Three-dimensional modeling apparatus and method for calibrating a nozzle for three-dimensional modeling

Abstract

To provide a technique capable of measuring positional displacement of a nozzle on a modeling plane of a stage in a three-dimensional modeling apparatus.SOLUTION: A three-dimensional modeling apparatus has: a discharge part having a nozzle; a stage having a modeling plane on which modeling material is layered; a positional changer for changing relative position between the nozzle and the stage; a controller for controlling the positional changer; and a measuring module used for measuring a difference of the nozzle from a reference position in the modeling plane on the basis of a first position of the nozzle in the modeling plane assumed to be positioned by the controller controlling the positional changer, and a second position of the nozzle in the modeling plane changed by the controller controlling the positional changer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Regarding a three-dimensional modeling device, Patent Document 1 discloses that the distance between the tip surface of the nozzle and the modeling surface of the stage on which the three-dimensional object is modeled is measured, and the distance is adjusted to a predetermined distance. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-812 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, the molding accuracy of a three-dimensional object can be improved by adjusting the height of the nozzle relative to the stage. However, for example, if the origin position of the nozzle on the molding surface of the stage is misaligned, it is not possible to accurately deposit material in the targeted area on the stage. Therefore, a technology that can measure the positional misalignment of the nozzle on the molding surface of the stage is desired. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, there is provided a three-dimensional modeling apparatus comprising: a discharge unit having a nozzle, a stage having a modeling surface on which a modeling material is deposited, a position change unit that changes the relative position of the nozzle and the stage, a control unit that controls the position change unit, and a measurement module that is used to measure a difference between a reference position of the nozzle within the modeling surface based on a first position of the nozzle within the modeling surface that is assumed to be located by the control unit controlling the position change unit, and a second position of the nozzle within the modeling surface that is changed by the control unit controlling the position change unit.

[0006] According to a second aspect of the present disclosure, there is provided a method for calibrating a nozzle for three-dimensional printing provided in a three-dimensional printing apparatus, the three-dimensional printing apparatus including: a discharge unit having a nozzle; a stage having a printing surface on which a printing material is deposited; a position change unit that changes the relative position of the nozzle and the stage; and a control unit that controls the position change unit, the calibration method measuring a difference between a reference position of the nozzle within the printing surface based on a first position of the nozzle within the printing surface that is assumed to be located by the control unit controlling the position change unit, and a second position of the nozzle within the printing surface that is changed by the control unit controlling the position change unit. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus according to a first embodiment. [Figure 2] FIG. 2 is a perspective view showing a schematic configuration of a flat screw. [Figure 3] FIG. 2 is a schematic plan view showing a screw facing portion. [Figure 4] FIG. 1 is an explanatory diagram schematically illustrating how a three-dimensional object is formed. [Figure 5] FIG. 2 is a perspective view showing a specific configuration of a stage. [Figure 6]FIG. 2 is an enlarged perspective view of a portion of the stage. [Figure 7] FIG. 7 is a plan view of FIG. 6. [Figure 8] 10 is a flowchart of a calibration process. [Figure 9] FIG. 10 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus according to a second embodiment. [Figure 10] FIG. 10 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus according to a third embodiment. [Figure 11] 10A and 10B are diagrams showing other examples of scratches formed in the third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] A. First embodiment: FIG. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional printing apparatus 10 according to a first embodiment. Arrows indicating mutually orthogonal X, Y, and Z directions are shown in FIG. 1. The X and Y directions are parallel to a horizontal plane, and the Z direction is a vertically upward direction. The arrows indicating the X, Y, and Z directions are also shown in other figures as appropriate so that the illustrated directions correspond to those in FIG. 1. In the following description, when specifying the direction, positive and negative signs are used in combination to indicate the direction indicated by the arrow in each figure, with "+" indicating the direction indicated by the arrow and "-" indicating the opposite direction. Hereinafter, the +Z direction will also be referred to as "up" and the -Z direction as "down."

[0009] The three-dimensional modeling device 10 includes a modeling unit 110 that generates and ejects modeling material, a stage 210 that has a modeling surface 211 on which the modeling material is deposited, a position change unit 230 that changes the relative position between the nozzle 61 and the stage 210, a control unit 101 that controls the position change unit 230, and a detection unit 310 that forms part of a measurement module 300.

[0010] Under the control of the control unit 101, the modeling unit 110 melts a solid material to form a paste-like modeling material and dispenses it onto the stage 210. Here, "melting" is a concept that includes plasticization, and refers not only to a material exhibiting fluidity when heated to a temperature above its melting point, but also to a material with a glass transition point softening and exhibiting fluidity when heated to a temperature above its glass transition point. The modeling unit 110 includes a material supply unit 20, which is a supply source of material before being converted into the modeling material, a modeling material generation unit 30 that converts the material into the modeling material, and a discharge unit 60 that dispenses the modeling material.

[0011] The material supply unit 20 supplies raw material MR to the modeling material generation unit 30 for generating a modeling material. The material supply unit 20 is configured, for example, by a hopper that stores the raw material MR. The material supply unit 20 has a discharge outlet at its bottom. The discharge outlet is connected to the modeling material generation unit 30 via a communication passage 22. The raw material MR is fed into the material supply unit 20 in the form of pellets, powder, or the like. In this embodiment, pellet-shaped ABS resin material is used.

[0012] The modeling material generation unit 30 melts the raw material MR supplied from the material supply unit 20 to generate a paste-like modeling material that exhibits fluidity, and guides the modeling material to the discharge unit 60. The modeling material generation unit 30 has a screw case 31, a drive motor 32, a flat screw 40, and a screw facing unit 50. The flat screw 40 is also called a rotor or a scroll, and the screw facing unit 50 is also called a barrel.

[0013] FIG. 2 is a perspective view showing the schematic configuration of the lower surface 48 side of the flat screw 40. To facilitate understanding of the technology, the flat screw 40 shown in FIG. 2 is shown with the positional relationship between the upper surface 47 and the lower surface 48 shown in FIG. 1 reversed in the vertical direction. FIG. 3 is a schematic plan view showing the upper surface 52 side of the screw-facing portion 50. The flat screw 40 has a roughly cylindrical shape whose height in the axial direction, which is the direction along its central axis, is smaller than its diameter. The flat screw 40 is positioned so that the rotation axis RX, which is its rotation center, is parallel to the Z direction.

[0014] The flat screw 40 is housed in a screw case 31. An upper surface 47 of the flat screw 40 is connected to a drive motor 32, and the flat screw 40 rotates in the screw case 31 by the rotational driving force generated by the drive motor 32. The drive motor 32 is driven under the control of the control unit 101. The flat screw 40 may be driven by the drive motor 32 via a reducer.

[0015] A spiral groove 42 is formed on a lower surface 48 of the flat screw 40, which is a surface that intersects with the rotation axis RX. The communication passage 22 of the material supply unit 20 described above communicates with the groove 42 from the side surface of the flat screw 40. As shown in FIG. 2 , in this embodiment, three grooves 42 are formed, separated by ridges 43. The number of grooves 42 is not limited to three, and may be one, or two or more. The groove 42 is not limited to a spiral shape, but may also be a spiral or involute curve shape, or may have a shape that extends in an arc from the center to the outer periphery.

[0016] The lower surface 48 of the flat screw 40 faces the upper surface 52 of the screw-facing portion 50, and a space is formed between the groove portion 42 of the lower surface 48 of the flat screw 40 and the upper surface 52 of the screw-facing portion 50. In the molding section 110, raw material MR is supplied from the material supply section 20 to the material inlet 44 shown in FIG. 2 into this space between the flat screw 40 and the screw-facing portion 50.

[0017] A heater 58 is embedded in the screw facing portion 50 to heat the raw material MR supplied into the groove portion 42 of the rotating flat screw 40. A plurality of guide grooves 54 are formed in the screw facing portion 50, connected to the communication holes 56 and extending spirally from the communication holes 56 toward the outer periphery. Note that one end of the guide grooves 54 does not have to be connected to the communication holes 56. Also, the guide grooves 54 can be omitted.

[0018] The raw material MR supplied into the groove 42 of the flat screw 40 is melted in the groove 42, flows along the groove 42 due to the rotation of the flat screw 40, and is guided to the central portion 46 of the flat screw 40 as a modeling material. The pasty modeling material that has flowed into the central portion 46 and exhibits fluidity is supplied to the discharge portion 60 through the communication hole 56 provided in the center of the screw facing portion 50 shown in FIG. 3. Note that it is not necessary for all types of substances constituting the modeling material to be melted. It is sufficient for the modeling material to be converted into a fluid state as a whole by melting at least some of the types of substances constituting the modeling material.

[0019] The discharge unit 60 includes a nozzle 61 for three-dimensional modeling that discharges the modeling material, a flow path 65 for the modeling material provided between the flat screw 40 and the nozzle 61, a flow rate adjustment unit 70 that opens and closes the flow path 65, and a suction unit 75 that sucks in and temporarily stores the modeling material. The nozzle 61 is connected to the communication hole 56 of the screw facing unit 50 through the flow path 65. The nozzle 61 discharges the modeling material generated in the modeling material generation unit 30 from an outlet 62 at its tip toward the stage 210. A heater may be arranged around the nozzle 61 to suppress a decrease in temperature of the modeling material discharged onto the stage 210.

[0020] The flow rate adjustment unit 70 changes the opening degree of the flow path 65 by rotating within the flow path 65. In this embodiment, the flow rate adjustment unit 70 is configured by a butterfly valve. The flow rate adjustment unit 70 is driven by a first drive unit 74 under the control of the control unit 101. The first drive unit 74 is configured by, for example, a stepping motor. The control unit 101 can adjust the flow rate of the modeling material flowing from the modeling material generation unit 30 to the nozzle 61, i.e., the flow rate of the modeling material discharged from the nozzle 61, by using the first drive unit 74 to control the rotation angle of the butterfly valve. The flow rate adjustment unit 70 adjusts the flow rate of the modeling material and also controls the on / off of the outflow of the modeling material.

[0021] The suction unit 75 is connected in the flow path 65 between the flow rate adjustment unit 70 and the discharge port 62. When the discharge of the modeling material from the nozzle 61 stops, the suction unit 75 temporarily sucks the modeling material in the flow path 65, thereby suppressing the tailing phenomenon in which the modeling material hangs like a string from the discharge port 62. In this embodiment, the suction unit 75 is configured with a plunger. The suction unit 75 is driven by a second drive unit 76 under the control of the control unit 101. The second drive unit 76 is configured with, for example, a stepping motor or a rack-and-pinion mechanism that converts the rotational force of the stepping motor into translational motion of the plunger.

[0022] For example, when the control unit 101 stops the discharge of the modeling material from the nozzle 61, it first controls the flow rate adjustment unit 70 to turn off the outflow of the modeling material, and then controls the suction unit 75 to suck the modeling material. When the control unit 101 resumes the discharge of the modeling material from the nozzle 61, it controls the suction unit 75 to discharge the material that has been sucked by the suction unit 75, and then controls the flow rate adjustment unit 70 to turn on the outflow of the modeling material. By controlling the flow rate adjustment unit 70 and the suction unit 75 in this way, the control unit 101 can improve the discharge responsiveness of the modeling material.

[0023] The stage 210 is disposed at a position facing the discharge port 62 of the nozzle 61. In the first embodiment, the modeling surface 211 of the stage 210 facing the discharge port 62 of the nozzle 61 is disposed so as to be parallel to the X and Y directions, i.e., the horizontal direction. During three-dimensional modeling, the three-dimensional modeling device 10 discharges a modeling material from the discharge unit 60 toward the modeling surface 211 of the stage 210 to stack layers, thereby forming a three-dimensional object. The stage 210 is equipped with a stage heater 212 as a heating unit. The stage heater 212 prevents a sudden drop in the temperature of the modeling material discharged onto the stage 210.

[0024] The position changing unit 230 changes the relative position between the nozzle 61 and the stage 210. In this embodiment, the position of the nozzle 61 is fixed, and the position changing unit 230 moves the stage 210. The position changing unit 230 is configured by a three-axis positioner that moves the stage 210 in three axial directions, that is, the X, Y, and Z directions, using the driving forces of three motors. The position changing unit 230 changes the relative positional relationship between the nozzle 61 and the stage 210 under the control of the control unit 101. In this specification, unless otherwise specified, moving the nozzle 61 means moving the nozzle 61 relative to the stage 210.

[0025] In other embodiments, instead of a configuration in which the position changer 230 moves the stage 210, a configuration in which the position changer 230 moves the nozzle 61 relative to the stage 210 while the position of the stage 210 is fixed may be employed. Alternatively, a configuration in which the position changer 230 moves the stage 210 in the Z direction and moves the nozzle 61 in the X and Y directions, or a configuration in which the position changer 230 moves the stage 210 in the X and Y directions and moves the nozzle 61 in the Z direction may be employed. Even with these configurations, the relative positional relationship between the nozzle 61 and the stage 210 can be changed.

[0026] The detection unit 310 is composed of a camera 311 that captures an image of the modeling surface 211 of the stage 210, and an arm unit 312 that movably supports the camera 311. The detection unit 310 is controlled by the control unit 101. In response to an instruction from the control unit 101, the detection unit 310 drives the arm unit 312 to move the camera 311 to a position facing the stage 210. The detection unit 310 then captures an image of a specified area on the stage 210 using the camera 311. The captured image is transmitted to the control unit 101.

[0027] The control unit 101 is a control device that controls the overall operation of the 3D printing apparatus 10. The control unit 101 is configured by a computer that includes one or more processors, a storage device, and an input / output interface that inputs and outputs signals from and to the outside. The control unit 101 fulfills its function as the printing processing unit 102 by the processor executing programs and instructions loaded onto the storage device. Note that the control unit 101 may also be realized by a combination of multiple circuits.

[0028] The modeling processing unit 102 controls the modeling unit 110 and the position changing unit 230 to model a three-dimensional object based on modeling data for modeling a three-dimensional object.

[0029] The modeling processing unit 102 generates layer data by slicing the shape of the three-dimensional object into multiple layers based on three-dimensional CAD data or the like that represents the shape of the three-dimensional object. Then, for each layer included in the layer data, it generates modeling data that includes path information that represents the movement path of the discharge unit 60 and discharge amount information that represents the amount of modeling material discharged on each movement path. The movement path of the discharge unit 60 is the path along which the nozzle 61 moves relatively along the modeling surface 211 of the stage 210 while discharging the modeling material.

[0030] The path information is composed of multiple partial paths. Each partial path is a linear path represented by a start point and an end point. Discharge amount information is individually associated with each partial path. In this embodiment, the discharge amount represented by the discharge amount information is the amount of modeling material discharged per unit time on that partial path. Note that in other embodiments, the total amount of modeling material discharged on the entire partial path may be associated with each partial path as discharge amount information.

[0031] FIG. 4 is an explanatory diagram schematically illustrating how a three-dimensional object is formed in the three-dimensional printing apparatus 10. As described above, in the three-dimensional printing apparatus 10, the solid raw material MR supplied to the grooves 42 of the rotating flat screw 40 is melted in the printing material generation unit 30 to generate the printing material MM. The control unit 101 discharges the printing material MM from the nozzle 61 while changing the position of the nozzle 61 relative to the stage 210 in a direction along the printing surface 211 of the stage 210, while maintaining the distance between the nozzle 61 and the printing surface 211 of the stage 210. The printing material MM discharged from the nozzle 61 is continuously deposited in the direction of movement of the nozzle 61. This scanning of the nozzle 61 forms a linear portion LP, which is a printing portion extending linearly along the scanning path of the nozzle 61. When forming the three-dimensional object, the control unit 101 controls the stage heater 212 to raise the temperature of the stage 210 to a predetermined temperature.

[0032] The control unit 101 forms layers ML by repeating the above-described scanning by the nozzle 61. After forming one layer ML, the control unit 101 moves the position of the nozzle 61 relative to the stage 210 in the Z direction. Then, a three-dimensional object is formed by stacking further layers ML on the layers ML that have been formed so far.

[0033] The control unit 101 may temporarily suspend the discharge of the modeling material from the nozzle 61, for example, when the nozzle 61 moves in the Z direction after completing one layer ML or when each layer has multiple independent modeling regions. In this case, the flow rate adjustment unit 70 closes the flow path 65 to stop the discharge of the modeling material MM from the discharge port 62. After changing the position of the nozzle 61, the control unit 101 opens the flow path 65 with the flow rate adjustment unit 70, thereby restarting the deposition of the modeling material MM from the new position of the nozzle 61.

[0034] 5 is a perspective view showing a specific configuration of the stage 210. The stage 210 has a substantially rectangular shape when viewed in the -Z direction, and is placed on a support base 220. The stage heater 212 shown in FIG. 1 is disposed between the stage 210 and the support base 220.

[0035] In this embodiment, linear grooves 224 extending along the Y direction are formed at equal intervals in the X direction on the modeling surface 211 of the stage 210. These grooves 224 are provided to generate an anchor effect for the modeling material dispensed onto the modeling surface 211. Note that in other embodiments, these grooves 224 may not be provided.

[0036] The stage 210 has a trapezoidal convex portion 213 protruding in the +X direction at its end in the +X direction. The support base 220 has a first stopper 221 for positioning the edge of the stage 210 in the +Y direction, and a second stopper 222 for positioning the edge of the stage 210 in the -X direction. The support base 220 also has a biasing portion 223 equipped with a spring for pressing the convex portion 213 provided on the stage 210 in the -X direction and the +Y direction. The stage 210 is positioned and fixed on the support base 220 by the first stopper 221, the second stopper 222, and the biasing portion 223 provided on the support base 220.

[0037] FIG. 6 is an enlarged perspective view of a portion of the stage 210. FIG. 7 is a plan view of FIG. 6. A plate-shaped scratch-forming member 214 is disposed at the corners of the stage 210 in the -X and -Y directions. The scratch-forming member 214, together with the detection unit 310 shown in FIG. 1, constitutes the measurement module 300. The scratch-forming member 214 is removably fixed to a support block 215 that fixes the scratch-forming member 214 to the stage 210. The support block 215 is removably fixed to the stage 210 at the corners of the stage 210 in the -X and -Y directions. With this structure, the scratch-forming member 214 is installed at a predetermined position on the stage 210.

[0038] A recess 216 into which the scratch-forming member 214 is fitted is formed on the upper surface of the support block 215. When viewed in the -Z direction, an edge 217 of the recess 216 in the -X direction coincides with an edge of the printing surface 211 in the -X direction. When viewed in the -Z direction, an edge 218 of the recess 216 in the -Y direction coincides with an edge of the printing surface 211 in the -Y direction. As shown in FIG. 7 , the intersection of the extensions of the edge 217 in the -X direction and the edge 218 in the -Y direction of the recess 216 coincides with the origin (0,0), which is the reference position of the printing surface 211.

[0039] The scratch-forming member 214 is a member in which scratches are formed by the scratch-forming nozzle 63 shown in FIG. 6. The scratch-forming nozzle 63 does not have an outlet, and the portion corresponding to the outlet has a pointed shape in the -Z direction. In other words, the scratch-forming nozzle 63 is a member that imitates the nozzle 61 and is not used to eject the modeling material. The scratch-forming nozzle 63 is attached to the ejection unit 60 so as to cover the nozzle 61. Specifically, the scratch-forming nozzle 63 is detachable from the ejection unit 60 by threading a thread formed on the inner surface of the scratch-forming nozzle 63 into a thread formed around the nozzle 61. With this configuration, the position of the nozzle 61 and the position of the scratch-forming nozzle 63 on the modeling surface 211 coincide. Note that in other embodiments, the nozzle 61 and the scratch-forming nozzle 63 may be configured to be interchangeably attached to the ejection unit 60.

[0040] The hardness of the scratch forming nozzle 63 is higher than the hardness of the scratch forming member 214. In this embodiment, hardness refers to Vickers hardness. The scratch forming nozzle 63 is made of, for example, mechanical structural carbon steel or carbon chromium bearing steel. In contrast, the scratch forming member 214 is made of, for example, aluminum. Therefore, the control unit 101 controls the position changing unit 230 to relatively move the discharge unit 60 to which the scratch forming nozzle 63 is attached in the -Z direction and press it against the scratch forming member 214, whereby a point-like scratch SK is formed in the scratch forming member 214 by the sharp tip of the scratch forming nozzle 63.

[0041] The control unit 101 photographs the scratch SK together with the support block 215 using the camera 311 provided in the detection unit 310, and measures the distance from the edge of the recess 216 formed in the support block 215 in the -X direction to the scratch SK, and the distance from the edge of the recess 216 in the -Y direction to the scratch SK through image analysis. In this way, the position of the scratch SK relative to the origin of the printing surface 211, i.e., the position of the nozzle 61 relative to the origin of the printing surface 211, can be measured.

[0042] 8 is a flowchart of the calibration process executed by the control unit 101. This process is executed at a predetermined timing, for example, before shipping the 3D printing apparatus 10 or after replacing the stage 210. Note that it is assumed that the scratch forming nozzle 63 is attached to the discharge unit 60 before starting the calibration process.

[0043] In step S10, the control unit 101 controls the stage heater 212 to raise the temperature of the stage 210 to the temperature during modeling of a three-dimensional object. This allows the calibration process to be performed in an environment similar to that during actual three-dimensional modeling.

[0044] In step S20, the control unit 101 performs a scratch formation process in which the scratch formation nozzle 63 is used to form scratches on the scratch formation member 214. In this scratch formation process, the control unit 101 first determines a first position on the printing surface 211 where the nozzle 61 is expected to be located by controlling the position change unit 230. The first position is, for example, 10 mm in the +X direction and 10 mm in the +Y direction from the origin of the printing surface 211. The first position is determined as a position where scratches can be reliably formed on the scratch formation member 214. Next, the control unit 101 controls the position change unit 230 to move the scratch formation nozzle 63 to the first position on the printing surface 211. Then, the control unit 101 controls the position change unit 230 to relatively move the scratch formation nozzle 63 in the −Z direction, thereby forming scratches on the scratch formation member 214. The operation realized by the scratch formation process is called a scratch formation operation.

[0045] In step S30, the control unit 101 performs a flaw measurement process to measure the flaw position. In this flaw measurement process, the control unit 101 controls the detection unit 310 to move the camera 311 onto the printing surface 211. Then, the control unit 101 controls the camera 311 to capture an image including the flaw-forming member 214 and the support block 215. The control unit 101 acquires the image from the camera 311 and measures the flaw position by analyzing the image. The measured flaw position is referred to as the second position. The second position is the position of the nozzle 61 on the printing surface 211 changed by the control unit 101 controlling the position change unit 230. In other words, the first position described above is the assumed position of the nozzle 61 on the printing surface 211, while the second position is the actual position of the nozzle 61 on the printing surface 211. If there is no positional deviation of the nozzle 61, the second position and the first position coincide with each other.

[0046] In step S40, the control unit 101 performs a correction value calculation process. In this correction value calculation process, the control unit 101 calculates the difference between the first position and the second position in the X direction and the difference between the first position and the second position in the Y direction. For example, if the coordinates (X, Y) of the first position are (10 mm, 10 mm) and the coordinates (X, Y) of the second position are (12 mm, 9 mm), the difference between the reference position of the nozzle 61 on the printing surface 211, i.e., the origin, is (+2 mm, -1 mm). The control unit 101 then calculates the correction value to eliminate this difference as (-2 mm, +1 mm).

[0047] The control unit 101 stores the correction values ​​calculated by the calibration process described above in a non-volatile manner in its own storage device. When three-dimensional printing is performed by the modeling processing unit 102, the control unit 101 corrects the command values ​​indicating the coordinates of the nozzle 61, which are sent from the control unit 101 to the position changing unit 230, in accordance with the correction values ​​stored in the storage device. This makes it possible to perform three-dimensional printing while correcting the position of the nozzle 61. Note that the control unit 101 may also correct path information included in the modeling data used for three-dimensional printing in accordance with the correction values. This also makes it possible to perform three-dimensional printing while correcting the position of the nozzle 61.

[0048] The three-dimensional printing apparatus 10 in the first embodiment described above includes a measurement module 300 for measuring the positional deviation of the nozzle 61. In this embodiment, the measurement module 300 is used to measure the difference between the nozzle 61 and a reference position on the printing surface 211, i.e., the positional deviation of the nozzle 61 from the origin of the printing surface 211, based on a first position on the printing surface 211 of the nozzle 61 that is assumed to be located by the control unit 101 controlling the position changing unit 230, and a second position on the printing surface 211 of the nozzle 61 that is changed by the control unit 101 controlling the position changing unit 230.

[0049] Furthermore, the measurement module 300 used in this embodiment includes a detection unit 310 having a camera 311 for detecting the second position. Therefore, the second position, which is the actual position of the nozzle 61, can be easily measured.

[0050] Furthermore, in this embodiment, three-dimensional printing is performed by controlling the position changing unit 230 based on the measurement results using the measurement module 300. Therefore, a three-dimensional object can be printed by controlling the position changing unit 230 so as to correct the positional deviation of the nozzle 61. As a result, for example, it is possible to eject the printing material with high accuracy into the grooves 224 formed on the printing surface 211.

[0051] The three-dimensional modeling apparatus 10 of this embodiment also has a scratch forming member 214 installed at a predetermined position on the stage 210. The control unit 101 controls the position changing unit 230 to move the scratch forming nozzle 63 to a first position and bring the tip of the scratch forming nozzle 63 into contact with the scratch forming member 214, thereby performing a scratch forming operation to form a scratch SK for measuring a second position. Therefore, the position of the scratch SK formed on the scratch forming member 214 can be measured as a second position, which is the actual position of the nozzle 61 corresponding to the first position, which is the assumed position of the nozzle 61.

[0052] In this embodiment, the discharge unit 60 is configured to allow the scratch forming nozzle 63, which does not have a discharge port, to be detachable. This makes it possible to prevent the nozzle 63 from being deteriorated by the scratch forming operation on the scratch forming member 214.

[0053] Furthermore, in this embodiment, the hardness of the scratch forming nozzle 63 is higher than the hardness of the scratch forming member 214. Therefore, it is possible to prevent the scratch forming nozzle 63 from being deteriorated by the scratch forming operation.

[0054] Furthermore, in this embodiment, in the calibration process, the scratch formation operation is performed after the stage 210 is heated by the stage heater 212. Therefore, the positional deviation of the nozzle 61 can be measured taking into account the thermal expansion of the stage 210 during the formation of a three-dimensional object.

[0055] In the first embodiment, the position of the scratch is measured using the camera 311 provided in the detection unit 310. Alternatively, the position of the scratch may be measured by a user using a measuring instrument such as a caliper, and the measured value may be input to the control unit 101 using a predetermined input device.

[0056] B. Second embodiment: 9 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus 10B according to the second embodiment. In the first embodiment described above, a correction value for correcting the position of the nozzle 61 is calculated based on the measurement results obtained using the measurement module 300, and the correction value is used to control the movement of the nozzle 61. In contrast, the three-dimensional modeling apparatus 10B according to the second embodiment has a correction unit 400 that physically corrects the position of the nozzle 61 based on the measurement results obtained using the measurement module 300.

[0057] 9, the correction unit 400 includes a first adjustment screw 401 that moves the discharge unit 60, including the nozzle 61, in the +X or −X direction, and a second adjustment screw 402 that moves the discharge unit 60 in the +Y or −Y direction. For example, a user may use the measurement module 300 to measure the difference between the first position and the second position, and physically correct the position of the nozzle 61 by manipulating the first adjustment screw 401 and the second adjustment screw 402 so that the difference becomes zero. In this way, the relative position between the nozzle 61 and the stage 210 can be corrected.

[0058] In the second embodiment, the correction unit 400 is configured to physically correct the position of the nozzle 61. Alternatively, the correction unit 400 may be configured to physically correct the installation position of the position change unit 230.

[0059] C. Third embodiment: FIG. 10 is an explanatory diagram showing a schematic configuration of a three-dimensional printing apparatus 10C according to the third embodiment. In the first embodiment described above, the discharge unit 60 includes one nozzle 61. In contrast, the discharge unit 60C according to the third embodiment includes two nozzles for three-dimensional printing. Specifically, the discharge unit 60C includes a first discharge unit 601 and a second discharge unit 602. The first discharge unit 601 includes a first nozzle 611. The second discharge unit 602 includes a second nozzle 612. For example, different materials are discharged from the first nozzle 611 and the second nozzle 612. The different materials may be, for example, when one material is a material for printing and the other is a material for supporting. Other examples of different materials include materials with different colors or materials with different qualities.

[0060] In the calibration process in the third embodiment, the control unit 101 forms scratches on the scratch-forming member 214 using the nozzles provided in each discharge unit 60. For example, the scratch-forming nozzle 63 attached to the first nozzle 611 forms a scratch at a position of coordinates (10 mm, 10 mm), and the scratch-forming nozzle 63 attached to the second nozzle 612 forms a scratch at a position of coordinates (15 mm, 15 mm). The positions of these scratches are then measured. For example, if the position of the scratch formed by the scratch-forming nozzle 63 attached to the first nozzle 611 is (10 mm, 10 mm) while the position of the scratch formed by the scratch-forming nozzle 63 attached to the second nozzle 612 is (16 mm, 15 mm), this means that the two nozzles are misaligned by 1 mm in the X direction. Therefore, the control unit 101 controls the position change unit 230 to eliminate this misalignment during the modeling process using the second nozzle 612, thereby enabling three-dimensional modeling to be performed while eliminating the misalignment between the nozzles. Incidentally, the misalignment between the nozzles may be eliminated by physically adjusting the position of at least one of the first discharge section 601 and the second discharge section 602, as in the second embodiment.

[0061] Fig. 11 is a diagram showing another example of scratches formed in the third embodiment. In the third embodiment, for example, as shown in Fig. 11, an L-shaped scratch SK1 may be formed by a scratch forming nozzle 63 attached to a first nozzle 611, and an L-shaped scratch SK2 may be formed at a position separated from the scratch SK1 by a scratch forming nozzle 63 attached to a second nozzle 612. Then, by measuring the distance between these scratches SK1 and SK2 in the X and Y directions, it is possible to measure the positional deviation between the nozzles.

[0062] D. Other Embodiments: (D1) In the above embodiment, for example, the position of the nozzle 61 may be measured directly without using the scratch forming member 214 or the scratch forming nozzle 63 by moving and positioning the camera 311 between the nozzle 61 and the stage 210 and using the camera 311 to photograph the nozzle 61 from below. Also, instead of using the camera 311, the position of the nozzle 61 may be measured using various optical sensors, such as a shape measurement sensor using a two-dimensional laser.

[0063] (D2) In the above embodiment, scratches are formed in the scratch-forming member 214 by the scratch-forming nozzle 63, and the position of the scratch is measured as the position of the nozzle 61. In contrast to this, for example, the nozzle 61 may eject the modeling material in a dotted or linear pattern onto the modeling surface 211 of the stage 210, and the positional deviation of the nozzle 61 may be measured by measuring the position of the modeling material on the modeling surface 211.

[0064] (D3) In the above embodiment, scratches are formed in the scratch-forming member 214 by the scratch-forming nozzle 63. Alternatively, scratches may be formed in the scratch-forming member 214 by the discharge nozzle 61. For example, the control unit 101 can form a dent scratch in the scratch-forming member 214 by relatively moving the nozzle 61 in the −Z direction so as to press the nozzle 61 against the scratch-forming member 214. Note that when scratches are formed by the nozzle 61, it is preferable that the hardness of the nozzle 61 is higher than the hardness of the scratch-forming member 214.

[0065] (D4) In the above embodiment, the wound forming member 214 is attached to the stage 210 by a support block 215. However, the support block 215 is not essential, and the wound forming member 214 may be attached directly to the stage 210.

[0066] (D5) In the above embodiment, the stage 210 is provided with a stage heater 212. However, the stage 210 does not have to be provided with a stage heater 212. In this case, heating of the stage 210 in the calibration process shown in FIG. 8 is omitted.

[0067] (D6) In the above embodiment, the control unit 101 performs the scratch formation operation after heating the stage 210 during the calibration process. However, the control unit 101 may perform the scratch formation operation both before and after heating the stage 210 during the calibration process. The control unit 101 then uses the detection unit 310 to measure the positions of two scratches formed before and after heating, and calculates the difference between those positions. This allows the control unit 101 to measure not only the positional deviation of the nozzle 61, but also the amount of thermal expansion of the stage 210 in the planar direction.

[0068] E. Other forms: The present disclosure is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit thereof. For example, the technical features of the embodiments corresponding to the technical features in each aspect described below can be appropriately replaced or combined to solve some or all of the above-described problems or achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted.

[0069] (1) According to a first aspect of the present disclosure, there is provided a three-dimensional printing apparatus comprising: a discharge unit having a nozzle, a stage having a printing surface on which a printing material is deposited, a position change unit that changes the relative position of the nozzle and the stage, a control unit that controls the position change unit, and a measurement module that is used to measure a difference between a reference position of the nozzle within the printing surface based on a first position of the nozzle within the printing surface that is assumed to be located by the control unit controlling the position change unit, and a second position of the nozzle within the printing surface that is changed by the control unit controlling the position change unit. With this configuration, it is possible to measure the positional deviation of the nozzle within the modeling surface of the stage.

[0070] (2) In the above aspect, the measurement module may have a detection unit that detects the second position. With this aspect, the second position can be easily measured.

[0071] (3) In the above aspect, the control unit may control the position changing unit based on a measurement result obtained using the measurement module. In this aspect, a three-dimensional object can be formed by controlling the position changing unit to correct a positional deviation of the nozzle.

[0072] (4) In the above-described embodiment, a correction unit may be provided that corrects the relative position between the nozzle and the stage based on the measurement results obtained using the measurement module. In this embodiment, the nozzle position can be corrected based on the difference between the measured nozzle position and a reference position.

[0073] (5) In the above embodiment, the measurement module may have a scratch forming member installed at a predetermined position on the stage, and the control unit may control the position changing unit to move the nozzle relatively to the first position and bring the tip of the nozzle into contact with the scratch forming member, thereby performing a scratch forming operation to form a scratch for measuring the second position. With this embodiment, the position of the scratch formed on the scratch forming member can be measured as the second position.

[0074] (6) In the above-described embodiment, the discharge unit may be configured to be able to detachably mount a scratch-forming nozzle that does not have a discharge port as the nozzle. In this embodiment, it is possible to suppress deterioration of the nozzle due to the scratch-forming operation on the scratch-forming member.

[0075] (7) In the above embodiment, the hardness of the scratch forming nozzle may be higher than the hardness of the scratch forming member. In this embodiment, deterioration of the scratch forming nozzle can be suppressed.

[0076] (8) In the above-described embodiment, a heating unit may be provided for heating the stage, and the control unit may perform the scratch forming operation after the heating unit heats the stage. In this embodiment, the nozzle position deviation can be measured taking into account thermal expansion of the stage.

[0077] (9) In the above-described embodiment, the control unit may perform the scratch forming operation before heating the stage in addition to after heating the stage by the heating unit. In this embodiment, the amount of thermal expansion of the stage can be easily measured.

[0078] (10) In the above embodiment, the discharge unit may include a first discharge unit and a second discharge unit, and the control unit may perform a second measurement operation of bringing a tip of a nozzle provided in the first discharge unit and a tip of a nozzle provided in the second discharge unit into contact with the scratch forming member. With this embodiment, it is possible to measure the positional deviation between the two nozzles.

[0079] (11) According to a second aspect of the present disclosure, there is provided a method for calibrating a nozzle for three-dimensional printing provided in a three-dimensional printing apparatus, the three-dimensional printing apparatus including: a discharge unit having a nozzle; a stage having a printing surface on which a printing material is deposited; a position change unit that changes the relative position of the nozzle and the stage; and a control unit that controls the position change unit, the calibration method measuring a difference between a reference position of the nozzle within the printing surface based on a first position of the nozzle within the printing surface that is assumed to be located by the control unit controlling the position change unit, and a second position of the nozzle within the printing surface that is changed by the control unit controlling the position change unit. [Explanation of symbols]

[0080] 10, 10B, 10C... Three-dimensional modeling device, 20... Material supply unit, 22... Connecting passage, 30... Modeling material generation unit, 31... Screw case, 32... Drive motor, 40... Flat screw, 42... Groove portion, 43... Convex ridge portion, 44... Material inlet, 46... Center portion, 47... Upper surface, 48... Lower surface, 50... Screw facing portion, 52... Upper surface, 54... Guide groove, 56... Connecting hole, 58... Heater, 60, 60C... Discharge unit, 61... Nozzle, 62... Discharge outlet, 63... Wound formation nozzle, 65... Flow path, 70... Flow rate adjustment unit, 74... First drive unit, 75... Suction unit, 76... Second drive unit, 101... Control unit, 102... Modeling Processing unit, 110... modeling unit, 210... stage, 211... modeling surface, 212... stage heater, 213... convex portion, 214... scratch forming member, 215... support block, 216... concave portion, 217, 218... edge, 220... support base, 221... first stopper, 222... second stopper, 223... biasing portion, 224... groove, 230... position changing portion, 300... measurement module, 310... detection unit, 311... camera, 312... arm portion, 400... correction unit, 401... first adjusting screw, 402... second adjusting screw, 601... first discharge portion, 602... second discharge portion, 611... first nozzle, 612... second nozzle

Claims

1. a discharge unit having a nozzle; a stage having a building surface on which a building material is deposited; a position changer that changes the relative position between the nozzle and the stage; a control unit that controls the position change unit; The control unit controls the position change unit to position the no. a first position of the die on the modeling surface, and and a second position of the nozzle on the modeling surface, which is changed accordingly. a measuring module used to measure the difference from a reference position within the modeling surface; and The measurement module is a wound forming section installed at a predetermined position on the stage. It has materials, The control unit controls the position change unit to relatively move the nozzle to the first position. and bringing the tip of the nozzle into contact with the surface of the wound forming member, thereby measuring the second position. a wound forming operation to form a wound for the The discharge unit is configured so that a nozzle for forming a wound without a discharge port can be detachably attached as the nozzle. It has been Three-dimensional printing equipment.

2. The three-dimensional modeling apparatus according to claim 1, The measurement module includes a detection unit that detects the second position.

3. The three-dimensional modeling apparatus according to claim 1 or 2, The control unit controls the position change unit based on the measurement result using the measurement module. Controlled 3D modeling device.

4. The three-dimensional modeling apparatus according to claim 1 or 2, Based on the measurement results using the measurement module, A three-dimensional modeling apparatus having a correction unit that corrects a relative position.

5. A three-dimensional printing apparatus according to any one of claims 1 to 4, A three-dimensional modeling apparatus, wherein the hardness of the scratch forming nozzle is higher than the hardness of the scratch forming member.

6. The three-dimensional modeling apparatus according to any one of claims 1 to 5, a heating unit that heats the stage, the control unit performs the scratch forming operation after the heating unit heats the stage. Former modeling device.

7. The three-dimensional modeling apparatus according to claim 6, The control unit controls the heating unit to control the heating of the stage before the heating of the stage in addition to the heating of the stage by the heating unit. The three-dimensional printing apparatus also performs the scratch forming operation.

8. The three-dimensional modeling apparatus according to any one of claims 1 to 7, the discharge unit includes a first discharge unit and a second discharge unit, The control unit, in the scratch forming operation, a tip of a nozzle provided in the second discharge unit is brought into contact with the wound forming member; Device.

9. A method for calibrating a nozzle for three-dimensional printing provided in a three-dimensional printing apparatus, comprising: The three-dimensional modeling device includes: A discharge section having a nozzle configured to be detachable with a wound forming nozzle that does not have a discharge port. and, A modeling surface on which a modeling material is deposited and a scratch forming member installed at a predetermined position. a stage having a position changer that changes the relative position between the nozzle and the stage; a control unit that controls the position change unit, The control unit controls the position change unit to position the no. a first position of the die on the modeling surface, and and a second position of the nozzle on the modeling surface, which is changed accordingly. a position change unit for changing the position of the shaping tool from a reference position on the shaping surface; The nozzle is moved relatively to the first position to bring the tip of the nozzle into contact with the wound forming member. a scratch forming operation for forming a scratch for measuring the second position by causing the scratch to be formed; Calibration method.

Images