Method for manufacturing a three-dimensional object and three-dimensional modeling device

Abstract

To provide a manufacturing method of a three-dimensional molded article capable of reducing difference in level generated on a surface of the three-dimensional molded article.SOLUTION: A molding method of a three-dimensional molded article using a cutting tool capable of cutting by a first length in a cutting direction includes: a first part molding step in which a molding material is laminated to mold a first part in which the length in the cutting direction is shorter than the first length; a first part cutting step in which the first part is cut in the cutting direction by the cutting tool; and a second part molding step in which the molding material is laminated to mold a second part which is connected to a first end surface in an opposite direction to the cutting direction of the first part and has the length in the cutting direction shorter than the first part.SELECTED DRAWING: Figure 10

Description

[Technical Field]

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

[0002] 2. Description of the Related Art Three-dimensional modeling apparatuses are known that place a fluid material at a desired position to form a three-dimensional object.

[0003] For example, Patent Document 1 describes a model-making device that includes a modeling machine that forms a model by a fused deposition modeling method and a modeling machine that cuts the model formed by the modeling machine. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2019-31011 Summary of the Invention [Problem to be solved by the invention]

[0005] In the above-described object manufacturing apparatus, when a three-dimensional object is manufactured by repeating the steps of modeling and cutting, when a new layer is stacked on a cut layer, the cut layer is distorted due to the contraction stress of the new layer, which may result in unevenness on the surface of the object. [Means for solving the problem]

[0006] One aspect of the method for producing a three-dimensional object of the present invention includes: A method for forming a three-dimensional object using a cutting tool capable of cutting a first length in a cutting direction, a first portion forming step of stacking a forming material to form a first portion whose length in the cutting direction is shorter than the first length; a first portion cutting step of cutting the first portion in the cutting direction by the cutting tool; a second portion forming process in which the forming material is stacked and connected to a first end surface of the first portion opposite to the cutting direction, thereby forming a second portion having a length in the cutting direction shorter than that of the first portion; Includes.

[0007] One aspect of the three-dimensional fabrication device of the present invention is a modeling machine that stacks modeling materials; a cutting machine having a cutting tool capable of cutting a first length in a cutting direction; a control unit that controls the molding machine and the cutting machine; Including, The control unit a process of stacking the modeling material in the modeling machine to model a first portion whose length in the cutting direction is shorter than the first length; a process of causing the cutting machine to cut the first portion in the cutting direction using the cutting tool; a process of causing the molding machine to stack the molding material and connect it to a first end face of the first portion opposite to the cutting direction, and molding a second portion having a length in the cutting direction shorter than that of the first portion; Do the following. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram schematically illustrating a three-dimensional modeling apparatus according to an embodiment of the present invention. [Figure 2] FIG. 2 is a cross-sectional view schematically showing a modeling machine of the three-dimensional modeling apparatus according to the embodiment. [Figure 3] FIG. 2 is a perspective view schematically showing a flat screw of the three-dimensional modeling apparatus according to the embodiment. [Figure 4] FIG. 2 is a plan view schematically showing a barrel of the three-dimensional modeling apparatus according to the embodiment. [Figure 5] 6 is a flowchart for explaining a data generation process of the three-dimensional modeling apparatus according to the present embodiment. [Figure 6] FIG. 2 is a perspective view schematically showing a first shape of the three-dimensional modeling apparatus according to the embodiment. [Figure 7] FIG. 4 is a perspective view schematically showing a second shape of the three-dimensional modeling apparatus according to the embodiment. [Figure 8] FIG. 10 is a perspective view schematically showing a third form of the three-dimensional modeling apparatus according to the embodiment. [Figure 9] FIG. 2 is a diagram schematically showing a first modeling data portion and a first cutting data portion of the three-dimensional modeling apparatus according to the embodiment. [Figure 10] 4 is a flowchart for explaining a process for realizing the manufacture of a three-dimensional object according to the present embodiment. [Figure 11] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 12] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 13] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 14] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 15] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 16] 5A to 5C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to the embodiment. [Figure 17] 10A to 10C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to a reference example. [Figure 18] 10A to 10C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to a reference example. [Figure 19] 10A to 10C are cross-sectional views schematically illustrating a manufacturing process of a three-dimensional object according to a reference example. DETAILED DESCRIPTION OF THE INVENTION

[0009] Preferred embodiments of the present invention will be described in detail below with reference to the drawings. Note that the embodiments described below do not unduly limit the content of the present invention as defined in the claims. Furthermore, not all of the configurations described below are necessarily essential components of the present invention.

[0010] 1. Three-dimensional printing equipment Configuration First, a three-dimensional printing apparatus according to this embodiment will be described with reference to the drawings. Fig. 1 is a diagram schematically illustrating a three-dimensional printing apparatus 10 according to this embodiment. Note that Fig. 1 illustrates an X-axis, a Y-axis, and a Z-axis as three mutually orthogonal axes. The X-axis direction and the Y-axis direction are, for example, horizontal directions. The Z-axis direction is, for example, vertical directions.

[0011] As shown in FIG. 1, the three-dimensional modeling apparatus 10 includes, for example, a modeling machine 100, a cutting machine 200, a stage 300, a moving mechanism 400, a control unit 500, and an information processing device 510.

[0012] The three-dimensional modeling apparatus 10 drives the movement mechanism 400 to change the relative position between the nozzle 62 and the stage 300 while discharging the modeling material from the nozzle 62 of the modeling machine 100 onto the stage 300. In this way, the modeling machine 100 deposits the modeling material on the stage 300.

[0013] Furthermore, the three-dimensional printing apparatus 10 rotates the cutting tool 210 of the cutter 200 while driving the movement mechanism 400 to change the relative position between the cutting tool 210 and the stage 300. As a result, the cutter 200 cuts the modeling material stacked on the stage 300. In this way, the three-dimensional printing apparatus 10 prints a three-dimensional object OB having a desired shape. For convenience, the three-dimensional object OB is illustrated in a simplified form in FIG. 1.

[0014] The molding machine 100 discharges a molding material from the nozzle 62 toward the molding surface 310 of the stage 300. The detailed configuration of the molding machine 100 will be described later.

[0015] The cutter 200 has a cutting tool 210 attached to its tip. In the illustrated example, the cutting tool 210 is a rod-shaped member extending in the Z-axis direction. The cutter 200 is a cutting device that cuts the modeling material stacked on the stage 300 by rotating the cutting tool 210 around a rotation axis parallel to the Z-axis. Examples of the cutting tool 210 include a flat end mill and a ball end mill. The cutter 200 detects the position of the tip of the cutting tool 210 using, for example, a position detection sensor and transmits the detection result to the control unit 500. The control unit 500 uses the detection result from the cutter 200 to control the relative positional relationship between the cutting tool 210 and the stacked modeling material using the movement mechanism 400 to perform cutting. The cutter 200 may also have a static eliminator such as an ionizer.

[0016] A modeling material is deposited on the modeling surface 310 of the stage 300. The stage 300 is moved by a movement mechanism 400.

[0017] The movement mechanism 400 changes the relative positions of the modeling machine 100, the cutting machine 200, and the stage 300. In the illustrated example, the movement mechanism 400 moves the stage 300 relative to the modeling machine 100 and the cutting machine 200. The movement mechanism 400 is configured, for example, by a three-axis positioner that moves the stage 300 in the X-axis, Y-axis, and Z-axis directions using the driving forces of three motors. The motors of the movement mechanism 400 are driven under the control of the control unit 500.

[0018] The moving mechanism 400 may be configured to move the molding machine 100 and the cutting machine 200 without moving the stage 300. Alternatively, the moving mechanism 400 may be configured to move both the molding machine 100 and the cutting machine 200 and the stage 300.

[0019] The control unit 500 is configured, for example, by a computer having a processor, a main memory device, and an input / output interface for inputting and outputting signals from and to the outside. The control unit 500 performs various functions, for example, by the processor executing a program loaded into the main memory device. The control unit 500 controls the molding machine 100, the cutting machine 200, and the movement mechanism 400. Note that the control unit 500 may be configured not by a computer, but by a combination of multiple circuits.

[0020] The information processing device 510 is connected to the control unit 500. The information processing device 510 is configured, for example, by a computer having a processor, a main memory device, and an input / output interface for inputting and outputting signals to and from the outside. The information processing device 510 performs various functions, for example, by the processor executing a program loaded into the main memory device. The information processing device 510 has a data generation unit 512. As described below, the data generation unit 512 generates modeling data and cutting data used by the control unit 500 to control the modeling machine 100, the cutting machine 200, and the movement mechanism 400.

[0021] 2 is a cross-sectional view schematically showing the molding machine 100. As shown in FIG. 2, the molding machine 100 has, for example, a material supply unit 20, a melting unit 30, a discharge unit 60, and a reheating unit 70.

[0022] Pellet-shaped or powder-shaped materials are fed into the material feeding section 20. An example of a pellet-shaped material is ABS (Acrylonitrile Butadiene Styrene). The material feeding section 20 is configured, for example, by a hopper. The material feeding section 20 and the melting section 30 are connected by a feeding path 22 provided below the material feeding section 20. The material fed into the material feeding section 20 is supplied to the melting section 30 via the feeding path 22.

[0023] The melting unit 30 has, for example, a screw case 32, a drive motor 34, a flat screw 40, and a barrel 50. The melting unit 30 melts the solid material supplied from the material supply unit 20 to produce a fluid, paste-like modeling material, which is then supplied to the nozzle 62.

[0024] The screw case 32 houses a flat screw 40. A drive motor 34 is fixed to the top surface of the screw case 32.

[0025] The flat screw 40 has a generally cylindrical shape with its height in the direction of the central axis RX being smaller than its diameter. In the illustrated example, the flat screw 40 is disposed within the screw case 32 so that the central axis RX is parallel to the Z axis. The torque generated by the drive motor 34 causes the flat screw 40 to rotate about the central axis RX.

[0026] The flat screw 40 has a groove-forming surface 42 on the side opposite to the top surface 41. The groove-forming surface 42 is provided with a groove 45. Here, Fig. 3 is a perspective view that schematically shows the flat screw 40. For convenience, Fig. 3 shows a state in which the up-down positional relationship is reversed from the state shown in Fig. 2.

[0027] As shown in FIG. 3, the groove portion 45 of the flat screw 40 has, for example, a central portion 46, a spiral portion 47, and a material introduction portion 48.

[0028] The central portion 46 is a circular recess formed around the central axis RX of the flat screw 40. The central portion 46 faces a communication hole 56 provided in the barrel 50.

[0029] The spiral portion 47 is a groove that extends spirally, drawing an arc from the center portion 46 toward the outer periphery of the groove-forming surface 42. The spiral portion 47 may be configured to extend in the shape of an involute curve or a spiral. One end of the spiral portion 47 is connected to the center portion 46. The other end of the spiral portion 47 is connected to the material introduction portion 48.

[0030] The material introduction section 48 is a groove that is wider than the spiral section 47 and is provided on the outer peripheral edge of the groove forming surface 42. The material introduction section 48 continues to the side surface 43 of the flat screw 40. The material introduction section 48 introduces the material supplied from the material supply section 20 via the supply path 22 into the spiral section 47.

[0031] In the example shown in Figure 3, one spiral section 47 and one material introduction section 48 are provided from the central section 46 to the outer periphery, but multiple spiral sections 47 and multiple material introduction sections 48 may be provided from the central section 46 to the outer periphery.

[0032] As shown in FIG. 2 , the barrel 50 is provided below the flat screw 40. The barrel 50 has a screw-facing surface 52 that faces the groove-forming surface 42 of the flat screw 40. A heater 58 is built into the barrel 50. The temperature of the heater 58 is controlled by a control unit 500. Note that the location of the heater 58 is not particularly limited as long as it can heat the modeling material, and the heater 58 may be built into the flat screw 40 or provided somewhere other than the flat screw 40 and the barrel 50.

[0033] A communication hole 56 is provided in the center of the screw-facing surface 52 of the barrel 50. The communication hole 56 communicates with a nozzle flow path 64. Here, FIG. 4 is a plan view schematically showing the barrel 50.

[0034] As shown in FIG. 4, the screw-facing surface 52 of the barrel 50 is provided with a guide groove 54 and a communicating hole 56. A plurality of guide grooves 54 are provided. The plurality of guide grooves 54 are provided around the communicating hole 56 in a plan view (as viewed from the Z-axis direction). One end of the guide groove 54 is connected to the communicating hole 56, and the guide groove 54 extends in a spiral shape from the communicating hole 56 toward the outer periphery of the screw-facing surface 52. The guide groove 54 has the function of guiding the molding material to the communicating hole 56. Note that the guide groove 54 does not necessarily have to be provided.

[0035] As shown in FIG. 2, the discharge section 60 has a nozzle 62. The nozzle 62 is provided with a nozzle flow path 64 and a nozzle hole 66. The nozzle flow path 64 is connected to the communication hole 56 of the melting section 30. The nozzle hole 66 is connected to the nozzle flow path 64. The nozzle hole 66 is an opening provided at the tip portion of the nozzle 62. The planar shape of the nozzle hole 66 is, for example, circular. The modeling material supplied from the melting section 30 to the nozzle 62 is discharged from the nozzle hole 66.

[0036] The reheating unit 70 reheats the modeling material that has been deposited and hardened on the stage 300. The reheating unit 70 is, for example, a heater provided near the nozzle 62. The temperature of the reheating unit 70 is controlled by the control unit 500.

[0037] 2 shows three motors 410 of the movement mechanism 400. The movement mechanism 400 moves the stage 300 in the X-axis direction, the Y-axis direction, and the Z-axis direction using the three motors 410. For convenience, the movement mechanism 400 is illustrated in a simplified form in FIG.

[0038] 1.2. Data generation process The modeling data and cutting data generated by the data generation process are data used by the control unit 500 to control the modeling machine 100, the cutting machine 200, and the movement mechanism 400. The data generation process is executed by the data generation unit 512 of the information processing device 510.

[0039] The modeling data is used to model the three-dimensional object OB. The modeling data is data for controlling the modeling machine 100 and the movement mechanism 400. The cutting data is used to cut the three-dimensional object OB. The cutting data is data for controlling the cutting machine 200 and the movement mechanism 400.

[0040] 5 is a flowchart for explaining the data generation process in data generation unit 512. Data generation unit 512 starts the data generation process when information processing device 510 receives a predetermined start operation. Each step of the data generation process will be explained below in order.

[0041] 1.2.1. Step S11 First, as shown in Fig. 5, the data generating unit 512 acquires first shape data (step S11). Here, Fig. 6 is a perspective view that schematically shows the first shape SP1 represented by the first shape data.

[0042] The first shape SP1 is a shape representing a three-dimensional object OB created using, for example, three-dimensional CAD (computer-aided design) software, three-dimensional CG (computer graphics) software, etc. The first shape SP1 is a design shape of the three-dimensional object OB. The first shape data is, for example, data in an STL (Standard Triangulated Language) format, an IGES (Initial Graphics Exchange Specification) format, a STEP (Standard for the Exchange of Product) format, etc.

[0043] The data generation unit 512 acquires first shape data created by the information processing device 510 using, for example, three-dimensional CAD software. The data generation unit 512 may acquire first shape data created outside the information processing device 510 via a recording medium such as a USB (Universal Serial Bus) memory. In the example shown in Fig. 6, the first shape SP1 has a tubular shape. The first shape SP1 has an inner wall surface 610 and a surface 620 opposite to the inner wall surface 610.

[0044] 1.2.2. Step S12 Next, as shown in FIG. 5, the data generation unit 512 sets the position and orientation at which the three-dimensional object OB represented by the first shape SP1 is to be placed on the stage 300 (step S12).

[0045] Specifically, the data generator 512 sets the position and orientation of the first shape SP1 on the stage 300 according to the position and orientation specified by the user. In the example shown in Fig. 6, the position and orientation of the first shape SP1 on the stage 300 are set so that the central axis CL of the first shape SP1 is parallel to the Z axis.

[0046] 1.2.3. Step S13 Next, as shown in Fig. 5, the data generation unit 512 generates second shape data representing a second shape using the first shape data and information relating to the cutting process to be performed on the three-dimensional object OB (step S13). The information relating to the cutting process to be performed on the three-dimensional object OB is, for example, information input by a user to the information processing device 510. Here, Fig. 7 is a perspective view schematically showing the second shape SP2 represented by the second shape data. For convenience, in Fig. 7, the printing surface 310 of the stage 300 is indicated by a two-dot chain line.

[0047] 7, the second shape SP2 is the shape of a three-dimensional object OB in which, for example, a cutting portion 706 is added to the first shape SP1. Note that the portion included in both the first shape SP1 and the second shape SP2 is also referred to as a main body portion 704. The main body portion 704 and the cutting portion 706 are collectively referred to as a formed portion 702.

[0048] The cutting portion 706 is a cutting allowance for cutting the three-dimensional object OB. The data generating unit 512 places the cutting portion 706 according to the position and dimensions of the cutting process specified by the user, for example. In the illustrated example, the cutting portion 706 is placed on the inner wall surface 610.

[0049] In the illustrated example, a bulkhead 630 is disposed between the modeling unit 702 and the stage 300. The bulkhead 630 separates the cutting unit 706 from the stage 300. The bulkhead 630 can suppress interference with the stage 300 when the cutting machine 200 performs cutting on the three-dimensional object OB. The data generation unit 512, for example, disposes the bulkhead 630 at a position designated by a user. When removing the cutting unit 706 by cutting from the modeling unit 702 formed according to the second shape SP2, the data generation unit 512 may determine whether the cutting machine 200 will interfere with the stage 300. If it is determined that the cutting machine 200 will interfere with the stage 300, the data generation unit 512 may dispose the bulkhead 630.

[0050] 1.2.4. Step S14 Next, as shown in Figures 5 and 7, the data generation unit 512 determines whether the length Ls of the cutting portion 706 in the cutting direction (-Z axis direction) is longer than the cutting length (first length) Le of the cutting tool 210 in the -Z axis direction (step S14).

[0051] Specifically, the data generating unit 512 uses the second shape data and information related to the cutting tool 210 to determine whether the length Ls of the cutting portion 706 is longer than the cuttable length Le of the cutting tool 210.

[0052] The cuttable length Le is the maximum length that can be cut in the cutting direction by the cutting tool 210. For example, when the cutting tool 210 is inserted into the hollow portion from one end of a tube arranged so that its central axis is aligned with the Z axis, and a cutting allowance provided on the inner wall surface 610 of the tube is cut, the distance in the Z axis direction from one end of the tube to the limit position at which cutting can be performed is the cuttable length Le in the cutting direction of the cutting tool 210. The cutting direction is the opposite direction to the layering direction of the modeling material.

[0053] 1.2.5. Step S15 If it is determined that the length Ls of the cutting portion 706 is longer than the cuttable length Le of the cutting tool 210 ("YES" in step S14), the data generation unit 512 uses the second shape data to generate third shape data representing a third shape SP3 (step S15), as shown in Fig. 5. Here, Fig. 8 is a perspective view schematically showing the third shape SP3 represented by the third shape data.

[0054] The third shape SP3 is the shape of the three-dimensional object OB divided into multiple parts, as shown in Fig. 8. The data generation unit 512 sets the third shape SP3 by dividing the forming portion 702 of the second shape SP2 so that the length of each part in the Z axis direction is shorter than the cuttable length Le of the cutting tool 210. In the example shown, the data generation unit 512 divides the forming portion 702 of the second shape SP2 into a first part 710, a second part 720, and a third part 730 to generate the third shape SP3.

[0055] The first portion 710 is disposed between the stage 300 and the second portion 720. The second portion 720 is disposed between the first portion 710 and the third portion 730. The length L1 of the first portion 710 in the -Z axis direction, the length L2 of the second portion 720 in the -Z axis direction, and the length L3 of the third portion 730 in the -Z axis direction are all shorter than the cutting length Le of the cutting tool 210 in the -Z axis direction.

[0056] The length L2 of the second portion 720 in the -Z axis direction is shorter than the length L1 of the first portion 710 in the -Z axis direction. The length L3 of the third portion 730 in the -Z axis direction is shorter than the length L2 of the second portion 720 in the Y axis direction. In this way, the data generation unit 512 sets the multiple portions so that the length of each portion in the -Z axis direction decreases with increasing distance from the stage 300.

[0057] Here, when the length of first portion 710 in the -Z axis direction is L1, the Young's modulus of first portion 710 is E, and the second moment of area of ​​first portion 710 is I, the contractile force w of second portion 720 satisfies the following formula (1). Note that the second moment of area can be determined from the cross-sectional shape of first portion 710 by a known method.

[0058] w≦0.009EI / L1 3 ···(1)

[0059] Generally, when the displacement is δ, the following formula (2) is satisfied according to the cantilever concentrated load formula.

[0060] δ=wL1 3 / 3EI (2)

[0061] When a step occurs on the surface 620 at the boundary between the first portion 710 and the second portion 720, the step corresponds to δ in equation (2). Here, the roughness of the surface 620 of the first portion 710 when the first portion 710 is cut with the cutting tool 210 is 0.003 mm. Therefore, if equation (1) is satisfied, even if a step occurs on the surface 620 at the boundary between the first portion 710 and the second portion 720, the height of the step can be kept to 0.003 mm or less.

[0062] In the -Z axis direction, the combined length of the first portion 710 and the second portion 720 is longer than the cuttable length Le. In the -Z axis direction, for example, the combined length of the second portion 720 and the third portion 730 is longer than the cuttable length Le.

[0063] In a plan view, the first portion 710, the second portion 720, and the third portion 730 have a shape that surrounds the space K. In a plan view, the first portion 710, the second portion 720, and the third portion 730 have, for example, an annular shape.

[0064] If it is not determined that the length Ls of the cutting portion 706 is longer than the cutting length Le of the cutting tool 210 ("NO" in step S14), the data generation unit 512 skips the processing of step S15 and proceeds to the next processing.

[0065] 1.2.6. Step S16 Next, as shown in FIG. 5, the data generating unit 512 generates cross-sectional data using the third shape data (step S16).

[0066] The cross-sectional data represents the cross-sectional shape when the third shape SP3 is cut along a plane parallel to the printing surface 310 of the stage 300. The data generation unit 512 cuts the third shape SP3 at intervals corresponding to the thickness of one layer of the printing material to be stacked on the stage 300 by the three-dimensional printing device 10, thereby generating multiple pieces of cross-sectional data. The thickness of one layer of the printing material to be stacked on the stage 300 by the three-dimensional printing device 10 is set, for example, by the user. Note that if step S15 is omitted and the third shape data is not generated, the data generation unit 512 generates the cross-sectional data using the second shape data.

[0067] 1.2.7. Step S17 Next, as shown in Fig. 5, the data generating unit 512 generates a modeling path using the cross-sectional data, and generates a cutting path using the third shape data (step S17). Fig. 8 schematically shows the modeling path Pm and the cutting path Pc generated by the data generating unit 512.

[0068] 8, the modeling path Pm is a scanning path of the nozzle 62, which moves while discharging the modeling material, relative to the stage 300. The cutting path Pc is a scanning path of the cutting tool 210, which moves while cutting the layered modeling material, relative to the stage 300. Multiple modeling paths Pm and multiple cutting paths Pc are generated, for example, depending on the number of layers of modeling material in the three-dimensional modeled object OB.

[0069] 1.2.8. Step S18 5, the data generation unit 512 generates and outputs modeling data and cutting data (step S18). The data generation unit 512 generates and outputs the modeling data and cutting data expressed, for example, by G-code, M-code, or the like.

[0070] The modeling data includes information about the modeling path Pm. Furthermore, the modeling data includes information about, for example, the discharge rate, which is the flow rate of the modeling material discharged from the nozzle 62, the rotation speed of the drive motor 34 that rotates the flat screw 40, the temperature of the heater 58 built into the barrel 50, and the temperature of the reheating unit 70. This information is set, for example, by the user.

[0071] The cutting data includes information about the cutting path Pc. Furthermore, the cutting data includes information about, for example, the rotation speed of the cutting tool 210 and the feed rate of the cutting tool 210. This information is set, for example, by the user.

[0072] The modeling data and the cutting data are represented in one data set, which may include, for example, a bulkhead modeling data portion, a bulkhead cutting data portion, a first modeling data portion, a first cutting data portion, a second modeling data portion, a second cutting data portion, a third modeling data portion, and a third cutting data portion.

[0073] The bulkhead-forming data portion, the first forming data portion, the second forming data portion, and the third forming data portion are data for forming the bulkhead 630, the first portion 710, the second portion 720, and the third portion 730, respectively. The bulkhead-cutting data portion, the first cutting data portion, the second cutting data portion, and the third cutting data portion are data for cutting the bulkhead 630, the first portion 710, the second portion 720, and the third portion 730, respectively. The bulkhead-forming data portion, the bulkhead-cutting data portion, the first forming data portion, the first cutting data portion, the second forming data portion, the second cutting data portion, the third forming data portion, and the third cutting data portion are set in this order.

[0074] 9 is a diagram schematically illustrating the first modeling data portion Dm1 and the first cutting data portion Dc1 generated by the data generating unit 512. The modeling data and the cutting data are read and interpreted in order from top to bottom in FIG.

[0075] As shown in FIG. 9, for example, commands COM1, COM2, COM3, and COM4 are set in the first modeling data portion Dm1.

[0076] Command COM1 moves the nozzle 62 to coordinates (X, Y, Z) = (55, 50, 20). These coordinates represent the relative position of the nozzle 62 with respect to the stage 300. Command COM2 moves the nozzle 62 from coordinates (X, Y, Z) = (55, 50, 20) to coordinates (X, Y, Z) = (50, 55, 20), and ejects 10 units of modeling material from the nozzle 62 while the nozzle 62 moves through this section. Command COM3 moves the nozzle 62 from coordinates (X, Y, Z) = (50, 55, 20) to coordinates (X, Y, Z) = (45, 60, 20), and ejects 10 units of modeling material from the nozzle 62 while the nozzle 62 moves through this section. Explanation of the sequence between commands COM3 and COM4 will be omitted, and then command COM4 ends modeling of the first portion 710.

[0077] In the first cutting data portion Dc1, for example, a command COM5, a command COM6, and a command COM7 are set.

[0078] Command COM5 moves cutting tool 210 to coordinates (X,Y,Z)=(55,60,20). Command COM6 moves cutting tool 210 from coordinates (X,Y,Z)=(55,60,20) to coordinates (X,Y,Z)=(50,55,20) at a feedrate of 10 units. Thereafter, command KOM7 ends cutting of first portion 710.

[0079] Then, as shown in FIG. 5, the data generation unit 512 ends the data generation process.

[0080] 2. Manufacturing method for three-dimensional objects 2.1. Each process Next, a method for manufacturing a three-dimensional object OB according to this embodiment will be described with reference to the drawings. Fig. 10 is a flowchart for explaining a process for realizing the manufacturing of a three-dimensional object OB according to this embodiment. This process is executed by the control unit 500 when, for example, a predetermined start operation is performed by the user on an operation panel provided in the three-dimensional printing apparatus 10 or on the information processing device 510. Each step of this process will be described below in order.

[0081] 2.1.1. Step S21 First, as shown in FIG. 10, the control unit 500 performs a process of acquiring the above-described modeling data and cutting data from the information processing device 510 as a data acquiring step.

[0082] The control unit 500 acquires the modeling data and the cutting data from the information processing device 510, for example, via wired communication. Note that the control unit 500 may acquire the modeling data and the cutting data from the information processing device 510 via wireless communication or a recording medium such as a USB memory.

[0083] 2.1.2. Step S22 Next, the control unit 500 performs a material generating process, for example, by controlling the rotation of the flat screw 40 and the temperature of the heater 58 built into the barrel 50, to melt the material and generate a modeling material.

[0084] In the material generation process, as shown in FIGS. 2 and 3 , the material stored in the material supply unit 20 is supplied to the material introduction unit 48 from the side surface 43 of the rotating flat screw 40 via the supply path 22. The material supplied to the material introduction unit 48 is transported to the spiral portion 47 by the rotation of the flat screw 40. The material transported to the spiral portion 47 is melted by the rotation of the flat screw 40 and heating by the heater 58, generating a fluid, paste-like modeling material. The generated modeling material is transported through the spiral portion 47 toward the center portion 46 and supplied to the nozzle 62 through the communication hole 56. The modeling material continues to be generated during the modeling process, which will be described later.

[0085] 2.1.3. Step S23 Next, the control unit 500 performs a process of forming the bulk portion 630 by causing the modeling machine 100 and the moving mechanism 400 to stack the modeling material on the stage 300 in accordance with the modeling data, as a bulk portion-forming step.

[0086] Specifically, the control unit 500 ejects a modeling material from the nozzle 62 toward the stage 300 while changing the relative position between the nozzle 62 of the modeling machine 100 and the stage 300, thereby forming a bulk portion 630 on the stage 300.

[0087] 2.1.4. Step S24 Next, the control unit 500 performs a process as a partial modeling step in which the modeling machine 100 and the moving mechanism 400 stack modeling material on the bulky portion 630 to model a stacked body in accordance with the modeling data. The length of this stacked body in the −Z-axis direction is shorter than the cuttable length Le of the cutting tool 210 in the −Z-axis direction.

[0088] First, in step S24, the control unit 500 causes the reheating unit 70 to heat the laminate. The control unit 500 causes the reheating unit 70 to heat the end surface of the laminate for a predetermined time. The heating time is set depending on, for example, the type of material and the temperature of the reheating unit 70. The control unit 500 sets the heating time using, for example, a map that represents the relationship between the temperature of the reheating unit 70 and the heating time. The map can be set by examining, through a pre-conducted test, the time required for the temperature of the end surface of the laminate to reach a predetermined temperature that exceeds the glass transition point of the building material. Note that the control unit 500 may set the heating time using a function that represents the relationship between the temperature of the reheating unit 70 and the heating time, rather than a map.

[0089] Next, the control unit 500 discharges the modeling material from the nozzle 62 toward the stage 300 while changing the relative position between the nozzle 62 of the modeling machine 100 and the stage 300 , thereby modeling a laminate on the bulk portion 630 .

[0090] 2.1.5. Step S25 Next, the control unit 500 performs a partial cutting process in which the cutter 200 and the moving mechanism 400 use the cutting tool 210 to cut the cutting allowance provided on the laminate in the −Z axis direction in accordance with the cutting data.

[0091] Specifically, the control unit 500 processes the laminate to the desired dimensions and surface roughness by bringing the rotating cutting tool 210 into contact with the cutting allowance of the laminate while changing the relative position between the cutting tool 210 and the stage 300.

[0092] 2.1.6. Step S26 Next, the control unit 500 determines whether or not the production of the three-dimensional object OB is completed.

[0093] The completion of the production of the three-dimensional object OB means that the production of the three-dimensional object OB has been completed according to the modeling path represented in the modeling data, and then the cutting of the three-dimensional object OB has been completed according to the cutting path represented in the cutting data. The control unit 500 uses the modeling data and the cutting data to determine whether the production of the three-dimensional object OB has been completed.

[0094] If it is determined that the production of the three-dimensional object OB is complete (YES in step S26), the control unit 500 ends the process.

[0095] If the control unit 500 does not determine that the manufacturing of the three-dimensional object OB is complete ("NO" in step S26), the control unit 500 returns to step S24 and repeats the processes from step S24 to step S26. The control unit 500 repeatedly performs the partial manufacturing step (step S24) and the partial cutting step (step S25) until it determines that the manufacturing of the three-dimensional object OB is complete in step S26. The partial manufacturing step and the partial cutting step are each performed at least twice.

[0096] As a result, the laminates are connected along the Z axis, and a three-dimensional object OB is produced whose length in the −Z axis direction is longer than the cuttable length Le of the cutting tool 210. Then, the control unit 500 ends the process.

[0097] 2.2. Partial molding process and partial cutting process Next, the partial modeling step (step S24) and the partial cutting step (step S25) will be described in detail with reference to the drawings. An example in which the partial modeling step and the partial cutting step are each performed three times will be described below. Note that the number of partial modeling steps and partial cutting steps is not particularly limited as long as it is two or more.

[0098] 2.2.1. First Part Forming Process and First Part Cutting Process 11 is a cross-sectional view schematically showing the first partial modeling step. The first partial modeling step is the first partial modeling step.

[0099] First, in the first portion forming process, the bulk portion 630 is heated. Specifically, the control unit 500 executes the process of step S24 described above and causes the reheating unit 70 to heat the bulk portion 630.

[0100] 11 , the modeling material is stacked to form a first portion 710 whose length L1 in the −Z-axis direction is shorter than the cuttable length Le in the −Z-axis direction of the cutting tool 210. Specifically, in the first portion modeling process, the control unit 500 executes the processing of step S24 described above in accordance with the modeling data, thereby causing the modeling machine 100 to stack the modeling material to form the first portion 710 whose length L1 is shorter than the length Le.

[0101] The first portion 710 has a first end surface 712. The first end surface 712 is the end surface of the first portion 710 opposite the stage 300. In the example shown, the first end surface 712 is the end surface opposite (in the +Z axis direction) to the cutting direction (in the -Z axis direction). The first portion 710 formed on the stage 300 hardens by, for example, absorbing heat from the stage 300 or the atmosphere. The first portion 710 has a forming portion 702 including a main body portion 704 and a cutting portion 706.

[0102] In the illustrated example, before the first portion-forming process, a bulk portion-forming process is performed in which a forming material is stacked on the stage 300 to form a bulk portion 630 that ensures a distance between the first portion 710 and the stage 300. The bulk portion-forming process and the first portion-forming process are performed, for example, consecutively. The first portion 710 is placed on the stage 300 via the bulk portion 630.

[0103] 12 is a cross-sectional view schematically showing the first partial cutting step, which is a first partial cutting step.

[0104] 12 , in the first portion cutting step, the first portion 710 is cut in the −Z-axis direction using the cutting tool 210. Specifically, in the first portion cutting step, the control unit 500 executes the process of step S25 described above in accordance with the cutting data, thereby causing the cutting machine 200 to cut the cutting portion 706 of the first portion 710. In the illustrated example, the control unit 500 aligns the rotation axis of the cutting tool 210 with the Z-axis and inserts the cutting tool 210 into the hollow portion of the tubular first portion 710. Then, the control unit 500 brings the rotating cutting tool 210 into contact with the cutting portion 706 of the first portion 710, thereby causing the cutting tool 210 to cut the cutting portion 706.

[0105] 2.2.2. Second part molding process and second part cutting process 13 is a cross-sectional view schematically showing the second partial modeling step, which is a second partial modeling step.

[0106] First, in the second-portion-forming process, the first end surface 712 of the first portion 710 is heated. Specifically, the control unit 500 executes the process of step S24 described above and causes the reheating unit 70 to heat the first end surface 712. In this way, the second-portion-forming process includes a heating process of heating the first end surface 712.

[0107] 13 , the modeling material is stacked to connect to the first end surface 712 of the first portion 710, and a second portion 720 having a length L2 in the −Z-axis direction that is shorter than that of the first portion 710 is modeled. Specifically, in the second portion modeling process, the control unit 500 executes the processing of step S24 in accordance with the modeling data, thereby causing the modeling machine 100 to stack the modeling material on the first portion 710 and model the second portion 720 having a length L2 that is shorter than the length L1.

[0108] The second portion 720 has a second end face 722. The second end face 722 is the end face of the second portion 720 on the opposite side to the stage 300. In the example shown, the second end face 722 is the end face on the opposite side (+Z axis direction) to the cutting direction (-Z axis direction).

[0109] 14 is a cross-sectional view schematically showing the second partial cutting step, which is a second partial cutting step.

[0110] 14, in the second portion cutting step, the second portion 720 is cut in the −Z-axis direction using the cutting tool 210. Specifically, in the second portion cutting step, the control unit 500 causes the cutting machine 200 to cut the cutting portion 706 of the second portion 720 by executing the process of step S25 described above in accordance with the cutting data.

[0111] 2.2.3. Third Part Forming Process and Third Part Cutting Process 15 is a cross-sectional view schematically showing the third partial modeling step, which is a third partial modeling step.

[0112] First, in the third portion forming process, the second end surface 722 of the second portion 720 is heated. Specifically, the control unit 500 executes the process of step S24 described above and causes the reheating unit 70 to heat the second end surface 722.

[0113] 15 , the third portion-forming process stacks the modeling material to connect to the second end surface 722 of the second portion 720, and forms a third portion 730 whose length L2 in the -Z axis direction is shorter than that of the second portion 720. Specifically, in the third portion-forming process, the control unit 500 executes the processing of step S24 in accordance with the modeling data, thereby causing the modeling machine 100 to stack the modeling material on the second portion 720 and form a third portion 730 whose length L3 is shorter than the length L2.

[0114] 16 is a cross-sectional view schematically showing the third partial cutting step, which is a third partial cutting step.

[0115] 16, in the third portion cutting step, the third portion 730 is cut in the −Z-axis direction using the cutting tool 210. Specifically, in the third portion cutting step, the control unit 500 causes the cutting machine 200 to cut the cutting portion 706 of the third portion 730 by executing the process of step S25 described above in accordance with the cutting data.

[0116] The control unit 500 ends the modeling process, for example, after the third partial cutting step. After the modeling process is completed, the user separates the three-dimensional object OB from the stage 300, removes the bulky portion 630, or sinters the three-dimensional object OB in a furnace, thereby manufacturing a three-dimensional object OB according to the design shape.

[0117] 2.3. Effects The method for manufacturing a three-dimensional object OB includes a first portion forming process in which a forming material is stacked to form a first portion 710 whose length in the -Z axis direction is shorter than the cuttable length Le; a first portion cutting process in which the first portion 710 is cut in the -Z axis direction using a cutting tool 210; and a second portion forming process in which a forming material is stacked to connect to a first end face 712 of the first portion 710 to form a second portion 720 whose length in the -Z axis direction is shorter than the first portion 710.

[0118] Therefore, in the method for manufacturing the three-dimensional object OB, the contraction stress of the second portion 720 can be reduced compared to when the length of the second portion in the -Z axis direction is equal to or greater than the length of the first portion in the -Z axis direction, which reduces the step that occurs at the boundary between the first portion 710 and the second portion 720 on the surface 620 of the three-dimensional object OB.

[0119] For example, as shown in FIG. 17 , when a second portion 1720 whose length in the −Z axis direction is equal to or longer than that of the first portion 1710 is formed on a first portion 1710, the second portion 1720 shrinks when allowed to cool naturally after formation. In this case, the second portion 1720 is likely to collapse inward, particularly when the shapes of the first portion 1710 and the second portion 1720 enclose a space in a plan view. When the second portion 1720 collapses inward, as shown in FIG. 18 , the first portion 1710 distorts and collapses inward along with the second portion 1720. If cutting is performed in this state, a step U appears on the surface 1620, as shown in FIG. 19 . Note that FIGS. 17 to 19 are cross-sectional views that schematically illustrate a manufacturing process for a three-dimensionally shaped object according to a reference example.

[0120] As described above, in the method for manufacturing the three-dimensional object OB, the second portion 720 is formed so that its length in the -Z axis direction is shorter than that of the first portion 710, thereby reducing the volume of the second portion 720. This reduces the contraction stress generated in the second portion 720, and reduces the step generated on the surface 620 of the three-dimensional object OB.

[0121] In the manufacturing method of the three-dimensional object OB, the combined length of the first portion 710 and the second portion 720 in the -Z-axis direction is longer than the cuttable length Le. For example, if the first portion and the second portion are formed by stacking modeling material at once, the cutting tool will not reach the combined length, leaving a cut portion. However, in the manufacturing method of the three-dimensional object OB, the first-portion cutting step is performed between the first-portion modeling step and the second-portion modeling step. Therefore, even if the combined length of the first portion 710 and the second portion 720 is longer than the cuttable length Le, the cut portion 706 can be cut into the desired shape by the cutting tool 210 without leaving a cut portion 706.

[0122] In the method for manufacturing the three-dimensional object OB, the shapes of the first portion 710 and the second portion 720 in the −Z axis direction are shapes that surround the space K. As described above, when the first portion 710 and the second portion 720 have shapes that surround the space K, the second portion 720 is likely to collapse inward. Even in such a case, in the method for manufacturing the three-dimensional object OB, the length L2 of the second portion 720 in the −Z axis direction is shorter than the length L1 of the first portion 710 in the −Z axis direction, so that the step that occurs on the surface 620 can be reduced.

[0123] In the method for manufacturing the three-dimensional object OB, when the length of the first portion 710 in the −Z-axis direction is L1, the Young's modulus of the first portion 710 is E, and the second moment of area of ​​the first portion 710 is I, the contraction force w of the second portion 720 satisfies the following condition: w≦0.009EI / L1 3 Therefore, even if a step occurs on surface 620 at the boundary between first portion 710 and second portion 720, the height of the step can be kept to 0.003 mm or less, making the step less visible.

[0124] In the method for manufacturing the three-dimensional object OB, the second-portion forming step includes a heating step of heating the first end surface 712 of the first portion 710. Therefore, in the method for manufacturing the three-dimensional object OB, it is possible to improve the adhesion between the first portion 710 and the second portion 720. This makes it possible to improve the mechanical strength of the three-dimensional object OB.

[0125] The method for manufacturing the three-dimensional object OB includes, before the first-portion cutting step, a bulk portion forming step of stacking a forming material on the stage 300 to form a bulk portion 630 that ensures a distance between the first portion 710 and the stage 300. Therefore, in the method for manufacturing the three-dimensional object OB, interference between the cutting machine 200 and the stage 300 can be suppressed in the first-portion cutting step.

[0126] The manufacturing method of the three-dimensional object OB includes a second-portion cutting step of cutting the second portion 720 in the -Z axis direction using the cutting tool 210, and a third-portion forming step of stacking a forming material and connecting it to the second end surface 722 of the second portion 720 to form a third portion 730 whose length in the -Z axis direction is shorter than that of the second portion 720. Therefore, in the manufacturing method of the three-dimensional object OB, it is possible to reduce the contraction stress of the third portion 730 compared to when the length of the third portion in the -Z axis direction is equal to or longer than the length of the second portion in the -Y axis direction. This makes it possible to reduce the step that occurs at the boundary between the second portion 720 and the third portion 730 on the surface 620 of the three-dimensional object OB.

[0127] 3. Variations In the above example, pelletized ABS was used as the modeling material for forming the three-dimensional object. However, materials that can be used in the modeling machine 100 can include materials that are primarily made of various materials, such as thermoplastic materials other than ABS, metal materials, and ceramic materials. Here, the term "primary material" refers to the material that forms the core of the shape of the three-dimensional object, and is a material that accounts for 50% or more by weight of the three-dimensional object. The above-mentioned modeling materials include those in which the primary material is melted alone, and those in which some components contained in the primary material are melted and formed into a paste.

[0128] When a thermoplastic material is used as the main material, the modeling material is generated by plasticizing the material in the melting section 30. "Plasticization" means that the thermoplastic material softens and becomes fluid when heated to a temperature above the glass transition point.

[0129] Examples of thermoplastic materials that can be used include thermoplastic resins, such as general-purpose engineering plastics like polypropylene (PP), polyethylene (PE), polyacetal (POM), polyvinyl chloride (PVC), polyamide (PA), acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polyphenylene sulfide (PPS), polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate, as well as engineering plastics like polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone (PEEK).

[0130] The thermoplastic material may contain pigments, metals, ceramics, and other additives such as wax, flame retardants, antioxidants, and thermal stabilizers. The thermoplastic material is plasticized and converted into a molten state in the melting section 30 by the rotation of the flat screw 40 and the heat of the heater 58. After being ejected from the nozzle hole 66, the modeling material hardens as the temperature drops.

[0131] The thermoplastic material is preferably heated to or above its glass transition point and completely melted before being injected from the nozzle hole 66. For example, the glass transition point of ABS is approximately 120°C, and it is preferably approximately 200°C when injected from the nozzle hole 66. In order to inject the modeling material in such a high temperature state, a heater may be provided around the nozzle hole 66. "Melting" not only means that the thermoplastic material is heated to a temperature above its melting point and becomes liquid, but also means that the thermoplastic material is plasticized.

[0132] In the molding machine 100, for example, a metal material may be used as the main material instead of the thermoplastic material described above. In this case, it is desirable that a powder material made by powdering the metal material is mixed with a component that melts when the molding material is generated, and then the powder material is introduced into the melting section 30.

[0133] Examples of metal materials include single metals such as magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), and nickel (Ni), as well as alloys containing one or more of these metals, as well as maraging steel, stainless steel, cobalt-chromium-molybdenum, titanium alloys, nickel alloys, aluminum alloys, cobalt alloys, and cobalt-chromium alloys.

[0134] In the molding machine 100, a ceramic material can be used as the main material instead of the above-mentioned metal material. Examples of the ceramic material include oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, and zirconium oxide, and non-oxide ceramics such as aluminum nitride. When the above-mentioned metal or ceramic material is used as the main material, the molding material placed on the stage 300 may be hardened by sintering using, for example, laser irradiation or hot air.

[0135] The powder material of the metallic material or ceramic material fed into the material supply unit 20 may be a mixed material obtained by mixing multiple types of powder of a single metal, alloy powder, or ceramic material. The powder material of the metallic material or ceramic material may also be coated with, for example, the thermoplastic resin described above or other thermoplastic resins. In this case, the thermoplastic resin may be melted in the melting unit 30 to exhibit fluidity.

[0136] A solvent, for example, may be added to the powder material of the metal material or ceramic material fed into the material supply unit 20. Examples of the solvent include water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetates such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and isobutyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide-based solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and 2,6-lutidine; tetraalkylammonium acetates (e.g., tetrabutylammonium acetate); and ionic liquids such as butyl carbitol acetate.

[0137] Additionally, for example, a binder may be added to the powder material of the metal material or ceramic material fed into the material supply unit 20. Examples of binders include acrylic resin, epoxy resin, silicone resin, cellulose-based resin, other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), and other thermoplastic resins.

[0138] The present invention includes configurations that are substantially the same as the configurations described in the embodiments, for example, configurations with the same functions, methods, and results, or configurations with the same purpose and effects. The present invention also includes configurations that replace non-essential parts of the configurations described in the embodiments. The present invention also includes configurations that achieve the same effects or purposes as the configurations described in the embodiments. The present invention also includes configurations that add publicly known technology to the configurations described in the embodiments.

[0139] The following can be derived from the above-described embodiment.

[0140] One aspect of the method for producing a three-dimensional object includes: A method for forming a three-dimensional object using a cutting tool capable of cutting a first length in a cutting direction, a first portion forming step of stacking a forming material to form a first portion whose length in the cutting direction is shorter than the first length; a first portion cutting step of cutting the first portion in the cutting direction by the cutting tool; a second portion forming process in which the forming material is stacked and connected to a first end surface of the first portion opposite to the cutting direction, thereby forming a second portion having a length in the cutting direction shorter than that of the first portion; Includes.

[0141] According to this method for manufacturing a three-dimensional object, the contraction stress of the second portion can be reduced compared to when the length of the second portion in the cutting direction is equal to or greater than the length of the first portion in the cutting direction, thereby reducing the step that occurs at the boundary between the first and second portions on the surface of the three-dimensional object.

[0142] In one aspect of the method for producing a three-dimensional object, The cutting direction may be opposite to the layering direction of the building material.

[0143] In one aspect of the method for producing a three-dimensional object, In the cutting direction, the combined length of the first portion and the second portion may be longer than the first length.

[0144] According to this method for manufacturing a three-dimensional object, the first portion cutting process is performed between the first portion modeling process and the second portion modeling process, so even if the combined length of the first portion and the second portion is longer than the cuttable length, it is possible to cut it into the desired shape using a cutting tool without leaving any cut portions.

[0145] In one aspect of the method for producing a three-dimensional object, The first portion and the second portion may have a shape that surrounds a space in the cutting direction.

[0146] According to this method for manufacturing a three-dimensional object, the length of the second portion in the cutting direction is shorter than the length of the first portion in the cutting direction, so even if the second portion is prone to falling inward, the steps that occur on the surface of the three-dimensional object can be reduced.

[0147] In one aspect of the method for producing a three-dimensional object, When the length of the first portion in the cutting direction is L1, the Young's modulus of the first portion is E, and the second moment of area of ​​the first portion is I, the contraction force w of the second portion is w≦0.009EI / L1 3 may satisfy the following relationship.

[0148] According to this method for manufacturing a three-dimensional object, even if a step occurs at the boundary between the first portion and the second portion on the surface of the three-dimensional object, the step can be made less visible.

[0149] In one aspect of the method for producing a three-dimensional object, The second portion shaping step may include a heating step of heating the first end surface.

[0150] According to this method for manufacturing a three-dimensional object, it is possible to improve the adhesion between the first portion and the second portion.

[0151] In one aspect of the method for producing a three-dimensional object, The method may include, before the first portion forming step, a bulk portion forming step of stacking the forming material on a stage to form a bulk portion that ensures a distance between the first portion and the stage.

[0152] According to this method for manufacturing a three-dimensional object, interference between the cutting machine and the stage can be suppressed in the first partial cutting step.

[0153] In one aspect of the method for producing a three-dimensional object, a second portion cutting step of cutting the second portion in the cutting direction by the cutting tool; a third portion forming process in which the forming material is stacked and connected to a second end surface of the second portion opposite to the cutting direction, thereby forming a third portion having a length in the cutting direction shorter than that of the second portion; may include:

[0154] According to this method for manufacturing a three-dimensional object, it is possible to reduce the step that occurs at the boundary between the second portion and the third portion on the surface of the three-dimensional object.

[0155] One aspect of the three-dimensional printing apparatus is a modeling machine that stacks modeling materials; a cutting machine having a cutting tool capable of cutting a first length in a cutting direction; a control unit that controls the molding machine and the cutting machine; Including, The control unit a process of stacking the modeling material in the modeling machine to model a first portion whose length in the cutting direction is shorter than the first length; a process of causing the cutting machine to cut the first portion in the cutting direction using the cutting tool; a process of causing the molding machine to stack the molding material and connect it to a first end face of the first portion opposite to the cutting direction, and molding a second portion having a length in the cutting direction shorter than that of the first portion; Do the following.

[0156] This three-dimensional modeling apparatus can reduce the step that occurs at the boundary between the first portion and the second portion on the surface of the three-dimensional model. [Explanation of symbols]

[0157] 10...three-dimensional modeling device, 20...material supply section, 22...supply path, 30...melting section, 32...screw case, 34...drive motor, 40...flat screw, 41...upper surface, 42...groove forming surface, 43...side, 45...groove section, 46...center section, 47...vortex section, 48...material introduction section, 50...barrel, 52...screw opposing surface, 54...guide groove, 56...communicating hole, 58...heater, 60...discharge section, 62...nozzle, 64...nozzle flow path, 66...nozzle hole, 100...forming Forming machine, 200...cutting machine, 300...stage, 310...forming surface, 400...movement mechanism, 410...motor, 500...control unit, 510...information processing device, 512...data generation unit, 610...inner wall surface, 620...surface, 630...bulk portion, 702...forming unit, 704...main body, 706...cutting unit, 710...first portion, 712...first end surface, 720...second portion, 722...second end surface, 730...third portion, 1620...surface, 1710...first portion, 1720...second portion

Claims

1. A method of forming a three-dimensional object using a cutting tool having a first length in the longitudinal direction. A molding method, comprising: By stacking layers of the build material on the stage, the inner wall surface extends along the first direction. The first portion has a tubular shape and a length along the first direction that is shorter than the first length. a first portion forming step of forming a first portion; a first portion cutting step of cutting an inner wall surface of the first portion by the cutting tool; a pipe having an inner wall surface extending along a second direction and connected to a first end surface of the first portion; a length along the second direction that is shorter than the first portion and shorter than the first length; a second portion forming step of forming a second portion; a second portion cutting step of cutting an inner wall surface of the second portion by the cutting tool; The second portion has a tubular shape with an inner wall surface extending along a third direction, and is connected to the first portion. the second portion is connected to a second end surface opposite to the end surface of the first portion, and the length in the third direction is shorter than that of the second portion. and a third portion forming step of forming the third portion. A method for manufacturing three-dimensional objects.

2. In claim 1, The first direction and the second direction are directions along the stacking direction of the layers. A method for manufacturing three-dimensional objects.

3. In claim 1 or 2, The total length of the first portion and the second portion in the direction along the stacking direction of the layers is longer than the first length, A method for manufacturing three-dimensional objects.

4. In any one of claims 1 to 3, The length of the first portion in the first direction is L1, the Young's modulus of the first portion is E, and the first portion When the second moment of area is I, the contraction force w of the second portion is w≦0.009E The relationship I / L13 is satisfied. A method for manufacturing three-dimensional objects.

5. In any one of claims 1 to 4, The second portion forming step includes a heating step of heating the first end surface. A method for manufacturing three-dimensional objects.

6. In any one of claims 1 to 5, Before the first part forming step, the forming material is stacked on the stage, and the first part is formed. A bulk portion forming step of forming a bulk portion that ensures a distance between the component and the stage, A method for manufacturing three-dimensional objects.

7. a modeling machine that stacks modeling materials; a cutting machine having a cutting tool having a first longitudinal length; a control unit that controls the molding machine and the cutting machine, The control unit causes the modeling machine to stack a layer of modeling material on a stage, a first portion having a tubular shape with an inner wall surface extending along a first direction, forming the first portion, the first portion having a length shorter than the first length; a process of causing the cutting machine to cut the inner wall surface of the first portion using the cutting tool; By stacking layers of the modeling material in the modeling machine, an inner wall surface is formed along the second direction. a second portion having an elongated tubular shape and connected to the first end surface of the first portion, the second portion having a length along the direction shorter than the first portion and shorter than the first length; A process of forming the a process of causing the cutting machine to cut the inner wall surface of the second portion using the cutting tool; By stacking layers of the modeling material in the modeling machine, an inner wall surface is formed along a third direction. a second end of the second portion opposite to the end face connected to the first portion; a third portion connected to the surface, the third portion having a length along the third direction shorter than that of the second portion; forming the third portion; A three-dimensional printing device that performs the above.

Images