sectional shape used in the second design method is circular, and a mesh (unit shape, unit cell) is used, and examples of a structure W in which multiple meshes are connected together are shown in Figures 24 and 25.

[0096] 24(a) to 24(d) show an example in which eight shaped portions W1f (FIG. 26) formed by connecting the end points of two shaped portions W1, W1 that are 180° out of phase with each other around the Z axis are connected together to form a mesh on the same circumference. In the example shown, a circular space is formed in the center, but this space may be filled with any other connecting structure that is connected to the shaped portion W1f.

[0097] In addition, the examples shown in Figures 25(a) to 25(d) are formed by connecting the end points of two shaped parts W1, W1 that are mirror-symmetrical with respect to the XZ plane or the YZ plane, forming a mesh of shaped parts W1g (Figure 27), and connecting multiple parts, for example, three parts in each of the X-axis and Y-axis directions.

[0098] The examples of the shaped object W shown in FIGS. 24 and 25 have high rigidity and exhibit different physical properties in different parts.

[0099] Furthermore, the example of the shaped object W shown in Figures 26 and 27 forms a rotationally symmetrical square leaf curve when viewed from the Z-axis direction, and exhibits a spring-like shape that is expandable and contractible in the Z-axis direction, resulting in a shaped object W with excellent springiness and cushioning properties (as shown in Figures 28(a) and 28(b)). It can also be used as a frame for wheels, handles, etc., and because of its aesthetic appeal, it can also be used as a picture frame by using the outer edge as a hanging part. Furthermore, it is a porous material that can be used as at least part of a filter, net, cushion, equipment, rainwater storage tank, plant growth medium, water treatment filter, and especially a filter bed for water purification. Furthermore, unlike typical cushions made of polyurethane, it maintains breathability even when compressed by the weight of sitting, for example. Furthermore, because it is porous, it can be washed completely, can be showered from the back, and does not require the human body or pet to be turned over, which helps reduce the burden on the caregiver.Since the surface area that comes into contact with the skin is small, more parts can be washed, it is less likely to develop mold and is easier to keep clean, and the seat is non-slip, so it can be used ideally as a washable cushion for nursing care or for pets, or a bath chair.

[0100] 26(a) and 26(b) as a stand-alone shaped object W, for example, by suspending the central portion or the like from a hanging portion, the shaped portion can be used as a holder for hooking the handle H of a hanging object such as an umbrella or a walking stick from the outside or inside, a holder for hanging a hanging object such as a bag via a hooking member such as an S-hook, a clothes drying device for hanging laundry via a hanger, or a chandelier or indirect lighting by hanging a light bulb. Furthermore, when the shaped portion W1 shown in FIG. 26 is used as a stand-alone shaped object W, since it expands and contracts in the Z-axis direction, the "petal" portion for hooking the hanging object can be shifted circumferentially to position the hanging object at a distance, and the shaped portion W1 gradually expands in the Z-axis direction depending on the weight of the hanging object, resulting in different hanging heights for the hanging object. Therefore, for example, if the hanging items are laundry, they are less likely to overlap with each other, allowing them to dry faster. Also, the range Z of the "petal" part that remains parallel even when extended in the Z-axis direction can be used as a flat drying area for drying laundry flat. Furthermore, since the sculpted object W is expandable in the Z-axis direction, it can be stored in a shrunk state when not in use. In this case, it is recommended to fix it with a fixing member such as a ribbon or rubber. Because the "petal" part functions as a hanging part, the sculpted object W can also be used as an interior decoration (wall decoration) by hanging it on the wall.

[0101] 24 and 25, which are formed by arranging multiple shaping portions W1, the physical properties of different portions vary depending on the arrangement. Therefore, by utilizing rotational symmetry during design and excluding unnecessary portions and designing only desired portions as necessary using the shaping data D, it is possible to manufacture a shaped object W with desired physical properties (strength). For example, in the case of the shaped object W shown in Fig. 24, the central portion is densely packed and highly rigid, while the outer edge portion is sparsely packed, highly elastic, and composed of curves. Therefore, as shown in Fig. 29, when only the central portion is shaped, a lightweight shaped object W can be obtained that is strong and, due to its circular shape, is particularly resistant to lateral forces. The rotationally symmetrical shape distributes the load, resulting in a shaped object W that is also strong in the thickness direction. Furthermore, when used as a filter material or carrier for food waste treatment, for example, the sharp portions can crush food waste, making it suitable. Furthermore, in the case of the object W shown in FIG. 29, the tips of the curves of the "petal" portions extend counterclockwise in FIG. 29(a). This allows for particularly strong rotation in the counterclockwise direction, making it suitable for use as a rotating component that rotates in a fixed direction, such as the handle of a coffee mill or sewing machine, or as a roller. The roller may be, for example, a leveling roller, or a cookie roller that applies floral or wavy patterns to fabric using the cross-sectional portions C1 and C2. When used as a roller, it is suitable because it can be inscribed in a circle by adjusting the coefficients a and e of Xt and Yt in Equation (1). Furthermore, for other uses, for example, by using a phosphorescent molding material, it can be used as a circular object such as a Christmas wreath that glows even in dark environments, or as a security measure by placing it in an entryway, living room, etc. Furthermore, as shown in FIG. 30, by molding only the outer edge, a lightweight and highly elastic object W can be obtained. Furthermore, the object W can be shaped not only into a circular shape, but also into a Reuleaux polygonal shape, for example. By rotating it with a motor or the like, it can be used as a cleaning tool that can remove dust from the corners of a room, or as a dishwasher brush that can remove dirt from every corner of dishes. It can also be used effectively, for example, to collect dead microorganisms and algae that have adhered to a hydroponic nutrient solution tank.

[0102] In the example of the object W shown in FIG. 30, any structure or component can be inserted into the central opening. For example, by connecting or integrally molding an axial member to the opening, the object can be used as a hand mixer for stirring liquids such as milk or protein. By using a food 3D printer 1 and using a sweet material that is hard at room temperature, such as chocolate or sugar (tortoiseshell candy), as the modeling material to create the object W, it is possible to add sweetness to the liquid while stirring. Furthermore, if the object W is formed into a hollow shape with a frame-like cross section, it can be used as a straw, or if the cross section is formed into a solid shape with a flat cross section, it can be used as edible tableware. Furthermore, if a shape defined by a torus knot or a Lissajous curve is inserted into the opening, the object W can be formed in a single stroke. The diameter of the opening can also be determined arbitrarily. If the opening is set large and only the curved, linear outer edge of the 3D printer W1 is used, and a standard plate-shaped 3D printer is placed inside the opening, the 3D printer W can function as a warp prevention support, preventing warpage during molding by alleviating stress acting on the outer edge of the plate-shaped 3D printer W1. After molding, the outer edge of the 3D printer W1 can be broken off and removed, resulting in a highly accurate 3D printer W with reduced warpage. For large 3D printers, typical support shapes, especially lattice shapes, are prone to fracture during support removal and often have sharp edges. In contrast, the present embodiment integrates the support with the 3D printer W using a curved, cornerless structure based on a continuous function, thereby not only speeding up the printing process but also improving safety and reducing the burden on the worker. Furthermore, if the 3D printer 1 is a pellet printer, the removed support can be re-ground for reuse, contributing to environmental considerations. Furthermore, the 3D printers W shown in Figures 29 and 30 have a charming appearance and are attractive.

[0103] 31 to 33 are examples of a modeled portion W1 (modeled object W) that is modeled based on a square lobe curve where Zt = k cos(h + r t) cos3t in Equation (1), taking into account ease of modeling using the 3D printer 1, and where a = e > k, b = f, d = 3 / 4, r = 1, and t = 0 to 8π [rad]. The examples shown in FIGS. 31(a) to 31(d) and the examples shown in FIGS. 32(a) to 32(d) each have a rectangular cross-sectional shape, and the modeling data can be designed using either the first or second design method. The examples shown in FIGS. 33(a) to 33(d) are examples of modeling data designed using the second design method, with the cross-sectional shape being circular.

[0104] These examples of the shaped portion W1 (object W) have a complex shape that forms a rotationally symmetric square leaf curve when viewed from the Z-axis direction, gradually expanding from the Z-axis position toward the -Z-axis direction and folding back toward the +Z-axis direction. These porous structures not only have a beautiful appearance, but can also be used as filter media, nets, cushions, buffer materials for dispersing pressure caused by changes in shape between the wearer's skin and prosthetics (such as prosthetic limbs or artificial joints), rainwater storage tanks, plant growth media, water treatment filters, and at least part of filter beds for water purification. As shown in Figure 34, support-less shaping is facilitated by adjusting Xt, Yt, and Zt in equation (1) so that the lower end of the outer edge 27 is positioned on the shaping table 5 and supports the object W. Furthermore, load-bearing and impact resistance can be imparted by adjusting the cross-sectional shape of the shaping data to increase thickness. Furthermore, the outer periphery of the shaping portion W1 (shaped object W) is symmetrically inscribed in a predetermined circle when viewed from the Z-axis direction. Therefore, as shown in FIG. 35(a), when inserted into the inner surface of the cylindrical placement portion 28, which forms a conduit for a fluid, particularly a liquid, by slightly compressing it toward the center, the shaping portion W1 returns to its original shape and is held in pressure contact with the inner surface, allowing for easy and stable attachment. Furthermore, the symmetrical shape of the shaping portion W1 (shaped object W) makes it difficult for an operator to make a mistake in the attachment direction. Furthermore, because each shaping portion W1 is linearly formed, it is easy to grasp and remove the shaping portion W1. Furthermore, as shown in FIG. 35(b), if the shaping portion W1 (shaped object W) is larger than the placement portion 28, the shaping portion W can be turned upside down and the outer edge 27 hooked onto the placement portion 28 to hold it in place.

[0105] In addition, the examples shown in Figures 36(a) to 36(e) are of a formed part W1 (formed object W) formed based on a square lobe curve set as Zt = k·cos(h+r·t) in equation (1) with a = e = k, b = f, r = 1 / 2, d = g = 1, and t = 0 to 4π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0106] The examples shown in Figures 37(a) to 37(e) are of a part W1 (object W) formed based on a square lobe curve set as Zt=k·sin(h+d·t) in equation (1) with a=e=k, b=f, r=1 / 2, d=g=1, and t=0 to 4π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0107] Furthermore, the examples shown in Figures 38(a) to 38(d) are of a formed part W1 (formed object W) formed based on a square lobe curve set as Zt=k·sin(h+r·t) in equation (1) with a=e=k, b=f, r=5 / 2, d=g=1, and t=0 to 4π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0108] The examples of the shaped portion W1 (shaped object W) in Figures 36 to 38 form a rotationally symmetric square lobe curve when viewed from the Z-axis direction, and each has a different shape when viewed from each direction, allowing for bias in the ease with which fluids such as air and water pass through, so that the shaped portion W1 (shaped object W) can be effectively used as a filtering medium (filter), for example. Furthermore, in the case of the shaped portion W1 (shaped object W) shown in Figure 38, since there are no corners in the path, it can also be used as a support stand for a luggage rack or the like with an excellent design on which luggage or the like can be placed, and only the upper half or the lower half can also be used as a conical filter.

[0109] Furthermore, compared to a structure in which linear lattice structures are regularly connected, when multiple shaped portions W1 are connected by intersecting loop shapes, the connection positions can be set arbitrarily, and by appropriately selecting the shaping material, it is possible to provide connecting portions with various properties and set the performance of the shaped object W. For example, by adding thickness to the connecting portions at desired locations, it is possible to provide a shaped object W with excellent impact resistance.

[0110] Furthermore, the examples shown in Figures 39(a) to 39(e) are examples of a shaped portion W1 (shaped object W) shaped based on a square lobe curve set by Equation (1) where Zt = kt and a = e, b = f, r = 3 / 2, d = g = 1, and t = 0 to π [rad]. The cross-sectional shape 21 is rugby ball-shaped, formed by the intersection of two circles CI1 and CI2. The two circles CI1 and CI2 may have the same diameter or different diameters. Furthermore, the closer the center-to-center distance between the circles CI1 and CI2, the more rounded the cross-sectional shape 21 becomes, and the farther the center-to-center distance, the more sharp the cross-sectional shape 21 becomes. In other words, the cross-sectional shape 21 can be easily controlled by arbitrarily setting the diameters and center-to-center distance of the intersecting circles CI1 and CI2. This shaped portion W1 (shaped object W) constitutes at least a portion of a porous structure, as in the above examples. The arc-shaped portion 21b of the cross-sectional shape 21 forms a smooth curved surface (curve) in the forming part W1 (formed object W), and functions as a tapered portion (guide portion) when inserted into a pipeline when used as, for example, a filter (filtering medium) etc. Also, by making the cross-sectional shape 21 more rounded, it is possible to adjust the angle so that the contact area for the misalignment between the upper and lower layers of the forming material caused by the inclination of the arc-shaped portion 21b of the cross-sectional shape 21 when stacked increases, thereby suppressing (mitigating) the rise angle from the forming table 5 and facilitating support-less forming.

[0111] The linearly formed shaping portion W1 may serve as a connecting portion connecting multiple structural portions 29, 29, as shown in Fig. 40. The structural portions 29 may have any shape, and the structural portions 29 do not need to have the same shape as one another. However, preferably, the structural portions 29 have a shape that can be formed in a single stroke using the nozzle 11 of the 3D printer 1, allowing the entire structure, including the shaping portion W1, to be continuously shaped by the 3D printer 1. Furthermore, because the shaping portion W1 forming the connecting portion is a linear body, it is possible, for example, to store or stably and in a space-saving manner the structural portions 29, 29 connected by the shaping portion W1, and then, when necessary, to break the shaping portion W1 and separate the structural portions 29, 29 for use. Depending on the size of the 3D printer 1, the shaping portion W1 can be used for a variety of purposes, from small, portable or emergency tableware that can be used by folding and separating the shaping portion W1, for example, with one structural portion 29 shaped like a spoon and the other shaped like a fork, to larger structural portions 29 such as traffic cones and poles. For example, if the structural portion 29 is a traffic cone or pole, it is possible to design and form holes with a diameter large enough to insert the structural portion 29, thereby using the breakable portion as a connecting portion for connecting the structural portions 29 side by side. Furthermore, by forming the structural portion 29 using a continuous curve that can be expressed as a parameter, such as a Lissajous curve, trochoid, or logarithmic spiral, it is possible to form the structural portion 29 integrally with the shaping portion W1 while achieving weight reduction. In this way, by forming the structural portion 29 and the shaping portion W1, preferably in whole or in part, in a shape that can be expressed as a continuous function, not only can the size and shape be freely designed by simply changing the coefficients, but the seamless movement of the nozzle 11 also allows for fast shaping. Furthermore, the spiral petal-shaped object W (formed portion W1) shown in Figure 7 and Figures 20 to 23 may be used to connect structural portions 29 such as traffic cones and poles in a chain-like manner. In this case, the petal shapes of the object W (formed portion W1) can easily catch on each other, preventing the connecting portions from coming loose.

[0112] Furthermore, the forming portion W1 is not limited to one having a three-dimensional structure in the Z-axis direction. For example, FIGS. 41 and 42 show examples of a planar forming portion W1 (formed object W).

[0113] The example shown in Figures 41(a) to 41(c) is a forming part W1 (object W) formed based on a square lobe curve in which Zt = k in equation (1) and a = e, r = 8, d = g = 1, t = 0 to 2π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0114] In addition, the example shown in Figures 42(a) to 42(c) is a forming part W1 (formed object W) formed based on a square lobe curve set at Zt=k in equation (1) with a=e, r=2, d=3, g=1, and t=0 to 2π [rad], and the forming data was designed using the second design method with a circular cross-sectional shape.

[0115] In these examples, support-less molding is facilitated by appropriately setting Zt according to the thickness, etc. Furthermore, since the outer periphery of the molded portion W1 (molded object W) is shaped so that its outer periphery is inscribed symmetrically in a predetermined circle when viewed from the Z-axis direction, it can be easily and stably attached by pressing it into a cylindrical placement portion forming a pipeline through which a fluid, particularly a liquid, passes, with its outer periphery held in pressure contact with the inner surface and its central portion curved toward the back of the placement portion. This allows it to be used as a filter or net, and can also be used as a pipeline cover by forming it with a diameter equal to or larger than the pipeline, achieving similar effects to those of the example shown in FIG. 31, etc. In particular, in the example shown in FIG. 41, molding can be performed in a short time by using a thick nozzle 11 preferably close to the diameter of the desired molded object W. Furthermore, in the example shown in FIG. 42, the larger number of "petal" portions allows it to be fitted to the inner periphery of a placement portion with various diameters. Furthermore, these examples can be suitably used as cushions, such as zabuton cushions, by selecting the molding material, cross-sectional thickness, etc. and molding them to large dimensions.

[0116] Next, the third design method will be described with reference to the drawings.

[0117] As shown in FIG. 43, the shaping data D is formed by connecting the cross-sectional shapes 21 along a line 22 defined by a square lobe curve that connects the centers of the cross-sectional shapes 21 set at different positions, for example, on different planes P1 and P2. In the illustrated example, the cross-sectional shapes 21 are the same, but they may be different. Also, although an example is given in which the planes P1 and P2 are perpendicular to each other, the angle between them is not important. Furthermore, the cross-sectional shapes 21 are not limited to planar shapes, but may be curved, and at least one of the cross-sectional shapes 21 may be a point. Furthermore, the cross-sectional shapes 21 are not limited to two that constitute the shaping section W1 (model W), but the cross-sectional shapes 21 at multiple positions in between may be sequentially connected.

[0118] An example of a shaping section W1 (shaped object W) manufactured based on shaping data designed using the third design method is shown in Figures 44(a) to 44(d). In this example, in Equation (1), Zt = kt is set, and based on the square lobe curve set by a = e, b = f, r = 3 / 2, d = g = 1, and t = 0 to π [rad], each cross-sectional shape is a Reuleaux triangle, and shaping is performed by connecting cross-sectional shapes on mutually perpendicular planes. Therefore, the shape has side edges that extend along the shaping table 5. The example shown in Figure 44 makes support-less shaping easier.

[0119] A fourth design method will be described with reference to the drawings.

[0120] In the fourth design method, a plurality of surfaces are formed using square curves, and the modeling data is designed by filling in the area enclosed by the surfaces.

[0121] For example, in the example shown in Figure 45, a surface is formed using a regular lobe curve and a line intersecting the regular lobe curve. As shown in Figure 45(a), an arbitrary closed regular lobe curve R is set, and the regular lobe curve R is divided into multiple ranges of t, for example, into halves, and a surface is formed that is surrounded by the regular lobe curve R and a straight line 30 connecting the end points of the ranges. The example shown in Figure 45(a) is an example of a regular lobe curve R set by Equation (1) as Zt=k·cos(h+r·t), with a=e=k, b=f, r=2, d=g=1, and t=0 to π [rad]. Within the regular lobe curve R, t is divided into two ranges: a first range Ra consisting of 0 to 0.5π [rad], and a second range Rb consisting of 0.5π to π [rad]. A straight line 30 is set connecting the endpoints of these ranges. Surface 31 (Figure 45(b)) consisting of line 30 and the first range Ra, surface 32 (Figure 45(c)) consisting of line 30 and the second range Rb, and surface 33 (Figure 45(d)) consisting of the first range Ra and the second range Rb are combined to fill the area enclosed by these surfaces 31 to 33, thereby designing solid printing data D1 (Figure 45(e)). Then, the design of the modeling data D1 is repeated within the required range of the parameter t, or if the modeling part W1 (modeled object W) to be manufactured has a symmetrical shape, the modeling data D1 is used as the base shape and is rotated or mirrored multiple times, and a Boolean sum is taken to form modeling data D for the modeling part W1 (modeled object W) of a solid shape having the square lobe curve R as its outer edge shape. In this embodiment, the modeling data D shown in Fig. 45(f) is designed, for example, by mirror-duplicating the modeling data D1 with respect to the YZ plane and taking a Boolean sum.

[0122] Examples of a molded part W1 (object W) molded based on this molded data D are shown in Figures 46(a) to 46(d). This molded part W1 (object W) has a block shape with a spherical envelope whose outer edge forms a rotationally symmetrical square lobe curve when viewed from the Z-axis direction and has four radially protruding arms 35. By using a hard molded material, it is suitable for use as a playground equipment or a laundry ball. In particular, when used as a laundry ball, it can be molded using a resin blended with fine powder of a stain-resistant or pyroelectric material, enabling repeated use. Furthermore, its symmetrical shape promotes water flow, making it easier to remove dirt from laundry. When molded using a soft material, it can also be used as a ball, a pet toy, or other object.

[0123] 47 to 51 show examples of a shaping portion W1 (shaping object W) manufactured based on shaping data designed by the fourth design method.

[0124] The examples shown in Figures 47(a) to 47(e) are similar to the square lobe curves constituting the part W1 (object W) shown in Figure 45. The example shown in Figures 47(a) to 47(e) shows the part W1 (object W) formed based on the square lobe curves defined by Equation (1), where Zt = k cos(h + r t) cos3t, where a = e > k, b = f, d = 3 / 4, r = 1, and t = 0 to 8π [rad]. The part W1 (object W) was formed based on solid-state printing data D designed using the same method as the example shown in Figure 45. The outer edge of the part W1 (object W) forms a rotationally symmetric square lobe curve when viewed from the Z-axis direction, and exhibits a skirt-like or hat-like shape that gradually widens in the Z-axis direction. Furthermore, the back side of the part W1 (object W) is formed with numerous ribs 36 extending in the Z-axis direction, providing the part W1 (object W) with high strength, particularly against external forces in the Z-axis direction.

[0125] 48(a) to 48(d) show examples of a shaped object W in which multiple connected shaped portions W1 shown in FIG. 47 are formed as a mesh. This shaped object W is formed by stacking multiple shaped portions W1 shown in FIG. 47, for example, three, in the Z-axis direction. This shaped object W is suitable for use as, for example, a lampshade. In this case, using a heat-resistant shaped material, for example, can withstand the heat dissipation of the lamp. Furthermore, by appropriately selecting the refractive index and transparency, or by including a reflective or glossy material such as glitter, it is possible to achieve a desirable light distribution design. In the shaped object W shown in FIG. 48, the shaped portions W1 can be connected by rotating them by a predetermined angle around the Z-axis, further improving the aesthetics and design.

[0126] 49(a) to 49(d) show examples of a shaping portion W1 (object W) obtained by deleting a portion of the shaping portion W1 shown in FIG. 47. In the example shown in FIG. 49, a portion of the shaping data for the shaping portion W1 shown in FIG. 47 may be deleted, or the shaping data may be rotated and copied around the Z axis, with the parameter t set within a range of, for example, π / 12 to 11π / 12 [rad]. The shaping portion W1 (object W) has an outer edge that forms a rotationally symmetric square lobe curve when viewed from the Z-axis direction, a skirt-like or hat-like shape that gradually widens in the Z-axis direction, and a through-hole 37 formed in the center in the Z-axis direction.

[0127] Furthermore, examples of a shaped object W formed by connecting multiple mesh-shaped portions W1 shown in FIG. 49 are shown in FIGS. 50(a) through 50(e). This shaped object W is formed by connecting multiple shaped portions W1 shown in FIG. 49, for example, three at a time, at equal intervals along the X-axis and Y-axis. This shaped object W can be used alone, as shown in FIG. 51(a), as a base-like support for supporting objects 38, such as eggs, spheres, cylinders, rolls of fabric, rolled paper, bobbins, and thread, inserted or fitted into the regularly arranged through-holes 37, or as a plant growth support for plant seedlings or bulbs. Because the shaped portion W1 (shaped object W) created using the 3D printer 1 is rigid, it can also be used as a reusable plant growth medium (growth mat) by removing entangled roots with a high-pressure washer or similar after harvesting the cultivated plants. Therefore, unlike conventional culture media such as urethane mats and agar, it can be used as a reusable, environmentally friendly plant growth medium. In particular, when the 3D printer 1 is a pellet-type printer, colorants such as carbon black, UV absorbers, light-scattering materials such as zinc oxide, and other light-blocking materials can be mixed into the raw materials and used to create the shapes, or the surface can be coated with these materials. This can inhibit the photosynthesis of algae, cyanobacteria, and photosynthetic bacteria, providing an anti-algae effect that prevents water pollution and stabilizes water quality. Depending on the modeling material, trace essential elements can also be supplied, promoting plant growth. Furthermore, since the supported objects 38 can be spaced apart, the printer is also suitable for storing supported objects 38 made of heat-sensitive materials, for example. Furthermore, spacing the supported objects 38 prevents neighboring plants from competing for nutrients, making it suitable for use when supporting plant seedlings or bulbs. Furthermore, for example, if a plant is harvested and the remaining roots and stems are crushed and scattered on the soil, and then water or a gel such as an agar medium containing fertilizer and microorganisms is poured over it, the decayed roots and stems can be used as fertilizer, and the shaped object W can also prevent water evaporation, stimulating the activity of microorganisms such as bacteria and fungi, or soil organisms, and thus regenerating the soil. In particular, if the shaped object W is made using biodegradable plastics such as PLA as a modeling material while maintaining the required strength, the environmental impact of such uses can be further reduced.

[0128] Furthermore, as shown in Figure 51(b), for example, the supported object 38 may be supported by being sandwiched between the upper and lower parts at the position of the through holes 37 of the paired forming parts W, or multiple formed objects W may be stacked in the Z-axis direction to hold the supported object 38.

[0129] Furthermore, since the shaped object W made of resin can be used repeatedly as a support, it is more economical and places less of a burden on the environment than disposable supports made of paper or the like.

[0130] Furthermore, the modeling data designed by the fourth design method is not limited to those using curved surfaces, but may also be planar. For example, in the example shown in FIG. 52(a), a planar surface 40 shown in FIG. 52(b) is formed using the contour of a square lobe curve R in Equation (1) where Zt = k, a = e, b = f, d = 3, r = 2, and t = 0 to 2π [rad]. Then, thickness is added to the surface 40 to design the solid-shaped modeling data D shown in FIG. 52(c). Note that, in consideration of symmetry, the modeling data D may be designed by forming a surface only within the range of t = 0 to 0.5π [rad] using the square lobe curve of Equation (1), adding thickness to the surface, and then mirror-copying the surface to the XZ and YZ planes and performing a Boolean sum. The example shown in FIGS. 53(a) and 53(b) is a modeling part W1 (modeled object W) modeled based on the modeling data D shown in FIG. 52. An example of this shaped part W1 (shaped object W) has an outer edge that forms a rotationally symmetrical regular leaf curve when viewed from the Z-axis direction, and has a thin plate shape with four bulging parts 41 that protrude in an arc shape in the radial direction.For example, by using a soft shaping material to create a large size, it can be used as the main body of an umbrella or garden parasol with a beautiful petal-like appearance and good design, or, since it can be folded, it can also be used as a tent for use in emergencies.

[0131] It is also possible to form a shaped portion having any desired holes based on the shaping data D of the example shown in FIG. 52(c). For example, in the example shown in FIGS. 54(a) and 54(b), holes 42 are formed by hollowing out the surface of the shaping data in a polygonal shape, such as a rhombus (diamond shape). For example, by forming the shape of the holes 42 as a rhombus with its major axis in the radial direction of the shaped object W as viewed from the Z-axis direction, the holes 42 can be formed without using a support material, resulting in the best shape retention. The holes 42 may be arranged arbitrarily, but in this embodiment, they are evenly or approximately evenly spaced in the circumferential direction on multiple concentric circles. This example of the shaped portion W1 (shaped object W) is suitable for applications such as a filter, for example, by forming it thin using a soft shaping material. When the object W is symmetrically folded compactly and inserted into the placement portion 28 as shown in FIG. 55 , it returns to its original shape and the outer edge of the bulge 41 presses against the inner surface of the placement portion 28, ensuring stable attachment. This is particularly suitable for a conical placement portion 28. For example, by using the placement portion 28 as a coffee dripper, the object W can be used as a coffee filter. In this case, more stable attachment can be achieved by applying a tacky resin or adhesive to at least one of the contacting portions of the object W and the placement portion 28 in advance. Furthermore, by forming the object W from a stain-resistant material, for example, it can be washed with water and reused. Furthermore, by appropriately adjusting the coefficients in Equation (1), the object W can be used as an umbrella valve, a foldable funnel, a drying stand that doubles as a funnel, a vase, a menstrual cup, a portable urine collector, and other applications.

[0132] Furthermore, in the example shown in Figures 56(a) and 56(b), a hole 42 is formed using the square lobe curve R (shown in Figure 52(a)) that forms the modeling data D (shown in Figure 52(c)). This hole 42 is formed based on a sketch in which the square lobe curve R (shown in Figure 52(a)) is offset.

[0133] Also, by changing the offset contour of the sketch, it is possible to form, for example, as shown in the examples of Figures 57(a) to 57(c). In other words, the shape and size of the hole 42 can be changed depending on the offset contour.

[0134] These examples of the shaped part W1 (shaped object W) are suitable for applications such as filtration media (filters) by using, for example, a soft shaping material to form a thin shape, and by appropriately selecting the shaping material, they can also be used as at least a part of furniture, cushions, etc. with a good design. Furthermore, by using a shaping material with a low specific gravity, they can be used as furniture or cushions in normal times, and can also be used as life rings (inflatable rings) for saving lives in times of disaster. Compared to typical inflatable rings that are filled with air when needed, these shaped objects W can be used immediately and are not prone to bursting due to contact with, for example, drifting objects, making them particularly suitable for use in times of disaster.

[0135] In addition, the bulge 41 surrounding the hole 42 can be designed in any pattern, such as a honeycomb shape or a lattice shape, by setting the filling rate (infill) to any pattern using general slicer software, and the coarseness of the mesh can also be set.

[0136] Furthermore, the holes 42 do not need to be of the same shape, and their arrangement does not need to be regular. For example, by adjusting the thickness of the nozzle 11 (shown in FIG. 1) of the 3D printer 1 and the modeling speed, it is possible to easily form randomly shaped holes 42 in random arrangements between the stringy parts by intentionally causing stringy parts (air cuts) during modeling. For example, the example shown in FIG. 58 is an example in which the holes 42 are formed by modeling the modeling part W1 (modeled object W) shown in FIG. 30 while causing stringy parts.

[0137] Furthermore, the shaped object W (shaped portion W1) can also be applied to a foam generating means (foam generating device) 44 shown in Figures 59(a) and 59(b). The foam generating means 44 generates foam, particularly fine bubbles (microbubbles and nanobubbles), in a liquid. The foam generating means 44 includes a main body 49 having an upstream portion 46, a downstream portion 47, and a communication portion 48 that connects these portions. The upstream portion 46, the downstream portion 47, and the communication portion 48 are each formed cylindrically and integrally formed coaxially. In the direction in which the fluid passes, the upstream portion 46, the communication portion 48, and the downstream portion 47 are positioned side by side in this order from one end to the other. The upstream portion 46 has the largest inner diameter, the downstream portion 47 has an inner diameter equal to or smaller than that of the upstream portion 46, and the communicating portion 48 has an inner diameter significantly smaller than those of the upstream portion 46 and the downstream portion 47. Regarding the inner diameters of the upstream portion 46 and the downstream portion 47, the downstream portion 47 preferably has a smaller diameter, but may have the same diameter as the upstream portion 46. Regarding the inner diameter, a reduced-diameter portion 50 is formed, the diameter of which gradually decreases from the upstream portion 46 to the communicating portion 48, and an increased-diameter portion 51 is formed, the diameter of which gradually increases from the communicating portion 48 to the downstream portion 47. In the main portion 49, the pressure difference caused by these changes in inner diameter can generate foam by utilizing the Venturi effect. The shaped object W (shaped portion W1) is molded integrally with or attached to the main portion 49 in at least one of the upstream portion 46 and the downstream portion 47. For example, the examples of the shaped object W shown in FIGS. 46, 37, and 38 are preferably used for the upstream portion 46, and the examples of the shaped object W shown in FIGS. 8 to 10 and 20 to 22 are preferably used for the downstream portion 47. In this example, in addition to the Venturi effect caused by the change in the inner diameter of the main body portion 49, turbulence is generated by the shaped object W (shaped portion W1), making it possible to generate fine bubbles. Furthermore, a porous mesh member (filter) for further reducing the size of the bubbles may be attached to the downstream end of the downstream portion 47 or inside the communication portion 48. This mesh member is formed by stacking multiple mesh members, for example, three or more layers, each having fine pores. By attaching this mesh member, it is possible to increase or decrease the size of the bubbles depending on the size of the mesh.The mesh member is preferably one that is detachable from the main body 49, has a grip that allows for rotation adjustment, and is preferably one that can be changed as appropriate depending on the application of the foam generating means 44. The shape of the mesh may be a general lattice structure, one that can increase the surface area such as a gyroid, one that uses a torus knot, a Lissajous curve, a trochoid, or of course one that uses a regular lobe curve.

[0138] Figure 60(a) shows foam generated by the above-mentioned foam generating means 44. It can be seen that the foam generated by this embodiment shown in Figure 60(a) is more uniform and finer than the comparative example shown in Figure 60(b) (foam generated by a general air diffuser).

[0139] This foam generating means 44 can be widely used to send air downstream. For example, in aeration tanks in wastewater treatment (water treatment), it can increase the dissolved oxygen necessary for microorganisms to purify wastewater. It can also be used to agitate sludge in the tank, uniformly supplying oxygen to the water. It can also absorb organic matter such as oil and sterilize. It can also increase dissolved oxygen in hydroponic cultivation, supplying oxygen to plant roots and preventing root rot. It can also be used to cultivate microorganisms such as plankton, which serve as food for aquatic organisms such as shrimp and shellfish. Therefore, it is ideal for use in aquaculture and hydroponic cultivation systems that integrate hydroponic cultivation and aquariums.

[0140] Furthermore, the foam generating means 44 can also be applied to a washing machine. By generating foam by the foam generating means 44 in the detergent water fed into the washing machine, it is possible to improve the cleaning power, and by generating foam by the foam generating means 44 in the rinse water, it is also possible to remove organic matter and mineral components by coagulation and precipitation.

[0141] The foam generating means 44 can also be attached to the faucet of a shower or a water column. In this case, in addition to the cleaning effect of the foam, splashing of water when it hits the skin or a water pan can also be suppressed.

[0142] In addition, when connecting the forming parts W1, in addition to the method of connecting the forming parts W1 so that they interfere with each other, if at least a portion of the forming parts W1 form a closed loop shape, a method of connecting them in a chain-like manner so that the closed loop shapes do not intersect with each other may be used.

[0143] Furthermore, the multiple shaped portions W1 that are connected to form the shaped object W may each have the same shape, a mirror-symmetric shape, or shapes that are different in size (at least one of the coefficients a, e, and k in equation (1) is different).

[0144] According to the embodiment described above, the shaping portion W1 (shaped object W) has a curved structure defined by a square leaf curve, which allows for free shaping and free connection of the shaping portion W1, thereby further improving the degree of freedom in shaping. Furthermore, the curved structure makes it easier to grip than a linear structure, and the lack of sharp edges makes it safer.

[0145] By utilizing equation (1), which is a continuous function, and appropriately selecting its coefficients and parameters, it becomes possible to manufacture the formed part W1, i.e., the formed object W, in any shape, which has a complex shape that varies greatly depending on the viewing angle, and as explained above, it is possible to easily increase the shape variations of the formed part W1, i.e., the formed object W.

[0146] In particular, because a square lobe curve is a rotationally symmetric shape that is evenly inscribed in a circle, a shaped part W1 (shaped object W) having an outer shape defined based on the square lobe curve can be easily installed by fitting its outer part into a pipe or opening having a circular inner shape. Furthermore, because of its rotationally symmetric shape, the shaped part W1 (shaped object W) can also be suitably used as a flow straightening plate. For example, by installing the shaped part W1 (shaped object W) in the middle of a working fluid flow path, it can allow forward flow (forward flow) with low flow resistance while blocking reverse flow (backflow), making it suitable for stirring, etc. When liquid is passed through the flow straightening plate, it can prevent stagnation and uneven flow within the column. When used in a filtration device, for example, it can improve purification efficiency. Therefore, filtration devices equipped with flow straightening plates can be widely used in liquid purification applications such as water treatment and medical use. In addition, the shaped part W1 (shaped object W) can also be used as an air conditioner, such as a ventilation fan, an airplane propeller, a fan blade, a ceiling fan or air circulator that circulates air, etc.

[0147] By selecting Xt, Yt, and Zt in formula (1), the above-mentioned forming unit W1 (object W) can be shaped without overhangs that require support materials or bridges that extend horizontally to the surface of the forming table, and can be produced without supports using the 3D printer 1. Furthermore, when multiple forming units W1 are connected to form the object W, more complex shapes can be produced without supports.

[0148] The fused deposition model 3D printer, which is a molding manufacturing device for producing (shaping) the various molded objects (models) described above, may be a large pellet-type 3D printer with a nozzle diameter φ of 10 mm or more, and this large 3D printer can use inexpensively obtainable general pellet-shaped thermoplastic resin (recycled pellet material, etc.) as the molding material rather than a dedicated filament resin.

[0149] Furthermore, the object manufacturing device is not limited to a fused deposition modeling 3D printer, but may be, for example, a photolithography (DLP or SLA) 3D printer, or a 3D printer that uses metal as the modeling material, such as an SLM or DED printer.

[0150] Furthermore, the object manufacturing apparatus is not limited to a configuration in which a modeling head (discharge means) having a nozzle for discharging the modeling material is movable in the X-axis and Z-axis directions and a modeling table is movable in the Y-axis direction. It is sufficient that the modeling head is movable in at least three dimensions relative to the modeling table. For example, the modeling head may be movable in the X-axis and Y-axis directions and the modeling table may be movable in the Z-axis direction. Alternatively, the modeling head may be attached to the tip of a robot arm (preferably a six-axis robot arm) and may be movable in any direction, including the X-axis, Y-axis, and Z-axis directions. In particular, a model manufacturing apparatus with a rotatable modeling table is also suitable. Supportless modeling is possible with three-axis and six-axis 3D printers, which eliminates the need for supports, thereby shortening modeling time (improving the modeling speed of the object W). For example, if the object manufacturing device is a 6-axis modeling device, and the nozzle 11 does not interfere with the modeling section W1 (model W), it is possible to trace a square lobe curve, which is a continuous function, in one stroke, thereby improving the modeling speed of the model W. In particular, in the case of 8-axis and 9-axis modeling, the effect of improving the modeling speed by tracing a square lobe curve in one stroke, which has no corners and moves seamlessly and periodically, is significant. [Explanation of symbols]

[0151] 1. Fused deposition modeling 3D printer, a modeling device 5. Build table 15 lines 16 Surfaces 21 Cross-sectional shape 22 Side edge 29 Structural section CI1,CI2 yen D Modeling data R positive leaf curve W sculpture W1 Modeling Department

Claims

1. A shaped object manufactured by the shaped object manufacturing apparatus, The filter has a shaped portion having a loop shape defined based on a square lobe curve, and the outer surface portion forms at least a part of the filter medium. A sculpted object characterized by the above.

2. It is composed of multiple connected molding parts.

2. The object according to claim 1, wherein the object is a molded object.

3. The plurality of shaped portions are identical in shape or mirror-symmetric in shape to one another.

3. The shaped object according to claim 2.

4. The multiple shaped parts have different sizes and shapes.

3. The shaped object according to claim 2.

5. A method for designing a molded object, the molded object being manufactured by a molded object manufacturing device and having a molded part with a shape defined based on a square lobe curve, comprising: The modeling data for the modeling part is formed by setting the thickness of the surface that connects adjacent square curves with lines. A method for designing a molded object, comprising:

6. A method for designing a molded object, the molded object being manufactured by a molded object manufacturing device and having a molded part with a shape defined based on a square lobe curve, comprising: The specified cross-sectional shape is swept along a square curve to form the modeling data for the modeling part. A method for designing a molded object, comprising:

7. A method for designing a molded object, the molded object being manufactured by a molded object manufacturing device and having a molded part with a shape defined based on a square lobe curve, comprising: The cross-sectional shapes at different positions are joined along a square curve to form the modeling data for the modeling part. A method for designing a molded object, comprising:

8. A shaped object is manufactured by a shaped object manufacturing device based on the shaping data formed by the shaped object design method according to any one of claims 5 to 7. A method for manufacturing a shaped object, comprising:

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